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Staheli West DewPoint 6210 2015, Owner'S Manual, Page: 151 / 280

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Staheli West DewPoint 6210 2015 Owner'S Manual Download Page 151

©  2022 Staheli West

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Faults

Fault 217: Fuel Nozzle 1 Pressure Is Low in Low Fire

Indicates that fuel 1 nozzle pressure is 5% lower than pump pressure.

Causes

Troubleshooting

Fixes

• Fuel nozzle 1 & 2 sensor cables 

are crossed.

• Swap cables to appropriate sensor.

• Restricted fuel flow through the 

fuel solenoid valves.

• Inspect fuel path, check for 

overtightened fittings.

• Remove restrictions.

• Loose/Leaking fuel nozzle.

• Remove burner gun and inspect 

nozzle.

• Tighten/Replace nozzle.

• Faulty Sensor (Fuel pump or 

nozzle 1).

• Swap sensors to identify faulty 

sensor.

• Replace faulty sensor.

• Faulty O-ring in fuel gun 

assembly.

• Remove gun assembly and 

inspect O-ring. See test 22.

• Replace O-ring.

Fault 218: Fuel Nozzle 1 Pressure Is Low in High Fire

Indicates that fuel 1 nozzle pressure is 5% lower than pump pressure.

Causes

Troubleshooting

Fixes

• Restricted fuel flow through the 

fuel solenoid valves.

• Inspect fuel path, check for 

overtightened fittings.

• Remove restrictions.

• Loose/Leaking fuel nozzle.

• Remove burner gun and inspect 

nozzle.

• Tighten/Replace nozzle.

• Faulty sensor (Fuel pump or 

nozzle 1).

• Swap sensors to identify faulty 

sensor.

• Replace faulty sensor.

Fault 219: Fuel Nozzle 2 Pressure Is Low in High Fire

Indicates that fuel 2 nozzle pressure is 10% lower than pump pressure.

Causes

Troubleshooting

Fixes

• Restricted fuel flow through the 

fuel solenoid valves.

• Inspect fuel path, check for 

overtightened fittings.

• Remove restrictions.

• Loose/Leaking fuel nozzle.

• Remove burner gun and inspect 

nozzle.

• Tighten/Replace nozzle.

• Faulty sensor (Fuel pump or 

nozzle 2).

• Swap sensors to identify faulty 

sensor.

• Replace faulty sensor.

• Clogged burner fuel filter.

• Replace burner fuel filter.

• Restricted fuel flow through the 

fuel manifold.

• Remove each hose from the 

fuel manifold and check for 

appropriate flow.

• Remove restrictions.

• Faulty CR-3 relay.

• Swap with spare 120 V relay.

Summary of Contents for DewPoint 6210 2015

Page 1: ...0 2018 DewPoint 6210 2019 DewPoint 6210 2020 DewPoint 6210 2021 DewPoint 6210 2022 DewPoint 6210 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Inf...

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

Page 3: ...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 CONTACT YOUR DEALER FOR SERVICE ASSISTANCE Tests Tests Mainten...

Page 4: ...tments 53 Operation Common Operating Times 56 How to Start Steaming 57 Common Valve Settings 59 Simple Operation 60 Steam Rate Adjustment With a Gazeeka 61 Steam Rate Adjustment Without a Gazeeka 62 C...

Page 5: ...e Switch Off Louver Low Fire Position Is Set Abnormally High 141 Fault 46 127 Call Service 141 Fault 200 High Pressure Limit Switch HPLS Is Tripped 142 Fault 201 Turn Burner Switch ON 143 Fault 202 Op...

Page 6: ...rflowing 178 Fault 304 A Work Lights Will Not Turn On 178 Fault 304 B Side and Top Rear Work Lights Will Not Turn On 2015 2016 Machines Only 179 Fault 305 Touch Screen Controller Will Not Turn On 180...

Page 7: ...4 5 psi 207 Test 10 A Boiler Water Level Sensor Testing 207 Test 10 B Boiler Water Level Sensor Testing 2015 Machines Only 208 Test 11 Valve Repair 209 Test 12 Pump Service 210 Test 13 Input Card Test...

Page 8: ...t water or reverse osmosis treated water in the DewPoint machine Fill the supply tanks and add Boiler Guard water treatment chemical Set up your tractor steering stops Set up your moisture sensor Teac...

Page 9: ...rn 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 Explain...

Page 10: ...d problems caused by operator negligence or operator error are not covered The warranty period for the DewPoint machine starts from the date of first use Staheli West Parts offers a 1 year warranty on...

Page 11: ...ing Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Safety Safety Safety Decals 13 Tractor Requireme...

Page 12: ...Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety This P...

Page 13: ...l dangerous Keep All Shields in Place No Retirar las Tapas Mec nicas Hot Surfaces in Area Superficies Calientes Cercanas Do Not Climb No Subir Use a Safe Ladder or Steps to Service Upper Components Us...

Page 14: ...ci n de toma de fuerza en el In struction Manual para m s detalles To avoid excessive driveline wear adjust hitch height so that the machine runs level See PTO section of the Instruction Manual for fu...

Page 15: ...need a tractor with the following horsepower In order to stop the DewPoint machine and a big baler you will need a tractor equipped with a hydraulic trailer brake valve Adjust the amount the hydraulic...

Page 16: ...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...

Page 17: ...nguisher according to the maintenance schedule attached to the extinguisher If fire does occur use the fire extinguisher as directed on distinguisher Always stand upwind of flames Safe Procedures Open...

Page 18: ...n 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...

Page 19: ...ne needs to be full of fuel and water before the boiler safety test can occur Press Test Now Press Confirm Test Now Generator will start after this step Following the instructions on the screen press...

Page 20: ...Relief button to relieve pressure Reset the HPLS by pressing down on the Reset button The indicator turning green indicates proper function of Low Water 1 Repeat these steps for Low Water 2 Attach ai...

Page 21: ...Pressure Relief button until the OPLS resets If the indicators turn green for Burner Relay Fan VFD and Airflow Switch and turn red when the Burner is turned off they are functioning properly Ensure t...

Page 22: ...Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety This P...

Page 23: ...ater Equipment Selection 30 Water Treatment Chemical 32 Quality Blow Down Principles 33 Quality Settings 35 Baler Preparation 36 Install Baler Hardware 36 Install Cameras on Baler 36 Install Bale Mois...

Page 24: ...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...

Page 25: ...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 Connec...

Page 26: ...machine s is are working Remember that a DewPoint machine will operate from 3 6 hours on one load 1000 gallons of water Consider the distance to the field from the water source Remember that you can...

Page 27: ...27 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Saf...

Page 28: ...Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety...

Page 29: ...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 Softene...

Page 30: ...on 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 5...

Page 31: ...mpared 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 So...

Page 32: ...equirements 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 T...

Page 33: ...ext operation Whenever a different water supply source is used please select that water source from the Water Quality screen Water Quality Blow Down Principles Boiler Blow Down Boiler water quality ma...

Page 34: ...use Confirm the blow down request and continue baling while the blow down procedure is executed The waste water from the automatic surface blow down is discharged through the small red blow down hose...

Page 35: ...uirements Safety Safety Water Quality Settings 1 Turn on the screen and navigate to the Water Quality Maint 2 Select a water source name the source if desired 3 Enter the PPM Parts per Million for tha...

Page 36: ...w of the knotter area or knotter flags Mount one camera to provide a good view of the bale chute or bale accumulator INSTALL camera extension cables in the baler so they can connect to the 2 camera ca...

Page 37: ...cameras 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 mount...

Page 38: ...ation Requirements Pre Operation Requirements Safety Safety Install Air Hose Coupler 1 3 2 4 Locate the red air hose under the hood on the driver side Attach air hose coupler that fits your compressed...

Page 39: ...rements Safety Safety Valve Inspection Feed Water Pump Feed Water Actuator Circulation Isolation Valve Circulation Isolation Valve Boiler Drain Valve Feed Water Drain Valve Supply Water Filter T Strai...

Page 40: ...Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 3 2 4 Be sure to remove tie downs from flue caps before starting the generator Check engine oil use SAE 15W 4...

Page 41: ...quirements Safety Safety 1 3 5 2 4 Ensure that all relays are securely plugged in and latch is closed Make sure all circuit breakers are turned ON Make sure the toggle switch on the bottom of the PLC...

Page 42: ...ts Safety Safety Actuator Inspection 1 3 4 2 Turn on the red battery cutoff switch Turn on the machine by flipping the red rocker switch Plug in the touch screen to the DewPoint machine From the Menu...

Page 43: ...echnical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Actuator Inspection 8 7 9 6 Water Purge Valve 7 Feed Water Valve 8 Blowdown Valve Visually...

Page 44: ...ormation Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 2 Make sure all lug nuts are tightened to 260 ft lbs Inflate tires to proper psi Wheel Inspection 2 5...

Page 45: ...and secure hitch pin Tip Make sure DewPoint machine is full of water so it is at operating level before adjusting hitch height Connect chains in crossing pattern This prevents the chains from dragging...

Page 46: ...Connect PTO Blowdown hose Lights 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...

Page 47: ...PTO 3 point hitch Hydraulic hoses Brake and steering hoses All wire harnesses LEARN your turning radius and clearance limits with all machinery attached including accumulators if used TURNING ANGLE N...

Page 48: ...the supply water fill valve Slowly open the induction valve and suction 1 gallon of water treatment chemical into the supply tanks Always add 1 gallon of chemical for every 1000 gallons of water Your...

Page 49: ...switch Press Start All Press Confirm Start The DewPoint ensures safeties are in place and starts the burner fan A 30 second purge occurs before the burner ignites Follow the on screen instructions and...

Page 50: ...machine needs to be full of water in order to tune It is best to tune the burner at the location and alti tude where the DewPoint machine will be used Decrease louver position until dark smoke appears...

Page 51: ...is clear i e no bale or anything else The end of the bale should be inside the rear end of the baler doors by at least a foot Press Item to select the ENT for Air Cal item Press ENT to select an air p...

Page 52: ...ast 24 readings 120 5 24 Note that this time is the time spent analyzing not the real time on a clock If the Gazeeka 870 is on the ISObus reading the star wheel and knotter signals then the Peak and A...

Page 53: ...e valve Before moving depress brake pedal to test brake actuation Drive tractor about 10 MPH in an open area on a level dirt or gravel surface and depress the brake pedal to test braking power You sho...

Page 54: ...li West 54 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Saf...

Page 55: ...Irrigation 70 Cutting 71 Raking 72 DewPoint Machines 74 Baling With Steam 75 Suggested Moisture With Steam 76 Steaming Different Crops 77 Steam Effects in Different Temperatures 78 Judging Bale Moist...

Page 56: ...ratures to exceed 135 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 Oper...

Page 57: ...gree with the Owner Operator Agreement before he can move on to the Field Work screen The machine will prepare for field work This will take 5 30 minutes depending on how full the boiler is and the st...

Page 58: ...want the most output from The MASTER steam slider should be used to adjust the overall steam output The MASTER steam slider also adjusts all valves in the proportion you have set How to Start Steaming...

Page 59: ...steam valves around 70 and the bottom steam valves at 100 When a windrow has more moisture on bottom than on top start with the bottom steam valves around 70 and the top steam valves at 100 When bali...

Page 60: ...n 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 I...

Page 61: ...ith a Gazeeka REMEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS Steam Rate Change Gazeeka Reading Wait 2 Bales 2 Pick a target moisture level 12 14 3 Adjust steam rate based on the Gazeek...

Page 62: ...Adjustment Without a Gazeeka REMEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS Handheld moisture probes are inaccurate when reading recently steamed bales Wait for 1 hour to get a more ac...

Page 63: ...oting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Common Operation Turn steam off when Turning a...

Page 64: ...erating 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 te...

Page 65: ...ratures To initiate keep hot turn on the touch screen press Keep Hot Confirm Keep Hot The generator will start and the machine will start and build pressure like a normal start all The generator will...

Page 66: ...blowdown lasts is dependent 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 and where it will not spray on the...

Page 67: ...DewPoint machine Contact your dealer if you do not know your PPM number The blowdown will begin and hot water will purge out of the blowdown hose Ensure the blowdown hose is not kinked A kinked blowdo...

Page 68: ...his water purge system continues to operate until the machine is shut down The purpose of the water purge system is to prevent water from carrying over into the steam hoses and into the hay The water...

Page 69: ...target steam rate 12 psi default The steam purge is active at 50 and above on the master steam rate and it is deactivated when the master steam rate is below 50 It is deactivated on lower rates to pr...

Page 70: ...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...

Page 71: ...y 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 te...

Page 72: ...e 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...

Page 73: ...areful 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...

Page 74: ...lons 3800 Liters 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 Lite...

Page 75: ...14 14 22 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...

Page 76: ...nical 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...

Page 77: ...higher density more weight less dust consistent bales better effects with TMR Total Mixed Ration and hay press machinery Grasses Alfalfa Grass Higher density more weight less dust consistent bales red...

Page 78: ...elp 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...

Page 79: ...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...

Page 80: ...eam Accurate Accurate in cooler conditions similar read ings to natural dew for experienced balers only Accurate ONLY with even moisture dispersion Accurate ONLY with even moisture dispersion 3 Day Re...

Page 81: ...rly 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 measur...

Page 82: ...of high humidity where hay cannot be fully cured no stem moisture you may choose to use hay preservative along with steam application The steam application will reduce leaf loss and the preservative w...

Page 83: ...steam or natural dew the bale chamber pressure method of judging moisture is not accurate and is risky When baling with steam in the hot part of the day bale chamber pressure will nearly double to mai...

Page 84: ...e 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...

Page 85: ...sistance 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 off...

Page 86: ...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...

Page 87: ...l carry conductivity more readily than the entire profile of the crop being baled If an operator becomes very familiar with the typical offset of the moisture reading of this instrument compared to th...

Page 88: ...all 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 f...

Page 89: ...proach 135 F 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 probe type di...

Page 90: ...e but they are too hot to stack conventionally you can consider the following procedure Pick up and haul the bales from the field using your normal method DO NOT leave bales on a truck bale mover etc...

Page 91: ...97 Diagram 6a 2017 2022 97 Diagram 6b 2015 2016 98 Diagram 7a 2017 2022 98 Diagram 7b 2015 2016 99 Diagram 8 99 Diagram 9 100 Diagram 10 100 Diagram 11 101 Diagram 12 101 Diagram 13 101 Diagram 14 101...

Page 92: ...Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety This P...

Page 93: ...1 psi Low Fire Sensor 10349 Diagram 4 5 Fuel Nozzle 2 psi High Fire Sensor 10349 Diagram 4 5 Fuel Pressure Gauge 10709 Diagram 5 Fuel Pump Burner 10045 Diagram 5 Fuel Pump psi Sensor 10349 Diagram 5...

Page 94: ...ter Valve Actuator Boiler Door Temp Sensor Rear Furnace Door Flue Temp Sensor Water Purge Valve Actuator Steam Purge Valve Actuator Bottom Front Steam Valve Actuator Bottom Rear Steam Valve Actuator T...

Page 95: ...el Sensor Steam psi 1 Manual Steam Pressure Gauge Operating Pressure Limit Switch OPLS High Pressure Limit Switch HPLS Steam psi 2 Pigtail Valve Feed Water Temp Sensor Louver Actuator Burner Nozzles B...

Page 96: ...mp Fuel Pressure Gauge Fuel Nozzle 2 psi High Fire Sensor Fuel Nozzle 1 psi Low Fire Sensor Diagram 4b 2015 2016 Louver Actuator Burner Nozzles Burner Cone Airflow Switch Flame Detector Control Switch...

Page 97: ...ety Diagram 5b 2015 Diagram 6a 2017 2022 Purge Card Burner Controller Flame Amplifier Card Modbus Card Flame Detector Fuel Pump psi Sensor Front Boiler Sight Glass Airflow Switch Louver Actuator Burne...

Page 98: ...troller Low Water 1 2 Relays TS2 Terminal Strip 2 TS1 Terminal Strip 1 RR Relay Rail CB Circuit Breakers VFD Variable Frequency Drive Panel 3 Panel 2 Generator Controller Relay Pack TS1 Terminal Strip...

Page 99: ...upply Water Level Sensor Burner Fuel Filter Louver Actuator Ambient Temp Sensor Burner Fuel Pump Fuel Pressure Gauge Diagram 7b 2015 2016 Diagram 8 Panel 3 Panel 2 TS1 Terminal Strip 1 TS2 Terminal St...

Page 100: ...Pump Feed Water Actuator Boiler Drain Valve Supply Water Isolation Valve Circulation Pump Supply Water Fill Valve Hot Water Mixed Water Cold Water Diagram 9 Diagram 10 Supply Water Filter T Strainer F...

Page 101: ...4 Water System Feed Water Supply Water Circulation Water Feed Water Sparge Tube Circulation Water Sparge Tube Feed Water Temp Sensor Boiler Water Temp Sensor Y Strainer Feed Water Pump Circulation Pum...

Page 102: ...ements Safety Safety Diagram 15 Diagram 16 Steam Purge Actuator Water Purge Actuator Water Purge Hose Blowdown Actuator Feed Water Pump Bypass Hose Circulation Water Pump Bypass Hose Feed Water Pump C...

Page 103: ...hnical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Diagram 17 Propane System Tank Regulator 10 PSI Propane Pressure Sensor...

Page 104: ...ormation Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Field Work Screen Master Steam ON OFF Button Individual Steam ON OFF Buttons Master Steam Slider Master...

Page 105: ...rom the touch screen located in the tractor cab The DewPoint 6210 is powered by a 240 V generator A diesel burner heats water inside the boiler until boiling Steam is transferred through hoses into cu...

Page 106: ...3 6 Hours 120 200 Tons Load 110 180 Metric Tons Load 360 600 Tons Load 330 540 Metric Tons Load 9 18 Hours 350 Gal 1 300 L 300 Gal 1 100 L 29 000 lbs 13 200 kg Fully Loaded Supply Water Boiler Water F...

Page 107: ...6 Hours Ignition Engine 3 Cyl Diesel 240 VAC 21 Horse Power 12 000 Watts Alternator Bias Ply Floatation Tires Standard Four 4 550 45 22 5 Four 4 620 40 R22 5 52 psi Field Pressure 36 psi Field Pressur...

Page 108: ...le in Settings Alarm Status Screen Adjust in Settings Alarm Settings Low Water 1 Annunciate upon contact with water On Off Below 1 inch in sight glass Low Water 2 Annunciate upon contact with water On...

Page 109: ...Settings Boiler Pressure Screen Feed Water Temperature 0 300 F 100 240 F Above 150 F differential Disable in Settings Alarm Status Screen Adjust in Settings Alarm Settings Boiler Water Temperature 0...

Page 110: ...t Fuel Pump psi 0 500 psi 145 155 psi Nozzle 1 psi Not on 2015 Machines 0 500 psi 145 155 psi High Fire 20 psi less than pump Low Fire 30 psi less than pump Disable in Settings Alarm Status Screen Noz...

Page 111: ...r Steam Valve Actuator Feed Water Valve Actuator Blowdown Valve Actuator 1 GND 2 4 20mA 3 GND 4 12 V Actuators are interchangeable Connections are interchangeable Steam Purge Valve Actuator A GND B 24...

Page 112: ...es Manual LCD Display Using the Menu System Task Description Entering Menu When in the OFF mode press the enter button to bring up the menu Navigating Menu Once in the menu use the up and down arrows...

Page 113: ...ank success is achieved i e engine has started the GSC300 enters the RUN mode and the front panel ENGINE RUNNING LED will be lit Removing power while the controller is in the RUN mode may corrupt the...

Page 114: ...am Valve F4 5 Bottom Rear Steam Valve F5 5 Steam Water Purge F6 5 Feed Water Valve F7 5 Blowdown Valve F8 5 Louver Actuator Panel 3 AMP Component F1 15 12 V to Actuators F2 15 12 V to 24 V Power Regul...

Page 115: ...lve F5 5 Steam Water Purge F6 5 Feed Water Valve F7 5 Blowdown Valve F8 5 Louver Actuator Panel 3 AMP Component F1 15 12 V to Actuators F2 15 12 V to 12 V Power Regulator F3 2 12 V to PLC V0 Y0 3 F4 1...

Page 116: ...r winter storage we suggest turning the switch OFF to save the battery life The main circuit breaker is located on the passenger side of the generator The breaker needs to be turned ON to be able to o...

Page 117: ...ration Requirements Safety Safety Connections DT06 2S Work Lights DT06 3S Flue Temp Water Steam Purge DT06 4S Valve Actuators Tail Light Assembly M12 Temp Sensors Fuel Water Level Sensors Pres Sensors...

Page 118: ...Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety...

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

Page 120: ...t 120 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety S...

Page 121: ...ontrol Power Panel 1 Panel 1 Door Panel 2 Burner Door Switch Generator Plug 120 V to Control Power 120 V 120n 120 V GND SR1 24 V signal from SR1 telling the PLC that Control Power is ON 24 V signal to...

Page 122: ...iring 2017 2022 Panel 2 Panel 3 1 2 3 4 Connection 2A 12 V 12 V 24 V GND Fuel Glowplug Control Relay Touch Screen BAT BAT Crank Fuel Red Rocker Switch Touch Screen Ground Crank Coil Glowplug Coil Fuel...

Page 123: ...peration Pre Operation Requirements Pre Operation Requirements Safety Safety Touch Screen Wiring 2015 2016 Panel 2 Panel 3 1 2 3 4 Connection 2A 12 V 12 V 24 V GND 12 V GND GND 12 V 12 V 24 V GND 1 8...

Page 124: ...Pre Operation Requirements Pre Operation Requirements Safety Safety Panel 2 Relay Block Wiring 2017 2022 120 V to Feed Water Pump Start 120 V to CR 3 High Fire Relay 120 V to Circ Water Pump Start Bur...

Page 125: ...ration Requirements Pre Operation Requirements Safety Safety Panel 2 Relay Block Wiring 2015 2016 120 V to Feed Water Pump Start 120 V to CR 3 High Fire Relay 120 V to Circ Water Pump Start Burner Res...

Page 126: ...Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety...

Page 127: ...7 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safet...

Page 128: ...uel Pump psi 150 Nozzle psi Nozzle 1 Low Fire 150 Nozzle 1 2 High Fire 130 The fuel pump psi should be set at 150 This should give nozzle 1 a reading of 150 psi in low fire and nozzle 1 2 a reading of...

Page 129: ...rements Safety Safety Fan Motor Typical Amp Draw Low Fire 12 amps High Fire 15 amps Purge 19 amps The fan motor is a 3 phase 240 V motor This motor spins the fan and the fuel pump It is slowly ramped...

Page 130: ...5 GPH Gallons Per Hour nozzle sprays fuel on low fire and both nozzles spray fuel on high fire Disassemble the nozzles with a 5 8 wrench and a 5 32 Allen wrench Clogged or faulty nozzles can contribut...

Page 131: ...li West 131 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Sa...

Page 132: ...DEV001 No Device Found 171 Fault 250 Fuel Pump Pressure LOW 172 Fault 251 Propane Pressure HIGH 172 Fault 1 No Purge Card 134 Fault 14 High Fire Switch Purge Hold T19 High Fire Switch See Fault 222 1...

Page 133: ...Generator Controller Not Working Displayed on Screen 199 Fault 300 Low Water 1 or 2 Tripped 173 Fault 301 Boiler Not Filling Slowly Filling with Water See Fault 300 176 Fault 302 Faulty PLC Input Card...

Page 134: ...vailable swap it to see if it works Replace louver actuator check other causes before buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it back in...

Page 135: ...voltage Replace Repair wiring Fault 17 Main Flame Fail see Fault 220 Indicates that the flame detector cannot detect flame during run mode low fire high fire Causes Troubleshooting Fixes Clogged burn...

Page 136: ...latch CR 1 relay on to start the fan and blow out the fire Wait for flame to burn out Moisture in the flame detector lens Remove fish eye lens and photocell tip and inspect for moisture even the slig...

Page 137: ...ves Inspect fuel paths check for overtightened fittings Remove restrictions No fuel flow through the main and safety fuel solenoid valves Perform Test 2 Replace faulty fuel solenoid valve No fuel pump...

Page 138: ...t works Replace louver actuator check other causes before buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it back in Faulty wiring path from louv...

Page 139: ...ssembly and check for spark Clean ignition assembly Improper gap setting Remove assembly and check for spark Set electrode gap to 5 32 Test 5 Spark grounding to burner Remove assembly and check for sp...

Page 140: ...m 0 60 over 15 seconds Replace VFD Airflow switch out of adjustment Fan is spinning but airflow switch is not tripped Adjust airflow switch to most sensitive setting 0 4 Circuit breaker is tripped Che...

Page 141: ...lace louver actuator Low and high fire nozzles switched This can cause the fault because the operator will tune the burner too high to clear smoke Remove burner gun assembly and assure that the bigger...

Page 142: ...Wet Layup fills the boiler completely full of water Manually reset switch 1 or more pigtail valves are open Steam can be seen coming out of the front supply water tanks Close the open pigtail valves d...

Page 143: ...circuit breaker Main generator circuit breaker is tripped faulty Reset Replace the circuit breaker Part 10207 Generator plug disconnected Connect generator plug to burner Faulty generator end Check ge...

Page 144: ...are their readings to the manual pressure gauge on the top front of the boiler and select the sensor that matches the pressure reading to temporarily run on one steam psi sensor Replace steam pressure...

Page 145: ...Faulty dirty propane psi sensor Remove and inspect sensor Clean Replace propane psi sensor Clogged propane tank regulator Inspect regulator Clean Replace propane tank regulator Faulty wiring Inspect t...

Page 146: ...placed components Replace components in order shown below Causes Troubleshooting Fixes Faulty disconnected steam pressure sensor Compare steam pressure sensors against manual pressure gauge to determi...

Page 147: ...on the touch screen confirm temperature with infrared gun Clean the tubes Faulty flue temp sensor Confirm with an infrared gun that the actual temperature is not what is shown as the flue temp readin...

Page 148: ...ot running Pump contactor overload is tripped Inspect circulation pump contactor if yellow stripe is present in test window reset is required Reset pump contactor overload Panel 2 Circuit breaker is t...

Page 149: ...the wiring for ground continuity and proper voltage Replace Repair wiring Fault 211 Furnace Door Temp Is High Indicates that the rear furnace door is above 250 F Version 3 3 2 6 and older Indicates t...

Page 150: ...215 Manual Valve Operation Is ON Indicates that manual valve operation is on Menu Operations Manual Mode Fault 216 Pressure Detected on Fuel Nozzle 2 in Low Fire Indicates that fuel pressure is detect...

Page 151: ...gh Fire Indicates that fuel 1 nozzle pressure is 5 lower than pump pressure Causes Troubleshooting Fixes Restricted fuel flow through the fuel solenoid valves Inspect fuel path check for overtightened...

Page 152: ...low through the main and safety fuel solenoid valves Inspect fuel paths check for overtightened fittings Remove restrictions No fuel flow through the main and safety fuel solenoid valves Perform Test...

Page 153: ...louver actuator check other causes before buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it back in Faulty wiring path from louver actuator swi...

Page 154: ...to see if it works Replace louver actuator check other causes before buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it back in Faulty wiring pa...

Page 155: ...ator is available swap it to see if it works Replace louver actuator check other causes before buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it...

Page 156: ...opane regulator can cause abnormally high reading for the propane psi sensor Supply water level sensor isolation valve closed can cause a minimum or a maximum reading Find and fix the source of high r...

Page 157: ...newer machines Unplug burner controller modbus plug and generator modbus plug one at a time to determine whether it is fault 225 or fault 233 Replace modbus module PLC modbus connection shorting Disa...

Page 158: ...eed to check voltage during Start All Replace 24 V regulator Wiring issue Trace the 120 V wires using the louver actuator wiring diagram When the louver is closed T18 should have 120 V When the lover...

Page 159: ...rs Replace in line fuel filter Clogged engine fuel filter Replace every 250 hours Replace engine fuel filter Faulty lift pump Remove hose from output side of the lift pump and see if fuel comes out du...

Page 160: ...Follow the fuel line from tank to engine until blockage is found most common is the in line fuel filter but could be in the fuel manifold as well Replace in line fuel filter Replace engine fuel filter...

Page 161: ...check wiring for power and ground Troubleshooting table for 2015 2016 machines Causes Troubleshooting Fixes Engine failed to stop The engine failed to stop Turn off fuel valve Faulty glow plugs Cold w...

Page 162: ...hort in the PLC Port 2 DB9 cable end Disassemble the DB9 Cable end and inspect for isolation grounding Replace cable between PLC and burner controller Generator controller is not programmed Check to s...

Page 163: ...tery voltage is above 15v Check and test battery Replace battery if needed Low battery voltage Battery voltage is below normal Charge Replace battery Over frequency The generator is running faster tha...

Page 164: ...ne pre ignition use generator controller to turn engine off before it starts to crank Replace fuel lift pump Water in fuel bad fuel Check for water in fuel tanks drain water from bottom of tank There...

Page 165: ...in line fuel filter but could be in the fuel manifold as well Replace in line fuel filter Replace engine fuel filter Replace lift pump Remove any fuel blockages Open the water separator shutoff valve...

Page 166: ...oper amperage draw Less than 6 amps on each leg Replace overload Panel 2 Faulty wiring Inspect entire wiring path checking for continuity ground and proper voltage Repair Replace faulty wiring section...

Page 167: ...trol switch relay SR 1 did not annunciate Burner will not operate Causes Troubleshooting Fixes Generator shutting off unexpectedly The generator shutting off unexpectedly can cause this fault See faul...

Page 168: ...ssure limit switch relay SR 4 did not annunciate Burner will not operate Causes Troubleshooting Fixes Generator shutting off unexpectedly The generator shutting off unexpectedly can cause this fault S...

Page 169: ...that fan VFD SR 7 did not annunciate Burner will still operate Causes Troubleshooting Fixes Generator shutting off unexpectedly The generator shutting off unexpectedly can cause this fault See fault...

Page 170: ...uch screen and the PLC are incompatible Causes Troubleshooting Fixes An older newer steamer touch screen has been connected to a newer older steamer Check the version in Menu Information Version The f...

Page 171: ...y into both PLC and ethernet switch Re seat connection 2A Faulty network cable Run an external network cable from the touch screen to the ethernet switch If this fixes your problem you have a faulty n...

Page 172: ...oose set screw s on shaft coupler Inspect the fuel pump coupler set screws for tightness Tighten set screw s Burner fuel filter clogged Inspect burner fuel filter Replace burner fuel filter Napa 4006...

Page 173: ...40 60 and 100 open Swap connection with blowdown actuator to confirm faulty actuator Temporary Fix Menu Settings Water System and set Feed Water Induction Valve Min Open to 100 actuator will still ne...

Page 174: ...Check circuit breaker Panel 1 Reset circulation pump circuit breaker Panel 1 Yellow weatherproof 240 V plug loose disconnected Inspect yellow weatherproof plug to see if it is loose or has a bad conne...

Page 175: ...n Panel 1 2016 and earlier machines Check for moisture damage in the blue low water cutoff housing on top of the boiler water can travel down the conduit line and interfere with the low water cutoff s...

Page 176: ...ed indicator on top will be perpendicular to the pipe if it is closed Valve should not be closed Inspect the actuator to ensure it is still attached properly to the valve Inspect the coupler between t...

Page 177: ...lue temp sensor A faulty input card will normally give you abnormal readings on one or more inputs Determine which sensor caused the card to fail by unplugging each sensor linked to the input card one...

Page 178: ...r moves Menu Operations Manual Mode Ensure that the valve is coupled to the actuator correctly and that the valve is actually opening and closing Replace feed water valve actuator Part 10363 Boiler wa...

Page 179: ...not pressed on touch screen Green button ON Red button OFF Press light icon on touch screen Faulty light harness relay Test with spare 12 V relay 2014 s have a spare relay in Panel 1 Replace the in li...

Page 180: ...ch screen is lit up this indicates the 12 V system is functioning Replace with spare 12 V relay in Panel 3 Faulty 24 V regulator Panel 3 If the red rocker switch on the touch screen is lit up this ind...

Page 181: ...ves Close all pigtail valves don t forget the valve behind the man ual pressure gauge Faulty boiler sight glass check valve Inspect check valve for leaks Replace boiler sight glass check valve Rear Ta...

Page 182: ...setting Set fuel pressure to 150 psi Faulty louver actuator Test in Manual Mode to see if louver actuator moves Menu Operations Manual Mode If a spare louver actuator is available swap it to see if i...

Page 183: ...y voltage Start the generator Charge Replace battery Stuck valve causing blown fuse s Remove actuator and manually open close valve Check all fuses in Panel 2 3 Fuse should light up with a red LED if...

Page 184: ...rner controller if problem persists Low water 1 or 2 tripped Fault 300 See Fault 300 for more fixes Steam leaks Check hoses from DewPoint machine for leaks Check baler hardware for steam leaks Repair...

Page 185: ...rproof plug to see if it is loose or has a bad connection Reconnect yellow weatherproof plug behind the burner that gives 240 V to the pump Loose wires inside pump housing Inspect wire nuts and ensure...

Page 186: ...ker Panel 1 Yellow weatherproof 240 V plug loose disconnected Inspect yellow weatherproof plug to see if it is loose or has a bad connection Reconnect yellow weatherproof plug behind the burner that g...

Page 187: ...eam purge valve for testing Replace water purge valve See Fault 308 Water purge valve opening hose is clogged Listen for crackling noise in rear supply water tanks when the water purge valve opens Rem...

Page 188: ...project after touch screen has been reset No system found Factory reset screen then program screen See above for Reset to factory default procedure Faulty software Reprogram touch screen with appropr...

Page 189: ...he valve opens and there is no crackling noise this may indicate the water purge valve is clogged Unclog the water purge valve MAKE SURE THE BOILER IS NOT UNDER PRESSURE See 50 hour maintenance for un...

Page 190: ...t 320 PLC NAK Error Causes Troubleshooting Fixes Faulty Corrupted PLC programming Reload PLC program Faulty PLC Replace PLC Fault 321 Blown Valve Actuator Fuses Panel 2 F1 F7 5 amp Causes Troubleshoot...

Page 191: ...xes Faulty PLC Test for ground short Replace PLC Faulty analog sensor Test for ground short Replace analog sensor Faulty PLC in output card Test for ground short Replace PLC in output card Faulty PLC...

Page 192: ...round and proper voltage Repair Replace faulty wiring section Fault 330 Blown Fuse Panel 3 F8 1 5 amp Causes Troubleshooting Fixes Faulty touch screen Test for ground short Replace touch screen Faulty...

Page 193: ...xes Faulty PLC Test for ground short Replace PLC Faulty wiring Inspect entire wiring path checking for continuity ground and proper voltage Repair Replace faulty wiring section Fault 336 2015 2016 s O...

Page 194: ...roper voltage Repair Replace faulty wiring section Fault 340 2015 2016 s ONLY Blown Fuse Panel 3 F8 2 amp Causes Troubleshooting Fixes Faulty PLC in output card Test for ground short Replace PLC in ou...

Page 195: ...Repair Replace faulty wiring section Fault 345 Algae in Supply Tanks Causes Troubleshooting Fixes Missing lid on supply tanks letting sunlight enter tanks for algae to grow Check for missing lids Rep...

Page 196: ...or Replace 24 V regulator Fault 349 Boiler Taking Longer Than Normal to Heat Up Causes Troubleshooting Fixes A new properly tuned 6210 will take 12 minutes to heat from 100 F to 180 F Sooted up flue t...

Page 197: ...es before buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it back in Obstructed path of the louver actuator Remove actuator and manually move the...

Page 198: ...buying a new component Temporary fix Reset louver actuator by unplugging louver actuator and then plug it back in Obstructed path of the louver actuator Remove actuator and manually move the louver t...

Page 199: ...battery update kit with larger battery and cutoff switch Part Number 11062 Faulty 12 V regulator 2015 2016 machines Check if there is a green light on the 12 V regulator Panel 3 diagram 7B Replace 12...

Page 200: ...li West 200 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Sa...

Page 201: ...3 Input Card Testing See Fault 302 211 Test 14 A Program the VFD AB 156 AB 458 212 Test 14 B Program the VFD AB 459 212 Test 15 Fire Tube Cleaning 213 Test 16 Generator End Troubleshooting 216 A Excit...

Page 202: ...Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety This P...

Page 203: ...point it at a light source 3 Confirm the red FLAME LED lights up on the burner controller 4 Cover the flame detector and confirm that the red FLAME LED on the burner controller turns off This test co...

Page 204: ...zzes this indicates a faulty solenoid valve that needs cleaning or replacement 3 From the touch screen you should be able to watch the propane pressure drop by 0 5 psi if it opens properly 1 2 3 1 2 3...

Page 205: ...placed in the Run position 3 Remove top cap on the propane regulator with a flat head screwdriver 4 While observing the pilot flame through the sight glass adjust the regulator to stabilize the flame...

Page 206: ...n SR 3 and SR 4 as shown in 2 3 The multimeter will read continuity until the HPLS trips 4 Slowly pressurize the boiler while monitoring the steam pressure on the touch screen take note at what pressu...

Page 207: ...ssary Menu Diagnostics Inputs Outputs Analog Inputs the OPLS should be set to trip at 14 5 psi 5 After the OPLS trips release pressure to adjust OPLS by opening one of the pigtail valve releasing only...

Page 208: ...d verify that the touch screen reading reflects accurately Boiler Water Level Sensor Ohms Test 9 Shut off touch screen 10 Remove the top conduit cap and disconnect the three wires by removing the wire...

Page 209: ...on Be careful not to damage 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 t...

Page 210: ...4 DISPOSE OF CARDBOARD WASHER Be sure polished surface of seat is free of dirt and has not been damaged by insertion Remove excess soapy water INSTALLATION OF ROTATING PART OF SEAL UNIT Figure 5D 1 R...

Page 211: ...be swapped with the other input card to see if the problem follows that particular input card WARNING ensure you have replaced the suspected faulty sensor A faulty sensor can fry a new input card 1 Us...

Page 212: ...ess Mode 11 Use the up arrow and advance to P31 then press Mode 12 Use the up arrow and advance to 60 then press Mode Programming the VFD requires entering the password and adjusting 5 parameters P100...

Page 213: ...tached to a 7 foot rod socket set 1 Drain the boiler open the main boiler drain valve 2 Open blowdown valve and the water purge valve to drain additional water Menu Operations Manual Mode Shut off scr...

Page 214: ...sensor wire harness and remove the flue temp sensor use the nut not the head 10 Remove the rear door cover nuts and door temp sensor and bracket 11 Remove the rear door two people lift 12 Remove the i...

Page 215: ...rn box insulation with the brush as it pushes through the end of the tube 16 Brush top to bottom brush and vacuum each flue tube one at a time clean vacuum filter as needed 17 Inspect tightness of the...

Page 216: ...surge suppressor or replace generator Faulty diodes See Test E Replace all diodes or replace generator 1 5 2 3 4 1 Remove the 4 screws from the top of the generator cover with an 8mm wrench 2 Note th...

Page 217: ...y high resistance more than 100k or OL This means the main stator winding is good If there appears to be a short between any one of the output terminals and the generator housing the main stator has s...

Page 218: ...e suppressor should be replaced as well 1 Use an 8mm wrench socket to remove the 6 bolts to remove the back cover of the generator 2 Locate the diodes There are a total of six There are three with cat...

Page 219: ...ubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety Tests Test 17 Release Wires from Terminal Block Use a f...

Page 220: ...re is a 4 20mA wire that has continuity with the 24 V wire unplug the respective sensor 6 Test the wire again with the sensor unplugged If there is no continuity this indicates a faulty sensor If ther...

Page 221: ...her sensors to max out 4 Replace the faulty sensor before it ruins the input card or PLC If you cannot find a faulty sensor go to Test 18 A If replacing the faulty sensor does not fix the problem go t...

Page 222: ...has continuity with a ground GND wire unplug the respective sensor 6 Test the wire again with the sensor unplugged If there is no continuity this indicates a faulty sensor If there is still continuit...

Page 223: ...ill dark smoke appears 4 Increase louver position slowly until dark smoke disappears 5 Then increase louver position an additional 4 6 To tune high fire press High Tune and wait for the burner to reac...

Page 224: ...Requirements Pre Operation Requirements Safety Safety 1 With the touch screen on press and hold the top left corner of the screen for 5 seconds 2 Press OK 3 Press Settings 4 Press Adjust Touch Panel 5...

Page 225: ...will slide easily through the O ring without rolling it out of the O ring groove 5 Thread the isolation fitting into the tee cross fitting until the end of the inner tube nearly bottoms out or softly...

Page 226: ...tion Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 Unplug the modbus cable and remove any tape holding the modbus card in place 2 Remove the modbus card pulling out f...

Page 227: ...li West 227 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Sa...

Page 228: ...al CR 1 CR 2 Remove top blue wire from CR 2 and re land it here Terminal 7 Remove all wires from the bottom of CR 2 completely They are no longer needed in the panel When all the wires are removed and...

Page 229: ...he red wire and the black wire to the black wire Put a wire nut cap on the yellow wire 4 How to release wires from spring type terminal strips use in steps 6 7 9 10 5 In Panel 2 locate the first blue...

Page 230: ...li West 230 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Sa...

Page 231: ...ion Requirements Pre Operation Requirements Safety Safety Maintenance Maintenance Winterize 232 De Winterize 241 Daily Maintenance 245 Pre Operation 246 Post Operation 248 50 Hour Maintenance 249 250...

Page 232: ...quire attention for winterization Allow boiler to cool to 120 F before draining or removing plugs When should you winterize your DewPoint machine Before winter storage Anytime you expect the machine t...

Page 233: ...Operation Requirements Safety Safety Winterize 1 3 5 2 4 6 Go to Menu Write down all user settings as this data may be lost during long term storage Re input the numbers during de winterization From...

Page 234: ...s by sliding the grey slide bar all the way to the right and by turning them on if needed 1 4 Steam valves 5 Steam purge valve While still in the Manual Mode screen turn off the screen with the red ro...

Page 235: ...e supply water fill valve to drain supply tanks To prevent burns make sure water is below 120 F Open main boiler drain valve and be careful to not let hot water drain on your feet Unscrew and remove s...

Page 236: ...pump bottom drain plug and store it in the control panel box for winter Open circulation pump inlet valve should already be open Close boiler drain valve and open feed water drain valve Remove feed wa...

Page 237: ...Wrench Method b 25b Pipe Wrench Method b 27 After the Feed Water System has dried open and close the circulation isolation valve while vacuuming to dry out the circulation system Position valve so wa...

Page 238: ...and unplug the supply water level sensor under the right front water tank Unscrew and remove supply water level sensor Store the sensor where it won t freeze Dry out the pressure transducers and the...

Page 239: ...lug completely just slip the plug downward until the stud rests on the bottom of the hole and hand tighten the nut to keep the plug from falling into the hole If you want to completely remove the plug...

Page 240: ...rom the boiler and other systems If your fire tubes are in bad condition consider purchasing ReDew boiler de scaler to increase the efficiency and life of your DewPoint machine Remove a hand hole and...

Page 241: ...e de winterization procedures to ensure proper operation of your DewPoint 6210 machine SAFETY PRECAUTIONS Do not climb on machine to perform de winterization procedures Always use a ladder or other ap...

Page 242: ...ion Requirements Safety Safety De Winterize 1 3 5 2 4 6 Remove any bird or rodent nests from inside the boiler Ensure all hand hole plugs are tightened and secure Install the steam pressure sensors on...

Page 243: ...0 12 Ensure the pressure control flush hose is connected to the water tank fitting as shown Re install supply water filter T strainer as shown Close the feed water system drain valve Boiler front righ...

Page 244: ...Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety De Winterize 13 15 16 14 Inspect all 8 valves for frost damage Check flue caps for free operation T...

Page 245: ...r 5 8 Drain 30 40 gallons of water from boiler 9 Inspect gauges sensors and sight glasses 10 Purge steam through all baler hardware nozzles 11 POST OPERATION STEP S Clean generator and engine with com...

Page 246: ...eration Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 3 5 2 4 6 Grease PTO anti rotating shield Check engine oil level Close the supply water isolation valve Check en...

Page 247: ...and debris Ensure nozzles are not plugged 7 9 11 8 10 Clean out the filter Re install the filter Open the boiler drain valve and drain 30 40 gallons of water This helps prevent boil over by reducing...

Page 248: ...n Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 3 2 4 Clean generator and engine with compressed air Remove crop debris from enclosed areas Purge the Y strainer for 2...

Page 249: ...y 14 15 Clean flame detector lens 16 19 Clean inside the burner blast tube area 20 23 Purge steam through top front pigtail valves to clear the steam pressure sensor paths 24 Check water purge system...

Page 250: ...n Pre Operation Requirements Pre Operation Requirements Safety Safety 1 3 5 2 4 6 Grease every 50 hours Grease every 50 hours Check the battery and recharge if necessary Grease every 50 hours For 2015...

Page 251: ...he fuel from dripping Prime the generator Press OFF Press Run Manual Start Lift pump will turn on After 5 seconds press OFF Repeat this process untill water separator is filled Press Auto to return co...

Page 252: ...Operation Requirements Safety Safety 13 15 17 14 16 18 Connect an air compressor to the red igniter cleanout hose Unscrew the flame detector Unscrew the lens Open and close the valve several times to...

Page 253: ...To clean the burner blast tube area remove these 6 bolts Remove the burner cover While the boiler is under pressure open each of these pigtail valves one at a time to clear the steam pressure sensor...

Page 254: ...ler Look for any potential hotspots on the boiler doors Contact your dealer if any hotspots are found After removing the hose from the bottom of the water purge valve stick a long screwdriver or rod u...

Page 255: ...g Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 31 32 Inspect steam hoses and ensure there are no kinks or holes 5...

Page 256: ...li West 256 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Sa...

Page 257: ...ease axles 2 4 Check Adjust engine speed so that frequency is 61 62 5hz 5 7 Check Adjust generator cooling fan v belt 8 9 Change oil and oil filter 10 13 Replace in line fuel filter 14 Replace burner...

Page 258: ...irements Safety Safety 1 3 5 2 4 6 Grease the fan motor with 1 pump DO NOT OVER GREASE OVER GREASING WILL CAUSE PREMATURE MOTOR FAILURE Grease all zerks shown above Start the generator Grease all zerk...

Page 259: ...plug 1 After all oil has been drained from the engine reinstall the oil drain plug and tighten to 40 47 ft lb Dispose of oil properly Check for proper V belt tension Check for clearance 1 between the...

Page 260: ...1 to 7 1 qt lower upper dipstick Always keep the oil level between the upper and lower lines on the oil dipstick Warm up the engine for 5 minutes Shut it off for 10 minutes and recheck the oil level...

Page 261: ...oth nozzles and clean with denatured alcohol Then reinstall nozzles burner gun assembly and burner cover REINSTALL NOZZLES IN SAME POSITION Remove the Y strainer filter and clean Then reinstall the fi...

Page 262: ...ED AIR ON THE AIRFLOW SWITCH ITSELF 25 27 29 26 28 30 Remove the plastic cover on the airflow sensor by removing these two screws with a Phillips screwdriver Loosen the conduit fitting Remove conduit...

Page 263: ...ts Pre Operation Requirements Safety Safety 31 33 35 32 34 36 Remove the wires by loosening the top nuts with a 3 16 socket Clean the tip of the probe Remove the probes with a 13 16 deep socket Only t...

Page 264: ...Rotate tires front to rear Perform a boiler safety test Instructions are located in the front of this manual in the Safety section Remove one of the rear hand holes and inspect your fire tubes for sc...

Page 265: ...r time estimate above See 50 hour Perform 250 hour maintenance Not included in 6 hour time estimate above See 250 hour Clean water separator 1 4 Replace fuel filter on generator 5 Clean boiler flue tu...

Page 266: ...bes if needed See Test 15 Flue tube cleaning is necessary if a burner tune can no longer produce a clean burn smoke free 500 Hour Maintenance Close the fuel valve on the water separator Unscrew the re...

Page 267: ...t lb Check the wear on the brake gasket Open both inspection windows and check friction material thickness outside the reference line Replace when material thickness is less than 2mm outside the line...

Page 268: ...enance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 13 500 Hour Maintenance Greas...

Page 269: ...ty 1000 Hour Maintenance Checklist EVERY 1000 HOURS STEP S Perform 50 hour maintenance Not included in 6 hour time estimate above See 50 hour Perform 250 hour maintenance Not included in 6 hour time e...

Page 270: ...ning and closing the valves Standard valve clearance 0 15 0 25 mm 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 poss...

Page 271: ...ncluded in 2 hour time estimate above See 50 hour Perform 250 hour maintenance Not included in 2 hour time estimate above See 250 hour Perform 500 hour maintenance Not included in 2 hour time estimate...

Page 272: ...e castle nut 3 Tighten the rack nut while simultaneously rotating the wheel until the hub is slightly braked 4 Rotate the rack nut until a slot with the hole on the spindle is found and insert the ela...

Page 273: ...eshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 4 1500 Hour Maintenance Check screw torque indicated in th...

Page 274: ...ur Maintenance Checklist EVERY 2000 HOURS STEP S Perform 50 hour maintenance Not included in 2 hour time estimate above See 50 hour Perform 250 hour maintenance Not included in 2 hour time estimate ab...

Page 275: ...enance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safety Safety 1 2000 Hour Maintenance Repla...

Page 276: ...steam through top front pigtail valves x Check water purge system for blockages x Check blowdown system for blockages x Inspect front and rear of boiler by looking for any potential hotspots on the b...

Page 277: ...battery and recharge x Change oil and oil filter 15w 40 1st x Drain water separator x Clean radiator fins x Clean Replace inner and outer air filters x Replace in line fuel filter 1st x Clean water s...

Page 278: ...West 278 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safet...

Page 279: ...West 279 Tests Tests Maintenance Maintenance Troubleshooting Troubleshooting Technical Information Technical Information Operation Operation Pre Operation Requirements Pre Operation Requirements Safet...

Page 280: ...ly 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 R...

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