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Staheli West DewPoint 331 Owner'S Manual Download Page 186

©  2021 Staheli West

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50 Hour Maintenance Checklist

EVERY 50 HOURS

STEP(S)

Clean inside the burner blast tube area

1

Clean electrodes and fuel nozzles with compressed air

2

Clean flame detector lens

3

Check blowdown system for blockages

4

Inspect front and rear of boiler by looking for any potential hot spots on the boiler doors

5

Purge steam through top front pigtail valves to clear the steam pressure sensor paths

6-7

Grease PTO anti-rotating shields

8

Grease PTO bearings

9

Grease axles

9

Inspect baler hardware

10-11

1st 50 HOUR MAINTENANCE

Replace burner fuel filter (Napa 4006) (See 250 hour maintenance step 1)

Summary of Contents for DewPoint 331

Page 1: ...DewPoint 331 2021 DewPoint 331 2022 DewPoint 331 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 2: ... Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Quick Navigation Buttons ...

Page 3: ... YOUR DEALER FOR SERVICE ASSISTANCE When you see a QR code in this handbook scan the code with your smart phone or tablet to see the associated video or content iOS Download the App Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 4: ...Controller 42 Operation DewPoint 331 Operator Training 45 Common Operating Times 47 Touch Screen 48 How to Start Steaming 49 Common Valve Settings 51 Simple Operation 52 Steam Rate Adjustment With a Gazeeka 53 Steam Rate Adjustment Without a Gazeeka 54 Common Operation 55 Short Term Storage Wet Layup 56 Keep Hot 57 Blowdown System 58 Water Purge System 60 Steam Purge System 61 Irrigation 62 Cuttin...

Page 5: ... 119 Fault 1016 Airflow Not Detected in Main Ignition 119 Fault 1017 Airflow Not Detected in Run 119 Fault 1018 Airflow Not Detected in Post Purge 119 Fault 1020 Low Water 1 Detected in Start 120 Fault 1021 Low Water 1 Detected in Pre Purge 120 Fault 1022 Low Water 1 Detected in Purge 120 Fault 1023 Low Water 1 Detected in Pre Ignition 120 Fault 1024 Low Water 1 Detected in Spark Ignition 120 Faul...

Page 6: ...ge Low 126 Fault 1113 Burner Controller Output Supply 4 Voltage High 126 Fault 1114 Burner Controller Output Supply 4 Amperage High 126 Fault 1115 Flame Detector 12 V Supply Too Low 126 Fault 1116 Flame Detector 12 V Supply Too High 126 Fault 1117 Flame Detector Voltage Divider 8 5 V Too Low 126 Fault 1118 Flame Detector Voltage Divider 8 5 V Too High 126 Fault 1119 Burner Controller 5 V Supply To...

Page 7: ...ater Level 1 Sensor Amperage High 135 Fault 1241 Boiler Water Level 2 Sensor Not Connected 136 Fault 1242 Boiler Water Level 2 Sensor Amperage High 136 Fault 1243 Fuel Level PSI Sensor Not Connected 136 Fault 1244 Fuel Level PSI Sensor Amperage High 136 Fault 1245 Fuel Pump PSI Sensor Not Connected 137 Fault 1246 Fuel Pump PSI Sensor Amperage High 137 Fault 1247 Low Fire Nozzle PSI Sensor Not Conn...

Page 8: ...lt 1306 Top Rear Actuator Disconnected 151 Fault 1307 Top Rear Actuator Not Calibrated 151 Fault 1308 Top Rear Actuator Stuck Jammed 151 Fault 1309 Bottom Rear Actuator Disconnected 152 Fault 1310 Bottom Rear Actuator Not Calibrated 152 Fault 1311 Bottom Rear Actuator Stuck Jammed 152 Fault 1312 Oxygen Sensor Not Operating 152 Fault 1313 Oxygen Sensor Did Not Confirm The Presence of a Flame 152 Fa...

Page 9: ...ntenance Daily Maintenance 173 Pre Operation 174 Post Operation 176 50 Hour Maintenance 177 250 Hour Maintenance Yearly 181 500 Hour Maintenance 185 1000 Hour Maintenance 187 2000 Hour Maintenance 189 Winterize 191 Spring Start Up 196 Flue Tube Cleaning 198 Maintenance Schedule 202 Notes 203 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Informa...

Page 10: ...ur moisture sensor Teach the differences between microwave and contact moisture sensors with steam Teach the basics of the touch screen Turn on the steamer Shut off the steamer The importance of the PPM setting and how to set it based on your water test How to start the steamer Tune the burner low and high fire Field work screen overview Setting the steam valve proportions Ideal conditions Changin...

Page 11: ...wn is working Train how to confirm water purge is working Train how to confirm steam purge is working Train how to perform the yearly boiler safety test Safety devices what they do and where they are located Call dealer if more service is required I ______________________________ have received instructions on how to properly operate test service and clean the boiler I understand that the operating...

Page 12: ...est Parts offers a 1 year warranty on all parts from the date of purchase Staheli West Parts does not cover labor costs of replacing a warrantied part Warranty will not be honored if routine maintenance has not been performed To ensure warranty coverage use only OEM parts and filters DewPoint Machine Warranty Period Coverage Months Hours Parts Labor 0 12 Unlimited 100 100 Tests Tests Maintenance M...

Page 13: ...ubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Safety Safety Safety Decals 5 Tractor Requirements 7 Machine Faults 8 Safe Procedures 9 Boiler Jurisdiction 11 Boiler Safety Test 12 ...

Page 14: ...us Keep All Shields in Place No Retirar las Tapas Mecánicas Hot Surfaces in Area Superficies Calientes Cercanas Do Not Climb No Subir Use a Safe Ladder or Steps to Service Upper Components Use una Escalera Segura para Mantener los Componentes Superiores Hot Surfaces Inside Superficies Calientes Adentro Never Fire Boiler in Enclosed Area Nunca Prender la Caldera Adentro Safety Decals DO NOT REMOVE ...

Page 15: ...cción de toma de fuerza en el In struction Manual para más detalles To avoid excessive driveline wear adjust hitch height so that the machine runs level See PTO section of the Instruction Manual for further detail Para evitar el desgaste excesivo de toma de fuerza adjuste la altura del enganche de modo que la máquina funciona nivel Véase la sección de toma de fuerza en el In struction Manual para ...

Page 16: ...troller Included 1 4 Hose 1 4 Hose 1 4 Hose 3 4 Hose 5 8 Hose Case Drain 3 8 Flat Face QC 3 8 Parker 0303 050 P2 P1 H3 H5 H6 H4 Hydraulic Requirements Closed center hydraulic system is preferred Open center hydraulic system may require an oil cooler with the machine Minimum Recommended Hydraulic GPM Open Center 15 GPM Closed Center 15 GPM Maximum Recommended Hydraulic GPM Open Center 25 GPM Closed...

Page 17: ...ults have to be corrected and reset or the machine will not operate Faults will remain active but the machine may still operate There are two types of machine faults stop faults and warning faults Stop faults are more serious and the ma chine will not operate The operator will have to fix the problem before the fault can be reset Warning faults are less serious The machine may continue to operate ...

Page 18: ... machine Ensure that stepping and standing only happens in designated safe areas DO NOT step or climb areas specifically marked prohibited Doing so can cause serious injury or death Use caution when standing on the deck of the machine especially if deck is wet DO NOT operate with children near the machine Ensure that all children are kept at a safe distance Shields Guards Door All shields and guar...

Page 19: ... burner safeties Keep hands away from the louver Hands and or fingers can be pinched and lacerated by the fan Keep debris away from the louver to avoid pulling debris into the burner this will obstruct air flow Fire Safety Check the fire extinguisher according to the maintenance schedule attached to the extinguisher If fire does occur use the fire extinguisher as directed on distinguisher Always s...

Page 20: ...on Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Boiler Jurisdiction It is your responsibility to make sure your boiler is up to code and meets the legal requirements in your area For boiler jurisdiction information in your area navigate to https www nationalboard org PrintAllSynopsis aspx Jurisdiction Select ...

Page 21: ...oiler open one of the pig tail valves Make sure the manual gauge and the touch screen I O page shows 0 psi Close the pig tail valve after 0 psi in the boiler is confirmed Connect a compressed air hose to the test port Set the multi meter to Ohms Ω Locate the test port on top of the steamer behind the manual pressure gauge Connect an air chuck to the test port Use a flat head screwdriver to open up...

Page 22: ...urize up to 15 psi The meter will show OL Open Loop when the HPLS trips If the HPLS doesn t trip within 0 25 psi of 15 refer to Test 1005 Relieve pressure in the boiler by opening up one of the pigtail valves until it is around 10 psi The HPLS should trip at 15 psi 0 25 psi This means it is functioning as it should Keep pressurizing the boiler up to 20 psi or until the pressure relief valve opens ...

Page 23: ... 15 17 14 16 18 Connect the probes to each wire as shown The OPLS should trip at 14 5 psi 0 25 psi This means it is functioning as it should Boiler pressure HPLS and OPLS status can all be observed in the IO screen Pressurize the boiler The meter will show OL Open Loop when the OPLS trips If the OPLS doesn t trip within 0 25 psi of 14 5 refer to Test 1006 Make sure the boiler has operating level o...

Page 24: ...nputs Outputs Check the status of boiler low water 1 2 They should both say closed Boiler low water 1 tripped to Open If boiler water drains below the sight glass and one or both of the low waters still shows Closed replace the associated boiler water level sensor Open the boiler drain valve As the water drains both boiler low water 1 2 should trip to Open Both boiler low water 1 2 tripped to Open...

Page 25: ...er Softener 20 Reverse Osmosis Unit 21 Water Setup 22 Water Equipment Selection 23 Water Treatment Chemical 25 Water Quality Blowdown Principles 26 Water Quality Settings 28 Baler Preparation 29 Install Baler Hardware 29 Install Cameras on Baler 29 Install Bale Moisture Monitor on Baler 29 DewPoint Machine Preparation 30 Install Optional Custom Equipment 30 Install Cameras on DewPoint Machine 30 V...

Page 26: ... electrical outlet to operate the softener control system An enclosed insulated area which is protected from freezing An area or drain where bypass water consumed in the softener re charge process can be discharged Some areas with lower water quality may require a Reverse Osmosis RO System to remove impurities from the water This type of system will require A culinary or other water source where t...

Page 27: ...ter as it is pumped from the bulk water storage tank into the DewPoint machine or a water transport vehicle Connect 2 inch suction hose between the bulk water storage tank and the pump inlet chemical inductor TEE Connect 2 inch discharge hose to pump discharge fitting Set Up Water Softener or RO Unit Set up in an enclosed insulated area which is protected from freezing Connect to water supply Conn...

Page 28: ... to employ a water truck or trailer to transport water to the fields where the DewPoint machine s is are working Remember that a DewPoint machine will operate from 2 5 5 hours on one load 500 gallons of water Consider the distance to the field from the water source Use a tank made of either a black plastic steel or other light blocking material which will eliminate light infiltration to prevent al...

Page 29: ...t 20 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Water Softener ...

Page 30: ...1 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Reverse Osmosis Unit ...

Page 31: ...Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Water Setup Bulk Water Storage Tank Light Restricting to Prevent Algae Growth Water Transfer Pump Water Softener Unit Reverse Osmosis RO Unit or 0 5 Gallon Chemical 0 5 Gallon Container Ratio 1 1000 Chemical Water Water Treatment Chemical 55 Gallon ...

Page 32: ...ion Cost of Water Expelled Blowdown Amount of Water Expelled in Blowdown Reduction in Run Time Initial Equipment Cost Parts Per Million PPM of Source Water Parts Per Million PPM of Feed Water 0 0 500 500 1100 1100 Blowdown open 100 of time Reverse Osmosis Water Softener Reverse Osmosis Unit Required Reverse Osmosis Recommended 0 10 20 30 40 50 Carry Over Will Occur Run Time Loss Water Softener vs ...

Page 33: ...ompared to RO Prevents scale build up Low operating costs Reverse Osmosis Pros Reduces total ppm Prevents scale build up Longer DewPoint run time Can use for house shop and spraying operations Water Softener Cons Does not lower ppm High ppm can cause time loss Cannot work with water higher than 1100 total ppm Not recommended for water over 500 ppm of hard minerals Reverse Osmosis Cons Higher initi...

Page 34: ...Requirements Safety Safety Reverse Osmosis Water Soft Water Untreated Water Part 10945 Part 10033 Part 11636 Part 10944 Part 11082 Part 11637 Part 11634 Part 10034 N A Part 11635 Part 10790 N A Water Treatment Chemical 55 Gallon Organic 55 Gallon 15 Gallon Organic 15 Gallon Boiler Guard has 3 purposes Mix with supply water at a 1 1000 ratio 1 Scale Prevention 2 Rust Prevention 3 Foam Prevention ...

Page 35: ... the health and longevity of your boiler system Proper blowdown settings and procedures are a critical element in maintaining boiler water quality Blowdown frequency and volume Frequency of blowdown is dependent upon your water quality test Water tests prior to the use of the DewPoint machine provide the information you need to enter in the water quality screen for an appropriate blowdown schedule...

Page 36: ...er use Confirm the blowdown request and continue baling while the blowdown procedure is executed The waste water from the automatic surface blowdown is discharged through the small red blowdown hose behind the baler pickup Manual Bottom Blowdown at the Beginning of the Day Drain 30 50 gallons of water from the boiler in a safe location using the 2 inch boiler drain valve at the rear bottom end of ...

Page 37: ...ation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Water Quality Settings 1 Turn on the screen and navigate to the Water Quality 2 Enter the PPM Parts per Million for that particular source Failure to enter an accurate PPM will result in either too much or too little water being purged during each blowdown ...

Page 38: ...o provide a good view of the knotter area Mount one camera to provide a good view of the bale chute INSTALL camera extension cables in the baler so they can connect to the 2 camera cables that are mounted in the rear panel of the DewPoint machine and extend to each of the baler mounted cameras ROUTE and SECURE the camera cables with cable zip ties to prevent damage from mechanical components on th...

Page 39: ...ras just below the hole to the inside each tail work light assembly on each side of the DewPoint machine CONNECT camera cable to each camera and route secure each cable through the grommets mounted in each fender and in the inner fender walls as needed FOLLOW the routing of the wire harnesses that run to the tail work light assemblies so the end of each cable is inside the pump enclosure area insi...

Page 40: ...eration Requirements Safety Safety Valve Inspection Feed Water Actuator All valves are shown in normal operating positions Ensure all valves are in the positions shown below for normal operating positions Boiler Drain Valve Supply Water Fill Valve Supply Water Filter T Strainer Feed Water Pump Feed Water Isolation Valve Supply Water Isolation Valve Supply Water Tanks Supply Water Tanks ...

Page 41: ...e Operation Requirements Pre Operation Requirements Safety Safety Actuator Inspection 1 3 4 2 Press to activate Manual Mode Press then to access the Inputs Outputs page Use the Twist Knob to select and test all 7 actuators Visually inspect valves and actuators for damage Turn tractor key to power on Tractor does not need to be running to test the actuators ...

Page 42: ...g Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Actuator Inspection Water Purge Actuator Blowdown Actuator Feed Water Actuator Louver Actuator Bottom Steam Actuator Steam Purge Actuator Top Steam Actuator ...

Page 43: ...peration Pre Operation Requirements Pre Operation Requirements Safety Safety 1 2 Make sure all lug nuts are tightened to 81 ft lbs Inflate tires to 40 psi Wheel Inspection Tires BKT I 1 Farm Implement Size 14L 16 1SL 12 Ply Flotation Wheels 0 38 OFFSET 16 1 X W11C Tractor Preparation Battery Box Wire Harness 11547 Tractor Cab Wire Harness 11546 ...

Page 44: ...oor of the tractor that the harness can be routed through If the tractor does not have pop outs route the harness to the rear window of the tractor If tractor has a cutoff switch connect on the non battery open side Connect the tractor cab wire harness and connect all necessary components The AUX Power plug must be plugged in There is a spare AUX Power outlet provided to power anything else that i...

Page 45: ...Requirements Safety Safety 1 3 5 2 4 6 Insert and secure hitch pin Connect case drain return supply P1 P2 and the lights Connect case drain first and disconnect case drain last Case drain must be a return to sump Connect PTO Use a rubber strap to secure the chain so it won t drag through the windrow Connect the wire harnesses Secure anti rotating shield clip as shown DewPoint Hookup to Tractor ...

Page 46: ...wdown hose light harness camera harness hydraulic lines steam hoses and other equipment if necessary Be sure to adjust hitch height for optimal PTO angles Never operate with harsh PTO angles Insert and secure hitch pin Secure chain so it won t drag through the windrow Make sure the PTO knuckles are lined up on both the DewPoint machine and the baler Failure to do so will result in heavy vibrations...

Page 47: ... radius and clearance limits with all machinery attached TURNING ANGLE NOTES In a turn the angle between the baler and DewPoint machine will be sharper than the angle between the tractor and the DewPoint machine When coming out of a sharp turn quickly the angle between the DewPoint machine and the baler can increase dramatically It is best to come out of sharp turns gently Turning too sharp will c...

Page 48: ...ply water fill valve Slowly open the induction valve and suction 0 5 gallons of water treatment chemical into the supply tanks Always add 0 5 gallons of chemical for every 500 gallons of water Ratio 1 1000 Your water setup should be similar to the above picture To DewPoint Machine Start your water transfer pump to begin filling the DewPoint supply tanks with water When the tanks are nearly full re...

Page 49: ...ner turns on to heat the water and create steam pressure The steam purge and hold mode indicate startup is complete Engage the hydraulics and verify that pressure is detected the supply pressure icon will change from orange to grey Turn on the tractor Confirm whether it is a closed center or open center hydraulics This only needs to be selected once It will need to be changed if you change tractor...

Page 50: ... Fire louver setting and push the knob to select Press to deselect the Low Fire louver position Press and wait for the burner to reach Low Fire flue temperature to reach 150 F Press and wait for the burner to reach High Fire boiler water temperature of 180 F or steam pressure of 5 psi and repeat steps 3 5 Use the Twist Knob to adjust the louver position so the oxygen sensor reads within the optima...

Page 51: ...ailer brakes lock up q Turn power down using power knob 3 If braking was not sufficient q Turn power up using power knob 4 Repeat Step 3 until power has been set to a point just below wheel lock up or at a sufficient force as to achieve maximum braking power 5 Using the brake pedal make a few low speed stops to check the power setting Trailer braking is initiated and terminated via the stoplight s...

Page 52: ...eli West 43 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 53: ...et Layup 56 Keep Hot 57 Blowdown System 58 Water Purge System 60 Steam Purge System 61 Irrigation 62 Cutting 63 Raking 64 DewPoint Machines 66 Baling With Steam 67 Suggested Moisture With Steam 68 Steaming Different Crops 69 Steam Effects in Different Temperatures 70 Judging Bale Moisture 71 Moisture Sensors 72 Judging Bale Moisture with the Gazeeka Moisture Gauge 73 Judging Bale Moisture Visually...

Page 54: ...and functioning properly Operation Use only soft water or reverse osmosis treated water in the DewPoint machine Fill the supply tanks and add water treatment chemical Set up your tractor steering stops Set up your moisture sensor Teach the differences between microwave and contact moisture sensors with steam Teach the basics of the touch screen Turn on the steamer Shut off the steamer The importan...

Page 55: ...idity conditions with stem moisture You are responsible for how your bales turn out Service Cleaning Train how to perform daily maintenance Show where to find the maintenance schedule Train how to confirm blowdown is working Train how to confirm water purge is working Train how to confirm steam purge is working Train how to perform the yearly boiler safety test Safety devices what they do and wher...

Page 56: ...eratures to exceed 140 F Dry Climates Wetter Climates In wet climates DewPoint operators normally start baling in the morning as soon as the dew burns off and the hay is dry enough to start baling Operators often bale through the rest of the day as long as the internal bale temperatures don t exceed 140 F They often bale into the evening until the windrows become too saturated with dew 1 2 3 4 5 6...

Page 57: ... Safety Safety Touch Screen Power Fuel Level Boiler Water Level Increase Top Steam Ratio Decrease Bottom Steam Ratio Steam Pressure Supply Water Level Top Steam On Off Top Steam Output Burner Enable Water System Enable Hold Mode Blowdown Enable Menu Increase Bottom Steam Ratio Decrease Top Steam Ratio Bottom Steam On Off Bottom Steam Output Steam Rate Indicator Steam On Off Twist Knob Steam Ratio ...

Page 58: ...iler fills with water and the burner turns on to heat the water and create steam pressure Engage the hydraulics and verify that pressure is detected the supply pressure icon will change from orange to grey Turn on the tractor Confirm whether it is a closed center or open center hydraulics This only needs to be selected once It will need to be changed if you change tractors Open Center Closed Cente...

Page 59: ...team purge valve opens and releases steam pressure Turn the Twist Knob to adjust your steam rate We suggest starting at 40 Push the Twist Knob to turn on steam The circle on the Twist Knob will light up green while steam is on The Steam Rate indicator and the Steam Output indicators turn green as well to show that steam is on You are ready to start steaming Look at the following suggested steam se...

Page 60: ...ore moisture on top than on bottom start with the Steam Ratio Indicator closer to the bottom and the steam rate at 40 Adjust steam rate as needed When a windrow has more moisture on bottom than on top start with the Steam Ratio Indicator closer to the top and the steam rate at 40 Adjust steam rate as needed When baling in hot and dry conditions start with the Steam Ratio Indicator in the middle an...

Page 61: ...on 1 Check Current Windrow Condition 2 Set Steam Ratio 3 Set Steam Rate The steam ratio should not be changed unless the windrow condition changes 4 Bale 2 4 Bales with Steam 5 Adjust Steam Rate 5 10 If Necessary 6 Repeat Steps 4 5 Until Optimum Bale Moisture is Reached If Dry If Moisture on Bottom If Moisture on Top If Stem Moisture D O N O T B A L E Make steam rate changes based on the average A...

Page 62: ...MEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS Make steam rate changes based on the average Avg reading Adjust steam rate Steam Rate Change Gazeeka Reading Wait 2 Bales 2 Pick a target moisture level for small bales 12 18 3 Adjust steam rate based on the Gazeeka Avg reading 4 Wait for at least two bales before making more steam rate changes 1 Make sure the windrow is dry with no stem...

Page 63: ...ST TWO BALES BETWEEN MAKING ADJUSTMENTS Adjust steam rate Steam Rate Change Steamed Bale Wait 2 Bales Handheld moisture probes are inaccurate when reading recently steamed bales Wait for 1 hour to get a more accurate reading Wait 24 72 hours to obtain a precise reading 2 Increase steam rate until bales look good 3 Wait for at least two bales before making more steam rate changes 1 Make sure the wi...

Page 64: ...ooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Common Operation Turn steam off when Turning around at the end of windrows Slowing down Light Absent windrow spots ...

Page 65: ...ng level If it will sit for more than 30 days it should be winterized see winterization in the maintenance section Filling up the boiler completely with water is the preferred method for short term storage To do this engage tractor hydraulics Then go to manual mode and open the feed water actuator to 100 until water comes out of the pressure relief valve As soon as water comes out set the feed wat...

Page 66: ... used whenever the machine is subjected to less than 32 F 0 C temperatures To initiate keep hot start the machine like normal After the machine has reached operating pressure the steam purge valve will blow steam press the Hold Pause button Leave the tractor and steamer running the entire time the machine will be subjected to below freezing temperatures Using keep hot will prevent sensors plumbing...

Page 67: ...ty Safety As soon as the grey circle is complete a blowdown prompt will appear When prompted press the blowdown button The time until next blowdown is shown The blowdown button will turn blue and the blowdown icon will begin its timer Hot water will shoot out of the red blowdown hose behind baler pickup Make sure no one is underneath the baler before pressing Don t perform blowdown when stopped Bl...

Page 68: ...ependent on the PPM setting The higher the PPM the longer the blowdown It is recommended to route the rear blowdown hose behind the baler pickup where it will not spray on the baler tires Hot blowdown water has been known to cause premature wear on baler tires The purpose of the blowdown system is to prevent water from carrying over the steam hoses and into the hay It opens the blowdown actuator w...

Page 69: ...he water purge valve will close when 15 seconds has elapsed and when the water purge sensor is no longer detecting the water The purpose of the water purge system is to prevent water from carrying over the steam hoses and into the hay It opens the water purge actuator which purges excess water in the steam manifold back into the right rear supply tank If the water purge system gets clogged Fault 1...

Page 70: ...f The target steam rate is 12 psi The burner will shut off when the boiler pressure reaches 13 psi The steam purge valve opens to relieve pressure in the boiler at 12 5 psi The steam purge most commonly occurs during initial startup to purge oxygen and when turning at the end of a windrow when steam is turned off The steam purge valve is open when the Steam Purge indicator is black The steam purge...

Page 71: ...y for baling after it is cured This practice causes excessive machine tracking and crop damage when cutting raking baling and hauling hay It also slows the hay curing process causes inconsistencies in dry down and increases bleaching and the possibility of wet slugs in windrows of hay CONSIDER THIS CHANGE Irrigation Timing When using DewPoint technology you are able to re hydrate very dry hay for ...

Page 72: ...o Cut Hay producers often limit the acres of hay they cut each day because they are not sure how much baling they can actually get done each day with unpredictable natural dew conditions CONSIDER THIS CHANGE How Many Acres to Cut Since DewPoint technology allows operators to bale 12 24 hours per day almost anytime the hay is dry hay producers can schedule their harvest Simply decide how many acres...

Page 73: ...he field is too dry to form natural dew In humid climates or conditions you should avoid double raking hay too early perhaps even waiting until the morning you bale Double raking a day or two ahead of baling in high humidity conditions when there are heavy dews at night causes the dew moisture to sink to the bottom of the windrow after sunrise This moisture is very slow to migrate out of the windr...

Page 74: ...ound without the rake teeth touching the soil This requires careful daily attention to rake adjustment If rake teeth are set too low dirt and or dust will be raked into the hay This increases the ash content in your hay which decreases the feed value numbers on your hay tests This also decreases the monetary value of your crop If rake teeth are set too high you will leave valuable crop tonnage on ...

Page 75: ...500 Gallons 1900 Liters Amount of Boiler Chemical to Add Each Fill 1 1000 1 Gallon 3 8 Liters 0 5 Gallons 1 9 Liters Boiler Water Capacity 350 Gallons 1300 Liters 250 Gallons 950 Liters Fuel Capacity 300 Gallons 1100 Liters 120 Gallons 450 Liters Tractor Requirements Horse Power 200 275 Depending On Slopes 100 175 Depending On Slopes Min Hydraulic GPM N A 15 Recommended Hydraulic GPM N A 25 Hydrau...

Page 76: ...12 14 12 18 Accumulators Horizontal OK Horizontal OK Bale Band it Bale Baron only if bales are 115 F 45 C Suggested Moisture Sensor Gazeeka 870 Gazeeka 180s Colt Contact Moisture Sensors Hand Probe Star Wheel Other baler mounted sensors Contact moisture sensors read 3 5 high when testing recently steamed bales Wait 24 hours for the steam to dissipate and then the contact moisture sensors will read...

Page 77: ...hnical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Large Square Bales Small Square Bales Legumes Alfalfa 12 14 14 22 Grasses Alfalfa Grass 12 14 Forage Grasses Timothy Cereal Grains Oat 12 14 Wheat Triticale Beardless Barley Straw Suggested Moisture With Steam ...

Page 78: ...re leaves higher density more weight less dust consistent bales better effects with TMR and hay press machinery Grasses Alfalfa Grass Higher density more weight less dust consistent bales reduces springy characteristics of bales better effects with hay press machinery Forage Grasses Timothy Cereal Grains Oat Higher density more weight less dust consistent bales reduces springy characteristics of b...

Page 79: ...help flake formation while baling As the temperature rises and the operator uses more steam the flakes will become more and more cohesive The higher the temperature and the steam rate the more cohesive the flakes will be This is one reason why operators may choose to bale during cooler temperatures Bale Flake Characteristics Temperature More Cohesive Less Cohesive 40 F 60 F 80 F 100 F Ideal Flake ...

Page 80: ...our hay and the bale formation characteristics you and you market want in the finished product REMEMBER Steam applied to hay using the DewPoint machine will simulate a higher moisture effect than the actual moisture percentage that is applied FOR EXAMPLE Hay that is 8 moisture in the windrow can be baled at 12 moisture using steam from the DewPoint machine but will look like it was baled at 16 18 ...

Page 81: ...LY with even moisture dispersion 1 Day Reading Moisture level will drop 3 5 from initial reading Accurate With Stem Moisture Initial Reading with Steam Accurate Reads low 3 5 1 Day Reading Accurate There are a variety of moisture sensors or gauges on the market Be sure that your moisture measurement method is installed correctly properly calibrated well understood and working properly before balin...

Page 82: ...ximately 80 Similarly the amount of microwave energy absorbed in air is less than dry hay and in dry hay is much less than in water Thus if measured correctly these measurements can be a very sensitive method of measuring moisture in a bale of hay Whether the moisture detected in hay is from steam natural dew or stem moisture the GAZEEKA Moisture Gauge provides an accurate moisture reading when pr...

Page 83: ...se to use hay preservative along with steam application The steam application will reduce leaf loss and the preservative will prevent hay spoilage We do not recommend baling with stem moisture whether using steam or not unless You are using a proven preservative product You have tested the preservative product along with the use of steam and you know your limits Some producers have successfully ba...

Page 84: ...ge since the plunger does not come in direct contact with it When ob serving the rear end of a bale with the correct moisture level you should expect an excellent leaf pattern Leaves should be attached to stem and or somewhat wafered into the flakes in the bale Bale Conformation The sides of bales with a good moisture level should be compressed smooth and may be slick but of good color Bale shape ...

Page 85: ...esistance and any type of surface moisture will carry conductivity more readily than the entire profile of the crop being baled Fully Cured Hay If an operator becomes very familiar with the typical offset of the moisture reading of this instrument compared to the actual moisture in the bale he can learn to use a handheld contact type moisture sensor with reasonable effectiveness when baling fully ...

Page 86: ...e hay A stem of hay that is not fully cured may be relatively dry on the outside but green on the inside Therefore while the inside of the stem may be very conductive the conductivity between stems is typically much lower This insulates the signal between the measuring points on the sensor resulting in a lower overall reading at the time of baling Moisture readings with a handheld probe a few days...

Page 87: ...rall bale profile If you notice rising bale moisture readings over several days after baling you should monitor the bale moisture and temperature readings daily until these readings peak and begin to fall If bale temperature and moisture readings continue to rise to dangerous levels you should consult your local hay association and or fire department to avoid a stack fire In this case you should f...

Page 88: ...g with Steam page When bale temperatures approach the maximum either reduce steam injection rates or wait until a cooler time of day to bale How to Judge Bale Temperature Use a combination Handheld bale moisture temperature probe Use a bale temperature probe Part 11345 Insert thermometer into bale and allow to equalize for a few minutes to get a stable bale temperature reading When baling with hig...

Page 89: ... evening or night time can be hauled and stacked the next morning Hay baled in the early morning to mid morning before high steam rates are used can be hauled and stacked the same day Hay baled from mid morning through the early evening at high steam rates should not be hauled and stacked until the next morning Stacking High Temperature Steamed Hay When Weather Is a Threat If bales of hay must be ...

Page 90: ...eli West 81 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 91: ...formation Technical Information Components Location List 83 Diagram 1 84 Diagram 2 85 Diagram 3 86 Diagram 4 87 Diagram 5 87 Diagram 6 88 Diagram 7 88 Diagram 8 89 Diagram 9 90 Diagram 10 91 Diagram 11 92 Diagram 12 93 Diagram 13 94 Diagram 14 95 Hydraulic Systems 96 Field Work Screen 97 How The 331 Works 98 Machine Specifications 99 Sensors 100 Outputs 104 Actuators 105 Fuses 106 Off Delay Relay ...

Page 92: ... 3 12044 Fuel Filter 4 10054 Fuel Level Sensor 8 32870 Fuel Pump Pressure Gauge 5 33056 Fuel Pump Pressure Sensor 5 32982 Fuse Block 8 High Fire Nozzle 7 33080 High Fire Pressure Sensor 5 32982 High Fire Solenoid Valve 5 33058 High Pressure Limit Switch HPLS 3 10379 Hydraulic Block 12 14 28080 Hydraulic Case Drain Pressure Sensor 13 24132 Hydraulic Oil Cooler 8 12 14 32942 Component Diagram Part H...

Page 93: ... Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 1 Boiler Burner Fuel Tanks Water Tanks ...

Page 94: ... 2 Boiler Sight Glass Rear Furnace Door Flue Flue Temperature Sensor Feed Water Actuator Water Purge Sensor Oxygen Sensor Feed Water Pump Blowdown Actuator Supply Water Filter T Strainer Boiler Water Level Sensor 2 Steam Purge Actuator Boiler Water Level Sensor 1 Bottom Steam Actuator Bottom Steam Actuator Steam Purge Actuator Water Purge Actuator Water Purge Actuator Top Steam Actuator Top Steam ...

Page 95: ...Operation Requirements Safety Safety Diagram 3 Steam Pressure Sensor Front Turn Box High Pressure Limit Switch HPLS Operating Pressure Limit Switch OPLS Manual Steam Pressure Gauge Boiler Sight Glass Boiler Water Temperature Sensor Feed Water Pump Boiler Water Level Sensor 2 Boiler Water Level Sensor 1 Bottom Steam Actuator Steam Purge Actuator Top Steam Actuator Pressure Relief Valve ...

Page 96: ...ty Diagram 4 Diagram 5 Spark Coil Burner Fuel Pump Fuel Filter Louver Actuator Airflow Switches Airflow Switch 1 Low Fire High Fire Airflow Switch 2 Burner Sight Glass Overhung Load Adapter Fuel Pump Pressure Gauge Fuel Pump Pressure Sensor Low Fire Pressure Sensor High Fire Pressure Sensor Safety fuel solenoid Valve Low Fire Solenoid Valve High Fire Solenoid Valve Fan Motor Fan Motor Fan Speed Se...

Page 97: ...nformation Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 6 Diagram 7 Low Fire Nozzle High Fire Nozzle Flame Detector Tube Electrode Electrode Electrode Flame Detector Electrode Electrode Electrode Flame Detector Low Fire High Fire ...

Page 98: ...rmation Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 8 IOX Module Burner Controller Boiler Controller Fuse Block Hydraulic Oil Filter Supply Water Level Sensor Fuel Level Sensor Hydraulic Oil Cooler Optional Hydraulic Supply Filter Sensor Hydraulic Valve Block Hydraulic Block ...

Page 99: ...ical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 9 Feed Water Actuator Boiler Drain Valve Supply Water Fill Valve Supply Water Filter T Strainer Feed Water Pump Feed Water Isolation Valve Supply Water Isolation Valve Supply Water Tanks Supply Water Tanks ...

Page 100: ...ements Safety Safety Feed Water Diagram 10 Water System Supply Water Supply Water Level Sensor Supply Water Level Sensor Supply Water Fill Valve Supply Water Fill Valve Feed Pump Protection Sensor Feed Water Pump Pressure Sensor Check Valve Feed Water Actuator Feed Water Pump Feed Water Pump Feed Water Pump Feed Water Actuator Sparge Tube Supply Water Filter T Strainer Supply Water Filter T Strain...

Page 101: ...Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 11 From Water Purge Front Right Tank To Hydraulic Oil Cooler Optional Feed Pump Protection Sensor Feed Water Pump Supply Water Filter T Strainer Supply Water Level Sensor Supply Water Fill Valve Water Purge Actuator ...

Page 102: ...ing Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 12 Fan Motor Hydraulic Oil Filter Feed Water Pump Hydraulic Block Hydraulic Oil Cooler Optional Hydraulic System ...

Page 103: ...tion Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 13 Hydraulic Block Feed Pump ON OFF Solenoid Fan ON OFF Solenoid Hydraulic Return Pressure Fan Speed Control Open Center Hydraulic Supply Pressure Hydraulic Case Drain Pressure Feed Water Pump Flow Control Fan Speed Control Closed Center Hydraulic Pressure Relief Valve ...

Page 104: ...ooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 14 Supply Contingency Hose Fan Motor Hydraulic Oil Filter Hydraulic Oil Cooler Optional Feed Water Pump Hydraulic Block Return Case Drain ...

Page 105: ...eat because they send the hydraulic pump s full capacity to the DewPoint The DewPoint then bypasses all unnecessary flow back to the tractor If an operator has the option to run hydraulic pumps coupled at low rpm s or run one pump at higher rpm s they should run one pump at higher rpm s Turning down the flow on the SCV will create more heat within the tractor and is therefore not a good option The...

Page 106: ...fety Safety Field Work Screen Power Fuel Level Boiler Water Level Increase Top Steam Ratio Decrease Bottom Steam Ratio Steam Pressure Supply Water Level Top Steam On Off Top Steam Output Burner Enable Water System Enable Hold Mode Blowdown Enable Menu Increase Bottom Steam Ratio Decrease Top Steam Ratio Bottom Steam On Off Bottom Steam Output Steam Rate Indicator Steam On Off Twist Knob Steam Rati...

Page 107: ...Point 331 generates steam which is injected into hay windrows The ability to inject steam gives farmers the following benefits Added Bale Weight Added Value Risk Mitigation Increased Annual Yield Dew More With Less Better Lifestyle Boiler Burner Fuel Tanks Water Tanks The DewPoint 331 is powered by the 12 V tractor supply and the tractor hydraulic system A diesel burner heats water inside the boil...

Page 108: ... Pre Operation Requirements Safety Safety Capacity Run Time Output Dry Weight 7 300 lbs 3300 kg 500 Gal 1 900 L 2 5 5 Hours 40 80 Tons Load 35 70 Metric Tons Load 120 240 Tons Load 110 220 Metric Tons Load 7 5 15 Hours 250 Gal 950 L 120 Gal 450 L 16 000 lbs 7 250 kg Fully Loaded Supply Water Boiler Water Fuel Diesel 14 6 ft 4 47 m 9 ft 2 74 m 8 5 ft 2 59 m Machine Specifications ...

Page 109: ...ature 0 300 F 100 240 F DT06 4S Furnace Door Temperature 0 300 F 100 150 F 160 F 180 F DT06 4S Ambient Temperature 0 300 F 100 F DT06 4S Feed Pump Protection 0 30 psi 5 psi while pump is running 5 psi Shuts off pump DT06 4S Steam Pressure 0 30 psi 6 13 psi DT06 4S Supply Water Level 0 5 psi 0 500 gallons 0 500 gallons 50 gallons DT06 4S Fuel Level 0 5 psi 0 150 gallons 0 150 gallons 50 gallons DT0...

Page 110: ...i 100 psi DT06 3S High Fire Nozzle Pressure 0 500 psi 100 psi DT06 3S Hydraulic Supply Filter Normally Closed ON Not Restricted DT06 2S Baler Chamber Pressure Optional 0 3500 psi Depends on baler 5 psi DT06 3S Hydraulic Supply Pressure 0 3500 psi 40 psi 40 psi or fan speed 3600 DT06 3S Hydraulic Return Pressure 0 3500 psi 350 psi DT06 3S Hydraulic Case Drain Pressure 0 3500 psi 50 psi DT06 3S 12 V...

Page 111: ...With fan running 3 Way AMP Superseal Airflow Switch 2 Normally Open ON With fan running 3 Way AMP Superseal Flame Detector DT04 3P Boiler Water Level 1 Low Water 1 0 12 Inches Normally Closed Pictured Open 3 7 inches ON 8 inches 10 inches 2 inches differential DT06 4S Boiler Water Level 2 Low Water 2 0 12 Inches Normally Closed Pictured Open 3 7 inches ON 8 inches 10 inches 2 inches differential D...

Page 112: ...ty Sensors Sensor Function Range Normal Range Warning Trip Alarm Connector Wire Harness End Operating Pressure Switch Normally Closed 14 5 psi Spade High Pressure Limit Switch Normally Closed 15 psi Spade Water Purge Normally Open Closed On when detecting water 10 min water detection while steaming DT06 3S Oxygen Low Fire 1 85 2 3 High Fire 1 15 2 22 Outside of Normal Range DTM06 4S 12 V GND Signa...

Page 113: ...Harness End Safety Fuel Solenoid IP 67 DIN Low Fire Fuel Solenoid IP 67 DIN High Fire Fuel Solenoid IP 67 DIN Output Device Connector Wire Harness End Feed Pump ON OFF Solenoid DT06 2S Fan ON OFF Solenoid DT06 2S Fan Speed Control Open Center DT06 2S Fan Speed Control Closed Center DT06 2S Spark Coil Delphi 4 pin 1 2 3 4 GND 1 2 3 4 GND 1 2 3 4 GND 12 V GND 12 V GND 12 V GND 12 V GND GND GND 5 V O...

Page 114: ...nector Wire Harness End CAN Address Louver Actuator DT06 4S N A Water Purge Actuator DT06 4S N A Blowdown Actuator DT06 4S 1 Steam Purge Actuator DT06 4S 2 Top Steam Actuator DT06 4S 3 Bottom Steam Actuator DT06 4S 4 Feed Water Actuator DT06 4S 7 GND CAN 1 CAN 1 12 V GND CAN 2 CAN 2 12 V GND CAN 2 CAN 2 12 V GND CAN 2 CAN 2 12 V GND CAN 2 CAN 2 12 V GND CAN 2 CAN 2 12 V GND CAN 2 CAN 2 12 V Actuat...

Page 115: ... Supply Voltage 17 Diagnostic Port 4 Hydraulic Filter Switch 18 Water Purge Sensor 5 Oxygen Sensor 19 Hydraulic Fan Speed Control 6 Hydraulic Fan Feed Pump ON OFF 20 High Fire Fuel Solenoid 7 Safety Fuel Solenoid 21 Fan Speed Sensor 8 Water Purge Actuator 22 High Pressure Switch 9 Steam Purge Actuator 23 Operating Pressure Switch 10 Blowdown Actuator 24 Low Water 1 Switch 11 Feed Water Actuator 25...

Page 116: ...lay relay is set to ensure proper controller shutdown It also engages and disengages the battery cut off relay The off delay relay should be set to 2 5 seconds See below for how to set the relay properly The off delay relay is very important and should NEVER be replaced with a common 12 v relay 1 OFF 2 ON 12 v ON OFF 2 5 Second Off Delay Battery Cut Off Relay Battery Cut Off Relay Display Display ...

Page 117: ... CAV PIN1 SP858 20 AWG RED 109A F7 FUSE 20 AWG GRY 716B AIR FLOW 20 AWG RED 103A F1 FUSE 20 AWG GRY 705A LOW H2O BOILER 1 20 AWG GRY 707B LOW H2O BOILER 2 20 AWG RED 208 SW PWR PAGE 3 POWER GROUND ZONE H4 CAV 1 SP83 18 AWG RED 144A F41 FUSE 20 AWG GRY 705 LOW H2O BOILER 1 PAGE 8 IOX MODULE ZONE G26 CAV 9 P84 20 AWG RED 123A F20 FUSE 20 AWG RED 143A F40 FUSE 20 AWG VIO WHT 713B FLAME DECT 20 AWG VI...

Page 118: ...zzle 1 2 High Fire 220 The fuel pump psi should be set at 227 during high fire This should give Nozzle 1 a reading of 227 psi in Low Fire and Nozzle 1 2 a reading of 220 psi in High Fire To adjust the fuel pump psi insert a flat head screwdriver into the adjustment port Turn clockwise to increase psi and counter clockwise to decrease psi Make sure the manual gauge and the touch screen readings mat...

Page 119: ...eli West 110 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 120: ...r 2 Detected in Run 121 Fault 1037 Low Water 2 Detected in Post Purge 121 Fault 1040 High Pressure Detected in Start 122 Fault 1041 High Pressure Detected in Pre Purge 122 Fault 1042 High Pressure Detected in Purge 122 Fault 1043 High Pressure Detected in Pre Ignition 122 Fault 1044 High Pressure Detected in Spark Ignition 122 Fault 1045 High Pressure Detected in Main Ignition 122 Fault 1046 High ...

Page 121: ...07 Boiler Controller Output Supply 2 Voltage High 129 Fault 1208 Boiler Controller Output Supply 2 Amperage High 129 Fault 1209 Boiler Controller Output Supply 3 Voltage Low 129 Fault 1210 Boiler Controller Output Supply 3 Voltage High 130 Fault 1211 Boiler Controller Output Supply 3 Amperage High 130 Fault 1212 Boiler Controller Output Supply 4 Voltage Low 130 Fault 1213 Boiler Controller Output ...

Page 122: ... Boiler Water Level Too High Over 8 Inches 143 Fault 1266 Boiler Water Level Too High Over 10 Inches 143 Fault 1267 Fan Speed Over 4500 RPM 143 Fault 1269 Open Center Fan Speed Valve Short To Ground 144 Fault 1270 Fan ON OFF Solenoid Disconnected 144 Fault 1271 Fan ON OFF Solenoid Short To Ground 144 Fault 1272 Feed Water Pump ON OFF Solenoid Disconnected 144 Fault 1273 Feed Water Pump ON OFF Sole...

Page 123: ...Reach Commanded Position 153 Fault 1320 Bottom Steam Actuator Did Not Reach Commanded Position 154 Fault 1323 Feed Water Actuator Did Not Reach Commanded Position 154 Fault 1324 Louver Actuator Did Not Reach Commanded Position 154 Fault 1325 Steam Pressure Boiler Water Temp Differential 154 Fault 1326 Fuel Not Detected During Ignition 155 Fault 1327 High Fire Nozzle Pressure Low While in High Fire...

Page 124: ...nformation Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety How to Reset a Fault Fault Text Will Appear Here Press to close fault window Press to reset fault Faults have to be corrected and reset or the machine will not operate Faults will remain active but the machine may still operate ...

Page 125: ...rge Fault 1003 Flame Detected in Purge Fault 1004 Flame Detected in Pre Ignition Indicates flame was detected when there should be no flame Causes Troubleshooting Fixes Flame in boiler Check for burning smoldering debris inside the boiler Start the fan in Manual Mode to blow out the fire Wait for flame to burn out Faulty flame detector 3 Flame detector LED states Blinking No flame Solid Flame No L...

Page 126: ...e troubleshooting 3 Flame detector LED states Blinking No flame Solid Flame No LED Problem No power Replace flame detector Faulty flame detector voltage divider Solid LED with flame but fault 1005 still appears indicates a faulty flame detector voltage divider Replace flame detector voltage divider Dirty electrode s See 50 hour maintenance for burner gun cleaning See Test 1002 for spark testing Cl...

Page 127: ...l flow through the main and safety fuel solenoid valves Perform Test 1001 Replace faulty fuel solenoid valve Loose Leaking Faulty fuel nozzle Remove burner gun and inspect low fire nozzle Tighten Replace nozzle Low fuel pressure Check fault history for faults 1326 1331 Faulty flame detector 3 Flame detector LED states Blinking No flame Solid Flame No LED Problem No power Replace flame detector che...

Page 128: ...018 Airflow Not Detected in Post Purge Indicates airflow was not detected when there should be airflow See fault 1260 if fan is not starting Causes Troubleshooting Fixes Clogged airflow switch hoses filters Start the fan in manual mode and observe the airflow switch status should be closed This will cause fault 1010 to appear If fault 1010 does not appear continue troubleshooting Check the airflow...

Page 129: ...Main Ignition Fault 1026 Low Water 1 Detected in Run Fault 1027 Low Water 1 Detected in Post Purge Indicates the low water 1 sensor is detecting low boiler water level when the boiler water level should not be low Causes Troubleshooting Fixes Poor water quality See fault 2003 Drain boiler and refill with fresh water See fault 2003 for more causes and fixes Faulty feed water actuator Test in Manual...

Page 130: ... Fault 1037 Low Water 2 Detected in Post Purge Indicates the low water 2 sensor is detecting low boiler water level when the boiler water level should not be low Causes Troubleshooting Fixes Low water 1 Low water 2 sensors wire harness connections are crossed Ensure low water 1 is plugged into the front sensor and 2 is plugged into the rear sensor Swap wire harness connections at low water 1 2 sen...

Page 131: ...46 High Pressure Detected in Run Fault 1047 High Pressure Detected in Post Purge The High Pressure Limit Switch should trip at 15 PSI Causes Troubleshooting Fixes High pressure limit switch faulty out of calibration Perform Test 1005 Adjust the calibration nut to 15 PSI Replace high pressure limit switch Operating pressure control switch faulty out of calibration If the HPLS tripped at 15 psi or h...

Page 132: ...56 Operating Pressure Tripped in Run Fault 1057 Operating Pressure Tripped in Post Purge The Operating Pressure Control Switch should trip at 14 5 PSI Causes Troubleshooting Fixes Operating pressure control switch faulty out of calibration Perform Test 1006 Adjust the calibration nut to 14 5 PSI Replace operating pressure control switch Blown fuse 23 main fuse block Check fuse for blown symptoms R...

Page 133: ...ator and manually move the louver to feel if there is any resistance or obstructions Remove obstructions Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1100 Burner Controller Watchdog Reset If problem persists contact dealer replace controller Fault 1101 Battery Voltage High Over 16 5 V Burner Controller Check tractor battery If problem persis...

Page 134: ...spect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1107 Burner Controller Output Supply 2 Voltage High Check tractor battery If problem persists contact dealer replace controller Fault 1108 Burner Controller Output Supply 2 Amperage High Check tractor battery If problem persists contact dealer replace controller Fault 1109 Burner Controller Output Supply 3 Voltag...

Page 135: ...ller Output Supply 4 Voltage High Check tractor battery If problem persists contact dealer replace controller Fault 1114 Burner Controller Output Supply 4 Amperage High Check tractor battery If problem persists contact dealer replace controller Fault 1115 Flame Detector 12 V Supply Too Low Triggers when voltage is under 10 8 V Fault 1116 Flame Detector 12 V Supply Too High Triggers when voltage is...

Page 136: ...bleshooting Fixes Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Faulty burner controller Replace burner controller Fault 1125 Low Fire on off Solenoid Disconnected Indicates an open circuit during use Causes Troubleshooting Fixes Solenoid disconnected Connect solenoid Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair ...

Page 137: ...iring for ground continuity and proper voltage Repair Replace wiring Faulty solenoid Replace solenoid Fault 1130 Safety Fuel on off Solenoid Short To Ground Indicates the amperage draw is too high Causes Troubleshooting Fixes Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Faulty solenoid Replace solenoid Fault 1131 Spark Coil Disconnected Indicates ...

Page 138: ... contact dealer replace controller Fault 1205 Boiler Controller Output Supply 1 Amperage High Check tractor battery If problem persists contact dealer replace controller Fault 1206 Boiler Controller Output Supply 2 Voltage Low Check tractor battery If problem persists contact dealer replace controller Fault 1207 Boiler Controller Output Supply 2 Voltage High Check tractor battery If problem persis...

Page 139: ...on Inspect feed pump ON OFF solenoid wiring and connection Replace fuse 6 7 5 amp Replace hydraulic fan ON OFF solenoid Replace feed pump ON OFF solenoid Fault 1213 Boiler Controller Output Supply 4 Voltage High Check tractor battery If problem persists contact dealer replace controller Fault 1214 Boiler Controller Output Supply 4 Amperage High Check tractor battery If problem persists contact dea...

Page 140: ...iring Faulty sensor Replace sensor Fault 1222 Flue Temp Sensor Voltage High Indicates 4 5 volts is present on the signal wire Causes Troubleshooting Fixes Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Faulty sensor Replace sensor Fault 1223 Flue Temp is High Alarm 600F Fault 1224 Flue Temp is High Warning 550F Rising flue temperatures indicate the ...

Page 141: ...n the signal wire Causes Troubleshooting Fixes Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Faulty sensor Replace sensor Fault 1227 Furnace Door Temp Sensor Not Connected Indicates 0 5 volts is not present on the signal wire Causes Troubleshooting Fixes Sensor disconnected Connect sensor Faulty sensor Swap with compatible sensor See sensor page Re...

Page 142: ...on from excessive heat Replace rear furnace door insulation and rope gaskets Faulty sensor Use infrared thermometer to check rear furnace door area for normal temperatures Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1231 Ambient Temp Sensor Not Connected Indicates 0 5 volts is not present on the signal wire Causes Troubleshoo...

Page 143: ...ire for 5 seconds Causes Troubleshooting Fixes Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1235 Hydraulic Supply PSI Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Sensor disconnected Connect sensor Faulty sensor Swap ...

Page 144: ...al wire for 5 seconds Causes Troubleshooting Fixes Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1239 Boiler Water Level 1 Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Sensor disconnected Connect sensor Faulty sensor S...

Page 145: ...gnal wire for 5 seconds Causes Troubleshooting Fixes Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1243 Fuel Level PSI Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Sensor disconnected Connect sensor Faulty sensor Swap ...

Page 146: ...pped between pump and solenoid Start machine normally When fan turns the pressure should drop Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1247 Low Fire Nozzle PSI Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Sensor d...

Page 147: ... wire for 5 seconds Causes Troubleshooting Fixes Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1251 Supply Water Level Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Sensor disconnected Connect sensor Faulty sensor Swap ...

Page 148: ...e signal wire for 5 seconds Causes Troubleshooting Fixes Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1255 Steam Pressure Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Fault still active Sensor won t give correct readi...

Page 149: ...or Fault 1258 Baler Chamber Pressure Sensor Not Connected Indicates 4mA is not present on the signal wire Causes Troubleshooting Fixes Sensor disconnected Connect sensor Faulty sensor Swap with compatible sensor See sensor page Replace sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1259 Baler Chamber Pressure Sensor Amperage High Indica...

Page 150: ...blown symptoms Replace fuse 21 2 amp Faulty hydraulic supply pressure sensor Showing pressure when there is no pressure Replace hydraulic supply pressure sensor Tractor hydraulic oil level low empty Inspect the hydraulic oil level Fill hydraulic oil to appropriate level Faulty fan ON OFF solenoid Repair Replace solenoid Faulty fan speed control CC Machine operates on Open Center or Closed Center M...

Page 151: ... it stops then turn screw clockwise one full rotation Adjust feed water pump flow control to 2 4 gpm Fault 1263 Feed Pump Running Protection PSI Too Low Less Than 5 PSI Less than 5 psi was detected during pump run Causes Troubleshooting Fixes Plugged supply water filter Clean supply water filter No supply water Fill supply water tanks Faulty feed pump protection sensor Can be swapped with the stea...

Page 152: ...ater Level Too High Over 10 Inches Indicates the boiler water level has been reading more than 10 inches for 20 seconds Causes Troubleshooting Fixes Wet layup Have you performed a wet layup recently Wet layup fills the boiler completely full of water Drain water from boiler to desired level Faulty feed water actuator Test in manual mode Replace feed water actuator Poor water quality See fault 2003...

Page 153: ...ct the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1271 Fan ON OFF Solenoid Short To Ground Indicates the amperage draw is too high Causes Troubleshooting Fixes Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Faulty valve Replace valve Fault 1272 Feed Water Pump ON OFF Solenoid Disconnected Indicates an open circuit du...

Page 154: ...ed Water Actuator Not Opening Blown fuse 11 main fuse block Check fuse for blown symptoms Replace fuse 11 5 amp Faulty feed water actuator Test for functionality in Manual Mode Swap connection with blowdown actuator to confirm faulty actuator Replace feed water actuator Faulty feed water actuator wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Faulty check ...

Page 155: ...as not been programmed by the factory Causes Troubleshooting Fixes Faulty water purge actuator Replace water purge actuator Fault 1278 Blowdown Actuator Is Disconnected Indicates the CANBUS heartbeat communication is offline Causes Troubleshooting Fixes Blowdown actuator disconnected Connect blowdown actuator Blown fuse 10 main fuse block Check fuse for blown symptoms Replace fuse 10 5 amp Wrong C...

Page 156: ...tuator has not been programmed by the factory Causes Troubleshooting Fixes Faulty actuator Replace actuator Fault 1283 Steam Purge Actuator Stuck Jammed Indicates the internal encoder does not match the commanded actuator position Causes Troubleshooting Fixes Obstruction in valve Remove obstruction Faulty actuator Replace actuator Fault 1284 Top Steam Actuator Is Disconnected Indicates the CANBUS ...

Page 157: ...address the actuator See Test 1008 Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1288 Bottom Steam Actuator Is Not Calibrated Indicates the actuator has not been programmed by the factory Causes Troubleshooting Fixes Faulty actuator Replace actuator Fault 1289 Bottom Steam Actuator Stuck Jammed Indicates the internal encoder does not match th...

Page 158: ...eartbeat communication is offline Causes Troubleshooting Fixes Louver actuator disconnected Connect louver actuator Blown fuse 14 main fuse block Check fuse for blown symptoms Replace fuse 14 5 amp Wrong CAN address on the louver actuator Change the address to 0 then re address the actuator See Test 1008 Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wirin...

Page 159: ... 5 amp Unprogrammed burner controller Contact dealer Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1301 Boiler CANBUS Communication Failure Indicates the CANBUS heartbeat connection is offline Machine will not operate until fault is fixed Causes Troubleshooting Fixes DewPoint disconnected Connect main harness from tractor to DewPoint Disconne...

Page 160: ...ve blockage from water purge system Blown fuse 18 main fuse block Check fuse for blown symptoms Replace fuse 18 5 amp Faulty water purge sensor Replace water purge sensor Faulty wiring Inspect the wiring for ground continuity and proper voltage Repair Replace wiring Fault 1306 Top Rear Actuator Disconnected Indicates the CANBUS heartbeat communication is offline Causes Troubleshooting Fixes Top re...

Page 161: ... Fixes Faulty actuator Replace actuator Fault 1311 Bottom Rear Actuator Stuck Jammed Indicates the internal encoder does not match the commanded actuator position Causes Troubleshooting Fixes Obstruction in valve Remove obstruction Faulty actuator Replace actuator Fault 1312 Oxygen Sensor Not Operating The oxygen sensor never turned on and advanced to the operating state takes about 20 seconds Cau...

Page 162: ... See Test 1008 Replace actuator Part 34279 Fault 1317 Blowdown Actuator Did Not Reach Commanded Position Indicates the internal encoder does not match the commanded actuator position Causes Troubleshooting Fixes Obstruction in valve Remove obstruction Faulty actuator Swap with compatible actuator See Test 1008 Replace actuator Part 34242 Fault 1318 Steam Purge Actuator Did Not Reach Commanded Posi...

Page 163: ...uction Faulty actuator Swap with compatible actuator See Test 1008 Replace actuator Part 34242 Fault 1324 Louver Actuator Did Not Reach Commanded Position Indicates the internal encoder does not match the commanded actuator position Causes Troubleshooting Fixes Obstruction in louver Remove obstruction Faulty actuator Swap with compatible actuator See Test 1008 Replace actuator Part 34279 Fault 132...

Page 164: ...ler No Low fuel psi with fan turning Tighten set screw Restricted fuel flow through the low fire and safety fuel solenoid valves Inspect fuel paths check for overtightened fittings See Test 1001 Remove restrictions Clogged fuel lines Use compressed air to clear the lines Fault 1327 High Fire Nozzle Pressure Low While in High Fire Burner State High Fire High Fire Nozzle psi 20 of Fuel Pump psi for ...

Page 165: ...lter Replace fuel filter Part 10054 Loose Leaking fuel nozzle Remove burner gun and inspect nozzle Tighten Replace nozzle Clogged fuel lines Use compressed air to clear the lines Fault 1329 Low Fire Nozzle Pressure Low While in Low Fire Burner State Low Fire Low Fire Nozzle PSI 20 of Fuel Pump PSI for 20 seconds Causes Troubleshooting Fixes Fuel nozzle 1 2 sensor cables are crossed Swap cables to ...

Page 166: ...ire nozzle pressure sensor Replace nozzle pressure sensor Part 32982 Faulty high fire fuel solenoid Inspect high fire fuel solenoid for leaks Replace high fire fuel solenoid Fault 1331 Fuel Pump Pressure Low Burner State Purge Fuel Pump PSI 100psi for 10 seconds Causes Troubleshooting Fixes No fuel Inspect fuel tanks for empty qualities Fill fuel tanks Faulty fuel pump pressure sensor Swap with hi...

Page 167: ... Touch Screen Controller Will Not Turn On Causes Troubleshooting Fixes 12 V auxiliary not plugged in Located in the tractor cab Plug in 12 V auxiliary Tractor harness not plugged into battery box harness Inspect the 3 connectors ground positive 2 pin Deutsch Connect tractor cab harness to battery box harness Faulty 12 V off delay relay Located in the tractor cab wiring harness Replace 12 V off del...

Page 168: ... filter Faulty fuel pump Causes fluctuating fuel psi Replace fuel pump Incorrect fuel pressure setting Set fuel pressure to 227 psi during high fire Faulty louver actuator Test in Manual Mode to see if louver actuator moves Swap with water purge actuator Replace louver actuator Dirty flue tubes Inspect flue tubes from rear exhaust flue area Clean the tubes See flue tube cleaning in the Maintenance...

Page 169: ...aminants Clean the tanks and remove all contaminants Dissolved solids have not been drained out of the bottom of the boiler Drain 30 40 gallons of water out of the bottom of the boiler using the main boiler drain valve Scale has built up in the boiler Remove a hand hole cover and inspect boiler tubes for scale Use REDEW Boiler De scaler Part 11194 Use water treatment chemical Preventative Faulty s...

Page 170: ...ll need to be used Fault 2007 Camera Problems Causes Troubleshooting Fixes Faulty monitor Swap with known working monitor Replace monitor Faulty camera Swap with working camera Replace camera Faulty wire harness Swap with working wire harness Repair Replace wire harness Under voltage over voltage Test voltage to ensure 12 V Fix voltage problems Fault 2008 Boiler Taking Longer Than Normal to Heat U...

Page 171: ...n Pre Operation Requirements Pre Operation Requirements Safety Safety Tests Tests Test 1001 Fuel solenoid 163 Test 1002 Spark Test 164 Test 1003 Electrode Gap 165 Test 1004 Valve Repair 166 Test 1005 HPLS Calibration 167 Test 1006 OPLS Calibration 168 Test 1007 Burner Tune 169 Test 1008 Canbus Address Setting 170 Test 1009 Boiler Water Level Sensor 171 ...

Page 172: ...r hand on the fuel solenoid valves and confirm that it opens You should feel a click as it opens If it hums or buzzes this indicates a faulty solenoid valve that needs cleaning or replacement Before the startup bar reaches the Ignition point shown above place your hand on the safety low fire solenoid as shown in step 3 The burner status will also say Main Ignition when igniting Filling Boiler Heat...

Page 173: ...bulkhead Connect both spark coil wires together with the bulkhead and place the burner gun assembly on the deck as shown Start the machine like normal Remove the burner gun assembly When the machine gets to the Spark Ignition phase sparking should occur between the electrodes on the burner gun for 4 seconds Make sure it is sparking on the tips of the electrodes and sparking inside the tube If ther...

Page 174: ...hooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Test 1003 Electrode Gap Low Fire Nozzle High Fire Nozzle Flame Detector Tube Electrode 7 64 3mm 19 32 15mm 3 4 19mm Electrode Electrode Electrode ...

Page 175: ...age the surfaces on the valve where the seats will need to seal 1 Remove the retainer nut from the end of the valve and remove the outer seat and the ball the ball must be in the closed position before it can be removed 2 Remove the retainer nut on the stud at the top of the valve 3 Remove the stud and the inner seal by pressing the stud down into the valve and out the end 4 Remove the outer seal ...

Page 176: ... boiler while monitoring the boiler pressure Take note at what pressure the HPLS trips and whether adjustment is necessary Trip Point 15 psi Loosen the set screw with a 5 64 Allen key Set the multimeter to read ohms Ω Then connect the two leads to the two wires in the HPLS There should be continuity until the HPLS trips If adjustment is needed release pressure in the boiler by opening one of the p...

Page 177: ...boiler while monitoring the boiler pressure Take note at what pressure the OPLS trips and whether adjustment is necessary Trip Point 14 5 psi Loosen the set screw with a 5 64 Allen key Set the multimeter to read ohms Ω Then connect the two leads to the two wires in the OPLS There should be continuity until the OPLS trips If adjustment is needed release pressure in the boiler by opening one of the ...

Page 178: ...he Low Fire louver setting and push the knob to select Press to deselect the Low Fire louver position Press and wait for the burner to reach Low Fire flue temperature to reach 150 F Press and wait for the burner to reach High Fire boiler water temperature of 180 F or steam pressure of 5 psi and repeat steps 3 5 Use the Twist Knob to adjust the louver position so the oxygen sensor reads within the ...

Page 179: ...s Address Setting 1 3 4 2 Use needle nose pliers to remove the weatherproofing plug Use a small flat head screwdriver to set the canbus address Use needle nose pliers to pull 2 of the 3 metal pins out of the weatherproofing plug Remove the plastic nut shown above Actuator CAN Address Louver Actuator N A Water Purge Actuator N A Blowdown Actuator 1 Steam Purge Actuator 2 Top Steam Actuator 3 Bottom...

Page 180: ...avigate to the Inputs Outputs screen The boiler water level should be at 0 and the low water should be open shown above for sensor 2 Move the float 1 at a time and check that the water level reading matches the float position If the water level does not match replace the water level sensor 0 12 Low Water Open Low Water Closed Remove the sensor Reconnect the sensor with the float at the bottom With...

Page 181: ...tion Requirements Pre Operation Requirements Safety Safety Maintenance Maintenance Daily Maintenance 173 Pre Operation 174 Post Operation 176 50 Hour Maintenance 177 250 Hour Maintenance Yearly 181 500 Hour Maintenance 185 1000 Hour Maintenance 187 2000 Hour Maintenance 189 Winterize 191 Spring Start Up 196 Flue Tube Cleaning 198 Maintenance Schedule 202 Notes 203 ...

Page 182: ...y Maintenance Checklist PRE OPERATION STEP S Clean supply water filter T strainer 1 6 Drain boiler water for 10 seconds 7 Grease PTO weasler shaft 8 Inspect gauges sensors and sight glasses 9 Purge steam through baler hardware nozzles to clear debris 10 POST OPERATION STEP S Purge steam through baler hardware nozzles to clear debris 1 Remove crop debris from enclosed areas 2 1st OPERATION Check to...

Page 183: ...peration Requirements Safety Safety 1 3 5 2 4 6 Close the supply water isolation valve Clean the filter with water Open the supply water isolation valve Unscrew the supply water filter Re install the supply water filter Unscrew the supply water filter until water leaks out Then screw the supply water filter back in This purges any trapped air in the lines Daily Maintenance Pre Operation ...

Page 184: ...ion Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 7 9 8 10 Open the boiler drain valve and drain water for 10 seconds Inspect gauges sensors and sight glasses Grease the weasler shaft about 20 pumps Purge steam through baler hardware nozzles to clear debris Daily Maintenance Pre Operation 8 ...

Page 185: ...ubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 2 Remove crop debris from enclosed areas Daily Maintenance Post Operation Purge steam through baler hardware nozzles to clear debris ...

Page 186: ...be area 1 Clean electrodes and fuel nozzles with compressed air 2 Clean flame detector lens 3 Check blowdown system for blockages 4 Inspect front and rear of boiler by looking for any potential hot spots on the boiler doors 5 Purge steam through top front pigtail valves to clear the steam pressure sensor paths 6 7 Grease PTO anti rotating shields 8 Grease PTO bearings 9 Grease axles 9 Inspect bale...

Page 187: ... the flame detector and clean the lens Check blowdown hose and system for blockages or kinks Remove burner gun and clean electrodes and fuel nozzles with compressed air Inspect front and rear of boiler by looking for any potential hot spots on the boiler doors Paint will bubble and change color if excessive heat has occurred 50 Hour Maintenance Front Turn Box Rear Boiler Door Turn on the steamer a...

Page 188: ...ing and the bull pull hitch Grease all the zerks on the grease block located inside the rear door 50 Hour Maintenance While the boiler is under pressure open all four pigtail valves one at a time This purges any water debris out of the pigtail valves 50 50 Rear PTO Mid PTO R Axle R C Axle L C Axle L Axle 50 Hr 50 Hr 50 Hr 50 Hr 50 Hr 50 Hr 10 Pumps 10 Pumps 10 Pumps 10 Pumps 10 11 Inspect steam ho...

Page 189: ...eli West 180 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 190: ...uirements Safety Safety 250 Hour Maintenance Checklist EVERY 250 HOURS STEP S Perform 50 hour maintenance See 50 hour Replace burner fuel filter Napa 4006 1 Remove and clean burner gun nozzles 2 Remove and clean airflow switch sensors and air lines 3 Inspect boiler tubes for scale 4 Rotate tires front to rear 5 Check water purge system for blockages 6 Clean water purge sensor 7 Boiler Safety Test ...

Page 191: ...R INTO SWITCHES Re install when finished Rotate tires front to rear Remove the burner gun nozzles and clean with a solvent Remove one of the rear hand holes and inspect boiler tubes for scale If a lot of scale is present contact local dealer Tubes in picture are in good condition 250 Hour Maintenance Yearly While the boiler is under pressure open the water purge valve and listen for crackling in t...

Page 192: ...nical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Clean water purge sensor Make sure boiler is not under pressure before removing water purge sensor Perform boiler safety test See safety section for instructions 250 Hour Maintenance Yearly 7 8 Water Purge Sensor ...

Page 193: ...eli West 184 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 194: ...ts Pre Operation Requirements Safety Safety 500 Hour Maintenance Checklist EVERY 500 HOURS STEP S Perform 50 hour maintenance See 50 hour Perform 250 hour maintenance See 250 hour Clean boiler flue tubes top and bottom as needed 1 Inspect boiler rear door L brackets for tightness 23 ft lbs 2 Inspect boiler front smoke turn box insulation 3 Check torque on wheel nuts 81 ft lbs 4 ...

Page 195: ...ation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 3 2 4 Check torque on wheel nuts 81 ft lbs 500 Hour Maintenance Clean the flue tubes if needed See Flue Tube Cleaning Inspect the boiler front door insulation 9 16 Crow s Foot Inspect boiler rear door L brackets for tightness Tighten boiler rear door L brackets to 23 ft lbs ...

Page 196: ...cal Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1000 Hour Maintenance Checklist EVERY 1000 HOURS STEP S Perform 50 hour maintenance See 50 hour Perform 250 hour maintenance See 250 hour Perform 500 hour maintenance See 500 hour Clean out water side of the boiler 1 ...

Page 197: ...ormation Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 Clean out the water side of the boiler Remove all hand holes and camlocks Pressure wash as much of the internals of the boiler as possible Use a shop vac to vacuum everything out of the bottom of the boiler 1000 Hour Maintenance ...

Page 198: ...n Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 2000 Hour Maintenance Checklist EVERY 2000 HOURS STEP S Perform 50 hour maintenance See 50 hour Perform 250 hour maintenance See 250 hour Perform 500 hour maintenance See 500 hour Perform 1000 hour maintenance See 1000 hour Re pack wheel hub bearings with grease 1 ...

Page 199: ...Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 2000 Hour Maintenance Remove and re pack wheel hub bearings with grease ...

Page 200: ...rm winterization procedures Always use a ladder or other appropriate means to reach upper components which require attention for winterization When should you winterize your DewPoint machine Before winter storage Anytime you expect the machine to be exposed to temperatures below freezing when it is not in operation Anytime you plan to have the machine out of service for an extended time Tools Need...

Page 201: ... the boiler is under pressure open all four pigtail valves one at a time This purges any water debris out of the pigtail valves Turn off the tractor and the valves will stay open The next time the key is turned on the valves will close automatically For quicker drying start the machine and heat water until the steam purge opens Go to Manual Mode and open the valves Menu Inputs Outputs This will de...

Page 202: ...ning water in the boiler If machine is equipped with hydraulic oil cooler perform steps 11 12 Remove the bottom feed pump plug with a 7 16 wrench After the boiler is drained disconnect the boiler drain camlock and remove the assembly Remove the supply water filter and housing Remove the return hose on the front left water tank and blow compressed air through the hose This will clear water out of t...

Page 203: ... Unplug and remove the steam psi sensor Remove the feed pump protection sensor Remove hand hole Take picture of tubes to see the differences year to year Close the valve and remove the supply water level sensor Underneath front right tank Steam Pressure 0 30 psi Supply Water Level 0 5 psi Feed Pump Protection 0 30 psi Knock trapped water out of sensors Place sensors in an area that will not drop b...

Page 204: ...peration Requirements Pre Operation Requirements Safety Safety Winterize 19 21 23 20 22 Turn the tractor key on This will close all of the valves Turn the tractor key off Re install the supply water filter Put tie down straps on flue exhaust caps to prevent water birds rodents from entering the flue Re install the hand hole Re install the feed water pump plug ...

Page 205: ...irements Pre Operation Requirements Safety Safety Spring Start Up It is very important that you follow these procedures to ensure proper operation of your DewPoint machine SAFETY PRECAUTIONS Do not climb on machine to perform procedures Always use a ladder or other appropriate means to reach upper components Tools Needed Phillips Screwdriver Crescent Wrench 9 16 End Wrench ...

Page 206: ...flue exhaust caps and make sure they open freely Re install the steam pressure sensor Re install the feed pump protection sensor Re install the steam pressure supply water level and feed pump protection sensors Re install the supply water level sensor Test the pressure relief valve by lifting up the lever fully several times Steam Pressure 0 30 psi Supply Water Level 0 5 psi Feed Pump Protection 0...

Page 207: ... 2 4 6 Items Needed Safety goggles dust mask shop vac paint suit 1 5 flue tube brush Part 10178 attached to a 7 foot rod socket set Remove these 12 nuts with a 9 16 wrench socket Remove the 4 shields Remove the hood by removing these bolts with a 3 4 wrench socket Remove these 6 nuts and bolts with a 1 2 wrench socket Remove the 4 remaining nuts on the front door with a 9 16 wrench socket and remo...

Page 208: ...afety Flue Tube Cleaning 7 9 8 Remove all of the heat diffusers They are in the top section of tubes Clean the tubes one column at a time Clean the bottom tube first then insert the shop vac With the shop vac running clean each tube above until the column is clean keep the shop running and inserted in the bottom tube Clean vacuum filter as needed Get the shop vac and tube cleaning brush 1 2 3 4 5 ...

Page 209: ...ts Pre Operation Requirements Safety Safety Flue Tube Cleaning 10 12 11 11 13 12 Re install all of the heat diffusers Re install the front boiler door Tighten the 4 nuts shown above Re install the 4 shields Re install these 6 nuts and bolts with a 1 2 wrench socket Re install these 12 nuts with a 9 16 wrench socket Re install the hood Install these bolts with a 3 4 wrench socket ...

Page 210: ...eli West 201 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety ...

Page 211: ...m for blockages x Check blowdown system for blockages x Inspect front and rear of boiler by looking for any potential hot spots on the boiler doors x Purge steam through top front pigtail valves x Replace burner fuel filter Napa 4006 1st x Remove and clean burner gun nozzles x Remove and clean airflow switch sensors and air lines x Inspect boiler tubes for scale x Clean water purge sensor x Boiler...

Page 212: ... West 203 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Notes ...

Page 213: ... 2021 Staheli West 204 Notes ...

Page 214: ... 2021 Staheli West 205 Notes ...

Page 215: ... 2021 Staheli West 206 Notes ...

Page 216: ...tly packed with good leaf pattern Sides of bales should be smooth but not smeared Always use boiler water treat ment chemical in boiler water Always use appropriate water treatment equipment Softener RO to treat boiler water Make sure PPM setting in controller matches the results of your water test appear in bales check the PPM setting in the controller drain the water out of the boiler and concen...

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