chest heated ironers - alliance laundry system

CFFS500/2000CFFS500/2500CFFS500/3000CFFS500/3300Technical specificationsInstallation instructionsOperating instructionsMaintenance

(Electric heating)

Chest heated ironersInstruction m

anual

Part No D1478

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- The padding

- The feed bands.

- Chains

- Pump seals.

- Oil change.

- Transport damage.

- Components damaged by poor maintenance.

- Spare parts who are placed by a technician who is not trained or schooled by

--LACO.

WE CAN’T GIVE ANY WARRANTY TO THE FOLLOWING ELEMENTS:

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FOREWORD

This manual contains information on installation, use and maintenance.

The machine operator should read this manual carefully in order to get to know the machine

before starting it up.

In this document, we have tried to answer questions which might arise. For further

information or an explanation, please contact the After-Sales Service department.

The photos, drawings and text are as up-to-date as possible. Deviations may arise as a result

of technical improvements or special options chosen by the owner. The drawings may only be

used to explain and clarify how the machine works.

Under no circumstances should these be used for any other purposes.

This manual will also help you to get the best out of your machine.

If you require information or wish to order certain parts, it is important to always

specify the machine registration number.

LOCATION OF MACHINE REGISTRATION PLATE

Machine number plate + CE plate

can be found on the front in the

bottom right-hand corner.

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PART 1: INSTALLATION INSTRUCTIONS 6

1.1 HANDLING THE MACHINE 6 1.2 LAYOUT AND CONNECTIONS 7 1.3 TECHNICAL DATA AND DIMENSIONS 8 1.4 INSTALLATION 9 1.5 GENERAL. 13

PART 2: OPERATING INSTRUCTIONS 14

2.1 POINTS TO BE CHECKED ON A DAILY BASIS BEFORE START-UP 14 2.2 NORMAL USE – ABNORMAL USE 14 2.2.1 NORMAL USE 14

2.2.2 ABNORMAL USE 15 2.3 CONTINUOUS RISKS ASSOCIATED WITH THE MACHINE – MEASURES TO BE TAKEN 15 2.4 OPERATING PANEL 16 2.5 OPERATING INSTRUCTIONS 17 2.5.1 ADDITIONAL POINTS 17 2.6 SAFETY INSTRUCTIONS 18 2.6.1 THE HAZARD POINTS 18

2.6.2 SAFETY DEVICES 18 2.6.3 THINGS YOU SHOULD DEFINITELY NOT DO 18 2.6.4 RULES 18

2.6.5 MEASURES TO BE TAKEN IN AN EMERGENCY SITUATION 19

PART 3: MAINTENANCE INSTRUCTIONS 20

3.1 MAINTENANCE INSTRUCTIONS 20 3.2 OTHER MAINTENANCE INSTRUCTIONS 20 3.3 RISKS WHICH MAY ARISE AS A RESULT OF POOR MAINTENANCE 21 3.4 TYPES OF OIL 22 3.5 HYDRAULIC PRESSURE REGULATION 23 3.6 REPLACING AND SETTING THE TENSION OF THE FEED BELTS 24 3.7 SETTING THE SAFETY THERMOSTAT 24 3.8 PROBLEM SOLVING 25 3.8.1 THE MACHINE DOES NOT HEAT UP TO ANY TEMPERATURE AFTER SELECTING THE

PREHEATING FACILITY (TOUCHSCREEN) 25 3.8.2 THE MACHINE IS UP TO TEMPERATURE BUT THE IRONING BED WILL NOT CLOSE 25

3.8.3 THE IRONING BED IS CLOSED BUT THE ROLLER IS NOT ROTATING 25 3.8.4 THE EXHAUST SYSTEM IS NOT WORKING 26

3.8.5 NO CONTROL VOLTAGE 26 3.8.6 FOLDS IN LINEN 26

3.8.7 THE SAFETY THERMOSTAT DROPS OUT 27 3.8.9 CARRIAGES DO NOT OPEN 27 3.8.10 CARRIAGES REMAIN LIVE 27

3.8.11 GRIPPERS LET GO TOO EARLY 28 3.8.12 POOR LONGITUDINAL FOLD 28

3.8.13 MACHINE DOES NOT CARRY OUT THE FIRST CROSSFOLD 29 3.8.14 MACHINE DOES NOT CARRY OUT THE SECOND CROSSFOLD 29

3.8.15 MACHINE DOES NOT CARRY OUT THE THIRD CROSSFOLD 29 3.8.16 STACKING GRIPPER IS NOT HANDLING SHEETS PROPERLY 30 3.8.17 STACKING GRIPPER REMAINS ON TOP 30

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3.9 OIL CHANGE IN REDUCTION GEARBOX 31 3.10 THERMAL OIL CHANGE. 32 3.11 CLEANING OF THE BED. 34 3.12 ROLL PADDING REPLACEMENT. 35

PART 4: SCHEMATIC DIAGRAMS 42

4.1 CROSS-SECTION OF CROSSFOLD COUPLING 42 4.2 CROSS-SECTION OF STACKER 44 4.3 CROSS-SECTION OF EXIT BELT 45 4.4 DRIVE FOR FEED ROLLER TO IRONING ROLLER 46 4.5 HYDRAULIC CIRCUIT 47 4.6 METHOD OF FOLDING 48 4.7 CROSS-SECTION OF LONGITUDINAL FOLDING 49 4.8 DRIVE FOR CROSSFOLDER. 50 4.9 SET-UP FOR CONTACT FINGER GUARD. 51 4.10 VALVE ISLAND 52 4.11 PNEUMATIC DIAGRAM 53

PART 5 : FACTORY SETTINGS AND OPTIONS. 57

5.1 ALTIVAR 57 ALTIVAR 312 : 57 5.2 THERMAL OVERLOAD 68 5.3 LOADING BACKUP PROGRAMS ONTO THE B&R SCREEN WITH USB STICK. 68 5.4 ADJUSTABLE SUCTION VALVE (OPTION). 69

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PART 1: INSTALLATION INSTRUCTIONS

1.1 Handling the machine

NEVER LIFT THE MACHINE USING A FORKLIFT TRUCK

(This can cause irreparable damage) -

- Remove any obstacles under machine placement area.

- Fasten the lifting cables to the supplied lifting eye bolts on the top.

- Lift machine.

- Make sure cable is positioned correctly so that machine hangs horizontally.

- Make sure nobody walks under the load.

- Lift and relocate machine carefully, without sudden shocks or movements.

- Place machine on ground, as close to the permanent location as possible.

- If the machine needs further moving, use rollers.

Important: To use rollers, place rollers in four corners, distributing weight evenly.

- Once machine is in final position open hydraulic valve to release chest.

- Remove all packing materials.

- Level machine.

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1.2 Layout and connections

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1.3 Technical data and dimensions C500/2000 C500/2500 C500/3000 C500/3300

Roll Diameter

Length

500 mm

2000 mm

500 mm

2500 mm

500 mm

3000 mm

500 mm

3300 mm

Dimensions Height

Width

Depth

1430 mm

3833 mm

2155 mm

1430 mm

4333 mm

2155 mm

1430 mm

4833 mm

2155 mm

1430 mm

5133 mm

2155 mm

Speed Minimum

Maximum

1.5 m/min

5-12 m/min

1.5 m/min

5-12 m/min

1.5 m/min

5-12 m/min

1.5 m/min

5-12 m/min

Temperature Minimum

Maximum

150°C

175°C*

190°C*

150°C

175°C*

190°C*

150°C

175°C*

190°C*

150°C

175°C*

190°C*

Motors Roll

Fan

Hydr. pump

Circulation

pump

0.75 / 1.5 kW

0.25 kW

0.37 kW

2.2 kW

0.75 / 1.5 kW

0.25 kW

0.37 kW

2.2 kW

0.75 / 1.5 kW

0.25 kW

0.37 kW

2.2 kW

0.75 / 1.5 kW

0.25 kW

0.37 kW

2.2 kW

Heating

capacity

kW 30 40 45 45

Electr.

Connection

(D curve)

Cable section

220 V 50 Hz

380 V 50 Hz

230 V

400 V

100 A

50 A

3 x 25 mm² +PE

3 x 10 mm² + PE + N

125 A

63 A

3 x 35 mm² +PE

3 x 16 mm² + PE + N

125 A

80 A

3 x 35 mm² +PE

3 x 16 mm² + PE + N

125 A

80 A

3 x 35 mm² +PE

3 x 16 mm² + PE + N

Weight kg 1560 kg 1660 kg 1950 kg 2050 kg

Packaging H x D x W 1.5 x 1.7 x 3.9 m 1.5 x 1.7 x 4.4 m 1.5 x 1.7 x 4.9 m 1.5 x 1.7 x 5.2 m

Noise Decibels 65 dB 65 dB 65 dB 65 dB

Vapour outlet m³/h 650 650 650 650

°C (temp

170°C)

100°C 100°C 100°C 100°C

Throughput

Diameter

75 mm 75 mm 75 mm 75 mm

Air intake (100% dry air! )

l/min. 450 450 450 450

Pressure Min. 6 Bar Min. 6 Bar Min. 6 Bar Min. 6 Bar

Diameter ½” ½” ½” ½”

Air supply m³/h 2000 2000 2000 2000

Capacity Residual

moisture

50% temp.

175°

75 kg/h 95 kg/h 115 kg/h 125 kg/h

*Max. temperature for polyester is 175°C

Max. temperature for nomex is 190°C

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1.4 Installation

1. Unload the machine as described. (See 1. Handling the machine)

The best way to move the ironing machine is using a loading platform. The ironing

machine should be set up so that it is perfectly level.

There should be a space of at least 50 cm on the left and right of the machine in order

to enable installation and maintenance activities to be carried out.

The walls through which the air outlet pipes are routed should be made of non-

flammable material.

The ironing machine should have a sufficient air supply (2000 m²/h approx.)

(an insufficient air supply can cause the machine to overheat!)

Move the machine using the

lifting holes provided Do not lift the machine using

a crow bar

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2. Remove all packaging materials such as plastic and cardboard from the machine and

clean the ironing bed before heating up the machine.

Do not use explosive products to do this.

3. Remove the wooden blocks from underneath and set down the machine in such a way

that it is level.

4. Remove the lifting aids.

Packaging material

See also the drawings provided!

Remove wooden

blocks

Lifting eyes for cables

Screw the plugs provided

into the lifting holes.

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5. Electrical connection

Compare the type of cables and voltage with the machine data and bear the guidelines

in mind.

It is important for the electrical connection to be carried out by a technical specialist in

order to ensure that the installation complies with the standards and directives which

apply at the site where the machine is being installed.

The nominal cross-section of the line connection selected should be suitable for the

nominal electrical load specified on the ironing machine.

The ironing machine should be earthed in order to ensure that it operates correctly and

safely.

The main cable should be routed inside via the adapter sleeve which sits in the frame

at the side of the electrical battery.

The connecting cable can be connected to the main switch (L1-L2-L3-N-PE) in the

left-hand battery.

Once the main connections have been made, the main switch can be set to position 1

and the direction of rotation of all the motors should be checked! (to prevent damage)

6. Air connection

The connection to the machine is ½". The air pressure should be 6Bar with a flow of

450 l/min. The air must be 100% dry air!

7. Exhaust connection

The exhaust is located at the back on the right-hand side and has the following

dimensions:

Exhaust outlet: diameter 75 mm

Connection of the main

switch:

Ironing roller

exhaust

Air connection

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The law requires that the steam outlet be completely separate in order to prevent fire.

The vapour outlet should consist of a heat-resistant pipe (150°C).

In order to ensure that it works properly, this pipe should always be kept as short as

possible and should have as few bends as possible.

If an outlet duct is connected to a main duct, the angle of incidence should not exceed

45°.

If the distance from the outlet duct is greater than 5 metres, a series of exhausters

should also be fitted underneath the outlet duct or the pipe diameter should be

increased! (e.g. 125 mm instead of 75 mm)

Insulate both the gas and steam outlet pipes in order to prevent fire.

8. Install the bench horizontally at the back of the machine.

Undo bolts and rotate bench 90° so that you can

screw the same bolt back in and place the bench flat

(spirit level). Then tighten both bolts well.

Dismantle the protective plate at the back.

Allow the machine to warm up (adjust the temperature setting to 175°) and press

start and at the same time press against the finger guard so that the bed closes and

the roll does not turn. Loosen the tensioning screws and adjust the distance between

the bed and bench so that they are 2 mm apart. Then tighten the tensioning screws

again.

Tensioning screws at the

bottom of the bench

Distance between

bed and bench 2

mm

Fit and secure the protective plate.

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9. Tighten the felt around the roller as described later on in the manual.

10. The machine is now ready for use.

The heating system must be fully bled the first time the machine is warmed up.

This bleeding is done by removing the existing teflon hose.

There is another supplied hose at the top of the machine.

Fit this where the other hose was removed and take a metal bucket and put the hose

into the bottom of the bucket so the moisture can be captured.

Once the machine has warmed up, the supplied hose can be removed again and the

existing teflon hose replaced.

1.5 General.

- The service life of an ironing machine with a steel ironing bed is approximately 15

years with normal maintenance.

This is an estimate.

It is not binding.

No compensation may be claimed for a shorter service life.

- Noise level: 60-65 db depending on speed.

Existing

teflon hose

Size of metal bucket + supplied

teflon hose

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PART 2: OPERATING INSTRUCTIONS

2.1 Points to be checked on a daily basis before start-up

- Check the direction of rotation of all the motors.

- Check that all safety guards are in position and closed.

- Check that the finger guard is working properly and adjusted correctly.

This means that the opening between the finger guard and the feed belts should not be

more than 15 mm.

- Check that the emergency stop devices are working properly.

- Before starting, make sure that all the hazard areas are clear.

- Check that there are no foreign objects between the roller and the bed of the ironing

machine.

- Check the condition of the felt.

If the wire attaching the felt is exposed, it will have to be replaced.

- Check the condition of the feed belts.

- Clean the machine to remove any dust.

- Check the machine for leaks.

2.2 Normal use – Abnormal use

2.2.1 Normal use

- The machine is designed to be used for ironing all types of flat linen such as sheets,

double sheets, hand towels, pillows, handkerchiefs, etc. (No shorts or sheets with

loose-hanging ribbons!!)

- The maximum temperature is 190°C.

- The minimum temperature is 150°C.

- The temperature will have to be adapted to the felt (polyester up to 175°C and Nomex

up to 190°C)

- The machine settings for installation, the pressure of the felt, etc. should be in

accordance with the specifications in the manual.

- Maintenance should be carried out on the machine at regular intervals as described in

the manual.

- Only spare parts supplied by the manufacturer should be used.

The manufacturer will not accept any liability for defects or accidents due to improper

use of the machine or spare parts not supplied by the manufacturer.

- Do not allow hard objects to be fed between the roller and the bed.

- Do not allow meltable materials to be fed between the roller and the bed.

- Take account of all safety measures.

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2.2.2 Abnormal use

- Items to be ironed are not flat.

- Allowing the machine to operate under no-load conditions (without feeding in linen).

- Temperatures above 175°C if polyester felt is used and 190°C if Nomex felt is used.

- Cleaning the bed with hard materials (can cause irreparable damage).

- Operating the machine without taking precautionary safety measures.

- Failing to comply with safety measures.

2.3 Continuous risks associated with the machine – measures to be taken

- All the external pipes from the machine for the exhaust outlet and gas outlet pose a

real risk of burn injury.

For that reason, all these pipes should be insulated properly against direct contact and

protected.

- The personnel operating the machine should be trained so that they know what to do in

emergency situations, e.g. what to do if someone becomes trapped, what to do in the

event of a fire, how to analyse the machine, etc.

- The hot linen which comes out of the machine can cause burn injuries.

For that reason, it is necessary to wear personal protection such as gloves when

handling the linen.

- When the machine is in operation, keep inflammable materials as far away as possible.

There are still flammable materials present in the form of the felt, feed belts and the oil

in the machine.

The greatest risk is presented by dust.

In certain circumstances, dust can form a highly explosive mixture.

That is why it is essential to clean the machine regularly.

- Also create an equipotential connection so that no differences in potential can arise

between the machine and the surrounding metal structures in order to prevent flash-

over.

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2.4 Operating panel

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2.5 Operating instructions

See appendix to B&R manual.

Note:

- If the emergency stop button "S1" is activated, all the motors and the heating system

will be deactivated and the ironing bed will open automatically. The only way to

restart the machine is by turning the emergency stop button clockwise and pressing

button "S6" (RESET) again.

- If pressure is applied to the finger guard, the roller will stop immediately but the

temperature will remain constant and the bed will remain pressed against the roller.

- The machine can be restarted by pressing button "S6" (RESET).

Note:

- If the finger guard is activated, the bed will remain pressed against the roller. That is

why you are strongly advised to rotate the roller again or switch off the machine

completely.

2.5.1 Additional points

- Feed a piece of waxed fabric through the ironing machine 2 to 4 times a day in order

to wax the bed. If you do not do this, the bed will not provide a sufficiently smooth

surface and static electricity can be created, resulting in poor ironing quality.

- Never let the roller press against the bed unless it is rotating. Otherwise it will cause

damage to the felt.

- Clean the ironing bed regularly using a special cleaning cloth (available as an option

with the machine).

Finger guard

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2.6 Safety instructions

2.6.1 The hazard points

- Hot ironing bed.

- The entry point between the roller and the ironing bed.

- Hot linen at the exit point from the roller.

- Feed belts.

- Rotating elements (brush system).

- The carriage bar.

- Third crossfold.

2.6.2 Safety devices

- Emergency stop button at each corner and in the middle of the machine.

- Finger guard at the point of entry to the roller.

- Relais d’arrêt d’urgence

- Controlled supply of 24 VDC.

- Thermal insulation around the cables and the ironing bed.

2.6.3 Things you should definitely not do

- Do not stick your hands under the finger guard, between the feed belts or under the

carriage bar.

- Do not try to pull out items which have already been fed into the machine.

- Do not wear loose clothing, bracelets or rings. Tie long hair back.

- Never use the machine without the protection of safety equipment. Make sure that the

safety devices are closed before starting to use it.

- Never sit on or crawl onto the machine.

2.6.4 Rules

- Check that the safety devices are working properly on a daily basis.

- Stop the machine if any intervention is required or if any abnormality occurs.

- Train your employees so that they know what to do in an emergency situation.

- Do not wear loose clothing. Tie long hair back.

- Do not wear any jewellery.

- Wear gloves when handling hot linen.

- Read the operating instructions before working on the machine.

- Switch off the motors when working on the machine.

- Prevent the machine from starting up again while maintenance or repairs are being

carried out.

- Report any damage immediately.

- If you are working on hot components, wear protective clothing.

- Only clean the machine if it is completely cold and has been switched off.

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2.6.5 Measures to be taken in an emergency situation

Situation 1: Emergency stop function fails

- Stop the machine by operating the main switch.

- Check that the emergency stop facilities and other safety devices are working properly

on a regular basis.

Situation 2: A person becomes trapped between the roller and the ironing bed.

- Press the emergency stop button "S1".

- The ironing bed will be lowered automatically and the person can be freed.

- Call the emergency services and administer first aid.

Situation 3: Getting caught in the feed belts.

- Press the emergency stop button "S1".

- Cut away the feed belts.

Situation 4: Electrocution

- Disconnect the principal voltage immediately and only then free the person. Otherwise

there is a risk that you will be electrocuted. Administer first aid. Call the emergency

services immediately.

- Check earth leakage circuit breaker.

Situation 5: Fire

- Press the emergency stop button and switch off the principal voltage immediately.

- Put out the fire using a CO extinguisher if necessary!

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PART 3: MAINTENANCE INSTRUCTIONS

3.1 Maintenance instructions

Check that the safety equipment is working on a daily basis!

3.2 Other maintenance instructions

On a daily basis

- Feed a piece of waxed fabric (cleaning cloth) through the ironing machine some 2 to 4

times a day. (4 times when the linen doesn’t enters smoothly the chest, or when there

are creases in the linen.) (1 x wax ± 5min.)

- Clean the machine with a vacuum cleaner or with air pressure. (1 person ± 10min.)

4 x per year

- Clean the turbines on all the motors including those for the exhaust, circulation pump,

brush system, carriage bar, roll drive motor and the hydraulic pump.

(1 person ± 30min.)

2 x per year

- Check the tension of the chain and feed belts.

Every year

- Replace the gear oil. (1 person ± 30min.)

- Lubricate the chain. (1 person ± 5min.)

- Lubricate the roll drive bearing at the suction side. (Only 600 – 800)


Every 2 years:

- Change thermal oil every 2 years or every 3500 hours.

(1 person ± 6 hours)

Every 5 years:

- Change hydraulic oil every 5 years. (1 person ± 30 min.)

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Other instructions

- Drain the water in the tank pressure regulator (pneumatic air). (Min. once a week)


- Cleaning the chest and changing the roll padding.

(1 person ± 5 hours) (2 persons ± 4 hours)

- Changing the foldingbands.

(All the bands ± 8 hours) (1 band ± 20 – 60min.)

- If rust appears on the bed (water-salt deposits at the point of entry to the bed), then the

ironing bed should be cleaned using a special cloth which is available (cleaning cloth).

- Maintenance should be carried out in accordance with the maintenance schedule

enclosed. It should be carried out after the machine has been stopped and is cold.

The manufacturer will not accept any liability for defects or accidents due to failure to

carry out maintenance or poor maintenance resulting from or due to the use of

additional parts not supplied by the manufacturer.

3.3 Risks which may arise as a result of poor maintenance

- Rapid wear to gear wheels or bearings if they are not lubricated sufficiently.

- If the bearings are not lubricated sufficiently, this can cause a fire hazard.

- If the safety equipment is not checked on a daily basis, faults in the machine can lead

to serious accidents.

- If you wait too long before replacing the felt, this can cause irreparable damage to the

ironing bed.

- Dust on the machine can cause a fire or even an explosion.

- Worn or missing feed belts can pose a risk to fingers or the linen may get caught.

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3.4 Types of oil

ATTENTION:

Each mechanical drive uses its own specific type of oil. Therefore the

correct type of oil should be used when the oil is changed.

Roller drive gearbox

- Type of oil GOYA 220

- Oil changes The first time, after 6 months and then every year.

- Volume 1.2 litres

Alternative oil:

Q8 Goya 220

BP Energol GR XP 220

CASTROL Alpha Sp 220

ESSO Spartan Ep 220

FINA Giran 220

MOBIL Mobilgear 630

SHELL Omala EP 220

Chest

- Type of oil TEXATHERM HT 22

- Oil changes Every 2 years or every 3500 hours.

- Volume 50 litres

Alternative oil:

SYNLUBE Lubriplate

TRANSCAL BP Marine

SHELL CASSIDA Fluid HT

Hydraulic pump

- Type of oil HYDRO 46

- Oil changes Every 5 years

- Volume 2.5 litres

Alternative oil:

Q8 Hayden 46

BP Energol HLP 46

CASTROL Hyspin AW5 46

ESSO Nufo H 46

FINA Hydran 46

MOBIL DTE Medicure

SHELL Turbo T oil 46

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3.5 Hydraulic pressure regulation

Manometer

Set pressure

Max. 30 Bar

Recommended:

20 – 25 Bar

Oil tank drain

Oil: 2.5 litres

The oil filler

To adjust the hydraulic pressure of the ironing bed,

undo the black blind nut (using a no. 13 spanner).

Then undo the tensioning nut (the no. 13 spanner)

using an Allen key and turn it to the left (to reduce the

pressure) or right (to increase the pressure). (The

pressure can be read off on the manometer).

The max. pressure which can be set is 30 Bar.

Then tighten the nut again.

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3.6 Replacing and setting the tension of the feed belts

- Undo the two bolts using an M8 spanner.

- Move the guide plates towards the feed trough.

- Open the feed belts by removing the locking pin between the connecting hooks.

- Once the feed belts have been replaced, move the guide plates towards the ironing bed

and retighten the bolts on both sides.

The guide plates should be fitted so that the feed belts are firmly held under tension

and positioned as close as possible to the ironing bed.

3.7 Setting the safety thermostat

- Heat up the machine first of all (175°C) in order to set the safety thermostat.

- Wait 20 minutes so that the ironing bed is fully up to temperature.

- Use a flat-headed screwdriver and slowly turn the adjusting screw to the left until you

hear a click. This click means that the safety thermostat is open and the machine

cannot be heated up any further.

- Then use the flat-headed screwdriver and slowly turn the adjusting screw to the right

until you can press the red pushbutton so that the machine can be heated up again.

- This means that the safety thermostat is set approximately 10°C higher than the actual

ironing temperature set. Iron a few pieces of linen in order to check that the thermostat

does not take over.

- If the safety thermostat unexpectedly takes over during ironing, the linen (more than

55% relative moisture) may be too wet or the speed may be too high.

- To restart the machine, press the red pushbutton again.

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3.8 Problem solving

3.8.1 The machine does not heat up to any temperature after selecting the preheating

facility (touchscreen)

Possible causes

A. Failure of contactor K17 or K18.

B. Safety thermostat S8 is off.

C. Emergency stop has been activated.

D. Card module defective.

Solution

A. Replace contactor K17 or K18.

B. Reset safety thermostat S8

C. Unlock the emergency stop.

D. Replace card module.

3.8.2 The machine is up to temperature but the ironing bed will not close

Possible causes

A. Contactor is defective.

B. Pump motor is defective.

C. No oil in the pump.

D. Cylinder defective.

E. Card module is defective.

F. Thermal overload had failed.

Solution

A. Replace the contactor K8.

B. Check motor M2.

C. Check oil pump level or for leaks.

D. Replace the cylinder.

E. Card module defective.

F. Reset or replace the thermal overload Q8.

3.8.3 The ironing bed is closed but the roller is not rotating

Possible causes

A. Foot pedal has been pressed.

B. Pressure has been applied to the finger guard.

C. Frequency converter is defective.


Solution

A. Check or replace contact FDC4.

B. Check or replace contact FDC2.

C. Replace the frequency converter.


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3.8.4 The exhaust system is not working

Possible causes

A. Motor is defective.

B. Contactor is defective.

C. Thermal overload has failed.


Solution

A. Replace the motor.

B. Replace contactor K9

C. Reset or replace the thermal overload Q9.


3.8.5 No control voltage

Possible causes

A. Motor protection is off.

B. Main switch is defective.

C. Fuse has failed.

D. Transformer defective.

E. No primary voltage.

Solution

A. Activate motor protection.

B. Replace the main switch.

C. Reset or replace the fuse F2,F3,F4 or F5.

D. Replace the transformer.

E. Find problem with primary voltage.

3.8.6 Folds in linen

Possible causes

A. Temperature of the ironing bed is too low (below 150°C).

B. The ironing bed is very dirty.

C. Linen has not been rinsed properly.

Solution

A. Increase the operating temperature (normal 175°C).

B. Clean and wax the ironing bed.

C. Check the results after rinsing.

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3.8.7 The safety thermostat drops out

Possible causes

A. Temperature of the ironing bed is set too high (+ 175°C).

Solution

A. Reduce the temperature setting (max. 175°C).

3.8.9 Carriages do not open

Possible causes

A. Proximity switch Z5 is poorly adjusted.

B. No program has been set.

C. MC1 and/or MC2 not adjusted properly.

D. Emergency stop button has been pressed.

E. Carriage bar belt is defective.

Solution

A. Readjust proximity switch Z5.

B. Set program.

C. Readjust MC1 and/or MC2.

D. Reset emergency stop facilities to rest function.

E. Repair the carriage bar belt.

3.8.10 Carriages remain live

Possible causes

A. Photocell FC8 not adjusted properly.

B. Sheet is not being fed in properly.

C. Fault in frequency converter.

Solution

A. Readjust photocell FC8.

B. Feed in the sheet in the correct manner.

C. Set the frequency converter correctly.

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3.8.11 Grippers let go too early

Possible causes

A. Program not set properly.

B. Not enough pressure on the clamp pistons.

C. Photocell FC8 not adjusted properly.

D. No voltage being supplied to the photocells.

Solution

A. See appendix to O&M manual for the settings.

B. Apply more pressure to the clamp pistons (max. 3 bar).

C. Readjust photocell FC8.

D. Replace fuse F3 inputs.

3.8.12 Poor longitudinal fold

Possible causes

A. Sheets still too wet.

B. Temperature too low.

C. Belts are lying on top of each other.

D. Sheets not being fed in properly.

E. Pressure too low.

F. Static electricity in linen.

Solution

A. Rotate at slower speed.

B. Increase temperature.

C. Check the belts.

D. Feed in correctly.

E. Check air compressor.

F. Increase pressure.

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3.8.13 Machine does not carry out the first crossfold

Possible causes

A. Sheet is too big.

B. Photocell FC3 or FC5 defective.

C. Bypass cross 1 is on.

D. Air valve is broken.

Solution

A. If possible, make several longitudinal folds.

B. Replace photocell FC3 or FC5.

C. Remove bypass cross 1 from program.

D. Replace air valve.

3.8.14 Machine does not carry out the second crossfold

Possible causes

A. Sheet is much too thick.

B. Bypass cross 2 is on.

C. Photocell FC2 defective.

D. Air valve is defective.

Solution

A. Make fewer longitudinal folds in sheets.

B. Remove bypass cross 2 from program.

C. Replace photocell FC2.


3.8.15 Machine does not carry out the third crossfold

Possible causes.

A. Sheet much too thick for longitudinal folding.

B. Sheet much too thick for crossfolding.

C. Photocell FC1 defective.

D. Air valve is defective.

E. The blade is not adjusted properly.

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Solution

A. Make fewer longitudinal folds in sheets.

B. Make fewer crossfolds in sheets.

C. Replace photocell FC1.


E. Readjust the blade.

3.8.16 Stacking gripper is not handling sheets properly

Possible causes

A. Valve is defective.

B. Air cylinder braking is too strong.

B. Proximity switch Z1 defective.

C. Sheet too thick.

Solution

A. Replace valve.

B. Reduce air cylinder braking.

B. Replace proximity switch Z1.

C. Make fewer longitudinal folds or crossfolds.

3.8.17 Stacking gripper remains on top

Possible causes

A. Valve is defective.

B. Proximity switch Z2 defective.

C. Linen stack too high.

Solution

A. Replace valve.

B. Replace proximity switch Z2.

C. Adjust number of sheets on exit belt in program.

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CAUTION!

A. It is better just to crossfold big, thick sheets.

B. Whenever any work has to be carried out on the machine, it should be stopped by

activating an emergency stop. The purpose of this is to switch off all the moving parts

connected with the ironing, feeding, folding and stacking process.

C. On restarting, all protective doors, plates or Perspex screens are to be closed or fitted

again.

D. When the machine is restarted, mechanical movements can occur immediately.

3.9 Oil change in reduction gearbox

Note: Switch off the main switch..

Only change oil when the machine is cold.

Undo the screw at the bottom of the

reduction gearbox so that you can

drain the oil into a receptacle. N.B.: content see Oil types

Once the oil has completely drained from the reduction gearbox,

replace the screw at the bottom and tighten securely! (When

changing oil, it is better to replace the seal from the screw.)

Unscrew the filling plug at the top and

fill the reduction gearbox with new oil.

Note:Oil type GOAYA 220

Content: see Oil types

Then replace the filling plug and tighten

securely! (When changing oil, it is better

to replace the seal from the screw.)

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Disconnect the plug from the valve

Valve open

Close valve

Remove the plug

3.10 Thermal oil change.

Attention : Oil change can only happen when the oil got a temperature

of appr. 40 - 50°C, then the oil circulates better.

1. Shut the machine off with the main switch.

2. Close the stopcock at the bottom of the expansion tank and replace the stopper (for

safety).

3. Remove the plug of the stop valve at the bottom of the expansion tank.

4. Close the stop valve on the pressure line of the oil pump.

5. Remove the plug above the expansion tank.

6. Fill the expansion tank with thermal oil up to the shown level.

Attention : Replace every time the teflon hose every time you replace the oil.

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Bed vent

Oil level

Turn the plug back on

Connect the new teflon hose.

Put the teflon hose in a bucket.

7. Turn the plug back in the expansion tank.

8. Control the the oil level while heating up the machine. When we put new oil in the

machine then there is always moister in the oil. To avoid problems connect the extra

supplied Teflon hose to the top of the expansion tank to evacuate the moisture out of

the system.

9. After heating up the machine it is ready to work. The extra teflon hose can be taken

away and the existing one mounted again.

Please vent the bed at the top and the bottom Just to be sure there is nothing but oil in

the bed. Vent while the circulation pump is working.

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3.11 Cleaning of the bed. - There is no doubt that the life of all ironer clothing depends largely on the condition of the

beds. A clean smooth bed increases the life of any clothing and improves the quality of the

ironed linen.

A typical ironing problem like creasing on the leading edge is almost always due to a dirty

bed. Though not always visible residuals and salts will build up on the bed surface.

- Before cleaning the bed the causes of the deposit should be located. These are usually to be

found in the washing process :

- too hard water (lime deposit)

- PH value higher or lower than the ideal 6.5

- too high rest moisture (too much water to evaporate)

- bad rinsing (soap residuals).

- Cleaning of the bed :

1. When there is only build-up at the bed inlet, it can be removed by hand and with Scotch-

Brite (only when bed is cold).

2. When there is build-up on the whole bed:

- Drop the bed.

- Let the machine cool down ( 100°C).

- Open the scrapers.

- Wrap a cloth around the roll which will protect the padding against dust.

- Wind strips of Scotch-Brite around the rollers in wide lanes.

- Lower hydraulic pressure to 15 Bar.

- Push the slightly heated ( 100°C) bed against the roll and turn the roll for 2 to 3

hours.

- Keep watching to make sure the Scotch-Brite does not get loose.

- Remove all dust, then the Scotch-Brite and the cloth.

- Restore the original hydraulic pressure.

- Heat the bed and pass a wax cloth to grease the bed.

* Wax should be applied regularly but then sparingly (not too much) so as not to clog up the

suction clothing. Always use the cloth and never apply wax between roll and bed. It may

cause spots in the ironed items as then the padding takes the wax.

- For long time storage (seasonal work) prepare machine as follows :

- let the padding dry out

- Pass a wax cloth with much wax to prevent rusting

. - keep carrying out the annual maintenance (oil change, greasing...).

Before starting the ironer again : clean the bed!

Attention: On oil heated ironers (temperatures higher than 185° C)

too much wax constitutes a fire hazard.

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3.12 Roll padding replacement.

If the ironing machine is delivering reduced output and poorer ironing quality after a period of

time (1 year), this means the padding is worn.

The old padding is easily removed using a reversing switch located in the electrical

connection box.

- First clean the bed. ( See cleaning of the bed).

- Open the bed. ( machine at rest)

- Disassemble the feedingthrough.

- Disassemble the covers.

- Cut or detach the cords on the side of the padding.

- Turn the scrapers away of the padding as shown in the drawing.

- Let the roll turn backwards (with the switch) and take the padding so it rolls of the roll. Note

that the scrapers don’t falter in the padding, and that the padding doesn’t damages the

feedingplate.

- Check dimensions of the new delivered padding. ( length, width)

Mod.500 Padding

Ø Length (mm) Width (mm)

1750 3200 1950

2000 3200 2200

2200 3200 2400

2500 3200 2700

3000 3200 3200

3300 3200 3500

- Put a knot in the rope at both sides, so the rope can’t get out of the padding.

- Set the temperature at min. 120°C.

Knot in the rope ( 1 knot)

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- Then press preheating.

Glue ( type Vitabond VB100)

- Put the padding straight on the roll + push the padding against the roll. Place the padding on

the roll with the ropes at the bottom.

- Lower speed ( potentiometer) , then let the roll turn with the switch in the power box

( clockwise).

Spray glue over the

entire length with a

width of 10cm.

Preheating / Tension

± 10cm

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- While turning, make sure the padding is tensionned.

- When the padding enters the bed, stop the roll.( position switch “0” ). Close the bed (

working pressure max. 15Bar!) and let the roll turn. You can do this by pushing the start

button. Check that nothing rolls bad or keeps faltering. If you want to stop the roll, push the

fingerscreen or the footpedal. ( option)

- Make sure the ropes are not on the padding when the roll turns.

- Press the sides with a stump object. That prevents that something should halter / hang.

Startbutton

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- When the padding is completely on the roll ( 2 turns), increase working pressure and let the

roll turn for 15min. at a temperature of min.120°C and a higher speed.

Let the roll turn when the padding is too short ( max. 1 hour) If the padding is too long, stop

the roll and cut the padding. ( Cut when 3rd turn begins.) You can feel where the padding is

laying double. It is recommended to check the length of the padding after 1or 2 weeks and if

necessary cut the padding.

- Brush the padding ( positioning of the padding by turning the roll with the switch). Make

sure the bed is open. The brushing happens best with a steelbrush or a drill with a radial

steelbrush. Put something under the padding, like a wooden plank. So you can’t damage other

things.

Ideal length.

The padding is too

long. ( cut)

The padding is too short. ( Turn the roll

longer or change the padding.)

Wooden plank

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- Then use the steelbrush to create a smooth transition.

- Turn the roll.

- Stop the roll, and make 3 knots in the ropes at the sides of the padding. ( Tighten the knot as

hard as possible.)

Take the ropes.

Make 3 knots in it.

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- Let the roll turn and place the scrapers back in the correct position.

Cut the ends.

Push het ends and the knots back

with a stump object.

Too much pressure.

Too little pressure.

Good ( slight pressure)

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- Mount the feedingthrough.

- Mount the covers.

- If there are no comments, the padding is ready for use.

Never turn the roll whit pressure on the bed when the bed is cold!

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PART 4: SCHEMATIC DIAGRAMS

4.1 CROSS-SECTION OF CROSSFOLD COUPLING

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4.2 CROSS-SECTION OF STACKER

M8 type: 43900187

JOUCOMATIC type: C20 AS 25 DM

JOUCOMATIC type: C20 AS 25 SER

M8 TYPE: 43900187

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4.3 CROSS-SECTION OF EXIT BELT

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4.4 DRIVE FOR FEED ROLLER TO IRONING ROLLER

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4.5 HYDRAULIC CIRCUIT

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4.6 METHOD OF FOLDING

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4.7 CROSS-SECTION OF LONGITUDINAL FOLDING

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4.8 DRIVE FOR CROSSFOLDER.

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4.9 SET-UP FOR CONTACT FINGER GUARD.

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4.10 VALVE ISLAND

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4.11 PNEUMATIC DIAGRAM

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PART 5 : FACTORY SETTINGS AND OPTIONS.

5.1 Altivar

Altivar 312 :

Factory settings for Frequency invertor from Schneider. (ATV312)

( Push 2 sec. )

‘ESC’ ( Push 3 times )

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Factory settings for Frequency invertor from LACO. (ATV312 0.18kW)

- First enter factory settings from Schneider. ( As described on the previous page.)

- Then change the following parameters:

70


L


‘ESC’

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0.1

0.0

70

‘ESC’

‘ESC’

‘ESC’

0.1

‘ESC’

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0,8 (0.15 kW)


L i2

‘ESC’

‘ESC’


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L3

‘ESC’

Push 3 seconds

Push 3 seconds ‘ESC’ ( Push 2 times)

‘ESC’

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L12

‘ESC’ ( push 3 times)

3.0

‘ESC’

500


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Factory settings for Frequency invertor from LACO. (ATV312 0.75 – 1.5kW).

- First enter factory settings from Schneider. ( As described on the previous page.)

- Then change the following parameters:

0.1

70


‘ESC’

3.0

‘ESC’

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0.0

70

3,5 (0.75 kW) or 3,6 (1.5kW)

‘ESC’

‘ESC’


L i2

‘ESC’

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‘ESC’


L3

‘ESC’

Push 3 seconds

Push 3 seconds ‘ESC’ ( Push 2 times)

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‘ESC’

L12


2.0

‘ESC’

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How to reduce the roll drive motor noise with the frequency invertor. (ATV312)

Tune between 2 and 10

Tune the parameter between 2 and 10.

When you find the best parameter with the lowest

noise, you may push ‘enter’.

ATTENTION: When you tune the parameter

higher than 10, the motor can burn!


500


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5.2 Thermal overload Adjust with a screwdriver.

Q8 => 1.2A

Q9 => 0.7A

Q10 => 4.5A

Q11 => 0.4A

Q12 => 0.4A

Q13 => 0.6A

Q14 => 0.6A

5.3 Loading backup programs onto the B&R screen with USB stick.

Place the files “recept” and “settings” on the USB stick. They may not be in a folder on the

USB stick. This means, that you see the files when you open the USB stick on the computer.

Then we go with the USB stick to the machine and plug the USB stick into the USB input that

is the most backwards of the B&R screen.

Then we go on the B&R screen to “settings” “copy” “MEM” “MEMORY”

“restored from USB”. Shut the machine down, and put the machine on after 5 sec. The backup

programs are now loaded onto the B&R screen.

USB input

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5.4 Adjustable suction valve (option).

An adjustable suction valve allows the suction throughput to be regulated so that the roll is

not subject to cold suction but is still dry. The ideal temperature of the roll when the padding

returns to the ironing bed is approximately 40° C.

Valve can be adjusted

with a flat-head

screwdriver.

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