Ironer

IM Installation and Operation Manual October 25, 2011 Revision 1.3

Executive Summary The Installation and Operation manual for the IM Series of self-contained thermal uid ironers. This manual covers the IM-800 and IM-1200 Series self contained thermal uid 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 re or explosion or to prevent property damage, personal injury or death. Do not store or use gasoline or other ammable 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. Clear the room, building or area of all occupants. Immediately call your gas supplier from a neighbors phone. Follow the gas suppliers instructions. If you cannot reach your gas supplier, call the re department. Installation and service must be performed by a qualied installer, service agency or the gas supplier. Contact your local gas supplier to obtain particular instructions in the event that a user smells gas. Place this sheet and any other instructions obtained from your gas supplier in a prominent location.

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 difcult cleaning and replacement. Not heeding these instructions will certainly ruin you day.

ii

Contents

Important Safety Information 1.1 1.2 FOR YOUR SAFETY - CAUTION! . . . . . . . . . . . A Note of Caution . . . . . . . . . . . . . . . . . . . . .

i i ii 1 1 3 4 4 5 5 5 8 8 8 8 10

Important Instructions 2.1 2.2 2.3 2.4 2.5 Before Attempting Repairs . . . . . . . . . . . . . . . . Operator Safety Notes . . . . . . . . . . . . . . . . . . Parts Ordering Information . . . . . . . . . . . . . . . 2.3.1 Nameplate Location . . . . . . . . . . . . . . . Key Symbols . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . 2.5.1 Installation Notice . . . . . . . . . . . . . . . .

Machine Installation 3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 3.1.2 3.2 Receiving Inspection . . . . . . . . . . . . . . . Product Description . . . . . . . . . . . . . . .

Electrical & Gas Specications . . . . . . . . . . . . . .

iii

3.3

Work Rates . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 1 Roll 48x118 . . . . . . . . . . . . . . . . . . 1 Roll 32x118 . . . . . . . . . . . . . . . . . . 2 Roll 48x118 . . . . . . . . . . . . . . . . . . 2 Roll 32x118 . . . . . . . . . . . . . . . . . . Moisture Retention Correction Factors . . . . . Calculating Moisture Retention . . . . . . . . . Service Clearance . . . . . . . . . . . . . . . . . Floor Requirements . . . . . . . . . . . . . . . . Gas Requirements . . . . . . . . . . . . . . . . Thermal Fluid Requirements . . . . . . . . . . Exhaust Duct Requirements . . . . . . . . . . . Compressed Air Requirements . . . . . . . . . Electrical Requirements . . . . . . . . . . . . . Uncrating . . . . . . . . . . . . . . . . . . . . . Clean Gap Pieces . . . . . . . . . . . . . . . . . Placement and Alignment . . . . . . . . . . . . Moving the Ironer to Location . . . . . . . . . Positioning and Leveling . . . . . . . . . . . . Module Placement . . . . . . . . . . . . . . . . Internal Piping Connections . . . . . . . . . . .
iv

11 11 12 12 12 12 13 14 14 14 15 15 15 15 15 16 16 17 17 17 18 19 20

3.4

Site Requirements . . . . . . . . . . . . . . . . . . . . . 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7

3.5

Machine Placement . . . . . . . . . . . . . . . . . . . . 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7

3.6

Compressed Air Connections . . . . . . . . . . . . . . 3.6.1 3.6.2 Internal Connections . . . . . . . . . . . . . . . External Connection . . . . . . . . . . . . . . . Internal Electrical Connections . . . . . . . . . Exhaust Connection . . . . . . . . . . . . . . . Internal Duct Work . . . . . . . . . . . . . . . . External Duct Work . . . . . . . . . . . . . . . Make Up Air . . . . . . . . . . . . . . . . . . . Gas Pressure Requirements . . . . . . . . . . . Gas Line Connection . . . . . . . . . . . . . . . Regulator Venting . . . . . . . . . . . . . . . .

21 21 21 21 21 23 23 23 23 23 24 24 24 24 25 25 26 30 33 33 33 34

3.7 3.8

Electrical Connections . . . . . . . . . . . . . . . . . . 3.7.1 3.8.1 3.8.2 3.8.3 3.8.4 Exhaust Installation . . . . . . . . . . . . . . . . . . . .

3.9

Gas Connection . . . . . . . . . . . . . . . . . . . . . . 3.9.1 3.9.2 3.9.3

3.10 Thermal Fluid Connection & Filling . . . . . . . . . . 3.10.1 Thermal Fluid Familiarization . . . . . . . . . 3.10.2 Filling the System . . . . . . . . . . . . . . . . . 3.11 Riello Burner Setup . . . . . . . . . . . . . . . . . . . . 4 Operation 4.1 Operating Procedure . . . . . . . . . . . . . . . . . . . 4.1.1 4.1.2 Daily Inspection . . . . . . . . . . . . . . . . . Operating Tips . . . . . . . . . . . . . . . . . .
v

4.1.3 4.1.4 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 5

Shutdown Procedure . . . . . . . . . . . . . . . Waxing Procedure . . . . . . . . . . . . . . . . Cotton Sheets . . . . . . . . . . . . . . . . . . . Poly-Cotton Blend Sheets . . . . . . . . . . . . Dryness . . . . . . . . . . . . . . . . . . . . . . Taking A Break . . . . . . . . . . . . . . . . . . Running Small Pieces . . . . . . . . . . . . . . Ironing Speed and Temperature . . . . . . . .

34 34 36 36 36 36 37 37 37 38 38 44 44 44 47 47 48 50 51 51 53 53

Running the Ironer . . . . . . . . . . . . . . . . . . . .

Maintenance 5.1 5.2 5.3 5.4 Wrinkle Patterns . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Chest Adjustment . . . . . . . . . . . . . . . . . . . . . Drive Belt Adjustment . . . . . . . . . . . . . . . . . . 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.5 5.6 Drive Tension Adjustment . . . . . . . . . . . . Intermediate Tension Adjustment . . . . . . . Infeed Tension Adjustment . . . . . . . . . . . Interroll Tension Adjustment . . . . . . . . . . Feed Table Chain Adjustment . . . . . . . . . .

Roll Procession Adjustment . . . . . . . . . . . . . . . Roll Padding . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1 Trimming the Roll Padding . . . . . . . . . . .
vi

5.6.2 5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7 5.8 5.8.1 5.8.2 5.8.3 5.8.4 5.8.5 5.9 6

Roll Pad Discoloration (Yellowing) . . . . . . . Securing Tapes . . . . . . . . . . . . . . . . . . Materials . . . . . . . . . . . . . . . . . . . . . . Routing The Guide Tapes . . . . . . . . . . . . Gearbox Lubrication . . . . . . . . . . . . . . . Pump Setup and Alignment . . . . . . . . . . . Typical Pump Problems . . . . . . . . . . . . . Burner Cleaning . . . . . . . . . . . . . . . . . Fluid Life . . . . . . . . . . . . . . . . . . . . . System Cleaning . . . . . . . . . . . . . . . . . Fluid Filter Screen . . . . . . . . . . . . . . . . Pump Service . . . . . . . . . . . . . . . . . . . Thermal Fluid Draining . . . . . . . . . . . . .

54 55 55 56 56 57 58 58 59 62 62 62 62 63 63 64 73 73 73 74 74 74

Guide Tape . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal Fluid Maintenance . . . . . . . . . . . . . . .

Quarterly Safety System Test . . . . . . . . . . . . . .

Appendix 6.1 Proper Drum Storage . . . . . . . . . . . . . . . . . . . 6.1.1 6.1.2 6.1.3 6.1.4 Recommended Storage Life . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . Eliminate Confusion with Proper Labeling . . Clean Delivery . . . . . . . . . . . . . . . . . .
vii

6.1.5 6.2 6.3 6.4 6.5 6.6 6.7

Conclusion . . . . . . . . . . . . . . . . . . . .

75 77 82 90

Paratherm HE MSDS . . . . . . . . . . . . . . . . . . . Shell Thermia MSDS . . . . . . . . . . . . . . . . . . . Thermal Fluid Pump . . . . . . . . . . . . . . . . . . .

Riello Burner Manual . . . . . . . . . . . . . . . . . . . 117 Riello Burner Parts Manual . . . . . . . . . . . . . . . 138 North American Riello Burner Parts Manual . . . . . 143

viii

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. If you are in any way unsure of how to proceed with a repair or adjustment, consult this manual, a qualied maintenance technician, your local distributor, or the B&C Technologies Technical Service Department at 850-249-2222. Only trained and experienced personnel should attempt maintenance or repair work on this equipment. Follow all safety procedures including lock-out/tag-out procedures carefully. Ensure that any loose tting clothing or jewelry is tucked in or not worn to avoid being pulled into the machine. Remember, the machine has no brain - you must use your own. 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.

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. Read, follow, and obey these safety rules! The B&C Technologies Technical Service Department is available to answer any questions you may have about the operation and servicing of your machine. Please call with any questions or concerns about the operation of your machine.

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. NEVER REACH around the safety guards or into any area near heated surfaces or moving parts without rst powering down the machine and allowing it to cool. Failure to follow this instruction can lead to serious injury or death. Check operation of the nger safety guard at the start of every work shift. Activating this guard should stop the machine. If this important safety device is not working, power off the machine and notify your manager. DO NOT OPERATE THE MACHINE until the safety guard is working properly. Make sure that all guide tapes and belts are in place and tensioned properly. Missing or improperly adjusted tapes and belts will cause performance, quality, and production problems. Maintaining a proper waxing schedule also keeps the machine performing at peak efciency and quality. Only atwork should be processed in the ironer - processing goods the machine is not designed to handle can lead to damage to the machine or personal injury. Do not stand, sit, or kneel on any part of the ironers front or rear - these parts are not designed to carry your weight. Follow all lock-out/tag-out procedures when servicing the ironer. Remember, when servicing the machine, power must be disconnected at the main disconnect switch. Only you can protect yourself by reading and understanding these precautions. Help protect others by making sure all personnel follow these instructions. Do not wear loose clothing or jewelry while operating this machine. Stay away from moving parts and heated rolls. If in doubt, ask your manager or contact Technical Service to nd out how to safely operate the ironer. Remember, only those qualied should service the ironer.

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

2.3.1

Nameplate Location

When contacting B&C Technologies about your equipment, please make note of the model and serial number, located on the nameplate as shown in gure 2.1.

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 gures 2.2 on page 6 and 2.3 on page 7.

2.5
2.5.1

Safety Instructions
Installation Notice

For personal safety and for proper operation, the machine must be grounded in accordance with state and local codes and in the USA in accordance with the National Electric Code, article 25096. Elsewhere, the equipment should be grounded in accordance with ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1. The ground connection must be to a proven earth ground, not to conduit or water pipes. Natural Gas or Liquid Propane Gas (LP Gas) heated equipment installation must comply with state and local codes, and in the USA, in accordance with the National Fuel Gas Code. Elsewhere, the equipment should comply with ANSI Z22.1, or CSA B149. Provisions must be made for adequate make-up air and ventilation, and access for equipment service and installation. Installation and Operational Safety Instructions 1. Read all instructions prior to operating this equipment. 2. Ensure that the equipment is properly grounded before applying power and operation commences. 3. Do not process goods that have been previously cleaned in, soaked in, or exposed to gasoline, dry cleaning chemicals, or any other ammable or explosive materials, as they could catch re or explode without warning, even after being washed. 4. Do not allow children to play in or around or operate this equipment. 5. Check the operation of all safety interlocks at the start of every shift. If the interlocks do not stop the equipment immediately, the machine must be removed from service. Notify your immediate supervisor, and do not operate the machine. 6. Never attempt to service the machine while it is running. Never reach over, under, around, or behind any safety device, or into any area near moving parts or hot surfaces without shutting off power and allowing the machine to adequately cool. 5

Figure 2.2: Key Symbols

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 qualied 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. To reduce the risk of re, do not process plastics or articles containing foam rubber or similarly textured rubber-like materials. 12. Keep the area near the exhaust ducting clean and free of lint, dust, dirt or debris. 13. Keep the interior and exterior of the machine clean of lint, dirt, dust and debris. The interior of the machine, along with the exhaust ductwork should be periodically inspected and cleaned to avoid potential res (lint is highly ammable). 14. Improper installation, operation and maintenance of this machine can cause exposure to substances in the fuel or from combustion that can cause serious illness or death. The machine must be exhausted to the outside. 15. Always disconnect the electrical service from the machine and allow it to cool before performing service. 16. This machine must be installed according to the installation instructions. All exhaust, electrical connections, and gas or steam connections must comply with state and local codes and must be made by a licensed installer where required.

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 led with the carrier as soon as possible. Note: Warranty is VOID unless the equipment is installed according to instructions. The installation must comply with the minimum requirements listed in this manual. All national, state and local codes must be followed including but not limited to gas, electrical, plumbing and HVAC. Due to various requirements, statutory codes should be well understood before installation commences. The ironer is delivered in ready-to-connect modules. The supply and return lines for all utilities such as heat, compressed air, power, exhaust, etc. must be installed on site. Each module is covered with a protective plastic wrapping. The cover panels are normally mounted to the ironer module.

3.1.2

Product Description

1. Design And Construction The heavy-duty ironers are manufactured in modules. The modules can be combined into ironers of one to four units with diameters of 800 mm (32 in.) or 1200 mm (47 in.) in widths of 3000 mm (118 in.) or 3300 mm (130 in.). Other widths are available - consult the factory. 2. Modular System The modular design allows an increase of modules (up to four) to t the individual requirements of the particular installation.

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. Programmable speed selectors are available as an option. The selectors can only be modied by trained personnel. 5. Heating Chests Heating chests are constructed of heavy gauge boilerplates with stiffeners to take the required forces. The contact surfaces of the chests are ground and polished. The chests are adjustable and are mounted on rollers integrated in the main frame. 6. Bridging Chests The heated bridging chests (gap pieces) are specially designed to prevent a loss of heating efciency between the modules and ensure a high nish quality due to the uninterrupted heating surface by steam or oil passing through the bridging chest. Steam-heated chests consist of a copper heating coil embedded in the chest. Thermal Oil heated chests are of a special welded design to optimize heat transfer. The surfaces of the bridging chests are ground and polished. 7. Rolls The rolls consist of a perforated, large-diameter cylinder covered with felt or nomex padding. Each roll has its own vacuum fan that ensures the efcient removal of condensation. Each vacuum fan can be individually adjusted through a buttery ap located in the exhaust duct portion of the module. Through this individual adjustment, a constant temperature can be maintained at the padding. Each roll is mounted on the left side to a swing bracket with a self-aligning bearing. The right side is mounted to a slip-on gearbox integrated in a swing bracket. All available padding can be supplied to meet customer specications. 8. Roll Procession The speed difference between rolls is created by the variable pulley belts on the drive side of the slip-on gear boxes (similar to the gear box on the infeed belts). The procession between rolls should only be modied by trained personnel. 9. Roll Lifting Mechanism Each roll can be individually raised and lowered through a pneumatic cylinder arrangement. The controls are located on the left hand control panel. After shutting off the power or in case of a power failure the rolls are lifted automatically. A safety device built into the cylinders prevents the rolls from dropping in the event of a failure in the compressed air system. This safety device prevents damage to the padding. The pressure between roll and chest is created by the pneumatic cylinders. A pneumatic control valve, located on the right side of the rst 9

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 at belts. The belts are driven by a textured infeed roller. A nger guard, located at the end of the belts, stops the ironer and lifts the rst roller immediately if activated. 11. Utility Connections (when looking from the front) Electricity Compressed Air Exhaust Type 800 Type 1200 Type 800 Type 1200 Type 800 Type 1200 Left side Right side Right side Left side Right side Left side

12. Control Panels The left control panel includes emergency stop button, roll temperature, air pressure for each roll, steam inlet temperature, steam pressure The right control panel includes rate meter, speed selector lift and lower switch for each roller, switch for on and start, push button drive on, pilot light for main power, pilot light for overload, pilot light for control, push button for control, jog button (reverse), drive start push button, emergency stop and selector switch. 13. Electrical Components The electrical panel is located at the right side for model 1200 and Left side for model 800 of the rst module in an enclosure with a door that can only be open by a special key. All electrical components on the panel are DIN rail mounted for easy repair and maintenance. The serial plate is located on the left side in the enclosure. 14. Safety Features The infeed side is protected by a windowed heat-resistant nger guard that, if activated, will instantly stop the drive motor and raise the rst roll. Two emergency push buttons are located at either end of the ironer and should only be used in emergencies. If activated, these emergency buttons will shut off the ironer and raise all the rolls. All mechanical and electrical components are covered by sheet metal panels or located behind enclosures. Panels and service doors can only be opened with special keys. 15. Optional Canopies Canopies can be provided so that heat losses are reduced to a minimum. The canopies are of aluminum construction.

3.2

Electrical & Gas Specications

Refer to Table 3.1 for complete details on gas and electrical requirements. Gas must be provided between 1/2 and 2 PSI, with gas piping provided to meet the volume of gas required. Best re10

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 Model IM-12301-2T IM-12301-4T IM-12331-2T IM-12331-4T BTU 800,000 800,000 800,000 800,000 Volts FLA Breaker 200-230, 3ph, 50/60Hz 60 70 380-460, 3ph, 50/60Hz 30 40 200-230, 3ph, 50/60Hz 380-460, 3ph, 50/60Hz 200-230, 3ph, 50/60Hz 380-460, 3ph, 50/60Hz 200-230, 3ph, 50/60Hz 380-460, 3ph, 50/60Hz 200-230, 3ph, 50/60Hz 440-460, 3ph, 50/60Hz 200-230, 3ph, 50/60Hz 440-460, 3ph, 50/60Hz 200-230, 3ph, 50/60Hz 440-460, 3ph, 50/60Hz 200-230, 3ph, 50/60Hz 440-460, 3ph, 50/60Hz 61 31 81 41 85 42 54 27 55 27 69 35 71 36 70 40 90 50 100 50 60 40 70 40 80 50 80 50

IM-12302-2T 1,600,000 IM-12302-4T 1,600,000 IM-12332-2T 1,600,000 IM-12332-4T 1,600,000 IM-8301-2T IM-8301-4T IM-8331-2T IM-8331-4T IM-8302-2T IM-8302-4T IM-8332-2T IM-8332-4T 600,000 600,000 600,000 600,000 1,200,000 1,200,000 1,200,000 1,200,000

3.3
3.3.1
Goods g/m2

Work Rates
Realistic Work Rates for 1 Roll 48x118 (1200mm) Ironer
Working Temperature 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 200 22 19 14 200C / 390F ft/min kg/h lb/hr lb/yd2

Sheets @ 80% Bed Coverage 130 0.2400 14 160 0.2954 11 190 0.3508 10 Small Pieces @ 60% Bed Coverage 220 0.4062 9 280 0.5170 7.5 330 0.6093 7

46 36 33

260 260 260

573 573 573

16 13 11

52 43 36

290 290 290

639 639 639

18 15 12

59 49 39

320 320 320

706 706 706

72 62 46

380 380 380

838 838 838

30 25 23

215 225 260

474 496 573

10.5 9 8

34 30 26

250 270 295

551 595 650

12 10 8.5

39 33 28

285 300 310

628 662 684

14 11.5 10

46 38 33

330 345 370

728 761 816

11

3.3.2
Goods g/m2

Realistic Work Rates for 1 Roll 32x118 (800mm) Ironer

Working Temperature 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 lb/yd2

Sheets @ 80% Bed Coverage 130 0.2400 9 160 0.2954 7.5 190 0.3508 6.5 Small Pieces @ 60% Bed Coverage 220 0.4062 5.5 280 0.5170 4.5 330 0.6093 4

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 10.5

43 38 34

255 255 255

562 562 562

18 15 13

130 135 150

287 298 331

6.5 5.5 4.5

21 18 15

155 165 165

342 364 364

7 6 5

23 20 16

170 180 185

375 397 408

8.25 7 6

27 23 20

195 210 220

430 463 485

3.3.3
Goods g/m2

Realistic Work Rates for 2 Roll 48x118 (1200mm) Ironer

Working Temperature 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 200 48 42 32 200C / 390F ft/min kg/h lb/hr lb/yd2

Sheets @ 80% Bed Coverage 130 0.2400 32 160 0.2954 26 190 0.3508 24 Small Pieces @ 60% Bed Coverage 220 0.4062 20 280 0.5170 16 330 0.6093 15

105 85 79

580 580 580

1279 1279 1279

36 30 26

118 98 85

645 645 645

1422 1422 1422

40 34 28

131 112 92

710 710 710

1566 1566 1566

157 138 105

840 840 840

1852 1852 1852

66 52 49

475 480 550

1047 1058 1213

23 19 17

75 62 56

545 570 625

1202 1257 1378

25 21 19

82 69 62

595 630 700

1312 1389 1544

29 24 22

95 79 72

690 720 810

1521 1588 1786

3.3.4
Goods g/m2

Realistic Work Rates for 2 Roll 32x118 (800mm) Ironer

Working Temperature 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 lb/yd2

Sheets @ 80% Bed Coverage 130 0.2400 22 160 0.2954 19 190 0.3508 17 Small Pieces @ 60% Bed Coverage 220 0.4062 13 280 0.5170 11 330 0.6093 9

72 62 56

410 410 410

904 904 904

24 21 19

79 69 62

455 455 455

1003 1003 1003

26 23 21

85 75 69

500 500 500

1103 1103 1103

32 27 25

105 89 82

590 590 590

1301 1301 1301

43 36 30

310 330 330

684 728 728

15.5 13 11

51 43 36

370 390 405

816 860 893

17 14.5 12.5

56 48 41

405 435 460

893 959 1014

20 17.5 14

66 57 46

475 525 515

1047 1158 1136

Production rates based on initial moisture of 50%, nal moisture of 2%. Use the correction chart for further renement of production rates.

3.3.5

Moisture Retention Correction Factors

Correction Factor 1.39 1.29 1.19 1.12 1.06 1 0.95 0.91 0.87 0.83 12

Moisture retention 25% 30% 35% 40% 45% 50% 55% 60% 65% 70%

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 atgoods 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. Weigh the sample again and record the weight as W2. 4. Iron the sample goods a second time. 5. Weigh the sample a third time and record this as W3. From these weights one can nd: 1) The dry weight of the laundry, 2) The moisture retention of the ironed goods, 3) The initial moisture retention of the goods before ironing. To calculate moisture retention, use the following formulas: Moisture Retention (%) before ironing = (W1-W3)/ W3 Moisture Retention (%) after ironing = (W2-W3)/ W3 As a general guide: The Moisture Retention before ironing should be 30% to 50%. The Moisture Retention 5 minutes after ironing should be 2% to 4%. Fabric Weight is a major factor needed to determine the actual practical work rate for at goods. Fabric weight is typically expressed as g/m2 (grams per square meter), lbs/yd2 (lbs per square yard), or oz/yd2 (ounces per square yard). The fabric weight for the goods must be known to nd the proper ironing speed in the Work Rate Chart. The weight of the atwork can be determined easily by: 1. Measure the Length and Width of each of the 10 sample pieces used above. Multiply the measurements for each sheet to nd the total area of each piece (Area = Length x width). 2. Add the calculated area for all 10 pieces. 3. If the sheets are measured in inches, divide the sum by 1296 to convert to square yards (yd2 ). 4. Divide the total dry weight (W3 from above) by the area in square yards from step 3 to calculate the weight. Fabric weight = Total Weight (lbs) / Total Area(yd2 )

13

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 efciency. 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 ooring capable of supporting the weight of the machine without exing. Consult the general specications in the previous section for specic details on the machines weight and other technical specications. No special foundation, grouting, or anchoring is required by the manufacturer, but some shimming may be required so that the machine is completely level. Always follow local codes when performing a machinery installation. It is the responsibility of the installer to be familiar with the requirements of local codes.

14

3.4.3

Gas Requirements

The ironer requires a signicant 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 uid. Before commissioning, the machine must be properly lled with thermal uid. Follow the procedure outlined in the Maintenance section of this manual for specic procedures for lling and purging the system.

3.4.5

Exhaust Duct Requirements

A short run of pressurized gas ue vent ducting and a short run of exhaust vent ducting is required and must be procured locally. Adequate ventilation is required and must meet all local codes. Refer to the previous section for airows and other pertinent information. Important: Do not interrupt the ow of make-up air or the exhaust! Use the shortest possible path with the fewest number of bends to connect to the outlet ductwork. Measured back pressure should not exceed 0.3 inches of water column pressure for reliable ignition and best results. Note: Check for proper exhaust fan rotation direction before placing the equipment into service. If the rotation is incorrect, remove power from the machine and exchange any two incoming power leads.

3.4.6

Compressed Air Requirements

A clean and dry source of compressed air must be provided. This supply must meet the minimum requirements listed in the previous section for pressure and volume. Wet and/or dirty air will cause rapid deterioration of internal components and void your warranty on these parts. Install a compressed air dryer to prevent water build up in the airlines. Make sure to use best practice when installing air lines so that water does not damage internal air components - the machine should not be the low point in the air path.

3.4.7

Electrical Requirements

Pay attention to the nameplate of the machine - it contains the specic electrical requirements of the machine. Additional requirements can be found in the previous section.

15

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. The connection should be shielded in a liquid tight or approved exible conduit with proper conductor of correct size installed in accordance with National Electric Code (USA) or other applicable codes. The connection must be made by a qualied electrician using the wiring diagram provided with the machine. For personal safety and for proper operation, the machine must be grounded in accordance with state and local codes and in the USA in accordance with the National Electric Code, article 250-96. The ground connection must be to a proven earth ground, not to conduit or water pipes. Do not connect the ground to the neutral (N) leg at the terminal strip. If a DELTA supply system is used, the high leg should be connected to T or L3, as control power is derived from L1 & L2.

3.5
3.5.1

Machine Placement
Uncrating

Prior to removing the packaging from the machine, ensure that the installation site is acceptable and any necessary oor or foundation improvements or modications have been made. Remove all packaging materials from the machine including bagging, crating, straps and any other materials while leaving the machine attached to the pallet. Remove these and move to a safe place until called for: Optional canopies Optional railing All end frame panels Boiler ductwork Carefully check all enclosures and remove any other materials shipped with the machine. These items will be used later in the installation process, so move to a convenient place.

16

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 nely 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. Make sure the entire surface is cleaned of protectant.

3.5.3

Placement and Alignment

WARNING! Modules are heavy. Ensure that proper equipment and personnel are available to prevent injury or damage. Modules should only be moved by qualied machinery riggers using correct equipment. Each module section has a chest and roll arrangement and up to 4 modules can be combined. Keep in mind the following terminology: The front module contains the controls and electrical connection. The center module(s), if necessary, include no extra equipment. The rear module contains the boiler, gas connection and compressed air connection. Place the sections beginning with the rear module, then the center modules if so equipped and nally the front module. Once the rear module is placed, the position of the ironer becomes xed.

3.5.4

Moving the Ironer to Location

a) General The modules can be moved by using a fork lift or a crane with an appropriate sling system. The weight of the modules can be found in the technical data of the ironer. The minimum required entrance dimensions are: Type 800: 71 x 71in (1800 x 1800mm) Type 1200: 87 x 71in (2200 x 1800mm) For single roller ironers the minimum required entrance dimensions are: Type 800: 83 x 71in (2100 x 1800mm) Type 1200: 99 x 71in (2500 x 1800mm) b) Using a Fork Lift 17

Figure 3.2: Module Bolting NOTE: The fork lift used must have the required capacity and be tted 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 oor or overhead, such as power lines, ceiling beams and others. c) Using a Crane The transport brackets must be in position before attempting to move the modules with a crane. NOTE: The crane used must have the required capacity and be tted with appropriate slings and a spreader frame. The modules are to be moved in a horizontal position only. After the modules are in position, remove the transport brackets before mounting the modules together.

3.5.5

Positioning and Leveling

The ironer should be positioned as per installation drawing. The minimum required side distance to walls or other obstructions or equipment is 36 inches (915mm). NOTE: The module number can be found at the top of the side frame beside the connecting bracket (see gure 3.2).

18

Figure 3.3: Flange Cover Detail

3.5.6

Center/Front Module Placement

With the module still on its skid, move it near its nal position, about 12 inches (300mm) from the already placed module and remove the skid bolts. Place drip pans under the ange 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. Remove the ange shipping covers from the thermal uid supply and return connections. A small amount of uid will drain out. Wait until the ow completely stops before continuing.

Note: Follow local codes for handling the disposal of the thermal uid collected in the drip pans. Do not attempt to reuse this uid! Carefully clean the anges and any additional spilled thermal uid. Carefully dispose of the thermal uid and cleaning materials according to local codes. Using a crane or forklift, lift the module straight up and carefully remove the skid. Do not drop or twist the module. Move the module until it is directly above its nal location. The endframes of the modules will be in contact with one another. Carefully lower the section to its nal position. Ensure that the gap piece is aligned with the chest of the previously placed module. The gap piece should be slightly above the mating chest and extend just beyond the surface 19

Figure 3.4: Thermal Fluid Flange Bolt Tightening edge of the chest. The endframes must rest rmly on the oor. 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. The modules are to be leveled horizontally in two directions and must be parallel to each other. The holes for the roll pins (8 x 25) are drilled while the ironer is preassembled at the factory. Now tighten all bolts using the following torque values: (M8 = 16 ft-lb / 22 Nm) (M20 = 300 ft-lb / 420 Nm)

3.5.7

Internal Piping Connections

Once all modules are aligned, secured, and bolted together, the thermal uid piping must be connected. Starting at the rear module, connect the thermal uid piping to the next module using the gaskets and bolts provided. Use care to avoid damaging the gaskets during installation. Tighten the nuts and bolts by hand, then follow the crisscross pattern shown in gure 3.4. Repeat these steps for each additional module. After all internal thermal uid piping has been connected, recheck for level on all modules using a large carpenters level. 20

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 oor. Install the V-Belts between the drive pulleys and the driven pulleys. Secure the machine to the oor or foundation if required by local codes. *ACCESS LADDER (OPTIONAL) Install the access ladder to the rear mounting position. Ensure the assembly bolts are tight to prevent any accidents! Only authorized technicians are permitted access to the top of the machine *SAFETY RAILINGS (OPTIONAL) Install the safety railing to the machine ensure installation is secure before technicians again access to the machine top.

3.6
3.6.1

Compressed Air Connections

Internal Connections

On each side of the machine in the electrical raceways, compressed air connections must be made. Follow the numbering scheme to connect the air lines correctly.

3.6.2

External Connection

The IM Series ironers require compressed air in order to raise and lower the rolls. Clean, dry compressed air must be provided at a minimum pressure of 65PSI (4.5 bar). A 3/8NPT connection is provided on the right side of the front (infeed) module.

3.7
3.7.1

Electrical Connections
Internal Electrical Connections

There are multiple connections to be made between modules before main power can be applied, including control cabling, temperature probe cabling, and burner cabling. Note: Only a qualied electrician should complete the electrical connections inside the machine. Improper connections could lead to improper operation and serious injury. Do not connect main power to the machine until all internal connections are complete and veried.

21

Figure 3.5: Compressed Air Connection

Figure 3.6: Electrical Panel

22

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.

3.8.2

Internal Duct Work

The roll exhaust ducting is inside the left frame of the machine when facing the infeed side of the machine. Remove all packaging from the duct work, and connect using the supplied hose clamps. Verify the proper electrical phasing of the exhaust blowers and ensure that the blowers are rotating in the correct direction. Severe performance problems will occur if the phasing is incorrect.

3.8.3

External Duct Work

There are two separate exhaust systems on the IM Series ironer: A pressurized gas ue for the burner which heats the oil A non-pressurized vent for the roll evaporation blower Caution: Two separate ducts are to be used for the machine - one for the roll evaporation blower and one for the oil heater. The two systems cannot be combined. Note: Do not vent either system into a wall, ceiling or other enclosed area of a building.

3.8.4

Make Up Air

The IM Series ironer requires a constant supply of fresh air for combustion and make up air. Generally, the machine will require approximately 1.5 sq ft (0.14 sq m) of open area depending upon the size of the machine. Refer to the general specications for additional details. Check local codes to determine make up air requirements for the particular installations. Always follow local codes.

23

3.9
3.9.1

Gas Connection
Gas Pressure Requirements

The nameplate species 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 sufcient to meet the requirements of the nameplate. All labor and materials needed to connect the gas supply to the machine are to be locally procured. Always follow local codes and regulations to ensure proper installation.

3.9.2

Gas Line Connection

The gas connection is made on the nal roll of the ironer at the left side when facing the exit side of the machine. The gas line feeding the ironer must be at least a 2 inch line, regardless of the connection point size (varies with ironer model). The incoming gas line should be routed in such as way as to not interfere with service panel access and must not block any service access to the machine. Be certain to check all internal gas connections and tighten any unions in the event that any came loose during the shipping and installation process. Use pipe joint compound when making gas connections and ensure that all local codes and requirements are followed. Use the proper bell reducer when connecting the gas supply line to the ironer. It is best practice to include a union at the point of connection to facilitate future service and maintenance operations. Best performance will be achieved if the ironers gas feed is not shared with other equipment.

3.9.3

Regulator Venting

If so equipped, the top of the gas regulator must be vented in order to operate safely. Depending on local codes, either a vent cap or vent tube must be connected to the regulator, allowing the regulator diaphragm to breathe and to limit/vent any escape of gas should the regulator fail. Follow local codes requirements if a vent safety tube is used. The discharge end of the tube must be protected from the elements and insects or other debris that could clog the end of the tube. Route this line carefully using the shortest and straightest run possible.

24

3.10
3.10.1

Thermal Fluid Connection & Filling

Thermal Fluid Familiarization

Refer to the system diagrams on pages 28 and 29 for details on item nomenclature. 1. Thermal Fluid - The thermal uid used is either Paratherm HE, Shell Thermia B, or an equivalent Fluid. Also referred to as thermal oil, heat transfer uid. Formulations vary with different suppliers, but in general these uids are not highly hazardous. See Appendix for detailed information and MSDS. 2. Insulation - In some locations in the machine berglass based insulation is used. If any of this insulation becomes soaked with thermal uid it is important to remove, properly dispose of, and replace with new insulation as soon as possible. Thermal uid soaked berglass can generate spontaneous combustion res like oily rags in a dryer. 3. Valve A (Expansion Tank Valve) - This valve blocks the ow of thermal uid to and from the expansion tank. It should NEVER BE CLOSED during operation for any reason. Closing it can cause severe damage to your atwork ironer and/or severe personal injury. 4. Valve B (Pump inlet cut-off valve) This valve is used for servicing the thermal uid pump, lter screen, or drying out the thermal uid tank and should never be closed during normal operation. 5. Valve C (Pump outlet cut-off valve) - This valve is used for servicing the thermal uid pump or lter screen and should never be closed during normal operation. 6. Filter Screen - This is a trap for particulate matter in the oil circulation system. When the ironer is new, it is normal to nd a small amount of foreign material in the screen. As the ironer ages, pieces of carbon may be found. This indicates that the system needs to be cleaned with a special solvent. Contact your thermal uid supplier for a solvent and cleaning procedure. 7. Thermal Fluid Pump - This pump moves the uid around the system and is a high performance precision pump. Note that there is a weep hole under drive shaft at the end of the pump body. In normal operation there should not be a signicant amount of uid coming from this hole. Never plug this hole. Weeping uid indicates the need for new seals in the pump. See the thermal pump manual in the Appendix for more information. 8. Thermal Fluid Boiler - Although commonly called a boiler, the boiler is actually a high efciency heat exchanger. It transfers the heat from the burner into the thermal uid. 9. PS2 (Pressure Switch 2) - This normally open switch is connected to the inlet of the boiler. It goes closed when the inlet pressure reaches a pressure setting to conrm operation of the pump. On some machines there is an isolation valve feeding this pressure switch branch line if present this valve should never be closed.

25

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 conrm oil ow 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. This switch must be manually reset and if tripped will lock out operation of the heat source. 12. Valve D (Bleed Valve) - This valve allows purging air or other gases from the thermal uid system. It should always be kept closed during operation. 13. Valve E (Fill Valve) - This valve is located close to the pump inlet. This valve is used to ll or drain uid from the system. It should always be kept closed during operation. 14. Valve F - This is the high pressure gauge line valve. If this valve is present it must be kept open. Remove the handle from this valve at commissioning to prevent accidental closure. 15. Valve G - This is the low pressure gauge line valve. If this valve is present it must be kept open. Remove the handle from this valve at commissioning to prevent accidental closure.

3.10.2

Filling the System

This procedure details the recommended process for lling the thermal uid system and should be followed when commissioning a new machine or relling the machine with uid after service, or lling the system with cleaner (which is available from your thermal uid supplier). Do not attempt to service the thermal uid system unless you are properly trained and completely understand the operation of the machine. If there are any questions consult your distributor or the B&C Technologies Technical Service Department. For reference, see the system diagram in gure 3.7 on page 28. Perform this procedure with the Rolls in the raised position. 1. NEVER OPERATE THE THERMAL FLUID PUMP DRY!! Before lling the machine remove the seal weep hole in the thermal uid pump and ll it with thermal uid as described in the pump manual (see the appendix for details). Operating the pump with dry seals for only a few seconds will permanently damage the seals and is not covered under any warranty. 2. If commissioning a new machine, the system lter screen should be opened and cleaned before proceeding with the ll. 3. Make certain (check twice!) that the uid expansion tank is clean and free of debris or water. Make certain (check twice!) that the uid being used for lling is new, clean and contains no water. If lling from a previously opened drum, pump a gallon or so from the bottom of the drum into a clean bucket and look for water, rust, or other contamination. See the appendix for information about proper drum storage. 4. Connect a properly sized hose barb to outlet of valve E. Connect the ll hose from the barrel pump to this point and secure it to the barb with a hose clamp. 26

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 uid into the system. Continue until a steady stream of uid with little or no air comes out of the bleed tube into the 5 gallon bucket. 8. Close Valve D and continue pumping until the expansion tank is lled to 1/4 of its volume. 9. Close valve E and valve D. Open valves A, B, C (A and C should already be open). Make sure the expansion tank cap is in place. 10. The system should now be nearly full of oil, however there will still be some air bubbles in the boiler tubes and other locations. The system must now be purged of air. Before proceeding make certain that the master heat switch on the left control panel of the ironer is in the off position and the pump switch is in the manual position. The machine should also be completely assembled, powered, and commissioned before proceeding. During the remainder of this procedure you should pour uid accumulated in the 5 gallon bucket in the expansion tank when the bucket gets 1/2 to 3/4 full. You should also add thermal uid to the expansion tank to maintain a level of 1/4. 11. Proceed by turning the ironer on - the pump will start automatically. Leave the machine on for about 30 sec or until the pump cavitates. Then press the off button to stop the pump. 12. Open valve D, making sure the end of the tube is under the oil level in the bucket to prevent splashing, and let it run just until no more air or foam comes out. 13. Repeat from step 11 until no air bleeds out during the purge cycles and the pump no longer cavitates. 14. Set the mode switch on the burner to manual so the burner lights but does not go to high re. High re should not be used during initial degassing. 15. Set the main temperature control setpoint to 150o F (65o C). Turn on the machine and set the heat system control switch to on. 16. While the machine is running, periodically open (about every 30 sec) Valve D for a few seconds and release any accumulated air bubbles. If the pump cavitates, stop the machine and open valve D for a few seconds to release any air bubbles. Close valve D. 17. Repeat step 16 until no air is released and the pump no longer cavitates. 18. Set the main temperature control setpoint to 210o F (100o C). 19. Repeat step 16 until no air is released and the pump no longer cavitates. 20. On commissioning, the protective wax coating will be soft enough to remove using mops, old towels, or other methods. Remove as much wax as possible before unwrapping and lowering the rolls. Ensure that all plastic covering and tape is removed prior to dropping the rolls. 27

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.

28

Figure 3.8: Thermal Fluid System Valves

29

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 ring 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 ring rate. Note that the Gas disk should always be set at 0 when ring LP gas, only the air bypass is adjusted. 2. Remove and inspect the ame holder assembly verify the spacings specied in the manual for the pilot, ame rod, and ignition electrode. Make sure the ame rod is in the new position specied in the Riello service bulletin. 3. Dont adjust the red, blue, and orange cams on the damper servo, leave them at the 90-0-15 factory positions. 4. The gas supply pressure feeding the machine should be 2 psi (140mbar). Never exceed 5psi as this will damage the pilot regulator. 5. If this is a new startup, set the pilot regulator to 6 W.C. (15 mbar) for natural gas and the air damper at pilot to about 15 degrees on the damper dial (this is adjusted with the cam prole screws). 6. Set the main regulator on the Krom-Schroder to about 3.0 W.C. (7.4 mbar) for natural gas. 7. If this is a new startup, set the damper so it is fully open (at 90 degrees on the damper dial) at 90 degrees on the servo cam. 8. Set the jumper on burner terminal 30V11 to the 30VP position, or install a switch for easier future adjustment. 9. Make sure the throat on both Krom-Schroder solenoids is fully open (this adjustment is at the top of each solenoid). 10. Set the burner mode switch to manual 11. Now try to light the burner the pilot should light and nothing else. Manipulate the pilot regulator pressure in small increments until a stable clean pilot ame that relights easily results. 12. With a stable pilot set the jumper back on 30V11 (or ip the pilot switch if one was installed). 13. Now relight the burner, still in manual mode, and watch for the main burn to start. The pilot will now light for a few seconds, then the main burner will light, then the pilot will turn off after about 3 seconds. If the burner blows out when the main valve turns on then reduce the gas pressure setting on the Krom-Schroder regulator and try again. If a little faint blue main ame or no main ame appears, then decrease the damper setting slowly until a successful transfer from pilot to low-re results. 30

14. When a good crossover from pilot to main burn occurs regularly, continue. 15. Run the burner up to high re, 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 ue get the CO as low as possible. A CO level of 10 ppm or less can be achieved very easily. 16. Drop the burner to the next cam prole screw level and now set the damper position (very small adjustments) to achieve less than 50ppm CO at 3% to 6% O2 on a combustion analyzer. Again, a CO level of 10 ppm or less can be achieved very easily. 17. Repeat 15 until you reach the minimum ring point. It may be difcult to get the CO at min ring to less than 100ppm without running it too rich. The adjustment at this ring point is very touchy adjust the damper prole screws in very small increments. It may be necessary to increase the minimum ring point (red cam) on the servo and readjust the pilot pressure to attain reliable ignition and crossover with the burner now fully tuned. 18. Recheck pilot crossover and pilot stability by lighting and shutting the burner down several times. 19. With the burner at low re, increase the setting of the air ow pressure switch until the burner faults, then reduce the setting by 20%, for example if it cut out at 1.0 WC reduce the setting to 0.8 WC. 20. Check that the burner does not exceed the maximum ring rate specied for the ironer it is installed in. If it does, reduce the red cam position until the pressure corresponding to the max ring rate is measured at the gas pressure test point on top of the burner. Burner RS50M RS38M RS28M RS38M RS28M Rolls 3 2 1 2 1 Roll Size 48 (1200) 48 (1200) 48 (1200) 32 (800) 32 (800) MBTU/hr(max) 2.5 1.6 0.8 1.2 0.6 Mcal/hr 630 403 202 302 151

Natural Gas Initial Settings Summary

Burner Pilot Regulator Pressure Pilot Damper Main Regulator Pressure Max Fire Damper RS28/M 6.0WC (150mmWC) 15deg 3.0WC (75mmWC) 90deg RS38/M 6.0WC (150mmWC) 20deg 3.0WC (75mmWC) 90deg RS50/M 6.0WC (150mmWC) 20deg 3.0WC (75mmWC) 90deg

LP Gas Initial Settings Summary

Burner Pilot Regulator Pressure Pilot Damper Main Regulator Pressure Max Fire Damper RS28/M 3.0WC (75mmWC) 15deg 8.7WC (220mmWC) 90deg RS38/M 3.0WC (75mmWC) 20deg 11.4WC (290mmWC) 90deg RS50/M 3.0WC (75mmWC) 20deg 14.2WC (360mmWC) 90deg

31

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.

32

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. On the left control panel make sure the burner is off (green switch) and the oil pump switch is in the automatic position. 5. On the right control panel make sure all Roll switches are in the up position and the Blower is in the off position. 6. On the right control panel push the green on button. The machine will power up and the oil pump should start. Listen to the sound of the pump for irregular sounds or vibration. If you hear anything abnormal (slurping sounds, excessive vibration, etc.) please call for an inspection. 7. On the left control panel set the burner switch to on, and make sure the temperature is set for 330o F on the lower display. 8. When the burner lights the Heating On lamp will be lit. If there is a problem, one of the burner / alarm or low pressure / Gas lamp will turn on. If the burner alarm turns on, then you can press the burner reset button on the right panel to restart the burner If you have to reset the burner regularly please call for service. 9. The machine will take about 30 minutes to heat up (depending on how cold it was). During this time review the waxing procedures and prepare to wax the machine. 33

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. Any time you are not running the ironer you should raise the rolls (On the right panel set the Roll switches to up). This extends the life of the roll padding. Feed sheets and large items in the center of the ironer. With small pieces its best to spread them out across the ironer, however with a chest ironer you can safely run them in lanes.

4.1.3

Shutdown Procedure

1. One the Left panel set the burner switch to off. 2. On the right panel, set all roll switches to up, set the blower switch to off 3. Push the red off button. 4. The machine will power down except the oil pump will continue to run until the oil cools to a safe temperature. The pump will then turn off automatically.

4.1.4

Waxing Procedure

Every Monday

1. Wait for the ironer to warm up to at least 270o F (135o C). 2. Set the blower switch to off and set the speed to 10 15 ft/min (3 6 M/min). 3. Set the Folder to bypass or a waxing program. 4. Lower the rolls by setting all roll switches to down 5. Feed the wax cloth into the center of the ironer from the front edge with the aluminum scouring pad facing down and the wax ap up. 6. When the front edge of the wax ap is half way across the in-feed belts press the red off button on the right control panel. The wax cloth should be stopped in the ironer with the front edge of the wax pocket close to the safety gate. 34

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 ap 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 rst roll. 10. 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. 11. Take the wax cloth out of the folder and let it rest and cool for a minute to make it safer to handle. 12. 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. 13. 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. 14. Take the wax cloth out of the folder and let it rest and cool for a minute to make it safer to handle. 15. Move the wax cloth back to the front of the ironer. Position the front edge to the right side of the in-feed and feed the wax cloth again. 16. 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. 17. Take the wax cloth out of the folder and let it rest and cool for a few minutes. When cooled store the wax cloth either on a hanger bar or folded up inside a steel drum. Every 4 hours of operation

1. Wait for the ironer to warm up to at least 270o F (135o C). 2. Set the blower switch to off and set the speed to 10 to 15 ft/min (3 - 6 M/min). 3. Set the Folder to bypass or a waxing program. 4. Lower the rolls by setting all roll switches to down 5. Feed the wax cloth into of the ironer all the way to the right side with the front edge with the aluminum scouring pad facing down and the wax ap up do not add wax. 6. 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.

35

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. When cooled store the wax cloth either on a hanger bar or folded up inside a steel drum.

4.2

Running the Ironer

Proper operation of the IM chest ironer requires intelligence and diligence. One must take time to nd the speed and temperature combinations for the type of goods and moisture retention in their situation. Following is some common guidance:

4.2.1

Cotton Sheets

For these goods the temperature may be run as high as 410o F on the thermal uid units which allows very high processing speeds depending on the weight of the sheets.

4.2.2

Poly-Cotton Blend Sheets

Because of the synthetic ber content, these goods have lower water retention after centrifugal extraction than equivalent cotton at goods. Also, because the melt point of polyester ber can be between 340o F 365o F (170o C 185o C) it is bad practice to run these goods at higher temperatures. If the bers melt they will cause a residue which is difcult to remove.

4.2.3

Dryness

Goods should be considered dry enough coming out of the ironer when they feel dry 5 minutes after folding. This can be veried with a moisture retention test at goods should be dried only to 2% to 4% residual moisture retention. The operator must also understand there will be some inconsistency when drying goods of nonuniform fabric weight (like a mixture of old and new poly-cotton sheets). In these cases you must set up your process (temperature and rate) to accommodate this without damage to the goods or the ironer. Over drying the goods typically causes static cling problems in the folder and melted polyester residue deposits in the chests.

36

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.

4.2.5

Running Small Pieces

For the same reason stated in the previous section it is important to maximize bed coverage when running small pieces. Feeding small pieces in 2 lanes and never moving them around increases wear on the padding in the unused areas of the padding, is an extremely inefcient work practice, causes many other operational problems, and is thus expensive. Doing this will require more man-hours per piece, more BTUs per piece, and reduce the life of your roll padding. If small pieces must be processed and a 2 lane folder is installed, bypassing the folder and having 2 operators feeding 4 lanes (and moving them around) or 3 operators feeding 6 lanes (and moving them around) will reduce the cost associated with running small pieces. On the back end use 2 or 3 people to stack the goods at or folded in half. Additionally, reduce the ironer temperature to 330o F and reduce the speed accordingly so that the goods spend more time in the ironer. This technique will increase your throughput, drastically reduce the average BTUs and man-hours per piece, and increase the output quality and dryness consistency of difcult multilayer goods like pillow cases. A smart laundry manager knows that running the ironer faster and hotter does not always mean more work is being done.

4.2.6

Ironing Speed and Temperature

To determine the appropriate speed and temperature parameters for a given work type, one should rst determine the Moisture Retention of the work being processed. Next is to determine the weight per square yard (or square meter) of the material being processed (this is described further in the Moisture retention instructions on page 13). With these two pieces of information it is a simple matter to consult the Work Rate Chart for a quick answer.

37

Chapter 5 Maintenance
5.1 Wrinkle Patterns

The following gures will help to troubleshoot ironing problems based upon the types of wrinkles left in the atgoods upon exiting the ironer.

38

Figure 5.1: Wrinkle Pattern due to procession or excess roll speed differential

39

Figure 5.2: Wrinkle Pattern due to a slow infeed or too slow feeder speed

40

Figure 5.3: Wrinkle Pattern due the piece being held in the feeder causing the tail to pop forward into the input side of the ironer

41

Figure 5.4: Wrinkle Pattern caused by infeed misalignment (goods catching on the leading edge of the chest) or bridge misalignment

42

Figure 5.5: Wrinkle Pattern caused by residue in the rst chest. This is characterized by wrinkling across the leading edge. There is often a yellow stain at the front edge as well.

43

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 gure 5.6 on page 45). The chests are properly adusted at the factory and normally require no attention. The adjustment procedure is as follows: NOTE: Do not attempt adjustments on this machine if you are not trained and authorized to do so. Follow all lockout and tagout procedures and remove power before servicing this machine.

1. Loosen transport bolts in longitudinal (front-to-back) direction only. The chests can now move freely in one direction. Do not loosen the axial transport bolts at this time. 2. After the ironer has been at temperature for at least 6 hours, tighten the longitudinal bolts so that a gap of about 2mm (.08) remains and then tighten the lock nuts.

5.4

Drive Belt Adjustment

The transmission of power between the drive pulleys and the slip-on gear boxes for the rollers and the in feed conveyor occurs by means of a high-performance V-belt system. The proper adjustment of this V-belt system is an important aspect of avoiding abnormal wear of the belts and to guarantee optimal power transmission. Excessive tensioning of the belts will cause premature wear of the belts and bearings (caused by high radial forces). Insufcient tension will cause premature wear of the belts and a slip between the rollers which will again cause disruption of the procession between the rollers and generally poor ironing performance. The tension of the belts can be adjusted by means of moving the drive motor frame and/or adjusting the tension pulleys. After the initial set-up, the belts are to be checked after 100 operating hours. The deection force must always be measured perpendicular to the belt. The deection is equal to 1 mm. per 100 mm. (i.e. 1/8 per 1 foot) strand length. The deection force and the deection can be easily checked with a tension tester that is available from most auto parts stores. The tension tester consists of a calibrated spring measures on one side 44

Figure 5.6: Chest Alignment

45

Figure 5.7: Drive Belt Deection Tester Table 5.1: Drive Motor to Intermediate Pulley Belt Deection Table Ironer Size Working Width Deection 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 7.8-8.3

the deection and on the other side the deection force. The measured values are indicated on a scale via o-rings. See gure 5.7 on page 46.

1. Slide the lower O-ring on the deection scale to the required value, according to the tables. Set the upper O-ring to the 0 line of the deection force scale. 2. Set the tension tester vertically to the strand in its center. Apply force to the top of the tester so that the adjusted deection value is reached. A steel straight edge should be helpful to read the scale. 3. The upper O-ring has now moved downwards and shows the deection force. Read the value at the upper edge of the O-ring.

46

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 gure 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. Replace cover and restart operation.

5.4.2

Intermediate Pulley to Variable Pulley Tension Adjustment

1. To adjust the belt tension proceed as follows (refer to gure 5.9 on page 49 and the tension chart, table 5.2 on page 48): 47

Table 5.2: Intermediate pulley to Variable pulley belt tension Ironer Size Working Width Belt Size Deection 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 Deection 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. Loosen bolt of idler located swing arm and tighten with the tensioning bolt. 5. Retighten all fasteners. 6. Replace covers and restart operation.

5.4.3

Slip on Gear to Infeed Roll Tension Adjustment

To adjust the belt tension proceeds as follows (refer to the tension chart, table 5.3 on page 48): 1. Move the main power switch to the off position. 2. Remove the rst side cover on the right hand side. 3. The tensioner of the slip-on gear for the in feed roller is now accessible. 4. Loosen the nuts of the torque bar and adjust to required tension. 5. Retighten torque bar. 6. Replace rst cover and restart operation.

48

Figure 5.9: Tensioner Pulley Detail

49

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 gure 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.

50

Table 5.4: Roll to Roll Tension Chart Ironer Size 2x800 3x800 2x1200 3x1200 Belt Size Module Numbers Deection 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

5.4.5

Feed Table Chain Adjustment

To properly tension the infeed belts, locate the access hole on either side of the infeed table (see gure 5.11 on page 51). To tighten the infeed belts, rotate the bolts on both sides clockwise. To loosen the infeed belts, rotate the bolts on both sides counterclockwise.

5.5

Roll Procession Adjustment

The rolls on a multi-roll ironer must rotate at ever increasing rates through the ironer for best quality. This is accomplished by adjusting each rolls speed relative to the previous roll. This speed difference is small but of utmost importance. Too much procession, and the sheets will be overly stretched and guide tapes will be frequently damaged. Too little procession will cause wrinkling of the goods and feeding problems. Adjusting the procession follows these basic steps: 51

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 gure 5.12 on page 52 3. Run the machine so that the rst roll rotates 10 complete times, coming to rest at the mark 4. Move to the proceeding roll and measure the distance from the mark on the frame to the mark on the roll 5. Compare your results to the procession chart in table 5.5 on page 52

To adjust the roll procession: 52

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 ange. 5. Turn outer ange as required in 30 degree (rotate 12 oclock to 1 oclock for 30 degrees of rotation) steps. See gure 5.13 on page 53 6. Line up two threaded holes on outer ange of variable pulley with the grooves on the hub, insert set screws and tighten. 7. Tension the belts by means of the tension idler and tighten all fasteners.

5.6
5.6.1

Roll Padding
Trimming the Roll Padding

The roll padding must be trimmed periodically. More often when a new pad is installed (two to three times a month), less when the padding is aged and settled (once every two months). 53

Figure 5.14: Correct overlap for roll pad trimming Single roll ironers are particularly sensitive to improper padding overlap because they dont have a second roll to press the gap left by the rst 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. If the padding is underlapped, goods will usually show a damp or unpressed strip across the width of the roll. To correct this situation the bed pressure can be increased to accelerate the stretching (and wear) of the roll padding. Padding should be trimmed so that the tail of the last wrap makes 2 perfect layers of padding around the cylinder. It is generally agreed in the industry that the padding should be trimmed back as close as possible to or just before (5-10mm or 0.25-0.5 inches)the overlap point. If the padding is trimmed before the overlap point a very small but generally unnoticeable underlap condition will result. Refer to gure 5.14 on page 54 for correct roll pad overlap.

5.6.2

Roll Pad Discoloration (Yellowing)

The reason pads yellow prematurely is bad chemistry in the washer. The main problems are: 1. Bleach carry over this is caused by too much bleach or lack of rinsing.

54

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. The sour and alkali react in solution to form dissolved salts. This results in salt buildup in the roll padding clogged up padding results in ineffective moisture removal and results in performance problems. To correct, add a rinse and reduce the sour you are dumping in. 3. Final pH too high. the nal pH should be 5.5 to 6.0. This should be checked with a pH indicator a few times a day or once a shift. 4. Over-waxing or use of powdered wax.

5.7

Guide Tape

Functionally, guide tapes help pull material from one chest to the next and to keep goods from sticking to surfaces at transitions in the ironer. They are critical for ironer operation. It is normal to loose or break guide tapes occasionally - they must be continually replaced. Most laundries have maintenance people check the guide tapes (and do other maintenance) every morning before the machine is started up and heated for the day. Excessive tape breakage can be due to: Roll speed differential is too large. Reduce to 0.5%. See adjustment procedure in section 5.5. Guide tapes coming untied use a better knot (see section 5.7.1). Tapes are snagging on a transition edge, check chest and bridge alignment.

5.7.1

Securing Tapes

There is much continuing debate about how to tie guide tapes in an ironer. The preferred method seems to be fusing - where a special tool is used to melt them together however this is not always possible. The widely preferred knot is the square knot (aka reef knot). However modern guide tape materials are somewhat slippery and can allow a properly composed square knot to pull out. Refer to gure 5.15 on page 56 for instructions on tying a proper square knot as well as the more preferred surgeons knot, which is simply a square knot with an extra turn.

55

Figure 5.15: The surgeons 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 ber with a maximum service temperature of 220o C, perfect for high temperature ironing. Polyester (Polyethylene terephthalate) is a very common material, also used in polycotton sheets and other at goods. Polyester typically softens at 338o F (170o C) and should not be used at temperatures much above this. Polyester good for steam heated ironers. Polyester Aramid Blend - Good for steam and thermal uid ironers up to about 380o F (193o C). Nomex (Aramid) - This is the preferred material for all high speed high temperature ironers, particularly for Thermal uid heated ironers operating in excess of 380o F (193o C).

5.7.3

Routing The Guide Tapes

When installing guide tapes they should be routed through the machine as shown in gure 5.16. There are many methods of installing tapes, but the most people prefer to tie new tape to an 56

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

Gearbox Lubrication

Type: Darmex 140 or equivalent Use an SAE 140 (ISO 460) Weight Synthetic Gear Oil for replacement if Darmex 140 is unavailable. Interval: Change the gear oil after the rst 500 hours of operation, then every 2000 hours of operation. Capacity: IM800 - 7 liters (1.85 gal) per roll IM1200 - 12 liters (3.2 gal) per roll Procedure: 1. Move the main power switch to the off position 2. Remove right side covers. 3. Drain oil from gear box while it is still warm. 57

4. Loosen ller cap and ush gear box with ushing 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 0.0100.015 lower than the motor shaft to allow for thermal expansion of the pump body (see formula below). 2. The pump seals must be vented and lled with thermal oil. Remove the vent plug on top of the pump bearing housing and rotate the pump by hand several revolutions or until oil comes out of the vent. If oil does not come out, pour thermal oil into the vent slowly until it is completely full and no air is in the pump bearing housing. Replace the vent plug. 3. After the pump has been at operating temperature for 15 minutes the housing bolts must be retorqued to 30-35 Nm (22-25 ft-lb) to seat the main housing gasket. Failure to perform these procedures will result in premature seal failure. NEVER start the pump motor, even for a few seconds, until this has been done! Pump service procedures can be found in the appendix.

5.7.6

Typical Pump Problems

In normal operation there should be no thermal uid weeping from the leak-off hole in the pump. If there is uid leaking, the pump seals have been damaged. Following is a description of common ways seals are damaged: Mechanical seal failures on this type pump are normally attributable to installation or system operating errors more than true defects in the materials. The normal causes of failure (leaking seals) is misalignment which in turn is caused by: 1. Failure of the installing contractor to set the electric motor high in relation to the pump centerline when all equipment is cold. This thermal offset (0.00000635 x distance in inches from pump foot to pump centerline x thermal uid operating temperature in degrees F) is required so that when the system is hot and operating the pump and motor have the same shaft centerlines and the mechanical seal faces are thus in line and tight. 2. A second cause of mis-alignment is severe pipe stress caused by using the pump as an anchorage point for the discharge pipe and header. (B&C uses exible couplings to eliminate pipe stresses).

58

Figure 5.17: Riello Cleaning diagram 3. Another normal path of failure of the mechanical seal is failure to observe the ll 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. Remove the damper servo gas control arm (B)from the gas buttery cam by unscrewing the standoff post. 2. Remove the damper servo mounting cradle (C) screws. 3. Remove the blower intake cover (A) shown in gure 5.17. 4. You should have access to the inside of the blower cage. It can be easily cleaned from the inside with a shop-vac and a brush. 5. Reinstall the intake cover. 6. Reinstall the damper servo mounting cradle. 7. Reinstall the damper servo gas control arm, making sure it is mounted in the same hole you removed it from.

59

To clean the ame holder and ame 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 buttery (4). 5. Slide the burner head back about 2 inches on the rods (6) and then disconnect the ame sense and ignition electrode connectors. 6. Now slide the burner head back to the end of the rods and then pivot it up as shown in gure 5.18 and insert the retainer pin (9) in the hole. This will hold the burner head up for easier access. 7. Remove the brass test port (8) from the top of the burner this is also the fastener that holds the ame holder assembly (7) in place. See bottom right gure in gure 5.18. 8. Carefully lift (slightly) the ame holder assembly (7) and slide it out of the ame burner body. See bottom right gure in gure 5.18. 9. The ame holder, ame rod, and ignition electrode can now be accessed for easy service and cleaning. 10. Refer to gure 5.18 or the Appendix for more detailed information. 11. Assembly is the reverse of this process.

Figure 5.19 shows the ignition electrode and Flame rod position adjustments. This is a top view of the burner. The ame rod should be 1/8 inch (3 mm) from the face of the ame holder (a.k.a. diffuser plate). The ignition electrode should be 1/8 inch (3 mm) from the back of the ame holder (a.k.a. diffuser plate). This Ignition pilot tube should be 5/16 inch (8 mm) from the back of the ame holder (a.k.a. diffuser plate). See the Appendix for more detailed information.

60

Figure 5.18: Riello burner dissasembly

Figure 5.19: Riello Igniter detail

61

5.8
5.8.1

Thermal Fluid Maintenance

Fluid Life

The thermal uid 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 uid annually. For analysis contact you thermal uid supplier. Remember, the higher the working temperature, the shorter the uid life will be. Careful and conservative laundry managers can potentially have uid life of 2 years or more.

5.8.2

System Cleaning

Most thermal uid suppliers recommend cleaning the system in the ironer with a cleaning solvent when your uid is changed. This is a good practice as it will keep your system of carbon occlusions and other potential problematic foreign material. To clean the system you will in general proceed as follows: 1. Drain the system and clean the lter screen 2. Rell with a system cleaner, purge, and operate according to the suppliers recommendations 3. Drain the system and clean the lter screen 4. Rell with new Thermal Fluid

5.8.3

Fluid Filter Screen

The screen should be checked and cleaned bi-annually. Accumulation of carbon chunks, metal lings, or other abnormal debris can indicate problems before they become catastrophic. We recommend making notes on the condition of the screen in a maintenance log so you can compare results of the inspections. To clean the lter screen rst drain all uid from the system (if changing the uid) or proceed as follows: 1. Cool the ironer to 60C or lower (perform the procedure rst thing in the morning when the machine is cool if possible). 2. Close valves A, B, and C. This isolates the pump and lter screen for service so a minimal amount of uid is lost during the procedure. Refer to the thermal uid system diagram for valve nomenclature details. 3. Remove the plug in the bottom of the lter screen cover and drain the uid into a metal or oil safe plastic container at least 2 gallons in volume. 4. Remove the 4 bolts holding the lter screen cover plate on the bottom of the assembly. 62

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 uid 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.

5.8.4

Pump Service

For pump service instructions and parts information see the thermal uid pump manual in the Appendix. To drain the pump for service proceed as follows: 1. Cool the ironer to 60C or lower (perform the procedure rst thing in the morning when the machine is cool if possible). 2. Close valves A, B, and C. This isolates the pump and lter screen for service so a minimal amount of uid is lost during the procedure. Refer to the thermal uid system diagram for valve nomenclature details. 3. Remove the plug in the bottom of the lter screen cover and drain the uid into a metal oil safe plastic container at least 2 gallons in volume. 4. Service the pump as needed. It is recommended that you also clean the lter screen at this time. 5. Reassemble the pump and reinstall the screen if removed. 6. Double check your work! Is everything assembled properly and sealed? 7. Open valves A, B, and C. Refer to the thermal uid system diagram for valve nomenclature details. 8. Purge the air from the system as described in the Thermal Fluid Filling procedure starting at step 10, found earlier in this manual.

5.8.5

Thermal Fluid Draining

Before draining the thermal uid, make sure you have a container for it. The container size needed will vary with the the particular model of your ironer. To drain the system follow this procedure: 1. Cool the ironer to 60C or lower (perform the procedure rst thing in the morning when the machine is cool if possible). 63

Figure 5.20: Typical thermal pump assembly 2. Close Valve A. 3. Connect a suitable hose barb and hose to the uid 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 ow 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. When no more oil can be pumped out, remove the inline pump from the drain line and connect the ends together. Leave the open hose end in your barrel or container. 8. Close valves A and B. 9. Install a connector for a compressed air line to the bleed port at Valve D and open the valve. 10. Connect 40 psi clean and very dry compressed air supply to this port at Valve D. 11. Double check your connections. You will blow compressed air into the bleed port, this will push most of the oil out of the boiler coils, back through the pump, and out of the drain. 12. Disconnect the air line, close valves D and E, open valves A, B, and C.

5.9

Quarterly Safety System Test

Understanding and regularly testing the safety functions of the ironer is critical to continued safe operation and recognition of potential hazards before they result in accidents. The following sections are intended to be used in conjunction with the IM-Thermal Safety Check List worksheet, shown in tables 5.7 and 5.8. 64

Table 5.7: IM Family Quarterly Safety System Test Log INSPECTION DATE Item Tested By Test Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Infeed Safety Bar LF E-Stop RF E-Stop LR E-Stop RR E-Stop Access Cover Interlocks Electrical Panel Disconnect Main Stop Button Main Temperature Control Temperature limit Control Pump Shutdown Control Temperature High Limit Lockout Temperature High Limit Reset Burner Fault Lamp Burner Remote Fault Reset PS2 operation PS2 setting Nominal High Pressure Reading PS3 operation PS3 setting Nominal Low Pressure Reading / / Startup / / / / / / / /

65

Table 5.8: IM Family Quarterly Safety System Test Log INSPECTION DATE 22 23 Item High Pressure Reading Expansion Tank Valve Handle Switch Line Voltage Main Electrical Ground Connection Pump Current Roll 1 Vacuum Current Roll 2 Vacuum Current Roll Drive Current (rolls down, 100fpm) Control Primary Current Control 24V Secondary Current Control 110V Secondary Current Gas Pressure No Load Gas Pressure High Fire Low Pressure Switch High pressure Switch Blower Pressure Switch LFL Fault Combustion Analysis (annual) Primary Gas Valve Tightness Secondary Gas Valve Tightness Gas Plumbing Leak Check Pilot regulator inspection Lift cylinders Lock pins / / Startup / / / / / / / /

24 25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40 41 42 43 44 45

66

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. 5. Right Rear E-Stop - Test by starting the machine and then pressing the button. The machine must stop. 6. Access Cover Interlocks - Open each cover and make certain that the machine stops when the cover is opened. Tapped, bypassed, or otherwise nonfunctional switches must be corrected. Switches are located on each roll access cover and on the electrical control cabinet. 7. Electrical Panel Disconnect - Check that the disconnect is complete, the switch head is functional and the lockout operates correctly. Check that the trip level of the disconnect is set properly (if equipped) and record the setting. 8. Main Stop Button - Right front panel - Test by pushing the button when the machine is running. All functions of the machine should stop except the pump if the pump mode switch is in the Automatic position. 9. Main Temperature Control - Check that the controls process temperature matches the Limit and Pump shutdown controls within 2o C or 10o F when the machine is warmed up and no goods have been fed for several minutes. Make sure the temperature reading is not jumpy or otherwise unstable. 10. Temperature Limit Control Check that the controls process temperature matches the Main and Pump shutdown controls within 2o C or 10o F. Make sure the temperature reading is not jumpy or otherwise unstable. Make sure that the setpoint cannot be changed by pushing the up and down buttons. 11. Pump Shutdown Control Check that the controls process temperature matches the Limit and Main controls within 2o C or 10o F. Make sure the temperature reading is not jumpy or otherwise unstable. Verify that the pump shuts down when the machine cools below the setpoint. 12. Temperature High Limit Lockout - Unlock the high limit control and change the setpoint to some number below the process temperature or carefully touch a jumper to wire numbers 1 and 102 located on the rear of the control. The machine should lock out the burner operation and the Temperature Limit Lamp must light. Power the machine down with the main branch disconnect (external to the machine) - The machine must remain locked out when power is restored. If the lockout setpoint was changed, restore it to its original valve and relock the control. 67

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. Burner Remote Fault Reset - at the front of the machine press the Burner fault reset button to verify that the fault is cleared and operation of the burner is restored. 16. PS2 (High pressure switch) Operation Slowly Close Valve C in the oil system while the machine is running and the pump is energized. When the High pressure reading drops just below 50 PSI the burner should shut down. After the burner shuts down, open Valve C and verify that the burner operates properly. 17. PS2 High Pressure Switch Setting - Record the setpoint and differential settings indicated on the face of the pressure switch for deadband and threshold. 18. Normal High Pressure Reading Record the high pressure gauge reading when the machine is operated cold (oil below 50o C). This is the gauge next to the high pressure switch. 19. PS3 (Low Pressure Switch) Operation Slowly Close Valve B in the oil system while the machine is running and the pump is energized. When the low pressure reading rises above the setpoint (typically 20 PSI) the burner should shut down. After the burner shuts down, open Valve B and verify that the burner operates properly. 20. PS3 Low Pressure Switch Setting - Record the setpoint and differential settings indicated on the face of the pressure switch for deadband and threshold 21. Normal Low Pressure Reading Record the low pressure gauge reading when the machine is operated cold (oil below 50o C). This is the gauge next to the low pressure switch. 22. High Pressure Gauge reading Record the high pressure gauge reading when the machine is operated cold (oil below 50o C). This is the gauge located in the side panel just downstream from Valve C. 23. Expansion Tank Valve Handle Switch (Valve A) - make sure the warning hang tag is present on the valve. Unlock and close the valve the machine should shut down when the valve is closed. Verify that it will not restart. Open the valve and lock it open verify that the machine restarts normally. 24. Line Voltage - use a reliable calibrated AC Voltmeter to measure the electrical service voltage from L1-L2, L2-L3, L1-L3. Do not measure line to ground. The 3 voltage readings should be within 2%. If an imbalance exists have it corrected immediately. Record the median line voltage. 25. Main Ground Connection - This is a high leakage current device, hence an excellent ground connection is critical. Check the screws securing the PE lug to the main panel using a screwdriver make certain that they are very tight. Using a screwdriver make sure the PE ground conductor from the service is securely tightened into the PE lug. Check the conductor for 68

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. Measurement should be made in the 3 conductors after contactor K5M labeled U5, V5, and W5. The 3 readings should be within 2A of each other if an imbalance exists have it corrected. Record the average of the 3 readings on the sheet. 27. Roll 1 Vacuum Current - While the machine is running and the roll vacuum switch turned on, use a calibrated reliable AC Current clamp meter to measure the operating current in each conductor to the motor. Measurement should be made in the 3 conductors after contactor K2M labeled U3, V3, W3. The 3 readings should be within 1A of each other if an imbalance exists have it corrected. Record the average of the 3 readings on the sheet. 28. Roll 2 Vacuum Current - While the machine is running and the roll vacuum switch turned on, use a calibrated reliable AC Current clamp meter to measure the operating current in each conductor to the motor. Measurement should be made in the 3 conductors after contactor K3M labeled U4, V4, W4. The 3 readings should be within 1A of each other if an imbalance exists have it corrected. Record the average of the 3 readings on the sheet. 29. Roll Drive Current - With the machine a temperature lower than 50C, set the speed reference switch to internal or pot position. Lower the rolls and increase the speed slowly using the potentiometer on the panel to a stable reading of 100fpm or 30.5mpm. Read the roll drive current from the display on the inverter and record it in the log sheet. 30. Control Primary Current While the machine is running and the roll vacuum switch turned on, use a calibrated reliable AC Current clamp meter to measure the operating current at the primary side of the control transformer at RT or ST and record it in the log sheet. 31. Control 24V Secondary Current While the machine is running and the roll vacuum switch turned on, use a calibrated reliable AC Current clamp meter to measure the operating current at the 24V ACH side of the control transformer in the conductor labeled 24VACL and record it in the log sheet. 32. Control 120V Secondary Current While the machine is running and the roll vacuum switch turned on, use a calibrated reliable AC Current clamp meter to measure the operating current at the 120V ACH side of the control transformer in the conductor labeled 120VACL and record it in the log sheet. 33. Gas Pressure No Load - Read the gas pressure on the gauge at the front of the machine when the burner if off. Verify the reading with a manometer if possible and record the pressure in the log sheet. 34. Gas Pressure High Fire - Read the gas pressure on the gauge at the front of the machine when the burner operating at high re. Verify the reading with a manometer if possible and record the pressure in the log sheet. 69

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. The low gas pressure lamp on the front of the ironer should turn off and burner operation should resume. 36. High Pressure Switch - verify operation of the high gas pressure switch by recording its setting in the log sheet and then lowering the setting dial to a pressure below the regulator setting while the burner is operating. When the switch trips the burner should shut down. Restore the switch to its original setting and press the reset button on the switch body, burner operation should resume. 37. Blower Pressure Switch - The blower pressure switch on the burner body should be set according to the procedure in the burner manual at start-up. Record the setting in the log sheet. 38. LFL Fault - While the burner is energized press the fault window in on the Siemens LFL combustion control and verify that the LFLs orange fault lamp lights up and stays on. Press the window again to extinguish the fault lamp and reset the control. If any abnormal operation is observed replace the LFL. 39. Combustion Analysis - it is prudent and required in many locations that a qualied technician perform a combustion analysis on the burner annually to verify safe operation. A combustion analysis must also be performed at start-up and the results recorded in B&Cs IM Family Burner Startup Report worksheet shown in Table 5.9. Initial the log sheet if a proper combustion analysis has been performed. 40. Primary Gas Valve Tightness - This test should be performed by a trained technician following prudent and required safety measures. This test veries that the gas valve is sealing properly. When the test is completed record the result in the sheet. 41. Secondary Gas Valve Tightness - This test should be performed by a trained technician following prudent and required safety measures. This test veries that the gas valve is sealing properly. When the test is completed record the result in the sheet. 42. Gas Plumbing Leak Check - using a rich soap solution or a gas leak test solution, check all joints in the main and pilot gas lines for leaks. Also check the gas gauge line to the front of the machine. Correct any leaks found. 43. Pilot Regulator Inspection - inspect the pilot regulator for body cracks and diaphragm leaks. Inspect the regulator vent line and make sure that it is not clogged and is free owing. If a main regulator is installed on the machine perform the same inspection on it. 44. Lift cylinders - operate the ironer lift cylinders. Make sure they all operate smoothly and evenly with no jerking or sticking. When the rolls are up remove the top air line from each cylinder and check for abnormal air leakage indicating that the lift cylinder piston seals are damaged.

70

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.

71

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. (uA) Delivery Pressure (inWC) Approximate BTU/hr Exhaust Blower Setting:

Pilot

Low Fire

Mid. 1

Mid. 2

Mid. 3

High Fire

72

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 lubricants additive package. For example, lubricants containing rust inhibitors may lose performance after as little as six months in storage. Conversely, some turbine uids 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. Employ a FIFO (First In, First Out) rotation of stored uids to ensure that lubricant storage life is not accidentally exceeded. And, learn how to read the coded date on the container label. Shelf life is based on ideal storage conditions for your uids. Most manufacturers provide a recommended storage procedure to maximize lubricant shelf life. The following conditions have been proven to adversely affect a lubricants storage life: Varying Temperatures Temperature uctuations will cause movement of air between the atmosphere and the head-space of the container (thermal siphoning). For partially full containers, with greater head-space, this air movement is increased. Although the drum is sealed and does not leak lubricant through the bung, a rigid container still inhales air when the temperature drops and exhales as the temperature rises. Along with the air, moisture and small airborne particles enter the oil container possibly leading to degradation of the base stock and additives. Also, water might condense within the drum, drop to the bottom and get pumped to the machine during a top-off. Temperature Extremes Extreme hot or cold can cause chemical degradation. As mentioned earlier, rust inhibitors may suffer signicant performance losses after only six months of normal storage. Depending upon the formulation, a rust inhibitor may have poor solubility in base oils leading to precipitation during storage. This precipitation is greatly accelerated during cold storage. Humid Environment Petroleum-based lubricants are hygroscopic. When exposed to humid air, they naturally absorb airborne moisture. The moisture immediately begins to degrade the additive package and accelerates oxidation of the lubricants base stock once it is put into service.

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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 oclock positions). Ideally, lubricants are stored in the horizontal position on proper storage racks allowing the containers to be rotated and used on a rst-in, rst-out basis Outdoor Storage While indoor storage is recommended, this is not always possible due to environmental, nancial or space constraints. If lubricants must be stored outdoors, track lubricant consumption carefully and replenish inventories just-in-time to minimize exposure to adverse conditions. If lubricants must be stored outside, shelter them from rain, snow and other elements. Lay drums on their sides with the bungs in a horizontal (3 and 9 oclock) position below the lubricant level. This will greatly reduce the risk of the seals drying out and the ingestion of moisture caused by breathing. If the drums must be placed upright in outdoor storage, employ drum covers or tilt drums to drain the moisture that gathers on the top around the bungs. Opened containers Once the seal is broken and the container is put into use, care must be taken to ensure control over contamination ingress. If equipped with a proper pressure relief, bulk tanks should use lter breathers to control contamination ingestion. Drums and pails should be capped when not in use. If your drums are frequently used, bung breather lters may be your best solution.

6.1.3

Eliminate Confusion with Proper Labeling

Lubricant Identication Two common consequences of lubricant mismanagement are cross contamination and lubricant confusion. All drums must be clearly labeled and stenciled to ensure proper product identication. Avoid using labeling methods that are not legible or may wear out over time. Take extra care in the labeling of containers that must be stored outdoors since the elements may damage the label. Color coding labels simplies the process, reducing the risk of misapplication. If a color coding system is employed, be sure alpha or numeric information is also present to account for color blindness.

6.1.4

Clean Delivery

Even when taking the best care possible to store lubricants, they are subject to contamination ingression when lling or topping up systems. Therefore it is absolutely necessary that the lubricant be ltered with an appropriate lter element prior to entering your equipment. Here are some lubricant dispensing tips: Be sure that the proper transfer equipment is being used for the lubricant being dispensed. Whether you are topping up your system directly or lling a smaller portable container, be sure that the lubricant has been ltered. 74

 It is recommended that the oil be cycled through a high efciency lter element with a beta rating matching your equipment requirements. If your storage method exposes the lubricant to moist environments, two-stage ltering with a water absorbing lter element is highly recommended. When transferring lubricants to portable containers, be sure to avoid the use of galvanized containers since the additive in the lubricant may react with the zinc plating, forming metal soaps that clog small openings and orices in industrial machinery. Avoid using open or dirty containers for transfer purposes. Use properly identied, capped containers for low volume transfers.

6.1.5

Conclusion

An effective proactive maintenance program mandates effective storage and delivery of lubricants. Protecting your lubricants, and ultimately your equipment, from the harmful effects of contamination and lubricant degradation begins with proper in-plant storage. To ensure suitable storage of lubricants, containers should be stored indoors in a dry location where temperatures remain moderate at all times. Clearly identify lubricants and machine application to avoid confusion and the misapplication of products. And, be sure that the proper transfer equipment and procedures are employed for that specic lubricant. These simple steps can substantially impact the useful life of your lubricants and your equipment. Ref: Wills, George, Lubrication Fundamentals, Marcel Dekker, Inc., 1980.

75

76

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.com Emergency Telephone: 610-941-4900 Chemtrec (USA): 800-424-9300 Chemtrec (outside USA): 703-527-3887 SECTION 2 HAZARDS IDENTIFICATION

Emergency Overview
Almost water white oil with minimal odor when new. May turn dark and develop characteristic petroleum odor when product is used. Combustible liquid. Potential Health Effects: Eye: Non-irritating to eyes on direct contact before use. Used product may be mildly irritating to eyes. Skin: Non-irritating on direct single or repeated and prolonged contact when new. Repeated or prolonged contact of used product may cause skin irritation. Ingestion: No harmful effects are expected from ingesting unused product or small amounts of used product. Ingestion of used product may cause abdominal discomfort. Inhalation: Exposure to smoke or mist while product is in use may cause irritation to upper respiratory tract and lungs. SECTION 3 COMPOSITION/ INFORMATION ON IN GREDIENTS COMPONENTS Hydrotreated heavy paraffinic distillate SECTION 4 FIRST AID MEASURES Eye: Flush eyes with water. If symptoms persist, seek medical attention. If fluid is hot, treat burns and seek medical assistance. Skin: Wash exposed areas with warm water and soap. If fluid is hot, submerge injured area in cold water. Seek medical attention for severe burns. Ingestion: If abdominal discomfort occurs, seek medical attention. Inhalation: If smoke or mist is generated when fluid is in use, remove victim from exposure. If breathing has stopped or is irregular, administer artificial respiration and supply oxygen if available. If victim is unconscious, remove to fresh air and seek medical attention. CAS NUMBER 64742-54-7 AMOUNT 100%

_____________________________________________________________________
Revision Number: 1 Revision Date: 09/18/07 1 of 4 Paratherm HE

77

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. Avoid spreading burning liquid with water used for cooling purposes. Combustion Products: Airborne solids, liquids, and gases including carbon monoxide, carbon dioxide, and unidentified organic compounds. SECTION 6 ACCIDENTAL RELEASE MEASURES Protective Measures: This material may burn but will not ignite readily. Eliminate all sources of ignition in vicinity of spilled material. Use personal protection recommended in Section 8. Spill Management: Contain release to prevent further contamination of soil, surface water or groundwater. Use appropriate techniques such as non-combustible absorbent materials. Store collected material in a suitable, labeled container. Dispose of contaminated materials in a manner consistent with applicable regulations. If heated material is spilled, allow it to cool to ambient before proceeding with disposal methods. Keep area around hot, spilled material well ventilated. Reporting: Report spills to appropriate local authorities. This product is classified as an Oil under Section 311 of Clean Water Act. Discharge or spills that produce a visible sheen on surface water or in waterways/sewers that lead to surface water must be reported to appropriate authorities. SECTION 7 HANDLING AND STORAGE Precautionary Measures: Product is not hazardous. Use good personal hygiene practices. Fire extinguishers should be kept readily available. Clean up any spill promptly. Storage: Store closed containers away from heat, sparks, open flames, or oxidizing materials. Do not transfer to unmarked containers. Protect metal drums from direct sunlight and water. SECTION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION Exposure Limits: Component: Heavy paraffinic distillate
3

5 mg/m TWA 3 5 mg/m TWA 10 mg/m3 STEL 3 NIOSH: 2500 mg/m IDLH 3 As oil mist if generated: 5 mg/m NOHSC TWA

OSHA PEL: ACGIH TLV:

Engineering Controls: Use in a well-ventilated area Personal Protective Equipment: Eye/Face Protection: Where splashing is possible, wear safety glasses with side shields. Skin Protection: No protection required for short duration exposure to unused fluid. For prolonged or repeated exposure to used fluid, synthetic rubber (nitrile) protective covers (boots, aprons, gloves) may be desirable. If material will be handled while hot, wear insulated clothing. Use good personal hygiene practices before and after fluid handling. Respiratory Protection: No respiratory protection is normally required. If a mist or smoke is generated during use, wear a NIOSH certified organic vapor respirator with a dust and mist filter.

_____________________________________________________________________
Revision Number: 1 Revision Date: 09/18/07 2 of 4 Paratherm HE

78

SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES Appearance: Almost water white before use Odor: none pH: NA Density: 7.18 lb/gal @ 75 F Flashpoint: > 440F Cleveland Open Cup Vapor Pressure: <1mm @70F Vapor Density (Air = 1): >1 Evaporation Rate (BuAc = 1): <1 Boiling Point: >500F Solubility: Insoluble in water. Pour Point: -10F SECTION 10 STABILITY AND REACTIVITY Chemical Stability: Stable under normal storage and handling conditions. Conditions to Avoid: None Incompatibility With Other Materials: May react with strong oxidizing agents. Hazardous Polymerization: Hazardous polymerization will not occur. Hazardous Decomposition Products: None known. SECTION 11 TOXICOLOGICAL INFORMATION Acute Toxicity: Meets IP346 criteria of less than 3% PAH. No other data available. Not known to have any toxic effects. Carcinogenicity: NTP: No IARC: No OSHA: No SECTION 12 ECOLOGICAL INFORMATION Environmental Toxicity: Product is insoluble in water. Aquatic toxicology testing performed in Water Accommodated Fraction (WAF) Invertebrates: Fish: Water Flea (Daphnia magna) 100% survival in WAF Mysid Srhimp (Mysidopsis bahia) 100% survival in WAF Fathead Minnow (Pimphales promelas) 100% survival in WAF

Biodegradability: Product is not expected to be biodegradable SECTION 13 DISPOSAL CONSIDERATIONS Uncontaminated material can be burned for fuel value in an approved facility or can be removed by a licensed waste oil recycler. Used product that has been contaminated with a regulated material may need to be incinerated. Refer to state and local regulations for more detailed information. SECTION 14 TRANSPORT INFORMATION US DOT: Not regulated IATA & IMDG: Not regulated

_____________________________________________________________________
Revision Number: 1 Revision Date: 09/18/07 3 of 4 Paratherm HE

79

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. International Canada (WHMIS): Not controlled This material is listed on the following inventories; Australia (AICS) Canada (DSL) China Europe (EINECS) Korea (Existing and Evaluated Chemical Substances) Philippines (PICCS) Japan (ENCS) SECTION 16 OTHER INFORMATION Recommended Use: Heat transfer agent Date of Revision: 9/18/07 Reason for Revision: New NFPA RATINGS: Health: 0 Flammability: 1 0-Least, 1-Slight, 2-Moderate, 3-High, 4-Extreme Abbreviations that may have been used in this document
TLV STEL IDLH NOHSC < <= Threshold Limit Value Short-term Exposure Limit Immediate Danger to Life and Health Natl Occup. Health & Safety Comm. Less Than Less Than or Equal To TWA PEL CAS TLV > >= Time Weighted Average Permissible Exposure Limit Chemical Abstract Service Number Threshold Limit Value Greater Than Greater Than or Equal To

Reactivity: 0

Prepared according to the OSHA Hazard Communication Standard (29 CFR 1910.1200) and the ANSI MSDS Standard Z400.1). The above information is based on the data of which we are aware and is believed to be correct as of the date hereof. Since this information may be applied under conditions beyond our control and with which we may be unfamiliar and since data made available subsequent to the date hereof may suggest modifications of the information, we do not assume any responsibility for the results of its use. This information is furnished upon condition that the person receiving it shall make his own determination of the _____________________________________________________________________ suitability of the material for his particular purpose. Revision Number: 1 Revision Date: 09/18/07 4 of 4 Paratherm HE

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81

6.3

Shell Thermia MSDS

Material Safety Data Sheet

Thermia Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200

1. MATERIAL AND COMPANY IDENTIFICATION Material Name Uses : : Thermia Oil C Heat transfer oil.

Manufacturer/Supplier

MSDS Request

SOPUS Products PO Box 4427 Houston, TX 77210-4427 USA 877-276-7285

Emergency Telephone Number : 877-242-7400 Spill Information : 877-504-9351 Health Information 2. COMPOSITION/INFORMATION ON INGREDIENTS

The highly refined mineral oil contains <3% (w/w) DMSO-extract, according to IP346. Highly refined mineral oils and additives. 3. HAZARDS IDENTIFICATION Emergency Overview Amber. Dark grey. Liquid at room temperature. Semi-solid at room temperature. Slight hydrocarbon. Not classified as dangerous for supply or conveyance. Not classified as flammable but will burn. Not classified as dangerous for the environment.

Appearance and Odour

Health Hazards Safety Hazards Environmental Hazards Health Hazards Health Hazards Inhalation Skin Contact

: : :

: Not expected to be a health hazard when used under normal conditions. : Under normal conditions of use, this is not expected to be a primary route of exposure. : Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis. : May cause slight irritation to eyes. : Low toxicity if swallowed. : Used oil may contain harmful impurities. : Oil acne/folliculitis signs and symptoms may include formation of black pustules and spots on the skin of exposed areas. Ingestion may result in nausea, vomiting and/or diarrhoea. : Pre-existing medical conditions of the following organ(s) or organ system(s) may be aggravated by exposure to this material: Skin. : Not classified as dangerous for the environment.

Eye Contact Ingestion Other Information Signs and Symptoms

Aggravated Medical Condition Environmental Hazards

82 1/7
Print Date 07/14/2008 MSDS_US

Material Safety Data Sheet

Thermia Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200

Additional Information

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.

4. FIRST AID MEASURES General Information Inhalation Skin Contact : : : Not expected to be a health hazard when used under normal conditions. No treatment necessary under normal conditions of use. If symptoms persist, obtain medical advice. Remove contaminated clothing. Flush exposed area with water and follow by washing with soap if available. If persistent irritation occurs, obtain medical attention. Flush eye with copious quantities of water. If persistent irritation occurs, obtain medical attention. In general no treatment is necessary unless large quantities are swallowed, however, get medical advice. Treat symptomatically.

Eye Contact Ingestion Advice to Physician 5. FIRE FIGHTING MEASURES

: : :

Clear fire area of all non-emergency personnel. Flash point Upper / lower Flammability or Explosion limits Auto ignition temperature Specific Hazards : : Typical 210 C / 410 F (COC) >= 260 C / 500 F (Cleveland Open Cup) Typical 1 - 10 %(V)(based on mineral oil)

: :

Suitable Extinguishing Media Unsuitable Extinguishing Media Protective Equipment for Firefighters

: : :

> 320 C / 608 F Hazardous combustion products may include: A complex mixture of airborne solid and liquid particulates and gases (smoke). Carbon monoxide. Unidentified organic and inorganic compounds. Foam, water spray or fog. Dry chemical powder, carbon dioxide, sand or earth may be used for small fires only. Do not use water in a jet. Proper protective equipment including breathing apparatus must be worn when approaching a fire in a confined space.

6. ACCIDENTAL RELEASE MEASURES Avoid contact with spilled or released material. For guidance on selection of personal protective equipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information on disposal. Observe all relevant local and international regulations. Protective measures : Avoid contact with skin and eyes. Use appropriate containment to avoid environmental contamination. Prevent from spreading or entering drains, ditches or rivers by using sand, earth, or other appropriate barriers. Slippery when spilt. Avoid accidents, clean up immediately. 2/7 Print Date 07/14/2008 MSDS_US

Clean Up Methods

83

Material Safety Data Sheet

Thermia Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200

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. HANDLING AND STORAGE General Precautions : Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. Properly dispose of any contaminated rags or cleaning materials in order to prevent fires. Use the information in this data sheet as input to a risk assessment of local circumstances to help determine appropriate controls for safe handling, storage and disposal of this material. Avoid prolonged or repeated contact with skin. Avoid inhaling vapour and/or mists. When handling product in drums, safety footwear should be worn and proper handling equipment should be used. Keep container tightly closed and in a cool, well-ventilated place. Use properly labelled and closeable containers. Storage Temperature: 0 - 50 C / 32 - 122 F For containers or container linings, use mild steel or high density polyethylene. PVC. Polyethylene containers should not be exposed to high temperatures because of possible risk of distortion.

Handling

Storage

Recommended Materials Unsuitable Materials Additional Information

: : :

8. EXPOSURE CONTROLS/PERSONAL PROTECTION Occupational Exposure Limits Material Oil mist, mineral Oil mist, mineral Source ACGIH ACGIH Type TWA(Mist.) STEL(Mist.) ppm mg/m3 5 mg/m3 10 mg/m3 Notation

Exposure Controls

Personal Protective Equipment Respiratory Protection

: :

The level of protection and types of controls necessary will vary depending upon potential exposure conditions. Select controls based on a risk assessment of local circumstances. Appropriate measures include: Adequate ventilation to control airborne concentrations. Where material is heated, sprayed or mist formed, there is greater potential for airborne concentrations to be generated. Personal protective equipment (PPE) should meet recommended national standards. Check with PPE suppliers. No respiratory protection is ordinarily required under normal conditions of use. In accordance with good industrial hygiene 3/7

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Hand Protection

Eye Protection Protective Clothing Monitoring Methods

: : :

Environmental Exposure Controls

practices, precautions should be taken to avoid breathing of material. If engineering controls do not maintain airborne concentrations to a level which is adequate to protect worker health, select respiratory protection equipment suitable for the specific conditions of use and meeting relevant legislation. Check with respiratory protective equipment suppliers. Where air-filtering respirators are suitable, select an appropriate combination of mask and filter. Select a filter suitable for combined particulate/organic gases and vapours [boiling point >65 C (149 F)]. Where hand contact with the product may occur the use of gloves approved to relevant standards (e.g. Europe: EN374, US: F739) made from the following materials may provide suitable chemical protection: PVC, neoprene or nitrile rubber gloves. Suitability and durability of a glove is dependent on usage, e.g. frequency and duration of contact, chemical resistance of glove material, glove thickness, dexterity. Always seek advice from glove suppliers. Contaminated gloves should be replaced. Personal hygiene is a key element of effective hand care. Gloves must only be worn on clean hands. After using gloves, hands should be washed and dried thoroughly. Application of a non-perfumed moisturizer is recommended. Wear safety glasses or full face shield if splashes are likely to occur. Skin protection not ordinarily required beyond standard issue work clothes. Monitoring of the concentration of substances in the breathing zone of workers or in the general workplace may be required to confirm compliance with an OEL and adequacy of exposure controls. For some substances biological monitoring may also be appropriate. Minimise release to the environment. An environmental assessment must be made to ensure compliance with local environmental legislation.

9. PHYSICAL AND CHEMICAL PROPERTIES Appearance Odour pH Initial Boiling Point and Boiling Range Pour point Dropping point Flash point Upper / lower Flammability or Explosion limits Auto-ignition temperature Vapour pressure Density : Amber. Dark grey. Liquid at room temperature. Semi-solid at room temperature. : Slight hydrocarbon. : Not applicable. : > 280 C / 536 F estimated value(s) : Typical -12 C / 10 F Typical 220 C / 428 F : Typical 210 C / 410 F (COC) >= 260 C / 500 F (Cleveland Open Cup) : Typical 1 - 10 %(V) (based on mineral oil) : > 320 C / 608 F : < 0.5 Pa at 20 C / 68 F (estimated value(s)) : Typical 867 g/cm3 at 15 C / 59 F 4/7 Print Date 07/14/2008 MSDS_US

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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. STABILITY AND REACTIVITY Stability Conditions to Avoid Materials to Avoid Hazardous Decomposition Products : : : : Stable. Extremes of temperature and direct sunlight. Strong oxidising agents. Hazardous decomposition products are not expected to form during normal storage.

11. TOXICOLOGICAL INFORMATION Basis for Assessment Acute Oral Toxicity Acute Dermal Toxicity Acute Inhalation Toxicity Skin Irritation : : : : : Information given is based on data on the components and the toxicology of similar products. Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit Not considered to be an inhalation hazard under normal conditions of use. Expected to be slightly irritating. Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis. Expected to be slightly irritating. Inhalation of vapours or mists may cause irritation. Not expected to be a skin sensitiser. Not expected to be a hazard. Not considered a mutagenic hazard. Product contains mineral oils of types shown to be noncarcinogenic in animal skin-painting studies. Highly refined mineral oils are not classified as carcinogenic by the International Agency for Research on Cancer (IARC). Other components are not known to be associated with carcinogenic effects. Not expected to be a hazard. Used oils may contain harmful impurities that have accumulated during use. The concentration of such impurities will depend on use and they may present risks to health and the environment on disposal. ALL used oil should be handled with caution and skin contact avoided as far as possible.

Eye Irritation Respiratory Irritation Sensitisation Repeated Dose Toxicity Mutagenicity Carcinogenicity

: : : : : :

Reproductive and Developmental Toxicity Additional Information

: :

12. ECOLOGICAL INFORMATION Ecotoxicological data have not been determined specifically for this product. Information given is based on a knowledge of the components and the ecotoxicology of similar products. Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic 5/7 Print Date 07/14/2008 MSDS_US

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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. Mobility : Liquid under most environmental conditions. Floats on water. If it enters soil, it will adsorb to soil particles and will not be mobile. Expected to be not readily biodegradable. Major constituents are expected to be inherently biodegradable, but the product contains components that may persist in the environment. Contains components with the potential to bioaccumulate. Product is a mixture of non-volatile components, which are not expected to be released to air in any significant quantities. Not expected to have ozone depletion potential, photochemical ozone creation potential or global warming potential.

Persistence/degradability

Bioaccumulation Other Adverse Effects

: :

13. DISPOSAL CONSIDERATIONS Material Disposal : Recover or recycle if possible. It is the responsibility of the waste generator to determine the toxicity and physical properties of the material generated to determine the proper waste classification and disposal methods in compliance with applicable regulations. Do not dispose into the environment, in drains or in water courses. Dispose in accordance with prevailing regulations, preferably to a recognised collector or contractor. The competence of the collector or contractor should be established beforehand. Disposal should be in accordance with applicable regional, national, and local laws and regulations.

Container Disposal

Local Legislation

14. TRANSPORT INFORMATION

US Department of Transportation Classification (49CFR) This material is not subject to DOT regulations under 49 CFR Parts 171-180.

IMDG This material is not classified as dangerous under IMDG regulations. IATA (Country variations may apply) This material is not classified as dangerous under IATA regulations. 15. REGULATORY INFORMATION The regulatory information is not intended to be comprehensive. Other regulations may apply to this material. Federal Regulatory Status

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Material Safety Data Sheet

Thermia Oil C MSDS# 61260E Version 10.0 Effective Date 07/08/2008 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200

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.

State Regulatory Status California Safe Drinking Water and Toxic Enforcement Act (Proposition 65) This material does not contain any chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

16. OTHER INFORMATION NFPA Rating (Health, Fire, Reactivity) MSDS Version Number MSDS Effective Date MSDS Revisions MSDS Regulation MSDS Distribution : : : : : : 0, 1, 0 10.0 07/08/2008 A vertical bar (|) in the left margin indicates an amendment from the previous version. The content and format of this MSDS is in accordance with the OSHA Hazard Communication Standard, 29 CFR 1910.1200. The information in this document should be made available to all who may handle the product. The information contained herein is based on our current knowledge of the underlying data and is intended to describe the product for the purpose of health, safety and environmental requirements only. No warranty or guarantee is expressed or implied regarding the accuracy of these data or the results to be obtained from the use of the product.

Disclaimer

7/7 Print Date 07/14/2008 MSDS_US

88

89

6.4

Thermal Fluid Pump

Operating Instructions 1220.8-10 G2

Etanorm SYA
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. It is imperative to keep the operating instructions close to the unit or on the unit itself!

90
KSB Aktiengesellschaft

Etanorm SYA Contents

Page 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 5.3.1 5.3.2 5.4 5.4.1 5.5 5.6 5.7 5.7.1 5.7.2 5.7.3 6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.3 6.3.1 6.3.2 6.4 General 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 Transport and Interim Storage Transport Interim Storage / Preservation Description of the Product and Accessories Technical Specification Designation Design Details Permissible Forces and Moments at the Pump Nozzles Noise Characteristics Accessories Installation at Site Safety Regulations Checks to Be Carried out Prior to Installation Installing the Pump / Unit Aligning the Pump/Drive Place of Installation Connecting the Piping Auxiliary Connections Final Check Contact Guard Connection to Power Supply Connecting the Motor Setting the Time Relay Checking the Direction of Rotation Commissioning, Start-up / Shutdown Commissioning Lubricants Shaft Seal Priming the Pump and Checks to be Carried out Start-up Shutdown Operating Limits Temperature of Medium Handled Switching Frequency Minimum Flow Minimum Permissible Speeds Density of the Medium Handled Shutdown / Storage / Preservation Storage of New Pumps Measures to Be Taken for Prolonged Shutdown Returning to Service after Storage 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 6 6 6 7 7 7 7 7 8 8 9 9 9 9 9 9 9 9 9 9 9 9 10 10 10 10 10 10 10 10 10 10 10 10 7 7.1 7.2 7.2.1 7.2.2 7.3 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.5 7.5.1 7.5.2 7.5.3 7.6 7.6.1 7.6.2 7.6.3 8 9 9.1 9.2 9.3 9.4 Page Maintenance / Repair 11 General Instructions 11 Maintenance / Inspection 11 Supervision of Operation 11 Lubrication and Lubricant Change 11 Drainage / Disposal 11 Dismantling 12 Fundamental Instructions and Recommendations 12 Preparations for Dismantling 12 Pump 12 Mechanical Seal 12 Reassembly 12 Pump 12 Mechanical Seal 13 Tightening Torques 14 Spare Parts Stock 15 Interchangeability of Pump Components 15 Ordering Spare Parts 16 Recommended Spare Parts Stock for 2 Years Operation 16 Trouble-shooting Related Documents General Drawing and List of Components Etanorm SYA, SU 25 Exploded View and List of Components Etanorm SYA, SU 25 General Drawing and List of Components Etanorm SYA, SU 35, 55 Exploded View and List of Components Etanorm SYA, SU 35, 55 17 18 18 19 20 21

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Etanorm SYA Index

Section Page Accessories Admissible ambient temperature Aligning the Pump/Drive Auxiliary connections Bearing temperature Checking the direction of rotation Commissioning Commissioning, start-up Connecting the piping Connection to power supply Contact guard Deep-groove ball bearing Density of the medium handled Description of the product and accessories Design details Designation Diametral clearances Dismantling Disposal Drainage Exploded view, Etanorm SYA, SU 25 Exploded view, Etanorm SYA, SU 35, 55 Final check General General drawing, Etanorm SYA, SU 25 General drawing, Etanorm SYA, SU 35, 55 Grease change Grease quality Inspection Installation at site Installing the pump/unit Interchangeability of pump components Interim storage List of components, Etanorm SYA, SU 25 List of components, Etanorm SYA, SU 35, 55 Lubricant change Lubricant quantity Lubricants Maintenance Measures to be taken for prolonged shutdown Mechanical seal Minimum flow Minimum speed Motor connection Noise characteristics Non-compliance with safety instructions Operating limits Ordering spare parts Permissible forces and moments at the pump nozzles Personnel qualification and training Place of installation Plain bearing Preservation Priming the pump and checks to be carried out PTC-resistor connection 4.6 7.2.1 5.3.1 5.4.1 7.2.1 5.7.3 6.1 6 5.4 5.7 5.6 7.2.2.3 6.2.5 4 4.3 4.2 7.5.1 7.4 7.3 7.3 9.2 9.4 5.5 1 9.1 9.3 7.2.2.2 7.2.2.2 7.2 5 5.3 7.6.1 3.2 6 11 7 9 11 9 9 9 8 9 9 11 10 5 5 5 12 12 11 11 19 21 9 4 18 20 11 11 11 7 7 15 5 Reassembly Recommended spare parts stock Related documents Repair Returning to service after storage Section Page 7.5 7.6.3 9 7 6.4 12 16 18 11 10 4 4 4 4 7 9 10 10 10 10 11 10 10 14 9 5 17 5 5

Safety 2 Safety awareness 2.4 Safety instructions for maintenance, inspection and installation work 2.6 Safety instructions for the operator/user 2.5 Safety regulations, installation 5.1 Shaft seal 6.1.2 Shutdown 6.1.5 Shutdown/storage/preservation 6.3 Start-up 6.1.4 Storage 6.3.1 Supervision of operation 7.2.1 Switching frequency 6.2.2 Temperature of medium handled Tightening torques Time relay Transport Trouble-shooting Unauthorized modes of operation Unauthorized modification and manufacture of spare parts 6.2.1 7.5.3 5.7.2 3 8 2.8 2.7

9.1/9.2 18/19 9.3/9.4 20/21 7.2.2 11 7.2.2 11 6.1.1 9 7.2 6.3.2 7.4.4 6.2.3 6.2.4 5.7.1 4.5 2.3 6.2 7.6.2 4.4 2.2 5.3.2 7.5.1 3.2/6.3 6.1.3 5.7.1 11 10 12 10 10 9 6 4 10 16 6 4 8 12 5/10 9 9

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Etanorm SYA 1 General

Caution
2.2 Personnel Qualification and Training All personnel involved in the operation, maintenance, inspection and installation of the machine must be fully qualified to carry out the work involved. Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question is not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer / supplier to take care of such training. In addition, the operator is responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel. 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. Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the pump and to avoid any risks. These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel called in for installation. This pump / unit must not be operated beyond the limit values specified in the technical documentation for the medium handled, capacity, speed, density, pressure, temperature and motor rating. Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation. (Contact the manufacturer, if required.) The name plate indicates the type series / size, main operating data and works number; please quote this information in all queries, repeat orders and particularly when ordering spare parts. If you need any additional information or instructions exceeding the scope of this manual or in case of damage please contact KSBs nearest customer service centre. For noise characteristics please refer to section 4.5.

2.3 Non-compliance with Safety Instructions Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages. In particular, non-compliance can, for example, result in: - failure of important machine / unit functions - failure of prescribed maintenance and servicing practices - hazard to persons by electrical, mechanical and chemical effects - hazard to the environment due to leakage of hazardous substances.

2 Safety
These operating instructions contain fundamental information which must be complied with during installation, operation and maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible trained personnel / operators prior to installation and commissioning, and it must always be kept close to the location of operation of the machine / unit for easy access. Not only must the general safety instructions laid down in this chapter on Safety be complied with, but also the safety instructions outlined under specific headings. 2.1 Marking of Instructions in the Manual The safety instructions contained in this manual whose nonobservance might cause hazards to persons are specially marked with the general hazard sign, namely

2.4 Safety Awareness It is imperative to comply with the safety instructions contained in this manual, the relevant national health and safety regulations and the operators own internal work, operation and safety regulations.

2.5 Safety Instructions for the Operator / User - Any hot or cold components that could pose a hazard must be equipped with a guard by the operator. - Guards which are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed whilst the machine is operating. - Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to avoid any danger to persons and the environment. Pertinent legal provisions must be adhered to. - Electrical hazards must be eliminated. (In this respect refer to the relevant safety regulations applicable to different countries and/or the local energy supply companies.)

safety sign in accordance with DIN 4844 - W9. The electrical danger warning sign is

safety sign in accordance with DIN 4844 - W8. The word

Caution
is used to introduce safety instructions whose non-observance may lead to damage to the machine and its functions. Instructions attached directly to the machine, e.g. - arrow indicating the direction of rotation - markings for fluid connections must always be complied with and be kept in perfectly legible condition at all times.
4

2.6 Safety Instructions for Maintenance, Inspection and Installation Work The operator is responsible for ensuring that all maintenance, inspection and installation work be performed by authorized, qualified specialist personnel who are thoroughly familiar with the manual. The pump must have cooled down to ambient temperature. Pump pressure must have been released and the pump must have been drained.

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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. Please observe all instructions set out in the chapter on Commissioning before returning the machine to service. 2.7 Unauthorized Modification and Manufacture of Spare Parts Modifications or alterations of the machine are only permitted after consultation with the manufacturer. Original spare parts and accessories authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer for consequential damage. 2.8 Unauthorized Modes of Operation The warranty relating to the operational reliability and safety of the pump / unit supplied is only valid if the machine is used in accordance with its designated use as described in the following sections of these operating instructions. The limits stated in the data sheet must not be exceeded under any circumstances. 3.2 Interim Storage / Preservation When the unit is temporarily put into storage, only the wetted low alloy components (e.g. nodular cast iron JS1025 1), etc.) must be preserved. Commercially available preservatives can be used for this purpose. Please observe the manufacturers instructions for application/removal. The unit / pump should be stored in a dry room where the atmospheric humidity is as constant as possible. If stored outdoors, the unit and crates must be covered by waterproof material to avoid any contact with humidity. Protect all stored goods against humidity, dirt, Caution vermin and unauthorized access! All openings of the assembled unit components are closed and must only be opened when required during installation. All blank parts and surfaces of the pump are oiled or greased (silicone-free oil and grease) to protect them against corrosion.

4
4.1

Description of the Product and Accessories

Technical Specification

3
3.1

Transport and Interim Storage

Transport

Volute casing pumps for heat transfer (DIN 4754) or hot water circulation systems.

Transport of the unit requires proper preparation and handling. Always make sure that the pump or the unit remains in horizontal position during transport and cannot slip out of the transport suspension arrangement. Do not use lifting slings on the free shaft end of the pump or on the motor eyebolt. If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage to property.

4.2

Designation

EN 80 - 160 66 (6239) S Y A Type series Etanorm Pump size, e.g. Actual impeller diameter - 100 mm, e.g. 166 mm = (angular reduction of impeller vanes, e.g. Etanorm 80-160 actual diameter 162/139 mm) = Casing material nodular cast iron JS 1025 1) Heat transfer oil/Hot water variant
1) to EN 1563 = GJS-400-18-LT

4.3 Pump

Design Details

Design: Fig. 3.1-1 Transport of the complete unit

horizontal volute casing pump, single-stage, with ratings and main dimensions to EN 733, with bearing bracket in back pull-out design. Volute casing with integrally cast pump feet, with replaceable casing wear rings. coupling side: impeller side: grease-lubricated deepgroove ball bearing product-lubricated carbon bearing

Bearings:

Shaft seal:

mechanical seal

Fig. 3.1-2 Transport of the pump

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Etanorm SYA
4.4 Permissible Forces and Moments at the Pump Nozzles
t = 20 C FVmax FHmax Mtmax [kN] 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 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 5.43 5.43 6.08 6.16 6.28 7.70 7.70 7.86 7.57 9.50 9.84 9.32 9.23 10.53 10.53 [kN] 2.59 2.51 2.43 2.51 2.43 2.43 2.67 2.67 2.92 2.84 2.67 2.92 3.32 3.24 3.04 3.89 3.89 4.05 4.05 4.74 4.78 4.86 6.28 6.28 6.48 6.16 8.50 8.71 8.10 7.90 9.72 9.72 [kNm] 0.58 0.51 0.51 0.51 0.51 0.51 0.81 0.81 0.58 0.55 1.11 1.11 0.87 0.84 1.16 1.79 1.79 1.62 1.91 2.44 2.44 2.78 3.60 3.60 3.47 3.18 5.10 5.10 4.75 4.63 5.67 5.67
to pumps

4.5

Noise Characteristics
Surface sound pressure level L pA

Etanorm SYA

t = 300 C FVmax FHmax Mtmax [kN] 3.15 3.08 3.11 3.08 3.11 3.11 3.29 3.29 3.64 3.54 3.43 3.64 3.96 3.92 3.82 4.55 4.55 4.69 4.69 5.25 5.32 5.43 6.65 6.65 6.79 6.54 8.21 8.50 8.05 7.97 9.10 9.10 [kN] 2.24 2.17 2.10 2.17 2.10 2.10 2.31 2.31 2.52 2.46 2.31 2.52 2.87 2.80 2.63 3.36 3.36 3.50 3.50 4.10 4.13 4.20 5.43 5.43 5.60 5.32 7.34 7.53 7.00 6.83 8.40 8.40 [kNm] 0.50 0.44 0.44 0.44 0.44 0.44 0.70 0.70 0.50 0.48 0.96 0.96 0.75 0.73 1.00 1.55 1.55 1.40 1.65 2.10 2.10 2.40 3.10 3.10 3.00 2.75 4.40 4.40 4.10 4.00 4.90 4.90
cast iron

Rated power input PN (kW) 0,55 0,75 1,1 1,5 2,2 3,0 4,0 5,5 7,5 11,0 15,0 18,5 22,0 30,0 37,0 45,0 55,0 75,0 90,0 110,0

Pump only 1450 1/min dB 1) 46 48 50 51 53 55 57 58 60 62 63 64 65 67 68 69 70 72 73 74 2900 1/min dB 1) 48 50 52 53 55 57 59 60 62 64 66 67 68 69 71 72 73 74 75 76

Pump with motor 1450 1/min dB 2) 50 52 55 56 58 60 62 63 65 66 68 69 70 71 72 73 73 75 75 76 2900 1/min dB 2) 56 58 60 62 64 66 67 69 70 72 74 75 75 77 77 78 79 80 80 81

1) Measured at a distance of 1 m from the pump outline (to DIN 45 635 part 1 and 24) 2) Measured at a distance of 1 m from the complete unit outline (to DIN 45 635, part 1 and 24)

The values indicated apply JS 1025 3). 3) to EN 1563 = GJS-400-18-LT

made of nodular

The above noise characteristics apply to non-cavitating pump operation in the Qopt. range. 4.6 Accessories

FV FH FH

Drive Surface cooled IEC three phase squirrel cage motor

Caution

FH

1215:6/2

FH FV

When the pump is driven by an electric motor, the motors cooling air must flow in axial direction towards the pump end. Air velocity 3 m/s, measured at the drive side bearing end plate. When the pump is driven by an I.C. engine, only such air-cooled engines shall be used whose cooling air is drawn in and discharged over the coupling/flywheel. Flexible coupling with or without spacer Channel section steel or folded steel plate for the complete unit (pump and motor) in torsion-resistant design

Fig. 4.4-1 Forces and moments at the pump nozzles The following condition must be met:

Coupling Design: Baseplate:

IFVI IFVmaxI

IFHI IFHmaxI

IMtI IMtmaxI

Drive, coupling and baseplate can be supplied by KSB or the operator.

IFVI, IFHI and IMtI are the sums of the absolute values of the respective loads acting on the nozzles. These sums neither take into account the direction of the forces and moments nor their distribution among the nozzles.
6

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Etanorm SYA 5
5.1

Installation at Site
5.3.1 Aligning the Pump/Drive After fastening the baseplate on the foundation, Caution the coupling must be thoroughly checked and the pump set be realigned (at the motor), if required. Prior to checking the alignment/realignment, loosen support foot 183 and re-tighten without transmitting any stresses or strains. Coupling check and realignment must be effected even if pump and motor are supplied completely assembled and aligned on a common baseplate.

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. The test certificate must be kept close to the location of operation for easy access (e.g. foremans office). 5.2 Checks to be Carried out Prior to Installation All structural work required must have been prepared in accordance with the dimensions stated in the dimension table / installation plan. The concrete foundations shall have sufficient strength (min. B 15) to DIN 1045. Make sure that the concrete foundation has set firmly before placing the unit on it. Its surface shall be truly horizontal and even. 5.3 Installing the Pump/Unit After placing the unit on the foundation, align it with the help of a spirit level placed on the shaft/discharge nozzle. The correct distance between the coupling halves as specified in the installation plan must be observed. Shims shall be fitted between the baseplate/foundation frame and the foundation itself; they shall always be inserted to the left and right of the foundation bolts and in close proximity to these bolts. For a bolt-to-bolt clearance of more than 800 mm, additional shims must be inserted halfway between the adjoining holes. All shims must lie perfectly flush.
Shim

Motors with adjusting screw: In order to realign the coupling, first loosen the 4 hex. head bolts on the motor as well as the lock nuts. Turn adjusting screw by hand or by means of an open-jawed wrench until the coupling alignment is correct. Then re-tighten the 4 hex. head bolts and the lock nuts.

Support foot 183

Baseplate

800

Shim

Shim
Hex.head bolt Adjusting screw Lock nut

Foundation bolts

Fig. 5.3-1: Fitting required shims Tighten the foundation bolts evenly and firmly. Baseplates up to 400 mm wide made of channel section steel are torsion-resistant in their own right and need not be grouted. After fastening, baseplates more than 400 mm wide made of folded steel plate must be grouted up to the upper edge via the holes 120 mm) in the folded plate, using low-shrinkage Grout with low-shrinkage concrete.
concrete

Motors without adjusting screw: Differences in height between the pump axis and the motor axis must be compensated by fitting suitable bases. If the pump axis and the motor axis have the same height, both the pump and the motor are mounted directly on the baseplate. To realign the coupling, loosen the four hex. head bolts at the motor. Alignment is adjusted by fitting suitable sheet metal bases ZN 9 under the motor feet until alignment is correct. Then re-tighten the four hex. head bolts.

Support foot

Baseplate

Base

Baseplate faces closed with formwork

Fig. 5.3-2 Grouting the baseplate

96

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 5.4 Connecting the Piping Never use the pump itself as an anchorage point for the piping.

Caution

The piping-induced forces and moments acting on the pump flanges (e.g. due to torsion or thermal expansion) must not exceed the permissible forces and moments specified in section 4.4. The inlet line must be laid with a downward slope towards the pump to avoid the formation of air pockets. The pipelines must be anchored in close proximity to the pump and connected without transmitting any stresses or strains. The pump must not bear the weight of the pipelines. The nominal diameters of short pipelines shall be at least equal to the nominal diameters of the pump nozzles. For long pipelines the most economical nominal diameter has to be determined from case to case.

Gauge

Adapters to larger diameters should have a diffuser angle of approx. 8 in order to avoid any increase in pressure losses. It is recommended to install check and shut-off elements in the system, depending on the type of plant and pump. Thermal expansions of the pipelines must be compensated by appropriate measures so as not to impose any extra loads on the pump. An excessive, impermissible increase in the pipeline forces may cause leaks on the pump where the medium handled can escape into the atmosphere. Danger of life when hot media are handled! The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping. Before commissioning new installations, thoroughly clean, flush and blow through all vessels, pipelines and connections. Often welding beads, scale and other impurities only come off after a certain period of operation. Fit a strainer in the suction line to prevent them from entering the pump. The total cross section of the holes in the strainer shall be three times the cross section of the pipeline in order to avoid excessive pressure loss across the strainer due to clogging. Conical strainers with laid-in wire mesh having a mesh width of 1.25 mm and a wire diameter of 0.4 mm, of corrosion-resistant material, shall be used.

Fig. 5.3-4: Aligning a flexible coupling without spacer sleeve Straight-edge

Gauge Fig. 5.3-5: Aligning a flexible spacer-type coupling The radial and axial deviation between the two coupling halves shall not exceed 0.1 mm. This must also be ensured at operating temperature and under actual inlet pressure.

5.3.2 Place of Installation The volute casing and the discharge cover take on roughly the same temperature as the medium handled. The discharge cover and the bearing bracket must not be insulated. Take the necessary precautions to avoid burns.

1 2 3 4 5

Strainer housing Fine screen Perforated plate Pump suction nozzle Differential pressure gauge

Fig. 5.4-1 Conical strainer for the suction line

97

1211:19/4

Caution

Improper alignment of the unit can cause damage to both the coupling and the unit itself!

Etanorm SYA
5.4.1 Auxiliary Connections The dimensions and locations of the auxiliary connection required for the pump (leakage connection) are indicated on the installation plan or piping layout. This connection is required for proper funcCaution tioning of the pump and is therefore of vital importance! 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. 5.6 Contact Guard In compliance with the accident prevention regulations the pump must not be operated without a coupling guard. If the customer specifically requests not to include a coupling guard in our delivery, then the operator must supply one. 5.7 Connection to Power Supply Connection to the power supply must be effected by a trained electrician only. The applicable DIN VDE regulations 0100 and, for explosionproof units, 0165 shall be complied with. Check available mains voltage against the data on the motor rating plate and select appropriate start-up method. Make sure to observe the technical regulations stipulated by the local energy supply company when connecting the pump to the power supply. We strongly recommend to use a motor protection switch. DIN VDE 0170/0171 stipulates that explosion-proof motors, Ex type of protection IP 54, increased safety EEx, temperature class T3, must always be connected via a motor protection switch. 5.7.1 Connecting the Motor In compliance with DIN VDE 0530 - Part 8, the three-phase motors are always wired for clockwise rotation (looking at the motor shaft stub). The pumps direction of rotation is anticlockwise (looking at the suction flange). For the motors direction of rotation to match the pumps direction of rotation, the motor must be connected as shown in fig. 5.7-1 or 5.7-2, as applicable. D connection (low voltage) If required, connect the PTC resistors as per DIN 44081/ 44082 with the tripping unit in accordance with fig. 5.7.3.

Fig. 5.7-3 Connecting the PTC resistors 5.7.2 Setting the Time Relay Make sure that in the case of three-phase motors with star-delta starting method, switching over from star to delta will be effected at very short intervals. Prolonged switch-over intervals will result in pump damage. Setting of the time relay for star-delta starting: Y time to be set Motor rating < 3 sec. 30 kW < 5 sec. > 30 kW 5.7.3 Checking the Direction of Rotation The direction of rotation of the motor must correspond to the direction indicated by the arrow on the volute casing of the pump (clockwise, when viewed from the motor end). This can be verified by switching the pump on and then off again immediately. If the pump runs in the wrong direction of rotation, interchange any two phases L1, L2 or L3 of the power cable in the motor terminal box.

6
6.1

Commissioning, Start-up / Shutdown

Commissioning Before starting up the pump make sure that the Caution following requirements have been checked and fulfilled. - Make sure that the unit has been properly connected to the electric power supply and is equipped with all protection devices. - Make sure that the pump has been primed with the liquid to be pumped. - Verify the correct direction of rotation. - Make sure all auxiliary lines are connected and functioning. 6.1.1 Lubricants The grease-lubricated deep-groove ball bearing has been packed with grease in the factory. 6.1.2 Shaft Seal See sections 7.4.4 and 7.5.2. 6.1.3 Priming the Pump and Checks to Be Carried out Before start-up, the volute casing, the bearing bracket and the inlet line must be vented and primed with the liquid to be pumped. The pump can be primed with clean liquid from the system through the inlet line. Vent the volute casing by opening the discharge side shutoff valve. Vent and prime the bearing bracket by removing screwed plug 903.3. Rotate the shaft several times by hand during priming to ensure that the bearing bracket is completely vented (fluid escapes). After priming, screw the plug back into the vent hole. Depending on the system pressure and the temperature of the medium handled, hot medium may escape or spurt out as liquid or steam when the vent plug is removed. Danger of scalding! Protect electric components from escaping liquid! Dry-running will result in increased wear and Caution must be avoided!

Fig. 5.7.1 Connection diagram for three-phase motors, D connection Y connection (high voltage)

Fig. 5.7.2 Connection diagram for three-phase motors, Y connection

98

0910:3/2

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. 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. During operation, the pump inlet pressure must fall below the atmospheric pressure. Do not touch the pump, risk of burning! 6.2.4 Minimum Permissible Speeds For pump control systems with continuously variable speed adjustment: nmin = 800 1/min. 6.2.5 Density of the Medium Handled The power input of the pump will increase in proportion to the density of the medium handled. To avoid overloading of the motor, pump and coupling, the density of the medium must comply with the data specified on the purchase order. 6.3 Shutdown / Storage / Preservation Each KSB pump leaves the factory carefully assembled. If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump storage. 6.3.1 Storage of New Pumps - New pumps are supplied by our factory duly prepared for storage. Maximum protection for up to 12 months, if the pump is properly stored indoors. - Store the pump in a dry location. 6.3.2 Measures to Be Taken for Prolonged Shutdown 1. The pump remains installed; periodic check of operation In order to make sure that the pump is always ready for instant start-up and to prevent the formation of deposits within the pump and the pump intake area, start up the pump set regularly once a month or once every 3 months for a short time (approx. 5 minutes) during prolonged shutdown periods. Prior to an operation check run ensure that there is sufficient liquid available for operating the pump. 2. The pump is removed from the pipe and stored Before putting the pump into storage carry out all checks specified in section 7.1. Then apply appropriate preservatives: - Spray-coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative. Spray the preservative through the suction and discharge nozzles. It is advisable to close the nozzles (for ex. with plastic caps or similar). 6.4 Returning to Service after Storage

Caution reached and/or in the event of leakage, switch off

the unit and re-tighten the hex. nuts 920.1 and 920.2. For tightening torques please refer to section 7.5.3. 6.1.5 Shutdown Close the shut-off element in the discharge line. If the discharge line is equipped with a non-return or check valve, the shut-off element may remain open, provided there is back pressure in the line. Make sure the shut-off element in the inlet line is open when switching off the pump. Switch off the drive, making sure that the unit runs smoothly down to a standstill. Depending on the type of installation, the pump should have a sufficient run-down period - with the heat source shut off - until the medium handled has cooled down sufficiently to avoid a heat build-up in the pump. In the case of a prolonged shutdown, the shut-off valve in the inlet line must be closed. Close the auxiliary lines. In the event of frost and/or prolonged shutdowns, the pump (if handling water) must be drained or otherwise protected against freezing. 6.2 Operating Limits 6.2.1 Temperature of the Medium Handled Do not operate the pump at temperatures exCaution ceeding those specified on the data sheet or the name plate. 6.2.2 Switching Frequency To prevent high temperature increases in the motor and excessive loads on the pump, coupling, motor, seals and bearings, the switching frequency must not exceed 15 start-ups per hour (h). 6.2.3 Minimum Flow If the plant configuration is such that the pump might be operated against a closed discharge side valve, a minimum flow of ~ 25 % of Qopt. has to be ensured during this interval.

After the operating temperature has been

Before returning the pump to service carry out all checks and maintenance work specified in sections 7.1 and 7.2. In addition, the instructions laid down in the sections on Commissioning (6.1) and Operating Limits (6.2) must be observed. Upon completion of the work, all safety-related and protective equipment must be properly refitted and/or reactivated before starting the pump set.

10

99

Etanorm SYA 7 Maintenance / Repair

7.2.2 Lubrication and Lubricant Change 7.2.2.1 Lubrication The deep-groove ball bearing is grease-lubricated. For the required quantity refer to section 7.2.2.3. 7.2.2.2 Grease Quality / Grease Change The bearings are packed with high-quality lithium-soap grease. Under normal conditions the fill should last for 15,000 operating hours or 2 years. Under unfavourable operating conditions, e.g. high room temperature, high atmospheric humidity, dust-laden air, aggressive industrial atmosphere etc., the bearings should be checked earlier and cleaned and re-lubricated, if required. Use a high-quality lithium-soap grease, free of resin and acid, not liable to crumble and with good rust-preventive characteristics. The grease should have a penetration number between 2 and 3, corresponding to a worked penetration between 220 and 295 mm/10. Its drop point must not be below 175 C. The bearing cavities must only be half-filled with grease. If required, the bearings may be lubricated with greases of other soap bases. Since greases of differing soap bases must not be mixed, the bearings must be thoroughly cleaned beforehand. The re-lubrication intervals required must then be adjusted to the greases used. 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. Work on the unit must only be carried out with the electrical connections disconnected. Make sure that the pump set cannot be switched on accidentally. Pumps handling liquids posing health hazards must be decontaminated. When draining the medium see to it that there is no risk to persons or the environment. All relevant laws must be adhered to. 7.2 Maintenance / Inspection 7.2.1 Supervision of Operation After partial or complete drainage of the system, top up the bearing bracket as described in section 6.1.3. An insufficiently filled bearing bracket may cause damage to the plain bearing and the mechanical seal.

Caution

Caution

The generally applicable legal provisions for the disposal of lubricants must be adhered to.

Caution

The pump must run quietly and free from vibrations at all times.

7.2.2.3 Deep-groove ball bearings / Lubricant quantity Shaft unit 1) 25 35 55 Code 6305 Z C3 6307 Z C3 6311 Z C3 Lubricant per bearing approx. 5 g approx. 10 g approx. 15 g

The pump must never be allowed to run dry. Max. admissible ambient temperature: 40 C. The bearing temperature may exceed ambient temperature by up to 50 C but must never rise above +90 C (measured on the outside of the bearing bracket). Prolonged operation against a closed shut-off element is not permitted, in order to avoid a heat build-up in the liquid handled. Minimum flow required see 6.2.3. The shut-off element in the suction line must not be closed during operation. The mechanical seal shows only slight or invisible (vapour) leakage during operation. It is maintenance-free. Monitor the suction strainer and clean it whenever it shows signs of clogging, to prevent the development of vacuum in the pumps bearing bracket and thus the risk of dry-running of the bearing and mechanical seal. The outside of the bearing bracket must be kept free from dirt in order to make sure that the heat at the sealing chamber is reduced by the motor cooling air. Any stand-by pumps installed must be switched on and then immediately off again once a week to keep them operational. Attention shall be paid to the correct functioning of the auxiliary connections. 7.3

1) For shaft unit / pump size combinations refer to section 7.6.1.

Caution signs of wear, they must be replaced in due time.

If the flexible coupling elements begin to show

Drainage / Disposal If the pump was used for handling liquids posing health hazards, see to it that there is no risk to persons or the environment when draining the medium. All relevant laws must be heeded. If required, wear safety clothing and a protective mask. The flushing liquid used and any liquid residues in the pump must be properly collected and disposed of without posing any risk to persons or the environment.

100

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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. Pump pressure must have been released and the pump must have been drained. Dismantling and reassembly must always be carried out in accordance with the general drawing/exploded view. 7.4.1 Fundamental Instructions and Recommendations Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original spare parts (see 2.7). Observe the safety regulations laid down in section 7.1. Any work on the motor shall be governed by the specifications and regulations of the respective motor supplier. Dismantling and reassembly must always be carried out in the sequence shown in the exploded views on page 19 or 21. In case of damage please contact KSBs nearest customer service centre (see enclosed directory of addresses). 7.4.2 1 2 3 4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.2.2 5.2.3 5.2.4 Preparations for Dismantling Interrupt power supply. Disconnect all auxiliary supply lines. Remove the coupling guard. Coupling design without spacer sleeve Dismantling of pump unit: Disconnect the motor from the mains supply. Disconnect the motor from the baseplate. Shift the motor to decouple it from the pump. Detach the discharge and suction nozzles from the pipeline. Remove the pump from the baseplate. Volute casing remains on the baseplate and in the pipeline when the unit is dismantled: Disconnect the motor from the mains supply. Disconnect the motor from the baseplate. Shift the motor to decouple it from the pump. Detach support foot 183 from the baseplate and undo hex. nut 920.1 on the discharge cover. Pull the bearing bracket with discharge cover and cpl. rotor out of the casing (back pull-out unit). Spacer type coupling design Dismantling the pump unit: Disconnect the motor from the mains supply. Remove the coupling spacer. Detach the discharge and suction nozzles from the pipeline. Remove the pump from the baseplate. Volute casing remains on the baseplate and in the pipeline when the unit is dismantled: Disconnect the motor from the mains supply. Remove the coupling spacer. Detach support foot 183 from the baseplate and undo hex. nut 920.1 on the discharge cover. Pull the bearing bracket with discharge cover and cpl. rotor out of the casing (back pull-out unit). On larger pumps suspend or support the bearing bracket end in order to prevent the back pullout unit from tilting. After a prolonged period of operation the individual components may be hard to pull off the shaft. If this is the case, use a brand name penetrating agent and/or - if possible - an appropriate pull-off device.

Caution

Under no circumstances use force.

7.4.3 Pump The pump shall be dismantled in the sequence given in the exploded views shown on page 19 or 21, respectively. We recommend to place a drip pan under the whole length of the pump, which collects the medium flowing out during dismantling. The generally applicable legal provisions for disposal must be adhered to! When replacing joint rings 411.3 and 411.4 made of CrNi graphite, please note that the supporting material consists of a thin CrNi metal foil (see fig. 7.4-1) which may cause cutting injuries. Always remove these joint rings with suitable tools, taking adequate precautions.

Caution

Graphite

Metal foil

Fig. 7.4-1 Joint ring with metal foil

7.4.4 Mechanical seal In order to replace the mechanical seal, the pump must be dismantled.

7.5 Reassembly 7.5.1 Pump The pump must be reassembled in accordance with the rules of sound engineering practice. Reassembly shall be effected in the reverse order of dismantling. Make sure to reassemble the pump in the correct sequence.

12

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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, 7.5-3) Etanorm SYA, SU 55
Cover plate 400 210
1)

Etanorm SYA SU 25 1)

360 321
1215:8

330

Fig. 7.5-3 Mounting the deep-groove ball bearing SU 55 1)

1)

For shaft unit/pump size combinations see 7.6.1

Caution

Replacing the plain bearing

Cover plate
1211:117

- Removing the shaft and the plain bearing Remove shaft 210 from bearing bracket 330 towards the coupling. Press plain bearing 310 out of the bearing bracket. - Mounting the plain bearing Carefully press plain bearing 310 into bearing bracket 330 up to the stop.
Maximum clearance at plain bearing: As-new clearance at plain bearing:

Fig.7.5-1 Mounting the deep-groove ball bearing,shaftunit 251)

1) For shaft unit/pump size combinations see section 7.6.1

Etanorm SYA, SU 35 1)
Cover plate 400 210

SU 25 1) SU 35, 55 1)

0.35 mm 0.4 mm

0.08 - 0.13 0.08 - 0.13

- If the sealing area between the impeller neck and the casing wear ring is worn, causing an excessive sealing clearance 0.9 mm, the casing wear rings (502.1 and 502.2, if fitted) must be replaced. The as-new clearance between casing wear ring and impeller is 0.3 mm on diameter.
1)

For shaft unit/pump size combinations see 7.6.1

360 321
1215:7

7.5.2

Mechanical seal

330

Fig. 7.5-2 Mounting the deep-groove ball bearing SU 35 1)

1) For shaft unit/pump size combinations see 7.6.1

Reassembly is effected in reverse order to dismantling. The following rules shall be observed when mounting the mechanical seal: Extreme care and cleanliness. The protective wrapping of the contact faces must only be removed immediately before assembly takes place. Take care not to damage the seal faces and the O-rings. Clean the shaft and the seat ring holder and carefully remove any deposits.

102

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Etanorm SYA
7.5.3 Tightening Torques 7.5.3.1 Pump
G

1215:5/2

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 / 920.2 920.3 Thread size [mm] M8 M 10 M 12 M 10 M 12 M8 M 10 M 12 x 1,5 M 24 x 1,5 M 30 x 1,5 Tightening torque 1) MA [Nm] 20 - 25 30 - 35 40 - 50 30 - 35 40 - 50 20 - 25 30 - 35 20 - 50 60 - 170 80 - 280 A B Thread size [mm] M12 M16 M20 M12 Tightening torque 1) MA [Nm] 20 - 30 30 - 75 50 - 145 20 - 30

Motor on baseplate Position Thread size [mm] M6 M8 M10 M12 M16 M20 M24 M24 x 1.5 Tightening torque 1) MA [Nm] 5 - 10 5 - 10 10 - 15 20 - 30 30 - 75 50 - 145 75 - 250 75 - 250

C 7.5.3.2 Pump/Motor Assembly D

Coupling and coupling guard Position F G Fig. 7.5-5 Bolt tightening points, pump unit Thread size [mm] M6 M6 M8 M10 Tightening torque 1) MA [Nm] 5 - 10 13 18 44

1) for unlubricated threads

14

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Etanorm SYA
7.6 Spare Parts Stock 7.6.1 Interchangeability of Etanorm SYA, Etabloc SY, Etaline SY Components and Interchangeability of Component Parts
Bearing housing 2) Bearing bracket 1) Casing wear ring suction side 502.1 1 1 1 1 1 1 2 O 2 2 3 3 3 4 4 4 5 5 6 6 6 6 7 7 7 7 8 8 8 8 9 9 Bearing cover 1) Discharge cover Mechanical seal Support foot 1) Casing wear ring discharge side X 3 3 3 3 10 3 3 10 13 3 3 10 11 5 5 13 11 5 11 11 11 11 11 11 11 O O 12 12 12 X 502.2 15 Description Deep-groove ball bearing 1) Volute casing Plain bearing Seat ring holder 1) 476 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 2 2 3 3 3 3

Etanorm SYA

Etabloc SY

Etaline SY

Shaft unit

Part No. 102 163 183 210 230 310 321 330 350 360 433 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 2 2 3 3 3 3 471 1 1 1 1 1 1 1 1 1 1 1 1

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

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/..

40-160/.. 40-200/.. 50-160/.. 50-200/.. 65-160/.. 65-200/..

50-160/.. 50-200/..

80-160/.. 80-200/..

65-160/.. 65-200/..

100-160/..

80-160/..

100-170/..

O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O

1 1 2 1 2 3 1 2 3 O 1 2 3 7 4 O O 7 4 5 6 7 5 5 6 7 O O 8 9 8 10

1 2 3 2 3 4 2 3 4 7 3 3 4 7 3 4 5 7 4 O 5 6 5 5 7 6 6 6 9 8 9 8

1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 2 2 3 3 3 3

O 1 2 1 2 O O O O O O O O O O O O O O O O O O O O O O O O O O O

O O O O O 2 O O 2 3 O O 2 3 O O 3 3 O 3 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 2 2 3 3 3 3

1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 2 2 3 3 3 3

1 1 1 1 1 1 1

1 1

1 1

1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 2 2 3 3 3 3

1) Etanorm SYA only 2) Etabloc SY/Etaline SY only

1 1

Same number means same component

Components differ

Component not fitted

104

Seal cover 2)

Shaft 1)

Impeller

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 Number of pumps (including stand-by pumps) 2 3 4 5 6 and 7 8 and 9 10 and more Quantity of spare parts 1 1 1 2 2 2 20 % 1 1 1 2 2 2 20 % 1 1 2 2 3 4 100 % 1 2 off 1 1 2 2 2 3 25 % 1 1 1 2 2 2 20 % 4 6 8 8 9 12 150 %

210 230 321 330 433 502.1 -

Shaft Impeller (incl. casing wear ring 502.2) Deep-groove ball bearing Bearing bracket cpl. 1) Mechanical seal Casing wear ring Gaskets / Joint ring (set) 2)

1) Bearing bracket 330, cpl., including Part No. 210 310 321 330 360 411.1 412.1/.2 433 Description Shaft Plain bearing Deep-groove ball bearing Bearing bracket Bearing cover Joint ring O-ring Mechanical seal Part No. 476 550.1/.2/.3 901.1 903 916 920.3 930 932.1/.2 Description Seat ring holder Disc Hex. head bolt Screwed plug Plug Hex. nut Spring washer Circlip

2) Gasket / Joint ring (set), consisting of: Part No. 400 411.1/.3/.4 Description Gasket Joint ring

16

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Etanorm SYA 8 Trouble-shooting

Vibrations during pump operation Excessive rise of temperature inside the pump

Pump delivers insufficient flow rate Motor is overloaded Excessive pump discharge pressure

Increase in bearing temperature Leakage at the pump Excessive leakage at the shaft seal

* * * * * * * * * *

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. 2) Increase the speed (turbine, I.C. engine) Pump or piping are not completely vented or primed. Vent and/or prime. Clean vent hole. Supply line or impeller clogged. Remove deposits in the pump and/or piping. Formation of air pockets in the piping. NPSH available (positive suction head) is too low. Alter piping layout. Fit a vent valve. Check/alter liquid level. Install pump at a lower level. Fully open shut-off valve in the suction line. Change suction line, if the friction losses in the suction line are too high. Check any strainers installed. Observe permissible rate of pressure fall. Interchange two of the phases of the power supply cable. Increase speed. 2) Replace worn components by new ones.

* * * * * * * * * * * * * * * *

Reverse rotation. Speed is too low.

* *

Wear of internal pump parts.

Pump back pressure is lower than specified in the pur- Adjust duty point accurately. chase order. In case of persistent overloading, turn down impeller, if necessary. 2). Density or viscosity of the fluid pumped is higher than 2) stated in the purchase order. Speed is too high. Reduce speed. 2) Defective gasket. Replace the gasket between the volute casing and the discharge cover. Fit new shaft seal. Re-align.

* * * * *

Worn shaft seal. The unit is misaligned. Pump is warped or sympathetic vibrations in piping.

Check pipeline connections and secure fixing of pump; if required, reduce the distances between the pipe clamps. Fix the pipelines using anti-vibration material. Increased axial thrust. 2) Clean the balancing holes in the impeller. Replace the casing wear rings. Insufficient or excessive quantity of lubricant or unsuitable Top up, reduce or change lubricant. lubricant. Non-compliance with specified coupling distance. Correct distance according to the installation plan. Motor is running on two phases only. Replace the defective fuse. Check the electric cable connections. Clean the impeller. / Re-balance the impeller. Fit new bearings. Increase the minimum rate of flow.

* * * *

Rotor is out of balance. Defective bearings. Insufficient rate of flow.

1) The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. 2) Contact KSB.

106

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Etanorm SYA 9
9.1

Related Documents
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/.2

Description Joint ring O-ring Mechanical seal Seat ring holder Ring Casing wear ring Disc Hex. head bolt Stud with reduced shank

Part No. 903.1/.2/.3 916 920.1-/.3 930 932.1-/.3 940.1/.2 99-20 1M 6B 6D 8B

Description Screwed plug Plug Hex. nut Spring washer Circlip Key Repair kit Pressure gauge connection Medium drain Medium venting Leakage drain

18

107

Etanorm SYA
9.2 Exploded View and List of Components of Etanorm SYA, SU 25 1)

330 210 102 102 411.5 502.1 902.1 903.2 920.1 210 550.3 920.3 930 940.1/.2 310 321 360 411.1 412.1/.2 433 476 550.1/.2 901.1 903.3 916 932.1/.2 330

502.1 902.1 920.3

930 230 550.3 502.2 230 502.2

411.4

932.3 550.4 500 500 550.4 932.3

163

163 902.2 920.2 920.1 411.3 310

411.5 903.2

903.3 411.1 6D

901.1

6D 1M

8B 902.2 920.2

901.2 183

411.5 903.2 412.1/2 550.3 920.3 930 932.1/.2

6B

1215 : 14/6

99-20 210 550.3 920.3 930 940.1/.2 476 940.2 433 412.2 412.1 550.1 932.1 932.2

940.1

210

321

550.2

360

1)

For shaft unit / pump size combinations refer to section 7.6.1.

Part No. Description 102 163 183 210 230 310 321 330 360 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/.2

Description Joint ring O-ring Mechanical seal Seat ring holder Ring Casing wear ring Disc Hex. head bolt Stud with reduced shank

Part No. 903.1/.2/.3 916 920.1-/.3 930 932.1-/.3 940.1/.2 99-20

Description Screwed plug Plug Hex. nut Spring washer Circlip Key Repair kit

108

19

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 102 163 183 210 230 310 321 330 360 Volute casing Discharge cover Support foot Shaft Impeller Plain bearing Deep-groove ball bearing Bearing bracket Bearing cover

Part No. 400 411.1/.3/.4/.5 412.1/.2 433 476 500 502.1/.2 2) 550.1/.2/.4/.5 901.1/.2

Description Gasket Joint ring O-ring Mechanical seal Seat ring holder Ring Casing wear ring Disc Hex. head bolt

Part No. 902.1/.2 903.1/.2/.3 920.1-/.3 930 932.1/.3/.4 940.1/.2 99-20 1M 6B 6D 8B

Description Stud with reduced shank Screwed plug Hex. nut Spring washer Circlip Key Repair kit Pressure gauge connection Medium drain Medium venting Leakage drain

20

109

Etanorm SYA
9.4 Exploded View and List of Components of Etanorm SYA, SU 35, 55 1)

330 210 102 102 411.5 502.1 902.1 903.2 920.1 210 920.3 930 940.1/.2 310 321 360 400 411.1 412.1/.2 433 476 550.1/.2 901.1 902.2 903.3 920.2 932.1 330

502.1 902.1 920.3

930 230 230 502.2 502.2

411.4

932.3 550.4 500 500 550.4 932.3

163

3)

411.5 903.2

920.1 310 411.3 903.3 411.1

6D

6D 1M

902.2 920.2

8B

901.2 183

411.5 903.2 412.1/.2 920.3 930 932.1/.4

1215 : 17/6

99-20 932.4 210 920.3 930 940.1/.2 550.5 940.2

2) 2)

6B

476 433 412.2 412.1

550.1 932.1

400

360

940.1

210

321

550.2

901.1

1) For shaft unit / pump size combinations refer to section 7.6.1 2) Only on Etanorm SYA, shaft unit 55 3) Not fitted on pump size 150-400.1

Part No. Description 102 163 183 210 230 310 321 330 360 Volute casing Discharge cover Support foot Shaft Impeller Plain bearing Deep-groove ball bearing Bearing bracket Bearing cover

Part No. 400 411.1/.3/.4/.5 412.1/.2 433 476 500 502.1/.2 550.1/.2/.4/.5 901.1/.2

Description Gasket Joint ring O-ring Mechanical seal Seat ring holder Ring Casing wear ring Disc Hex. head bolt

Part No. 902.1/.2 903.1/.2/.3 920.1-/.3 930 932.1/.3/.4 940.1/.2 99-20

Description Stud with reduced shank Screwed plug Hex. nut Spring washer Circlip Key Repair kit

110

21

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. w i t h drive)! Example

Long-coupled pump Close-coupled version __________________________________________________________________________

Manufacturers Declaration
as per EC directive Machinery 98/37/EC Please note: The manufacturers declaration is only valid for pumps w i t h o u t drive. Commissioning is prohibited until evidence has been submitted that the drive the pump is to be assembled with complies with the provisions of EC directive 91/368/EEC. Commissioning is always subject to a declaration of conformity, in combination with the CE symbol, which has to be issued by the party assembling the pump with another machine. Example

Long-coupled pump
22

Close-coupled version

111

Bl. 1 0045.009-90

Konformittserklrung EC declaration of conformity Dclaration CE de conformit Declaracin de conformidad Declarao CE de conformidade Dichiarazione CE di conformit EG-verklaring van overeenstemming EU-overensstemmelseserklring Samsvarserklring EG-frskran om verensstmmelse Vaatimustenmukaisuusvakuutus

Hiermit erklren wir, da das Pumpenaggregat Herewith we declare that the pump unit Par la prsente, nous dclarons que le type de groupe moto-pompe Por la presente declaramos que el grupo Com a presente, declaramos que o grupo moto-bomba Si dichiara che il modello del gruppo di pompaggio Hiermee verklaren wij, dat het pompaggregaat Hermed erklres, at pumpetype Herved erklrer vi at pumpeaggregatet Hrmed frskrar vi att pumpaggregatet Vakuutamme, ett pumppukoneikko

Etanorm SYA
folgenden einschlgigen Bestimmungen in der jeweils gltigen Fassung entspricht: complies with the following relevant provisions as applicable in their current version: correspond aux dispositions pertinentes suivantes dans la version respective en vigueur: es conforme a las disposiciones siguientes en su redaccin vigente: est em conformidade com as disposies pertinentes, a sabe na sua verso corrente: conforme alle seguenti disposizioni pertinenti nella versione valida al momento: voldoet aan de huidige versie van de volgende bepalingen: er i overensstemmelse med flgende bestemmelser til en hver tid gyldig udgave: er i henhold til den til enhver tid gjeldende utgave av flgende EU-direktiv: r tillverkad i verensstmmelse med vastaa seuraavia mryksi kulloinkin voimassa olevassa muodossa:

EU- Richtlinie 98/37/EG Maschinen, Anhang II A, EU- Richtlinie 89/336/EWG Elektromagnetische Vertrglichkeit, Anhang I und EU- Richtlinie 73/23/EWG Niederspannungsrichtlinie, Anhang III B Machinery directive 98/37/EC, Annex II A, electromagnetic compatibility directive 89/336/EEC, Annex I and EC directive on low- voltage equipment 73/23/EEC, Annex III B La directive CE relative aux machines 98/37/CE, Annexe II A, directive CE relative la compatibilit lectromagntique 89/336/CEE, Annexe I et directive CE relative la basse tension 73/23/CEE, Annexe III B Las directrices de la CE 98/37/CE Maquinaria, anexo II A, 89/336/CEE Compatibilidad electromagntica, anexo I y 73/23/CEE Directriz de bajo voltaje, anexo III B Directiva CE mquinas 98/37/CE, Anexo II A, directiva CE compatibilidade electromagntica 89/336/CEE, Anexo I e la directiva sobre equipamento de baixa voltagem 73/23/CEE, Anexo III B Direttiva CE 98/37/CE relativa a macchinari, Appendice II A, direttiva CE 89/336/CEE relativa a compatibilit elettomagnetica, Appendice I e la Direttiva 73/23/CEE relativa a bassa tensione, Appendice III B

112

23

Bl. 2 0045.009-90

Machine- richtlijn 98/37/EG, Bijlage II A, de richtlijn 89/336/EEG i.v.m. elektromagnetische compatibiliteit, Bijlage I en de laagspanningsrichtlijn 73/23/EEG, Bijlage III B EU- lovgivning om maskiner 98/37/E F, Bilag II A, elektromagnetisk kompatibilitet 89/336/E F, Bilag I og EU- lovgivningen om elektrisk materiel for visse spndingsgrnser 73/23/E F, Bilag III B EU- direktiv 98/37/EG maskiner, vedlegg II A, 89/336/EWG elektromagnetisk kompatibilitet, vedlegg I og EU- direktiv 73/23/EWG lavspenningsdirektivet, vedlegg III B EG:s maskindirektiv 98/37/EC, Annex II A, Elektromanetisk kompatibilitet (EMC) 89/336/EEC, Annex I Lgspnningsdirektiv 73/23/EEC, Annex III B EU- direktiivin 98/37/ETY, liite II A,

EU- direktiivin 89/336/ETY Shkmagneettinen yhteensopivuus liite I ja EU- direktiivin 73/23ETY Matalajnnitedirektiivi, liite III B mukaan

Angewendete harmonisierte Normen, insbesondere Applied harmonized standards, in particular Normes harmonises utilises, notamment Normas concordantes aplicadas; en especial Normas harmonizadas utilizadas, em particula Norme armonizzate applicate, in particolare Gebruikte geharmoniseerde normen, in het bijzonder: De harmoniserde standarder, der er blevet anvendt, er i srdeleshed Anvendte harmoniserte normer, spesielt Tillmpade harmoniserade standarder, speciellt Sovelletut, harmonisoidut normit, erityisesti EN 809, EN 292-1, EN 292-2 EN 50081-1, EN 50081-2, EN 50082-1, EN 50082-2 Angewendete nationale technische Normen und Spezifikationen, insbesondere Applied national technical standards and specifications, in particular Normes et spcifications techniques nationales qui ont t utilises, notamment Normas y especificaciones tcnicas nacionales aplicadas; en especial Normas e especificaes nacionais utilizadas, em particular Norme e specifiche tecniche nazionali applicate, in particolare Gebruikte nationale technische normen en specificaties, in het bijzonder: De nationale normer og tekniske specifikationer, der er blevet benyttet, er Anvendte nasjonale tekniske normer og spesifikasjoner, spesielt Tillmpade nationella tekniska standarder och specifikationer, speciellt Sovelletut kansalliset tekniset normit, erityisesti

KSB Aktiengesellschaft
Leiter Produktentwicklung - Einstufige Pumpen Industrietechnik Unternehmensbereich Pumpen Industrie und Verfahrenstechnik KSB Aktiengesellschaft, Bahnhofsplatz 1, D91257 Pegnitz
24

113

Bl. 1 0045.003-90

Erklrung des Herstellers im Sinne der EU- Maschinenrichtlinie 98/37/EG, Anhang II B Declaration by the manufacturer as defined by machinery directive 98/37/EC Annex II B Dclaration du fabricant conformment la directive CE relative aux machines 98/37/CE, Annexe II B Declaracin del fabricante conforme con la Directiva CE sobre mquinas 98/37/CE, Anexo II B Declarao do Fabricante segundo directiva CE 98/37/CE, Anexo II B Dichiarazione del fabbricante ai sensi della direttiva CE 98/37/CE relativa a macchinari, Appendice II B Verklaring van de fabrikant inzake richtlijn 98/37/EG, voor machines, bijlage II B Fabrikantens erklring i henhold til EU- lovgivning om maskiner 98/37/EU, bilag II B Erklring fra produsent iflge EUs- maskindirektiv 98/37/EC, vedlegg II B Tillverkardeklaration enligt EU:s Maskindirektiv 98/37/EC, Annex II B Valmistajanvakuutus EU- konedirektiivin 98/37/ETY mukaan, Liite II B Hiermit erklren wir, da die Pumpe Herewith we declare that the pump Par la prsente, nous dclarons que la pompe Por la presente, declaramos que la bomba Com a presente, declaramos que a bomba Si dichiara che la pompa Hiermee verklaren wij, dat de pomp Hermed erklres, at pumpetype Hermed erklrer vi, at pumpen Hrmed frskrar vi att pumpen Vakuutamme, ett pumppu

Etanorm SYA
zum Einbau in eine Maschine 1) / Zusammenbau mit anderen Maschinen zu einer Maschine 1) bestimmt ist. Ihre Inbetriebnahme ist solange untersagt, bis festgestellt wurde, da die Maschine, in die diese Pumpe eingebaut werden soll, bzw. mit der diese Pumpe zusammengebaut werden soll, den Bestimmungen der EU-Richtlinie in der jeweils gltigen Fassung entspricht. is intended to be incorporated into machinery 1) or assembled with other machinery to constitute machinery 1) covered by this directive and must not be put into service until the machinery into which it is be incorporated or with which it is to be assembled has been declared in conformity with the provisions of the directive in its current version. est destine tre incorpore dans une machine 1) / tre assemble avec dautres machines afin de constituer une machine 1) et que sa mise en service est interdite avant que la machine dans laquelle elle sera incorpore / avec laquelle elle sera assemble nait t dclare conforme aux dispositions de la directive, dans la version respective en vigueur. est destinada a ser incorporada en una mquina 1) /a ser ensamblada con otras mquinas para conformar una mquina 1) y que su puesta en servicio est prohibida antes de que la mquina en la que vaya a ser incorporada o con la que vaya a ser ensamblada haya sido declarada conforme con las disposiciones de la Directiva en su redaccin vigente. se destina a ser instalada numa mquina 1) / ser montada com outras mquinas de modo a formar uma mquina 1) coberta por esta directiva e que proibida a colocao em servio da mesma antes de a mquina em que essa bomba vier a ser incorporada/montada ser declarada em conformidade com o disposto na directiva CE na sua verso corrente. destinata al montaggio in una macchina 1) / allassemblaggio con altre macchine a formare un macchinario 1) e che la sua messa in marcia vietata fin quando non sar stata accertata la conformit del macchinario, nel quale questa pompa viene montata o col quale detta pompa deve venir assiemata, alle disposizioni delle direttiva CE nella versione valida al momento. ertoe bestemd is, ingebouwd te worden in een machine 1) / samengebouwd wordt met andere machines tot n machine 1) en dat het in gebruik stellen verboden is, voordat vastgesteld is, dat de machine, waarin deze pomp wordt ingebouwd, in overeenstemming met de bepalingen van de richtlijn is. er bestemt til indbygning i en maskine 1) / samling med andre maskiner med henblik p at udgre en maskine 1) og at igangstningen forbydes indtil det er konstateret, at maskinen, som vor pumpe skal monteres i, svarer til EU-bestemmelserne af EU-lovgivningen til en hver tid gyldig udgave.

114

25

Bl. 1 0045.003-90

Erklrung des Herstellers im Sinne der EU- Maschinenrichtlinie 98/37/EG, Anhang II B Declaration by the manufacturer as defined by machinery directive 98/37/EC Annex II B Dclaration du fabricant conformment la directive CE relative aux machines 98/37/CE, Annexe II B Declaracin del fabricante conforme con la Directiva CE sobre mquinas 98/37/CE, Anexo II B Declarao do Fabricante segundo directiva CE 98/37/CE, Anexo II B Dichiarazione del fabbricante ai sensi della direttiva CE 98/37/CE relativa a macchinari, Appendice II B Verklaring van de fabrikant inzake richtlijn 98/37/EG, voor machines, bijlage II B Fabrikantens erklring i henhold til EU- lovgivning om maskiner 98/37/EU, bilag II B Erklring fra produsent iflge EUs- maskindirektiv 98/37/EC, vedlegg II B Tillverkardeklaration enligt EU:s Maskindirektiv 98/37/EC, Annex II B Valmistajanvakuutus EU- konedirektiivin 98/37/ETY mukaan, Liite II B Hiermit erklren wir, da die Pumpe Herewith we declare that the pump Par la prsente, nous dclarons que la pompe Por la presente, declaramos que la bomba Com a presente, declaramos que a bomba Si dichiara che la pompa Hiermee verklaren wij, dat de pomp Hermed erklres, at pumpetype Hermed erklrer vi, at pumpen Hrmed frskrar vi att pumpen Vakuutamme, ett pumppu

Etanorm SYA
zum Einbau in eine Maschine 1) / Zusammenbau mit anderen Maschinen zu einer Maschine 1) bestimmt ist. Ihre Inbetriebnahme ist solange untersagt, bis festgestellt wurde, da die Maschine, in die diese Pumpe eingebaut werden soll, bzw. mit der diese Pumpe zusammengebaut werden soll, den Bestimmungen der EU-Richtlinie in der jeweils gltigen Fassung entspricht. is intended to be incorporated into machinery 1) or assembled with other machinery to constitute machinery 1) covered by this directive and must not be put into service until the machinery into which it is be incorporated or with which it is to be assembled has been declared in conformity with the provisions of the directive in its current version. est destine tre incorpore dans une machine 1) / tre assemble avec dautres machines afin de constituer une machine 1) et que sa mise en service est interdite avant que la machine dans laquelle elle sera incorpore / avec laquelle elle sera assemble nait t dclare conforme aux dispositions de la directive, dans la version respective en vigueur. est destinada a ser incorporada en una mquina 1) /a ser ensamblada con otras mquinas para conformar una mquina 1) y que su puesta en servicio est prohibida antes de que la mquina en la que vaya a ser incorporada o con la que vaya a ser ensamblada haya sido declarada conforme con las disposiciones de la Directiva en su redaccin vigente. se destina a ser instalada numa mquina 1) / ser montada com outras mquinas de modo a formar uma mquina 1) coberta por esta directiva e que proibida a colocao em servio da mesma antes de a mquina em que essa bomba vier a ser incorporada/montada ser declarada em conformidade com o disposto na directiva CE na sua verso corrente. destinata al montaggio in una macchina 1) / allassemblaggio con altre macchine a formare un macchinario 1) e che la sua messa in marcia vietata fin quando non sar stata accertata la conformit del macchinario, nel quale questa pompa viene montata o col quale detta pompa deve venir assiemata, alle disposizioni delle direttiva CE nella versione valida al momento. ertoe bestemd is, ingebouwd te worden in een machine 1) / samengebouwd wordt met andere machines tot n machine 1) en dat het in gebruik stellen verboden is, voordat vastgesteld is, dat de machine, waarin deze pomp wordt ingebouwd, in overeenstemming met de bepalingen van de richtlijn is. er bestemt til indbygning i en maskine 1) / samling med andre maskiner med henblik p at udgre en maskine 1) og at igangstningen forbydes indtil det er konstateret, at maskinen, som vor pumpe skal monteres i, svarer til EU-bestemmelserne af EU-lovgivningen til en hver tid gyldig udgave.

115

25

116

6.5

Riello Burner Manual

Installation, use and maintenance instructions

Gas Burners

RS 28/M - 38/M - 50/M Low-High-Low or Modulating Operation

117

C6505055

CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packaging - Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3 4 4 4 4 5 5 6

WARNING
If you smell gas: Do not touch any electrical items. Open all windows. Close all gas supply valves. Contact your local gas authority immediately.

Do not store flammable or hazardous materials in the vicinity of fuel burning appliances. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or death. Refer to this manual for instructional or additional information. Consult a certified installer, service representative or the gas supplier for further assistance. Burner shall be installed in accordance with manufacturers requirements as outlined in this manual, local codes and authorities having jurisdiction.

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Combustion head adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Adjustments before rst ring. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Burner ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Burner calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 - Firing output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2 - Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 - Minimum output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4 - Intermediates outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6 - Low gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Factory wiring diagram - burner mounted LFL . . . . . . . . . . . . . . 15 Field wiring diagram - burner mounted LFL . . . . . . . . . . . . . . . . 16 Factory wiring - remote panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Appendix - Burner firing rates according to air density. . . . . . . . 18 Siemens LFL control sequence of operations . . . . . . . . . . . . . . 19 Siemens LFL control troubleshooting guide . . . . . . . . . . . . . . . . 20 Start up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N.B. Figures mentioned in the text are identied as follows: 1)(A) = part 1 of gure A, same page as text; 1)(A)p.4 = part 1 of gure A, page number 4.

118

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 SCFH WC RS 28/M 617 - 1232 181 - 361 198 58 1232 2.95 RS 38/M RS 38/M RS 50/M 880 - 1665 880 - 1665 1099 - 2201 258 - 488 258 - 488 322 - 645 266 266 321 78 78 94 Natural or propane gas 1665 1665 2201 2.6 2.6 2.83 Low - high-low or modulating Boilers: water, steam, thermal oil 32 - 104 (0 - 40 C) 140 (60 C) 120/1/60 208-230/460/575/3/60 3400 3400 370 - 0.5 550 - 0.75 120 208-230/460/575 5.2 3.2 - 1.6 - 1.3 45 120 V - 1 x 7 kV 1.6 A - 23 mA 600 750 NEMA 1 70 70 72

Motor capacitor Ignition transformer Electrical power consumption Electrical protection Noise levels (3)

F F max V/Ph/Hz rpm W - HP V A V V1 - V2 I1 - I2 W max dBA 68

(1) Reference conditions: Ambient temperature 68 F (20 C) - Barometric pressure 394 WC - Altitude 329 ft. (2) Pressure at test point 8)(A)p.4, with zero pressure in the combustion chamber, with open gas ring 2)(B)p.8 at maximum burner output (3) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.

Burner models designation:

Model RS 28/M Code C9521300 (3781070) C9621300 (3781072) C9522300 (3781270) C9622300 (3781272) C9522350 (3781470) C9522351 (3781470) C9622350 (3781472) C9622351 (3781472) C9523300 (3781670) C9523301 (3781670) C9623300 (3781672) C9623301 (3781672) Voltage 120/1/60 120/1/60 120/1/60 120/1/60 208-230/460/3/60 575/3/60 208-230/460/3/60 575/3/60 208-230/460/3/60 575/3/60 208-230/460/3/60 575/3/60 Flame safeguard Burner mounted Remote panel Burner mounted Remote panel Burner mounted Burner mounted Remote panel Remote panel Burner mounted Burner mounted Remote panel Remote panel

RS 38/M

RS 50/M

ACCESSORIES (optional):

Kit for LPG operation: The kit allows the RS 28-38-50/M burners to operate on LPG. RS 28/M MBtu/hr inch 81/2 3010270 358 - 1232 1313/16 81/2 3010271 RS 38/M 437 - 1665 1313/16 81/2 3010272 RS 50/M 549 - 1986 1313/16

Burner Output Blast tube length Code

Modulating control kit: Under modulating operation, the burner automatically adapts to one of an innite number of ring rates between the low and high ame output position, thus ensuring stable operating conditions in terms of temperature or pressure. Two components should be ordered: Modulating control to install to the burner; probe to install to the boiler. Parameter to be checked Temperature Pressure Range - 212...+ 932 F (- 100...+ 500 C) 0...36.3 PSI (0...2.5 bar) 0...232 PSI (0...16 bar) Probe Type Code PT 100 3010110 Output probe 3010213 4...20 mA 3010214 Modulating control Type Code RWF40 3010212

Gas train according to UL Standards: see page 9. Important: The installer is responsible for the supply and installation of any required safety device(s) not indicated in this manual.

Kit for lengthening the combustion head L = Standard length L1 = Length obtainable with the kit COD. 3010256 L = 81/2 COD. 3010257 L = 81/2 COD. 3010258 L = 81/2

L1 = 1313/16 L1 = 13 13/16 L1 = 13 13/16 3

RS 28/M RS 38/M RS 50/M

119

BURNER DESCRIPTION (A)

1 2 3 4 5 6 7 8 9 10 11 Combustion head Ignition electrode Screw for combustion head adjustment Sleeve Low air pressure switch (differential operating type) Flame sensor probe (ame rod) Air pressure test point Gas pressure test point and head xing screw Screws securing fan to sleeve Slide bars for opening the burner and inspecting the combustion head Servomotor controlling the gas buttery valve and air damper (by means of a variable prole cam mechanism). When the burner is not operating the air damper is fully closed in order to reduce heat loss. Plate with four hole knock-outs for electrical cable routing Air inlet to fan Gas input connection Gas buttery valve Boiler mounting ange Flame stability disk Flame inspection window Ignition pilot Motor contactor and thermal overload reset button (RS 38 - 50 three-phase) Plug-socket on ame rod probe cable Flame safeguard Power switch for different operations: automatic - manual - off Switch for: manual modulation of servomotor Burner terminal strip Air damper Bracket for mounting the PID modulating controller RWF40 (optional)

D2256

12 13 14 15 16 17 18 19 20
D2257

21 22 23

D2258

(A)

24 25 26

inch RS 28/M RS 38/M RS 50/M

lbs 84 88 91
D88

3931/32 2413/16 1911/16 3931/32 2413/16 1911/16 3931/32 2413/16 1911/16

Two types of burner failure may occur: FLAME SAFEGUARD LOCK-OUT: if the ame 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). PACKAGING - WEIGHT (B) - Approximate measurements The burners are shipped in cardboard boxes with the maximum dimensions shown in Table (B). The weight of the burner complete with packaging is indicated in table (B). MAX. DIMENSIONS (C) Approximate measurements The maximum dimensions of the burners are given in (C). Note that if you need to examine the combustion head, the burner must be pulled backward on the slide bars and turned upward. The maximum dimension of the burner, without the cover, when open is give by measurement H. M STANDARD EQUIPMENT 1 - Gas train ange 1 - Flange gasket 4 - Flange xing screws 1 - Burner head gasket 4 - Screws to secure the burner ange to the boiler: 3/ 8 W x 1 1 - Instruction booklet 1 - Spare parts list

(B)

D495

RS

D (1)

28 1823/32 1821/32 2213/16 81/2-1313/16 38 1823/32 1821/32 2213/16 81/2-1313/16

51/2 1327/32 67/16 317/8 41/4 65/8 11/2 51/2 1327/32 67/16 317/8 41/4 65/8 11/2

50 1823/32 1821/32 2213/16 81/2-1313/16 531/32 1327/32 67/16 317/8 41/4 65/8 11/2 (1) Blast tube: short - long (with kit)

(C)
4

120

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. RS 28/M RS 38/M RS 50/M = 198 MBtu/hr = 266 MBtu/hr = 321 MBtu/hr 58 kW 78 kW 94 kW

Important: The FIRING RATE value range has been obtained considering an ambient temperature of 68 F (20 C), and an atmospheric pressure of 394 WC and with the combustion head adjusted as shown on page 8. Note: The FIRING RATE areas given in gure (A) have been reduced by 10% with respect to the maximum range that can be reached.

Combustion chamber pressure WC

Consult Appendix on page 18 for operation at different surrounding temperatures and/or altitudes.

MINIMUM FURNACE DIMENSIONS (B)

The ring rates were set in relation to certied test boilers. Figure (B) indicates the diameter and length of the test combustion chamber. Example: output 1388 MBtu/hr: diameter 20 inch - length 4.9 ft.

(A)
Recommended furnace dimensions Diameter (inches)

Combustion chamber pressure WC

D2259

(B)
5

Length (feet)

D2918

121

RS 28/M
p ( WC) MBtu/hr kW A 624 699 795 891 986 1078 1174 1232 183 205 233 261 289 316 344 361 0.98 1.22 1.57 1.85 2.17 2.48 2.76 2.95 1 2 B 0.98 1.3 1.69 2.05 2.28 2.68 3.07 3.58 0.039 0.039 0.039 0.079 0.079 0.12 0.12 0.12

GAS PRESSURE
The adjacent tables are used to calculate manifold pressure taking into account combustion chamber pressure. 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. Column 2 Pressure loss at gas buttery valve 2)(B) with maximum opening: 90. Calculate the approximate maximum output of the burner as follows: - subtract the combustion chamber pressure from the gas pressure measured at test point 1)(B). - Find the nearest pressure value to your result in column 1A or B of the table for the burner in question. - Read off the corresponding output on the left. 2 A B 1.02 1.38 1.77 2.28 2.72 3.11 3.54 4.21 0.079 0.079 0.12 0.12 0.16 0.16 0.2 0.23 Example - RS 28/M: Maximum output operation Natural gas Gas ring 2)(B)p.8 adjusted as indicated in diagram (C)p.8. Gas pressure at test point 1)(B) = 2.36 WC Pressure in combustion chamber = 0.79 WC 2.36 - 0.79 = 1.57 WC A maximum output of 795 MBtu/hr shown in Table RS 28/M corresponds to 1.57 WC pressure, column 1A. This value serves as a rough guide, the effective delivery must be measured at the gas meter. To calculate the required gas manifold pressure at test point 1)(B), set the maximim output required from the burner operation: - nd the nearest output value in the table for the burner in question. - Read off the pressure at test point 1)(B) on the right in column 1A or B. - Add this value to the estimated pressure in the combustion chamber. Example - RS 28/M: Required burner maximum output operation: 795 MBtu/hr Natural gas Gas ring 2)(B)p.8 adjusted as diagram (C)p.8. Gas pressure at burner output of 795 MBtu/hr, taken from table RS 28, column 1A = 1.57 WC Pressure in combustion chamber = 0.79 WC 1.57 + 0.79 = 2.36 WC pressure required at test point 1)(B).

RS 38/M
p ( WC) MBtu/hr kW 1

870 979 1099 1211 1327 1440 1552 1665

255 287 322 355 389 422 455 488

1.02 1.22 1.46 1.69 1.89 2.13 2.36 2.6

RS 50/M
p ( WC) MBtu/hr kW A 1099 1249 1402 1552 1706 1856 2006 2197 322 366 411 455 500 544 588 644 0.87 1.14 1.42 1.69 1.97 2.2 2.48 2.83 1 2 B 0.87 1.3 1.61 2.01 2.36 2.76 3.15 3.78 0.12 0.16 0.2 0.23 0.28 0.35 0.39 0.47

(A)

(B)

D2786

122

INSTALLATION
inch RS 28/M RS 38/M RS 50/M A 69/32 69/32 69/32 B 813/16 813/16 813/16 C
3/8 3/8 3/8

W W W
D455

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. BLAST TUBE LENGTH (B) The length of the blast tube must be selected according to the indications provided by the manufacturer of the boiler, and it must be greater than the thickness of the boiler door complete with its insulation. The range of lengths available, L (inches), is as follows: Blast tube 10): short long RS 28/M 8 1/2 13 13/16 RS 38/M 8 1/2 13 13/16 RS 50/M 8 1/2 13 13/16

(A)

For boilers with front ue passes 13) or ame inversion chambers, protective insulation material 11) must be inserted between the boiler refractory 12) and the blast tube 10). This protective insulation must not compromise the extraction of the blast tube. For boilers having a water-cooled front, the insulation 11)-12)(B) is not required unless it is required by the boiler manufacturer.
D2260

(B)
Ignition pilot
Probe position

SECURING THE BURNER TO THE BOILER (B) Before securing the burner to the boiler, check through the blast tube opening to make sure that the ame sensor probe is correctly set in position, as shown in (C). Now detach the combustion head from the burner, g.(B): - Remove screw 14) and withdraw the cover 15). - Disengage the swivel coupling 4) from the graduated sector 5). - Remove the screws 2) from the slide bars 3) - Remove screw 1) and pull the burner back on slide bars 3) by about 4. Disconnect the wires from the probe and the electrode and then pull the burner completely off the slide bars, after removing the split pin from the slide bar 3). Secure the ange 9)(B) to the boiler plate, inserting the head gasket 6)(B). Use the 4 screws, also supplied with the unit, after rst protecting the thread with an anti-seize product. The seal between burner and boiler must be airtight. If you noticed any irregularities in the positions of the probe or ignition electrode during the check mentioned above, remove screw 1)(D), extract the internal part 2)(D) of the head and set up the two components correctly. Place the pilot and electrode as shown in fig. (C). The pilot works correctly at pressures ranging from 5 12 WC. Important To set the pilot without main burner operation, proceed as follows: - Move the jumper from terminals "30-V11" to terminals "30-VP", as given in fig. (E), this way the main valve is not energized. - With the burner in the manual position, hold the air damper in the minimum position and make the setting. - When the setting is correct, replace the jumper on 30V11.

Probe

Electrode

(C)

TOP VIEW

SIDE VIEW

D2261

IGNITION PILOT ADJUSTMENT

(D)

D2292

MB - Burner terminal strip

(E)
7

D2317

123

COMBUSTION HEAD ADJUSTMENT

Installation operations are now at the stage where the blast tube and sleeve are secured to the boiler as shown in g. (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, nd 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 identied is aligned with the front surface 5)(A) of the ange. Gas adjustment (B) Loosen screw 1)(B) and turn ring 2) until the notch identied is aligned with index 3). Tighten the screw 1) fully down. Example: the burner RS 38/M varies its output between: MIN = 378.7 and MAX = 1288 MBtu/hr. The MIN output of 378.7 MBtu/hr is not found in the values of table (D) and therefore diagram (C) is valid, from which it results that for a MAX output of 1288 MBtu/hr the gas and air adjustments are done on notch 3, as in g. (A) and (B). In this case the pressure load loss of the combustion head is given by column 1A page 6. Note Diagram (C) shows the ideal settings for the ring 2)(B). If the gas supply pressure is too low to reach the max output operation pressure indicated on page 6, and if the ring 2)(B) is not fully open, it can be opened wider by 1 or 2 notches. Continuing with the previous example, page 6 indicates that for burner RS 38/M with output of 1288 MBtu/hr a pressure of approximately 1.81 WC is necessary at test point 6)(A). If this pressure cannot be reached, open the ring 2)(B) to notch 4 or 5. Make sure that the combustion characteristics are satisfactory and free of pulsations. Burner max output B - The MIN burner output is found in the values of the table (D). Air adjustment The same as the previous case: follow diagramm (C). Gas adjustment The gas ring 2)(B) is always adjusted to position 0, irrespective of the MAX burner. In this case the pressure load loss of the combustion heads is given by column 1B page 6. Once you have nished setting up the head, ret the burner 4)(E) to the slide bars 3) at approximately 4 from the sleeve 5) - burner positioned as shown in g.(B)p.7 insert the ame rod cable and the ignition electrode cable and then slide the burner up to the sleeve so that it is positioned as shown in g.(E). Ret screws 2) on slide bars 3). Secure the burner to the sleeve by tightening screw 1) and then ret the split pin into one of two slide bars 3). Reconnect the swivel connector 8) to the graduated sector 7). Connect gas train and pilot train as shown in g. (A) page 9. Important When tting the burner on the two slide bars, it is advisable to gently draw out the high tension cable and ame detection probe cable until they are slightly stretched.

D2315

(A)
Notches (Air = Gas)
D2262

(B)

(C)
MODULATION MINIMUM OUTPUT: when the MIN output is within the value range given below, the gas ring 2)(B) is adjusted to zero. RS 28/M RS 38/M RS 50/M 198 - 280 MBtu/hr 266 - 375 MBtu/hr 321 - 488 MBtu/hr 58 - 82 kW 78 - 110 kW 94 - 143 kW

(D)

D2263

(E)

124

GAS PIPING
The main gas train must be connected to the gas attachment 1)(A), using ange 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 g.(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. The pilot gas train must be connected to the gas attachment 5)(A) and can enter the burner from the right or left side.

1 3 2

(A)

4
D2293

GAS TRAIN (B)

It must be type-approved according to required localstandards and is supplied separately from the burner. Note See the accompanying instructions for the gas train layout. KEY (B) 1 - Gas input pipe 2 - Manual valve 3 - Pressure regulator 4 - Low gas pressure switch 5 - 1st safety shut off valve 6 - 2nd safety shut off valve 7 - Standard issue burner gasket with ange 8 - Gas adjustment buttery valve 9 - Burner

TYPICAL UL SCHEMATIC GAS PIPING

GAS PILOT LINE

MAIN GAS LINE

(B)

D2294

125

LOW GAS PRESSURE SWITCH

AIR PRESSURE SWITCH

ADJUSTMENTS BEFORE FIRST FIRING

D2547

D2548

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. - Fit a U-type manometer (C) to the gas pressure test point on the sleeve. The manometer readings are used to calculate MAX. burner power using the tables on page 6. Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum. SERVOMOTOR (D) The servomotor provides simultaneous adjustment of the air damper, by means of the variable prole cam, and the gas buttery valve. The angle of rotation of the servomotor is equal to the angle on the graduated sector controlling the gas buttery valve. The servomotor rotates through 90 degrees in 25 seconds. Do not alter the factory setting for the cams; simply check that they are set as indicated below: Red cam : 90 Limits rotation toward maximum position. When the burner is at max output the gas buttery valve must be fully open: 90. Blue cam : 0 Limits rotation toward the minimum position. When the burner is shut down the air damper and the gas buttery valve must be closed: 0. Orange cam : 15 Adjusts the ignition position and the MIN output. BURNER STARTING Close the control circuit and set switch 1)(E) to MAN. As soon as the burner starts check the direction of rotation of the fan blade, looking through the ame inspection window 18)(A)p.4. BURNER FIRING Having completed the checks indicated in the previous heading, the pilot of the burner should re. If the motor starts but the ame does not appear and the ame safeguard goes into lock-out, reset and wait for a new ring attempt. Pilot adjustment has been illustrated on page. 7. Having adjusted the pilot, reconnect the main valve and ignite the main ame; it might require several attempts to purge the air from the gas lines or to adjust the valve with little gas. Once the burner has red, now proceed with calibration operations.

(A)

(B)

D2265

(C)
SERVOMOTOR
RED CAM BLUE CAM ORANGE CAM

RESET

(D) 1 2

D2266

(E)

D791

10

126

BURNER CALIBRATION 1 2
The optimum calibration of the burner requires an analysis of the ue gases at the boiler outlet. Adjust successively: 1 - First ring output 2 - Max. burner output 3 - Min. burner output 4 - Intermediate outputs between low and high re 5 - Air pressure switch 6 - Minimum gas pressure switch 1 - FIRING OUTPUT Pilot adjustment has been illustrated on page. 7. 2 - MAXIMUM OUTPUT Maximum output of the burner must be set within the ring rate range shown on page 5. In the above instructions we left the burner running in MIN. output operation. Now press switch 2)(A) increase output and keep it pressed until the servomotor has opened the air damper and the gas buttery valve to 90. Gas calibration Measure the gas delivery at the meter. A guideline indication can be calculated from the tables on page 6, simply read off the gas pressure on the Utype manometer, see g.(C) on page 10, and follow the instructions on page 6. - If delivery needs to be reduced, reduce outlet gas pressure and, if it is already very low, slightly close adjustment valve. - If delivery needs to be increased, increase outlet gas pressure.

D791

(A)

11

127

Adjusting air delivery Progressively adjust the end prole 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 ring rate range shown on page 5. Press switch 2)(A)p.11 output reduction until the servomotor has closed the air damper and the gas buttery valve to 15 (factory set adjustment). Adjusting gas delivery Measure the delivery of gas from the gas meter. - If this value is to be reduced, decrease the angle of orange cam (B) slightly by proceeding a little at a time until the angle is changed from 15 to 13 or 11.... - If it has to be increased press the switch output increase 2)(A)p.11 (i.e. open the gas buttery valve by 10-15), increase the orange cam angle (B) with small successive movements, i.e. take it from angle 15 to 17 - 19.... Then press the switch output decrease until the servomotor is taken to the minimum opening position and measure the gas delivery. Note The servomotor follows the adjustment of cam only when the cam angle is reduced. If it is necessary to increase the cam angle, rst increase the servomotor angle with the switch output increase, then increase the orange cam angle, and at the end bring the servomotor back to the MIN output position with the switch output decrease. Adjustment of air delivery Progressively adjust the starting prole of cam 4)(A) by turning the screws working throught the access hole 6)(A). 4 - INTERMEDIATE OUTPUTS Adjustment of gas delivery No adjustment of gas delivery is required. Adjustment of air delivery With the switch 1)(A) page 11 move in intermediate outputs and set the variable profile cam 4) by turning the screws 5). - If the burner operation is low-high it is sufcient to set only minimum and maximum ring rates - If the burner operation is modulating, all the points of modulation should be adjusted. When the adjustment is complete, release the servomotor and manually check there is no binding of the cam.

D2267

1 Servomotor 2 Lever, push to engage, push to release 3 Adjustable prole cam 4 Cam prole adjustment screws 5 Opening for access to screws 5 6 Index for graduated sector 8 7 Graduated sector for gas buttery valve

(A)

12

128

AIR PRESSURE SWITCH

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. If the burner locks out again, turn the dial anti-clockwise a little bit more. Attention: As a rule, the air pressure switch must prevent the formation of CO. To check this, insert a combustion analyser into the chimney, slowly close the fan suction inlet (for example with cardboard) and check that the burner locks out, before the CO in the fumes exceeds 400 ppm. The air pressure switch may operate in "differential" operation in two pipe system. If a negative pressure in the combustion chamber during pre-purging prevents the air pressure switch from switching, switching may be obtained by fitting a second pipe between the air pressure switch and the suction inlet of the fan. In this way the air pressure switch operates as differential pressure switch. 6 - LOW GAS PRESSURE SWITCH (B) Adjust the low gas pressure switch after having performed all the other burner adjustments with the pressure switch set at the start of the scale (B). With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out. Then turn the dial anti-clockwise by 0.8 WC and repeat burner starting to ensure it is uniform. If the burner locks out again, turn the dial anti-clockwise again by 0.4 WC. FLAME PRESENT CHECK (C) The burner is tted with an ionisation system (ame rod) which ensures that a ame is present. The minimum current for operation is 6 A. (or see appropriate documentation of ame safeguard manufacturer) The burner provides a much higher current, so that controls are not normally required. However, if it is necessary to measure the ionisation current, disconnect the plug-socket 21)(A)p.4 on the ionisation probe cable and insert a direct current microamperometer with a base scale of 100 A. Carefully check polarities!

D2548

(A)
LOW GAS PRESSURE SWITCH

D2547

(B)

D795

(C)

13

129

FLAME INSPECTION WINDOW

MAINTENANCE
Combustion The optimum calibration of the burner requires an analysis of the ue gases. Signicant 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 ame inspection window (A). Combustion head Open the burner and make sure that all components of the combustion head are in good condition, not deformed by the high temperatures, free of impurities from the surroundings and correctly positioned. If in doubt, disassemble the elbow tting 7)(B). Servomotor Disengage the cam from servomotor and turn it backward and forward by hand to make sure it is free moving. Now engage cam again. Burner Check for excess wear or loose screws in the mechanisms controlling the air damper and the gas buttery valve. Also make sure that the screws securing the electrical leads in the burner connections are fully tightened. Clean the outside of the burner, taking special care with the linkages joints and cam. Combustion Adjust the burner if the combustion values found at the beginning of the operation do not comply with the regulations in force, or do not correspond to good combustion. TO OPEN THE BURNER (B): - Switch off the electrical power. - Remove screw 1) and withdraw cover 2). - Disengage the swivel coupling 3) from the graduated sector 4). - Remove screw 5), the split pin 9) and pull the burner back by about 4 on the slide bars 6). - Disconnect the probe and electrode leads and then pull the burner fully back. - Turn the burner as shown in the gure and t the split pin 9) into one of the slide bar holes so that the burner remains in position. Now extract the gas distributor 7) after having removed the screw 8) and disconnecting the pilot gas line. TO CLOSE THE BURNER (B): - Remove the split pin 9) and push the burner until it is about 4 from the sleeve. - Re-connect the leads and slide in the burner until it comes to a stop. - Ret screw 5), the split pin 9) and pull the probe and electrode leads gently out until they are slightly stretched. - Re-couple the swivel coupling 3) to the graduated sector 4). - Connect the pilot gas line.

D484

(A)
OPENING THE BURNER

D2268

(B)

14

130

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.

(A)
Factory Wiring Diagram RS 38/M - RS 50/M three-phase With Siemens LFL control

D2269

D2876

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.

(B) ELECTRICAL SYSTEM

ELECTRICAL SYSTEM as set up by the manufacturer LAYOUT (A) Burner RS 28/M - RS 38/M (single-phase) LAYOUT (B) Burners RS 38/M - RS 50/M (three-phase)

D2270

D2877

DA MB MV PA RT S1

Models RS 38/M and RS 50/M leave the factory preset for 208230 V power supply. If 460 V power supply is used, change the motor connection from delta to star and change the setting of the thermal cut-out as well. Key to Layouts (A) - (B) C - Capacitor CMV - Motor contactor

S2

SM SO SP TA TB

Siemens LFL Control box Burner terminal strip Fan motor Air pressure switch Thermal overload Switch for following operations: MAN = manual AUT = automatic OFF Button for: - = power reduction + = power increase Servomotor Ionisation probe (ame rod) Plug-socket Ignition transformer Burner ground

15

131

Field Wiring Diagram RS 28/M - RS 38/M Single-phase with burner mounted Siemens LFL control

ELECTRICAL CONNECTIONS
Use exible 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. KEY TO LAYOUTS (A) - (B) IN - Burner manual stop switch MB - Burner terminal strip PG - Min. gas pressure switch PS - Remote lock-out reset H1 - Remote lock-out signal H2 - Burner on signal H4 - Power on signal H5 - Permission ok OCR - High-low control. OC - Operating control. HL - High limit. Y0 - Pilot valve Y10 - Adjustment valve Y11 - Safety valve Y13 - Pilot valve (safety) LAYOUT (D) Connection of RWF40 and related probe to RS 2838-50/M burners (modulating operation) Note The OCR and OC controls are not required when the PID control RWF40 is connected, as their function is performed by the RWF40 itself. It can be connected to the terminals: - T1 -T2, to replace the remote control TL

(A)
Field Wiring Diagram RS 38/M - RS 50/M Three-phase With Burner mounted Siemens LFL control

D2271

(B)

D2272

RS 28/M

RS 38/M Singlephase 120 V T10

RS 38/M Three-phase

RS 50/M

Key to layout (D) BT - Temperature probe BP - Pressure probe MB - Burner terminal strip a - Red b - Red c - White d - White NOTES The setting of the thermal overload must be according to the total burner amperage draw. Models RS 38-50/M leave the factory preset for 208 230 V power supply. If 460 V power supply is used, change the motor connection from delta to star and change the setting of the thermal cutout as well. Models RS 28-38-50/M have been type- approved for intermittent operation. This means they should compulsorily be stopped at least once every 24 hours to enable the control box to check its own efciency at start-up. Burner halts are normally provided for automatically by the boiler load control system. If this is not the case, a time switch should be tted in series to IN to provide for burner shut-down at least once every 24 hours.

120 V F A T10

208 208 460 V 460 V 460 V 575 V 230 V 230 V T6 T6 T4 T6 T6 T4

(C) RWF40

(D)

D2322

16

132

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) ELECTRICAL SYSTEM

ELECTRICAL SYSTEM as set up by the manufacturer LAYOUT (A) Burner RS 28/M - RS 38/M (single-phase) The flame safeguard is in remote panel. See the internal electrical systems of the remote panel in order to have the complete wiring diagram. LAYOUT (B) Burners RS 38/M - RS 50/M (three-phase) The flame safeguard is in remote panel. See the internal electrical systems of the remote panel in order to have the complete wiring diagram. 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 (ame rod) SP - Plug-socket TA - Ignition transformer TB - Burner ground

17

133

APPENDIX - Burner firing rates according to air density

CORRECTION FACTOR F above sea level average barom. pressure W.C. 399 394 389 385 380 376 372 367 363 358 354 346 337 329 321 313 mbar 1013 1000 989 978 966 955 944 932 921 910 898 878 856 836 815 794
0 (0C) 41 (5C) 50 (10C)

Air temperature F (C)

59 (15C) 68 (20C) 77 (25C) 86 (30C) 104 (40F)

ft 0 329 658 987 1316 1645 1974 2303 2632 2961 3290 3947 4605 5263 5921 6579 (A)

m 0 100 200 300 400 500 600 700 800 900 1000 1200 1400 1600 1800 2000

1,087 1,073 1,061 1,050 1,037 1,025 1,013 1,000 0,988 0,977 0,964 0,942 0,919 0,897 0,875 0,852

1,068 1,054 1,042 1,031 1,018 1,007 0,995 0,982 0,971 0,959 0,946 0,925 0,902 0,881 0,859 0,837

1,049 1,035 1,024 1,013 1,000 0,989 0,977 0,965 0,954 0,942 0,930 0,909 0,886 0,866 0,844 0,822

1,031 1,017 1,006 0,995 0,983 0,972 0,960 0,948 0,937 0,926 0,914 0,893 0,871 0,851 0,829 0,808

1,013 1,000 0,989 0,978 0,966 0,955 0,944 0,932 0,921 0,910 0,898 0,878 0,856 0,836 0,815 0,794

0,996 0,983 0,972 0,962 0,950 0,939 0,928 0,916 0,906 0,895 0,883 0,863 0,842 0,822 0,801 0,781

0,980 0,967 0,956 0,946 0,934 0,923 0,913 0,901 0,891 0,880 0,868 0,849 0,828 0,808 0,788 0,768

0,948 0,936 0,926 0,916 0,904 0,894 0,884 0,872 0,862 0,852 0,841 0,822 0,801 0,783 0,763 0,743

The FIRING RATE area values have been obtained considering a surround- W.C. ing temperature of 68F (20C), and an atmospheric pressure of 398 W.C. and with the combustion head adjusted as shown on page 8. H2 The burner may be required to operate with combustion air at a higher temH3 H1 A perature and/or at higher altitudes. Heating of air and increase in altitude produce the same effect: the expansion of the air volume, i.e. the reduction of air density. D2617 Qe MBTU/h The burner fan's delivery remains substantially the same, but the oxygen (B) content per cubic meter and the fan's head are reduced. It is therefore important to know if the maximum output required of the burner at a given combustion chamber pressure remains within the burner's firing rate range even at different temperature and altitude conditions. Proceed as follows to check the above: 1 -Find the correction factor F in the Table (A) for the plant's air temperature and altitude. 2 -Divide the burner's delivery Q by F in order to obtain the equivalent delivery Qe:
Qe = Q : F (MBtu/hr)

3 -In the firing rate range of the burner, Fig. (B), indicate the work point defined by: Qe = equivalent delivery H1 = combustion chamber pressure The resulting point A must remain within the firing rate range. 4 -Plot a vertical line from Point A as shown in Figure (B) and find the maximum pressure H2 of the firing rate. 5 -Multiply H2 by F to obtain the maximum reduced pressure H3 of the firing rate.
H3 = H 2 x F ( W.C.)

If H3 is greater than H1, as shown in Fig. (B), the burner delivers the output required. If H3 is lower than H1, the burner's delivery must be reduced. A reduction in delivery is accompanied by a reduction of the pressure in the combustion chamber: Qr = reduced delivery H1r = reduced pressure
H1r = H1 x

( Qr Q )

Example, a 5% delivery reduction: Qr = Q x 0.95 H1r = H1 x (0.95)2 Steps 2 - 5 must now be repeated using the new Qr and H1r values. Important: the combustion head must be adjusted in respect to the equivalent delivery Qe.
18

134

Full Modulation

BURNER OPERATION
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 buttery are positioned to MIN. output. Ignition electrode strikes a spark. Pilot valve opens. The pilot ame is ignited. After about 12 s the main ame ignites and starting cycle ends. STEADY STATE OPERATION Burner without modulating control RWF40 At the end of the starting cycle, the servomotor control then passes to the load control for boiler pressure or temperature. (The ame safeguard continues, however, to check that the ame is present and that the air pressure switch is in the correct position.) If the temperature or pressure is low, the burner progressively increases its output to the MAX. value. If the temperature or pressure is high, the burner progressively decreases its output to the MIN. value. And so on. The burner locks out when demand for heat is less than the heat supplied by the burner at min. output. Load control opens. The servomotor returns to the 0 angle limited by contact with orange cam. The air damper closes completely to reduce thermal dispersion to a minimum. Every time output is changed, the servomotor automatically modies gas delivery (gas buttery valve) and air delivery (fan damper). Burner with modulating control RWF40 See the handbook enclosed with the modulating control. Switching times are given in seconds, in the burner startup sequence. LFL 1.335 Series 01 t1 30 t2 2 t3 4 t4 20 t5 optional

(A)
Low - High

D2273

t6 t7 t8 t9

optional 12 4 16

(B)

D2274

Legend for the times t1 Pre-purge time with air damper open t2 Safety time t3 Pre-ignition time, short (ignition transformer on terminal 16) t4 Interval between start of t2 and release of valve at terminal 19 t5 Interval between end of t4 and release of load controller or valve at terminal 20 t5 Running time of air damper into OPEN position t6 Running time of air damper into low-ame position (MIN) t7 Permissible after-burn time t8 Interval until OPEN command for the air damper is given t9 Running time of pilot FIRING FAILURE If the burner does not fire, it locks out within 2.5 seconds from opening the pilot valve and then within 5 seconds from opening the main valves. BURNER FLAME GOES OUT DURING OPERATION If the ame should accidentally go out during operation, the burner will lock out within 1s.

19

135

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 ames, leaking fuel valves, defects in the ame supervision circuit, etc.)

Interruption of startup sequence, because the OPEN signal has not been delivered to terminal 8 by limit switch a. Terminals 6, 7 and 14 remain under voltage until the fault has been corrected!

Lockout, because there is no air pressure indication at the beginning of air pressure control. Every air pressure failure after this moment in time leads to lock-out, too!

Lock-out due to a fault in the ame supervision circuit.

Interruption of startup sequence, because the position signal for the low-ame position has not been delivered to terminal 8 by auxiliary switch m. Terminals 6, 7 and 14 remain under voltage until the fault has been corrected!

Lock-out, because no ame signal is present after completion of the (1st) safety time.

Lock-out, because no ame signal has been received on completion of the 2nd safety time (ame signal of the main ame with interrupted pilot burners).

Lock-out, because the ame signal has been lost during burner operation.

If lock-out occurs at any other moment in time between the start and the pre-ignition which is not marked by a symbol, this is usually caused by a premature, i.e. faulty ame signal, e.g. caused by a self-igniting UV tube.

20

136

137

6.6

Riello Burner Parts Manual

Catalogo ricambi Spare parts list Catalogue pices dtaches Ersatzteile Katalog Catlogo recambios

Bruciatori di gas ad aria soffiata Blown gas burners Brleurs gaz air souffl Geblse-Gasbrenner Quemadores de gas
Funzionamento bistadio progressivo o modulante Progressive two-stage or modulating operation Fonctionnement 2 allures progressives ou modulant Gleitend-zweistufiger oder modulierender Betrieb Funcionamiento a dos llamas progresivas o modulante

COD.

MOD.

TYP.

3781012 3781013 3781412 3781413 3781612 3781613

RS 28/M RS 28/M RS 38/M RS 38/M RS 50/M RS 50/M

824 T1 824 T1 825 T1 825 T1 826 T1 826 T1

138

139
8173

* 825 T1 * 826 T1 3781613 *

DESCRIZIONE DESCRIPTION

824 T1

N. COD.
3781012 3781412 3781413 3781612 3781013

DESCRIPTION

BESCHREIBUNG

DENOMINACION

MATRICOLA BRUCIATORE BURNER SERIAL NUMBER MATRICULE BRULEUR BRENNER KENN-NUMMER MATRICULA QUEMADRES

RICAMBI CONSIGLIATI ADVISED PARTS RECHANGE CONSEIL EMPFOHLENE ERSATZTEILE RECAMBIOS ACONSEJADOS

1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23 23 24 25 26 27 28 29 30 30 30 31 32 32 33 33 33 33
COLLEG. PER SONDA

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 GIRANTE GIRANTE GIRANTE QUADRANTE FONOASSORBENTE BOCCA DASPIRAZIONE MO LLA SQUADRETTA PERNO LEVA CUSCINETTO VISORE PE R N O COFANO VITE MEMBRANA MOTORE APPARECCHIATURA CONDENSATORE AVVIATORE AVVIATORE SUPPORTO TRASFORMATORE INTERRUTTORE CHIAVETTA MOTORE MOTORE ALBERINO RACCORDO PRESSOSTATO ARIA SCUDO ANTERIORE
COLLEG.PER ELETTRODO GHIERA GHIERA GHIERA GOMITO TUBO ESTERNO TUBO ESTERNO TUBO INTERNO TUBO INTERNO TUBO INTERNO TUBO INTERNO

FAN FAN FAN GRADUATE SECTOR SOUND DAMPING AIR INTAKE S PR I N G SQUARE SCREW LEVER BEARING INSPECTION WINDOW BAR COVER SCREW MEMBRAN MOTOR CONTROL BOX CONDENSER STARTER STARTER SUPPORT TRANSFORMER SWITCH KEY MOTOR MOTOR SHORT SHAFT CONNECTOR AIR PRESSURE SWITCH FRONT SHIELD PROBE LEAD H.T. LEAD F E RRULE F E RRULE F E RRULE ELBOW EXTERIOR TUBE EXTERIOR TUBE INTERIOR TUBE INTERIOR TUBE INTERIOR TUBE INTERIOR TUBE
CONNEXION POUR ELECTRODE

**
TURBINE TURBINE TURBINE SECTEUR GRADUE INSONORISANT BOITIER DASPIRATION RESSORT EQUERRE-SUPPORT VIS CREUSE LEVIER ROULEMENT VISEUR GLISSIERE COFFRET VIS MEMBRANE MOTEUR BOITE DE CONTROLE CONDENSATEUR DEMARREUR DEMARREUR SUPPORT TRANSFORMATEUR INTERRUPTEUR CLAVETTE MOTEUR MOTEUR AXE MAMELON PRESSOSTAT AIR BOUCLIER AVANT CONNEXION POUR SONDE DISQUE DISQUE DISQUE COUDE TUYAU EXTERIEUR TUYAU EXTERIEUR TUYAU INTERIEUR TUYAU INTERIEUR TUYAU INTERIEUR TUYAU INTERIEUR GEBLSERAD GEBLSERAD GEBLSERAD SKALENSEGMENT GERUSCHDMMUNG ANSAUGFFNUNG FEDER HALTER HOHLKERNSCHRAUBE HEBELSCHRAUBE LAGER SICHTFENSTER BO LZ EN VERKLEIDUNG SCHRAUBE MEMBRANE MOTOR STEUERGERT KONDENSATOR ANLASSER ANLASSER HALTER ZNDTRANSFORMATOR SCHALTER PASSFEDER MOTOR MOTOR KLEINWELLE NIPPEL LUFTDRUCKWCHTER VORDERES SCHILD VERBINDUNG FR SONDE STELLRING STELLRING STELLRING SCHLITTEN AUSSERER ROHR AUSSERER ROHR INNERER ROHR INNERER ROHR INNERER ROHR INNERER ROHR
VERBINDUNG FR ELEKTRODE

TURBINA TURBINA TURBINA MIRILLA AISLAMIENTO ACSTICO BOCA ASPIRACION M U ELLE ESCUADRA G UA PALANCA COJINETE VISOR G U A ENVOLVENTE TORNILLO MEMBRANA MOTOR CAJA CONTROL CONDENSADOR ARRANCADOR ARRANCADOR CORCHETE TRANSFORMADOR INTERUCTOR CHAVETA MOTOR MOTOR ARBORILLO RA CORD

C C C

02484999999 02484999999

02484999999

C C

C B B C C

B C

C C

ESCUDO ANTERIOR

C A

CABLE SONDA DE IONIZACIN

CABLE ELECTRODO VIROLA VIROLA VIROLA CO DO TUBO EXTERNO TUBO EXTERNO TUBO INTERNO TUBO INTERNO TUBO INTERNO TUBO INTERNO

* = Versione Testa Lunga - Long Combustion Head Version - Version Tte Longue - Langer Brennkopf Ausfhrung - Version alargado de tubo llama

140

81 73

3781412 * 825 T1 3781413 3781612 * 826 T1 3781613 *

824 T1

N. COD.
3781012 3781013

DESCRIZIONE DESCRIPTION

DESCRIPTION

BESCHREIBUNG

DENOMINACION

MATRICOLA BRUCIATORE BURNER SERIAL NUMBER MATRICULE BRULEUR BRENNER KENN-NUMMER MATRICULA QUEMADRES

RICAMBI CONSIGLIATI ADVISED PARTS RECHANGE CONSEIL EMPFOHLENE ERSATZTEILE RECAMBIOS ACONSEJADOS

33 33 34 34 34 35 35 35 36 36 36 37 37 38 38 38 38 39 40 41 42 43 44 45 46 47 48 48 48 48 48 48 49 49 50 50 50 50 50 50 51 52 53 54 55

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

TUBO INTERNO TUBO INTERNO DISTRIBUTORE DISTRIBUTORE DISTRIBUTORE DISCO DISCO DISCO TUBETTO TUBETTO TUBETTO SONDA SONDA ELETTRODO ELETTRODO ELETTRODO ELETTRODO CAVALLOTTO SUPPORTO GUARNIZIONE RACCORDO PRESSOSTATO GAS PRESA GRUPPO MISURAZIONE GRUPPO REGOLAZIONE FRONTONE SQUADRETTA SQUADRETTA SQUADRETTA SQUADRETTA SQUADRETTA SQUADRETTA OTTURATORE OTTURATORE IMBUTO FIAMMA IMBUTO FIAMMA IMBUTO FIAMMA IMBUTO FIAMMA IMBUTO FIAMMA IMBUTO FIAMMA SCHERMO GRUPPO MISURAZIONE QUADRANTE ALBERO MANICOTTO MANICOTTO INTERIOR TUBE INTERIOR TUBE GAS HEAD GAS HEAD GAS HEAD DISC DISC DISC T UB E T UB E T UB E PROBE PROBE ELECTRODE ELECTRODE ELECTRODE ELECTRODE U BOLT SUPPORT SEAL CONNECTOR GAS PRESSURE SWITCH SOCKET TEST POINT CONTROL DEVICE FONT PIECE SQUARE SQUARE SQUARE SQUARE SQUARE SQUARE SHUTTER SHUTTER E ND CONE E ND CONE E ND CONE E ND CONE E ND CONE E ND CONE FLANGE GASKET TEST POINT GRADUATE SECTOR BUTTERFLY VALVE SHAFT MANIFOLD TUYAU INTERIEUR TUYAU INTERIEUR DISTRIBUTEUR DISTRIBUTEUR DISTRIBUTEUR DISQUE DISQUE DISQUE TUYAU TUYAU TUYAU SONDE SONDE ELECTRODE PORCELAINE ELECTRODE PORCELAINE ELECTRODE PORCELAINE ELECTRODE PORCELAINE CAVALIER SUPPORT RONDELLE MAMELON PRESSOSTAT GAZ PRISE PRISE DE PRESSION GROUPE OBTURATION FACADE EQUERRE-SUPPORT EQUERRE-SUPPORT EQUERRE-SUPPORT EQUERRE-SUPPORT EQUERRE-SUPPORT EQUERRE-SUPPORT OBTURATEUR OBTURATEUR EMBOUT GUEULARD EMBOUT GUEULARD EMBOUT GUEULARD EMBOUT GUEULARD EMBOUT GUEULARD EMBOUT GUEULARD ECRAN THERMIQUE PRISE DE PRESSION SECTEUR GRADUE AXE DE LA VANNE PAPILLON MANCHON

INNERER ROHR INNERER ROHR GASVERTEILER GASVERTEILER GASVERTEILER SCHEIBE SCHEIBE SCHEIBE RHRCHE N RHRCHE N RHRCHE N FHLER FHLER ELEKTRODE ELEKTRODE ELEKTRODE ELEKTRODE BGELBOLZEN HALTER METALLDICHTUNG NIPPEL GASDRUCKWCHTER STECKERBUCHSE MESSNIPPEL DRUCKREGULIERUNG VORDERTEIL HALTER HALTER HALTER HALTER HALTER HALTER SCHIEBER SCHIEBER FLAMMENROHR FLAMMENROHR FLAMMENROHR FLAMMENROHR FLAMMENROHR FLAMMENROHR FLANSCHDICHTUNG MESSNIPPEL SKALENSEGMENT SPINDEL GASDROSSEL GASANSCHLUSS

TUBO INTERNO TUBO INTERNO DISTRIBUIDOR DISTRIBUIDOR DISTRIBUIDOR DISCO DISCO DISCO TUBITO TUBITO TUBITO S O NDA S O NDA ELECTRODO ELECTRODO ELECTRODO ELECTRODO FIJACION ELECTRODO SOPORTE JUNTA RA CORD PRESOSTATO DEL AIRE CONECTOR

**

A A A

A A A A A A

GRUPO REGULACION SOPORTE QUEMADOR ESCUADRA ESCUADRA ESCUADRA ESCUADRA ESCUADRA ESCUADRA OBTURADOR OBTURADOR TUBO EXTREMO TUBO EXTREMO TUBO EXTREMO TUBO EXTREMO TUBO EXTREMO TUBO EXTREMO JUNTA AISLANTE

GRUPO TOMA DE PRESON

GRUPO TOMA DE PRESON

C C B B B B B B B A CUADRANTE

ARBORILLO MANGUITO

MANGUITO

* = Versione Testa Lunga - Long Combustion Head Version - Version Tte Longue - Langer Brennkopf Ausfhrung - Version alargado de tubo llama

141

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6.7

North American Riello Burner Parts Manual

Spare parts list Catalogo ricambi

Gas Burners Bruciatori di gas

Progressive two-stage or modulating operation Funzionamento bistadio progressivo o modulante

CODE

MODEL

C9521300 (3781070) C9522300 (3781270) C9522350 (3781470) C9522351 (3781475) C9523300 (3781670) C9523301 (3781675) (3781676)

RS 28/M RS 38/M RS 38/M RS 38/M RS 50/M RS 50/M RS 50/M

143

144
C6505066 - 2918310

70

C9521300 (3781070)

C9522300 (3781270)

C9522350 (3781470)

C9522351 (3781475)

C9523300 (3781670)

N.

CODE

C9523301 (3781675)

(3781676)

DESCRIPTION

DESCRIZIONE
BURNER SERIAL NUMBER MATRICOLA BRUCIATORE
ADVISED PARTS RICAMBI CONSIGLIATI

**

FAN FAN FAN GRADUATE SECTOR SOUND DAMPING AIR INTAKE SPRING CONDENSER BAR LEVER BEARING INSPECTION WINDOW BAR COVER COVER SCREW MEMBRAN PILOT TUBE CONTROL BOX LFL 1.335 CONTACTOR CONTACTOR CONTACTOR OVERLOAD 208-230/460V OVERLOAD 575V SUPPORT SUPPORT TRANSFORMER SWITCH SERVOMOTOR MOTOR 120V MOTOR 208-230/460V MOTOR 575V MOTOR 120V SHORT SHAFT CONNECTOR AIR PRESSURE SWITCH FRONT SHIELD FRONT SHIELD PROBE LEAD H.T.LEAD FERRULE FERRULE FERRULE GIRANTE GIRANTE GIRANTE QUADRANTE FONOASSORBENTE BOCCA D'ASPIRAZIONE MOLLA CONDENSATORE PERNO LEVA CUSCINETTO VISORE PERNO COFANO COFANO VITE MEMBRANA TUBO PILOTA APPARECCHIATURA LFL 1.335 CONTATTORE CONTATTORE CONTATTORE RELE' TERMICO 208-230/460V RELE' TERMICO 575V SUPPORTO SUPPORTO TRASFORMATORE INTERRUTTORE SERVOMOTORE MOTORE 120V MOTORE 208-230/460V MOTORE 575V MOTORE 120V ALBERINO RACCORDO PRESSOSTATO ARIA SCUDO ANTERIORE SCUDO ANTERIORE COLLEGAMENTO PER SONDA COLLEGAMENTO PER ELETTRODO GHIERA GHIERA GHIERA C C C

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

02484999999 02484999999

A C C

B C C C C C

B C B C C C C C B

A A

C6505066 - 2918310

145

C9521300 (3781070)

C9522300 (3781270)

C9522350 (3781470)

C9522351 (3781475)

C9523300 (3781670)

N.

CODE

C9523301 (3781675)

(3781676)

DESCRIPTION

DESCRIZIONE
BURNER SERIAL NUMBER MATRICOLA BRUCIATORE
ADVISED PARTS RICAMBI CONSIGLIATI

**
ELBOW EXTERIOR TUBE INTERIOR TUBE INTERIOR TUBE INTERIOR TUBE GAS HEAD GAS HEAD GAS HEAD DISC DISC DISC TUBE TUBE TUBE PROBE ELECTRODE U BOLT U BOLT SEAL PLUG SUPPORT AIR DAMPER ASSEMBLY TEST POINT CONTROL DEVICE FRONT PIECE SQUARE SQUARE SQUARE SHUTTER SHUTTER END CONE END CONE CONTROL BOX BASE CONTROL BOX BASE TEST POINT GRADUATE SECTOR BUTTERFLY VALVE SHAFT MANIFOLD INDEX SEAL FLANGE AND ELBOW FAIRLEAD HALF-SHELL GOMITO TUBO ESTERNO TUBO INTERNO TUBO INTERNO TUBO INTERNO DISTRIBUTORE DISTRIBUTORE DISTRIBUTORE DISCO DISCO DISCO TUBETTO TUBETTO TUBETTO SONDA ELETTRODO CAVALLOTTO CAVALLOTTO GUARNIZIONE TAPPO SUPPORTO GRUPPO SERRANDA GRUPPO MISURAZIONE GRUPPO REGOLAZIONE FRONTONE SQUADRETTA SQUADRETTA SQUADRETTA OTTURATORE OTTURATORE IMBUTO FIAMMA IMBUTO FIAMMA ZOCCOLO ZOCCOLO GRUPPO MISURAZIONE QUADRANTE ALBERO MANICOTTO MANICOTTO INDICE GUARNIZIONE FLANGIA E GOMITO PASSACAVO GUSCIO

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

A A A

A A

C C B B

C6505066 - 2918310

146

C9521300 (3781070)

C9522300 (3781270)

C9522350 (3781470)

C9522351 (3781475)

C9523300 (3781670)

N.

CODE

C9523301 (3781675)

(3781676)

DESCRIPTION

DESCRIZIONE
BURNER SERIAL NUMBER MATRICOLA BRUCIATORE
ADVISED PARTS RICAMBI CONSIGLIATI

**

STUD SPACER COWLING PIN JOINT PISTON SEAL TIE ROD CAM ASSEMBLY CAM-HOLDER SHAFT SPRING - LEVER PROTECTION COLONNETTA DISTANZIALE CUFFIA SNODO SFERICO ANELLO TIRANTE CAMMA COMPLETA ALBERO CAMMA MOLLA - LEVA PROTEZIONE

61 62 63 64 65 66 67 68 69 70

3013005 3003888 3003883 3006098 3003203 3003881 3012062 3013006 3013478 3013874

02494000000

A A C6505066 - 2918310

** A

= Spare parts for minimum fittings - Ricambi per dotazione minima A+B = Spare parts for basic safety fittings - Ricambi per dotazione base di sicurezza A+B+C = Spare parts for extended safety fittings - Ricambi per dotazione estesa di sicurezza

147