B&C Technologies IM Industrial Ironer User Manual

Ironer

IM Installation and Operation Manual

October 25, 2011

Revision 1.3

Executive Summary

The Installation and Operation manual for the IM Series of self-contained thermal fluid ironers. This manual covers the IM-800 and IM-1200 Series self contained thermal fluid ironers.

Chapter 1

Important Safety Information

1.1FOR YOUR SAFETY - CAUTION!

WARNING: For your safety the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

–Do not try to light any appliance

–Do not touch any electrical switch; do not use any phone in your building.

–Clear the room, building or area of all occupants.

–Immediately call your gas supplier from a neighbors phone. Follow the gas suppliers instructions.

–If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Contact your local gas supplier to obtain particular instructions in the event that a user smells gas. Place this sheet and any other instructions obtained from your gas supplier in a prominent location.

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1.2A Note of Caution

There is a protective coating applied to the chests of the ironer that MUST BE REMOVED prior to initial startup of the machine. Remove this protective coating prior to padding or applying heat. Failure to remove the coating can damage or destroy the chest and padding and will require difficult cleaning and replacement. Not heeding these instructions will certainly ruin you day.

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Contents

1	Important Safety Information			i
	1.1	FOR YOUR SAFETY - CAUTION! . . . . . . . . . . .		i
	1.2	A Note of Caution . . . . . . . . . . . . . . . . . . . . .		ii
2	Important Instructions			1
	2.1	Before Attempting Repairs . . . . . . . . . . . . . . . .		1
	2.2	Operator Safety Notes . . . . . . . . . . . . . . . . . .		3
	2.3	Parts Ordering Information . . . . . . . . . . . . . . .		4
		2.3.1	Nameplate Location . . . . . . . . . . . . . . .	4
	2.4	Key Symbols . . . . . . . . . . . . . . . . . . . . . . . .		5
	2.5	Safety Instructions . . . . . . . . . . . . . . . . . . . .		5
		2.5.1	Installation Notice . . . . . . . . . . . . . . . .	5
3	Machine Installation			8
	3.1	Installation . . . . . . . . . . . . . . . . . . . . . . . . .		8
		3.1.1	Receiving Inspection . . . . . . . . . . . . . . .	8
		3.1.2	Product Description . . . . . . . . . . . . . . .	8
	3.2	Electrical & Gas Specifications . . . . . . . . . . . . . .		10

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3.3 Work Rates . . . . . . . . . . . . . . . . . . . . . . . . .		11
3.3.1	1 Roll 48”x118” . . . . . . . . . . . . . . . . . .	11
3.3.2	1 Roll 32”x118” . . . . . . . . . . . . . . . . . .	12
3.3.3	2 Roll 48”x118” . . . . . . . . . . . . . . . . . .	12
3.3.4	2 Roll 32”x118” . . . . . . . . . . . . . . . . . .	12

3.3.5Moisture Retention Correction Factors . . . . . 12

3.3.6Calculating Moisture Retention . . . . . . . . . 13

3.4 Site Requirements . . . . . . . . . . . . . . . . . . . . .		14
3.4.1 Service Clearance . . . . . . . . . . . . . . . . .		14
3.4.2 Floor Requirements . . . . . . . . . . . . . . . .		14
3.4.3	Gas Requirements . . . . . . . . . . . . . . . .	15
3.4.4	Thermal Fluid Requirements . . . . . . . . . .	15

3.4.5Exhaust Duct Requirements . . . . . . . . . . . 15

3.4.6Compressed Air Requirements . . . . . . . . . 15

3.4.7	Electrical Requirements . . . . . . . . . . . . .	15
3.5 Machine Placement . . . . . . . . . . . . . . . . . . . .		16
3.5.1	Uncrating . . . . . . . . . . . . . . . . . . . . .	16
3.5.2	Clean Gap Pieces . . . . . . . . . . . . . . . . .	17

3.5.3Placement and Alignment . . . . . . . . . . . . 17

3.5.4	Moving the Ironer to Location . . . . . . . . .	17
3.5.5	Positioning and Leveling . . . . . . . . . . . .	18
3.5.6	Module Placement . . . . . . . . . . . . . . . .	19
3.5.7	Internal Piping Connections . . . . . . . . . . .	20

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3.6Compressed Air Connections . . . . . . . . . . . . . . 21

3.6.1	Internal Connections . . . . . . . . . . . . . . .	21
3.6.2	External Connection . . . . . . . . . . . . . . .	21
3.7 Electrical Connections . . . . . . . . . . . . . . . . . .		21

3.7.1Internal Electrical Connections . . . . . . . . . 21

3.8	Exhaust Installation . . . . . . . . . . . . . . . . . . . .		23
	3.8.1	Exhaust Connection . . . . . . . . . . . . . . .	23
	3.8.2 Internal Duct Work . . . . . . . . . . . . . . . .		23
	3.8.3	External Duct Work . . . . . . . . . . . . . . .	23
	3.8.4	Make Up Air . . . . . . . . . . . . . . . . . . .	23
3.9	Gas Connection . . . . . . . . . . . . . . . . . . . . . .		24

3.9.1Gas Pressure Requirements . . . . . . . . . . . 24

	3.9.2	Gas Line Connection . . . . . . . . . . . . . . .	24
	3.9.3	Regulator Venting . . . . . . . . . . . . . . . .	24
3.10	Thermal Fluid Connection & Filling . . . . . . . . . .		25
	3.10.1	Thermal Fluid Familiarization . . . . . . . . .	25
	3.10.2	Filling the System . . . . . . . . . . . . . . . . .	26
3.11	Riello Burner Setup . . . . . . . . . . . . . . . . . . . .		30
4 Operation			33
4.1	Operating Procedure . . . . . . . . . . . . . . . . . . .		33
	4.1.1	Daily Inspection . . . . . . . . . . . . . . . . .	33
	4.1.2	Operating Tips . . . . . . . . . . . . . . . . . .	34

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4.1.3 Shutdown Procedure . . . . . . . . . . . . . . .		34
4.1.4	Waxing Procedure . . . . . . . . . . . . . . . .	34
4.2 Running the Ironer . . . . . . . . . . . . . . . . . . . .		36
4.2.1	Cotton Sheets . . . . . . . . . . . . . . . . . . .	36
4.2.2	Poly-Cotton Blend Sheets . . . . . . . . . . . .	36
4.2.3	Dryness . . . . . . . . . . . . . . . . . . . . . .	36
4.2.4	Taking A Break . . . . . . . . . . . . . . . . . .	37
4.2.5	Running Small Pieces . . . . . . . . . . . . . .	37
4.2.6	Ironing Speed and Temperature . . . . . . . .	37
5 Maintenance		38
5.1 Wrinkle Patterns . . . . . . . . . . . . . . . . . . . . . .		38

5.2Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.3	Chest Adjustment . . . . . . . . . . . . . . . . . . . . .		44
5.4	Drive Belt Adjustment . . . . . . . . . . . . . . . . . .		44
	5.4.1 Drive Tension Adjustment . . . . . . . . . . . .		47
	5.4.2	Intermediate Tension Adjustment . . . . . . .	47
	5.4.3	Infeed Tension Adjustment . . . . . . . . . . .	48

5.4.4Interroll Tension Adjustment . . . . . . . . . . 50

	5.4.5	Feed Table Chain Adjustment . . . . . . . . . .	51
5.5	Roll Procession Adjustment . . . . . . . . . . . . . . .		51
5.6	Roll Padding . . . . . . . . . . . . . . . . . . . . . . . .		53
	5.6.1	Trimming the Roll Padding . . . . . . . . . . .	53

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5.6.2Roll Pad Discoloration (Yellowing) . . . . . . . 54

5.7 Guide Tape . . . . . . . . . . . . . . . . . . . . . . . . .	55
5.7.1 Securing Tapes . . . . . . . . . . . . . . . . . .	55

5.7.2Materials . . . . . . . . . . . . . . . . . . . . . . 56

5.7.3	Routing The Guide Tapes . . . . . . . . . . . .	56
5.7.4	Gearbox Lubrication . . . . . . . . . . . . . . .	57

5.7.5Pump Setup and Alignment . . . . . . . . . . . 58

5.7.6Typical Pump Problems . . . . . . . . . . . . . 58

5.7.7 Burner Cleaning . . . . . . . . . . . . . . . . . 59

5.8Thermal Fluid Maintenance . . . . . . . . . . . . . . . 62

5.8.1	Fluid Life . . . . . . . . . . . . . . . . . . . . .	62
5.8.2	System Cleaning . . . . . . . . . . . . . . . . .	62
5.8.3	Fluid Filter Screen . . . . . . . . . . . . . . . .	62
5.8.4	Pump Service . . . . . . . . . . . . . . . . . . .	63

5.8.5Thermal Fluid Draining . . . . . . . . . . . . . 63

5.9	Quarterly Safety System Test . . . . . . . . . . . . . .		64
6 Appendix			73
6.1	Proper Drum Storage . . . . . . . . . . . . . . . . . . .		73
	6.1.1	Recommended Storage Life . . . . . . . . . . .	73
	6.1.2 Storage . . . . . . . . . . . . . . . . . . . . . . .		74
	6.1.3	Eliminate Confusion with Proper Labeling . .	74
	6.1.4	Clean Delivery . . . . . . . . . . . . . . . . . .	74

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	6.1.5 Conclusion . . . . . . . . . . . . . . . . . . . .	75
6.2	Paratherm HE MSDS . . . . . . . . . . . . . . . . . . .	77
6.3	Shell Thermia MSDS . . . . . . . . . . . . . . . . . . .	82
6.4	Thermal Fluid Pump . . . . . . . . . . . . . . . . . . .	90

6.5Riello Burner Manual . . . . . . . . . . . . . . . . . . . 117

6.6	Riello Burner Parts Manual . . . . . . . . . . . . . . .	138
6.7	North American Riello Burner Parts Manual . . . . .	143

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Chapter 2

Important Instructions

2.1Before Attempting Repairs

Rollers and other moving parts can cause serious injury or death. Before attempting repairs, follow proper shutdown procedures, remove power, and allow the machine to fully cool before commencement of service. Before electrical service begins, allow at least 5 minutes after power has been removed to allow the AC inverter drive to discharge.

Safety is of primary concern with any maintenance or repair operation. If you are in any way unsure of how to proceed with a repair or adjustment, consult this manual, a qualified maintenance technician, your local distributor, or the B&C Technologies Technical Service Department at 850-249-2222.

Only trained and experienced personnel should attempt maintenance or repair work on this equipment. Follow all safety procedures including lock-out/tag-out procedures carefully. Ensure that any loose fitting clothing or jewelry is tucked in or not worn to avoid being pulled into the machine. Remember, the machine has no brain - you must use your own.

Before attempting repairs, follow proper shutdown procedures, remove power, and allow the machine to fully cool before commencement of service. Before electrical service begins, allow at least 5 minutes after power has been removed to allow the AC inverter drive to discharge.

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Never attempt to clean or service any area of the machine without removing power at the main disconnect and allowing time for the machine to cool completely.

There are certain jobs that must be performed with the ironer running at the slowest possible speed. In this instance, another person must be stationed at the disconnect to immediately remove power if needed. Always avoid moving rolls and be especially aware of pinch points where two or more rolls come together.

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

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2.2Operator Safety Notes

NEVER ATTEMPT TO REMOVE OR ADJUST JAMMED LINEN WHILE THE MACHINE IS IN OPERATION. Attempting to reposition or free jammed linen while the machine is under power can result in machine damage (best case) or serious injury or death (worst case). REMOVE POWER TO THE MACHINE and allow it to cool before attempting removal of jammed goods. Ironer surfaces can reach temperatures well in excess of 400 degrees Fahrenheit (205 degrees Celsius), not something you want to touch.

NEVER REACH around the safety guards or into any area near heated surfaces or moving parts without first powering down the machine and allowing it to cool. Failure to follow this instruction can lead to serious injury or death.

Check operation of the finger safety guard at the start of every work shift. Activating this guard should stop the machine. If this important safety device is not working, power off the machine and notify your manager. DO NOT OPERATE THE MACHINE until the safety guard is working properly.

Make sure that all guide tapes and belts are in place and tensioned properly. Missing or improperly adjusted tapes and belts will cause performance, quality, and production problems. Maintaining a proper waxing schedule also keeps the machine performing at peak efficiency and quality.

Only flatwork should be processed in the ironer - processing goods the machine is not designed to handle can lead to damage to the machine or personal injury.

Do not stand, sit, or kneel on any part of the ironers front or rear - these parts are not designed to carry your weight.

Follow all lock-out/tag-out procedures when servicing the ironer. Remember, when servicing the machine, power must be disconnected at the main disconnect switch.

Only you can protect yourself by reading and understanding these precautions. Help protect others by making sure all personnel follow these instructions. Do not wear loose clothing or jewelry while operating this machine. Stay away from moving parts and heated rolls.

If in doubt, ask your manager or contact Technical Service to find out how to safely operate the ironer. Remember, only those qualified should service the ironer.

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Figure 2.1: Serial Decal

2.3Parts Ordering Information

If you require literature or spare parts, please contact your local distributor. If a local distributor is unavailable, you may contact B&C Technologies directly at [phone] for the name of your nearest parts dealer.

For technical assistance in the United States, contact B&C Technologies: [phone] Phone

[phone] FAX [e-mail] www.bandctech.com

2.3.1 Nameplate Location

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

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2.4Key Symbols

Anyone operating or servicing this machine must follow the safety rules in this manual. Particular attention must be paid to the DANGER, WARNING, and CAUTION blocks which appear throughout the manual and shown in figures 2.2 on page 6 and 2.3 on page 7.

2.5Safety Instructions

2.5.1 Installation Notice

For personal safety and for proper operation, the machine must be grounded in accordance with state and local codes and in the USA in accordance with the National Electric Code, article 25096. Elsewhere, the equipment should be grounded in accordance with ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1. The ground connection must be to a proven earth ground, not to conduit or water pipes.

Natural Gas or Liquid Propane Gas (LP Gas) heated equipment installation must comply with state and local codes, and in the USA, in accordance with the National Fuel Gas Code. Elsewhere, the equipment should comply with ANSI Z22.1, or CSA B149.

Provisions must be made for adequate make-up air and ventilation, and access for equipment service and installation.

Installation and Operational Safety Instructions

1.Read all instructions prior to operating this equipment.

2.Ensure that the equipment is properly grounded before applying power and operation commences.

3.Do not process goods that have been previously cleaned in, soaked in, or exposed to gasoline, dry cleaning chemicals, or any other flammable or explosive materials, as they could catch fire or explode without warning, even after being washed.

4.Do not allow children to play in or around or operate this equipment.

5.Check the operation of all safety interlocks at the start of every shift. If the interlocks do not stop the equipment immediately, the machine must be removed from service. Notify your immediate supervisor, and do not operate the machine.

6.Never attempt to service the machine while it is running. Never reach over, under, around, or behind any safety device, or into any area near moving parts or hot surfaces without shutting off power and allowing the machine to adequately cool.

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Figure 2.2: Key Symbols

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Figure 2.3: Key Symbols

7.Read, understand, and follow all safety instructions. Do not come close to moving parts and hot surfaces. Do not wear loose clothing, jewelry, neckties, or any other garment that could become caught in the machine while operating or near the machine.

8.Only a qualified technician should attempt to service or repair the machine.

9.Do not install the machine in an area where it could be exposed to water or weather.

10.Do not alter or tamper with the control system.

11.To reduce the risk of fire, do not process plastics or articles containing foam rubber or similarly textured rubber-like materials.

12.Keep the area near the exhaust ducting clean and free of lint, dust, dirt or debris.

13.Keep the interior and exterior of the machine clean of lint, dirt, dust and debris. The interior of the machine, along with the exhaust ductwork should be periodically inspected and cleaned to avoid potential fires (lint is highly flammable).

14.Improper installation, operation and maintenance of this machine can cause exposure to substances in the fuel or from combustion that can cause serious illness or death. The machine must be exhausted to the outside.

15.Always disconnect the electrical service from the machine and allow it to cool before performing service.

16.This machine must be installed according to the installation instructions. All exhaust, electrical connections, and gas or steam connections must comply with state and local codes and must be made by a licensed installer where required.

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Chapter 3

Machine Installation

3.1Installation

3.1.1 Receiving Inspection

Upon receipt of the equipment, visually inspect for shipping damage and note any damage with the carrier before signing the shipping receipt, or advise the carrier of the damage as soon as it is noted.

If damage is discovered, a written claim must be filed with the carrier as soon as possible.

Note: Warranty is VOID unless the equipment is installed according to instructions. The installation must comply with the minimum requirements listed in this manual. All national, state and local codes must be followed including but not limited to gas, electrical, plumbing and HVAC. Due to various requirements, statutory codes should be well understood before installation commences.

The ironer is delivered in ready-to-connect modules. The supply and return lines for all utilities such as heat, compressed air, power, exhaust, etc. must be installed on site. Each module is covered with a protective plastic wrapping. The cover panels are normally mounted to the ironer module.

3.1.2 Product Description

1.Design And Construction

The heavy-duty ironers are manufactured in modules. The modules can be combined into ironers of one to four units with diameters of 800 mm (32 in.) or 1200 mm (47 in.) in widths of 3000 mm (118 in.) or 3300 mm (130 in.). Other widths are available - consult the factory.

2.Modular System

The modular design allows an increase of modules (up to four) to fit the individual requirements of the particular installation.

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3.Heating System

The ironers can be ordered for the following heating systems:

High Pressure Steam

Hot Oil / Thermal Fluid

4.Drive System General

The heavy-duty ironer is driven by a variable speed gear drive or a variable electric drive for the multi-roll units. The power is directed to a slip-on gear box on each roller and in feed conveyor through a high-performance V-belt system. The required in feed speed can be adjusted at the right control panel and can be monitored with the rate meter display. Programmable speed selectors are available as an option. The selectors can only be modified by trained personnel.

5.Heating Chests

Heating chests are constructed of heavy gauge boilerplates with stiffeners to take the required forces. The contact surfaces of the chests are ground and polished. The chests are adjustable and are mounted on rollers integrated in the main frame.

6.Bridging Chests

The heated bridging chests (gap pieces) are specially designed to prevent a loss of heating efficiency between the modules and ensure a high finish quality due to the uninterrupted heating surface by steam or oil passing through the bridging chest. Steam-heated chests consist of a copper heating coil embedded in the chest. Thermal Oil heated chests are of a special welded design to optimize heat transfer. The surfaces of the bridging chests are ground and polished.

7.Rolls

The rolls consist of a perforated, large-diameter cylinder covered with felt or nomex padding. Each roll has its own vacuum fan that ensures the efficient removal of condensation. Each vacuum fan can be individually adjusted through a butterfly flap located in the exhaust duct portion of the module. Through this individual adjustment, a constant temperature can be maintained at the padding. Each roll is mounted on the left side to a swing bracket with a self-aligning bearing. The right side is mounted to a slip-on gearbox integrated in a swing bracket. All available padding can be supplied to meet customer specifications.

8.Roll Procession

The speed difference between rolls is created by the variable pulley belts on the drive side of the slip-on gear boxes (similar to the gear box on the infeed belts). The procession between rolls should only be modified by trained personnel.

9.Roll Lifting Mechanism

Each roll can be individually raised and lowered through a pneumatic cylinder arrangement. The controls are located on the left hand control panel. After shutting off the power or in case of a power failure the rolls are lifted automatically. A safety device built into the cylinders prevents the rolls from dropping in the event of a failure in the compressed air system. This safety device prevents damage to the padding. The pressure between roll and chest is created by the pneumatic cylinders. A pneumatic control valve, located on the right side of the first

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module, controls the pressure which is monitored via a pressure gauge on the left control panel. As an option, individual pressure control of each roll is available.

10.Linen Infeed

The infeed of linen occurs on the front side of the ironer via wear and temperature resistant flat belts. The belts are driven by a textured infeed roller. A finger guard, located at the end of the belts, stops the ironer and lifts the first roller immediately if activated.

11.Utility Connections (when looking from the front)

Electricity	Type 800	Left side
	Type 1200	Right side
Compressed Air	Type 800	Right side
	Type 1200	Left side
Exhaust	Type 800	Right side
	Type 1200	Left side

12.Control Panels

The left control panel includes emergency stop button, roll temperature, air pressure for each roll, steam inlet temperature, steam pressure The right control panel includes rate meter, speed selector lift and lower switch for each roller, switch for on and start, push button drive on, pilot light for main power, pilot light for overload, pilot light for control, push button for control, jog button (reverse), drive start push button, emergency stop and selector switch.

13.Electrical Components

The electrical panel is located at the right side for model 1200 and Left side for model 800 of the first module in an enclosure with a door that can only be open by a special key. All electrical components on the panel are DIN rail mounted for easy repair and maintenance. The serial plate is located on the left side in the enclosure.

14.Safety Features

The infeed side is protected by a windowed heat-resistant finger guard that, if activated, will instantly stop the drive motor and raise the first roll. Two emergency push buttons are located at either end of the ironer and should only be used in emergencies. If activated, these emergency buttons will shut off the ironer and raise all the rolls. All mechanical and electrical components are covered by sheet metal panels or located behind enclosures. Panels and service doors can only be opened with special keys.

15.Optional Canopies

Canopies can be provided so that heat losses are reduced to a minimum. The canopies are of aluminum construction.

3.2Electrical & Gas Specifications

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

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sults will be obtained with a properly sized incoming gas line. Undersized gas lines will cause performance and burner issues.

Table 3.1: IM Electrical & Gas Requirements

Model	BTU	Volts	FLA	Breaker
IM-12301-2T	800,000	200-230, 3ph, 50/60Hz	60	70
IM-12301-4T	800,000	380-460, 3ph, 50/60Hz	30	40
IM-12331-2T	800,000	200-230, 3ph, 50/60Hz	61	70
IM-12331-4T	800,000	380-460, 3ph, 50/60Hz	31	40
IM-12302-2T	1,600,000	200-230, 3ph, 50/60Hz	81	90
IM-12302-4T	1,600,000	380-460, 3ph, 50/60Hz	41	50
IM-12332-2T	1,600,000	200-230, 3ph, 50/60Hz	85	100
IM-12332-4T	1,600,000	380-460, 3ph, 50/60Hz	42	50
IM-8301-2T	600,000	200-230, 3ph, 50/60Hz	54	60
IM-8301-4T	600,000	440-460, 3ph, 50/60Hz	27	40
IM-8331-2T	600,000	200-230, 3ph, 50/60Hz	55	70
IM-8331-4T	600,000	440-460, 3ph, 50/60Hz	27	40
IM-8302-2T	1,200,000	200-230, 3ph, 50/60Hz	69	80
IM-8302-4T	1,200,000	440-460, 3ph, 50/60Hz	35	50
IM-8332-2T	1,200,000	200-230, 3ph, 50/60Hz	71	80
IM-8332-4T	1,200,000	440-460, 3ph, 50/60Hz	36	50

3.3Work Rates

3.3.1 Realistic Work Rates for 1 Roll 48”x118” (1200mm) Ironer

	Goods									Working Temperature
				170C / 338F				180C / 356F				188C / 371F				200C / 390F
	g/m2	lb/yd2	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr
	Sheets @ 80% Bed Coverage														200
	130	0.2400	14	46	260	573	16	52	290	639	18	59	320	706	22	72	380	838
160		0.2954	11	36	260	573	13	43	290	639	15	49	320	706	19	62	380	838
190		0.3508	10	33	260	573	11	36	290	639	12	39	320	706	14	46	380	838
	Small Pieces @ 60% Bed Coverage
	220	0.4062	9	30	215	474	10.5	34	250	551	12	39	285	628	14	46	330	728
280		0.5170	7.5	25	225	496	9	30	270	595	10	33	300	662	11.5	38	345	761
330		0.6093	7	23	260	573	8	26	295	650	8.5	28	310	684	10	33	370	816

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

	Goods									Working Temperature
				170C / 338F				180C / 356F				188C / 371F				200C / 390F
	g/m2	lb/yd2	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr
	Sheets @ 80% Bed Coverage
	130	0.2400	9	30	175	386	10	33	195	430	11	36	215	474	13	43	255	562
160		0.2954	7.5	25	175	386	8.5	28	195	430	9.5	31	215	474	11.5	38	255	562
190		0.3508	6.5	21	175	386	7.5	25	195	430	8.5	28	215	474	10.5	34	255	562
	Small Pieces @ 60% Bed Coverage
	220	0.4062	5.5	18	130	287	6.5	21	155	342	7	23	170	375	8.25	27	195	430
280		0.5170	4.5	15	135	298	5.5	18	165	364	6	20	180	397	7	23	210	463
330		0.6093	4	13	150	331	4.5	15	165	364	5	16	185	408	6	20	220	485

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

	Goods									Working Temperature
				170C / 338F				180C / 356F				188C / 371F				200C / 390F
	g/m2	lb/yd2	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr
	Sheets @ 80% Bed Coverage														200
	130	0.2400	32	105	580	1279	36	118	645	1422	40	131	710	1566	48	157	840	1852
160		0.2954	26	85	580	1279	30	98	645	1422	34	112	710	1566	42	138	840	1852
190		0.3508	24	79	580	1279	26	85	645	1422	28	92	710	1566	32	105	840	1852
	Small Pieces @ 60% Bed Coverage
	220	0.4062	20	66	475	1047	23	75	545	1202	25	82	595	1312	29	95	690	1521
280		0.5170	16	52	480	1058	19	62	570	1257	21	69	630	1389	24	79	720	1588
330		0.6093	15	49	550	1213	17	56	625	1378	19	62	700	1544	22	72	810	1786

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

	Goods									Working Temperature
				170C / 338F				180C / 356F				188C / 371F				200C / 390F
	g/m2	lb/yd2	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr	m/min	ft/min	kg/h	lb/hr
	Sheets @ 80% Bed Coverage
	130	0.2400	22	72	410	904	24	79	455	1003	26	85	500	1103	32	105	590	1301
160		0.2954	19	62	410	904	21	69	455	1003	23	75	500	1103	27	89	590	1301
190		0.3508	17	56	410	904	19	62	455	1003	21	69	500	1103	25	82	590	1301
	Small Pieces @ 60% Bed Coverage
	220	0.4062	13	43	310	684	15.5	51	370	816	17	56	405	893	20	66	475	1047
280		0.5170	11	36	330	728	13	43	390	860	14.5	48	435	959	17.5	57	525	1158
330		0.6093	9	30	330	728	11	36	405	893	12.5	41	460	1014	14	46	515	1136

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

3.3.5 Moisture Retention Correction Factors

Moisture retention	Correction Factor
25%	1.39
30%	1.29
35%	1.19
40%	1.12
45%	1.06
50%	1
55%	0.95
60%	0.91
65%	0.87
70%	0.83

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3.3.6 Calculating Moisture Retention

Percent Moisture Retention is a measure the water remaining in the goods being processed. To determine the water retention of flatgoods being processed do the following:

1.Pull a sample of 10 pieces from the middle of the pile (goods on top tend to be dryer and will give false results).

2.Immediately weigh your sample of 10 goods and record that weight as ”W1”. 3. Pass them through the ironer once and wait 5 minutes.

3.Weigh the sample again and record the weight as ”W2”.

4.Iron the sample goods a second time.

5.Weigh the sample a third time and record this as ”W3”.

From these weights one can find: 1) The dry weight of the laundry, 2) The moisture retention of the ironed goods, 3) The initial moisture retention of the goods before ironing.

To calculate moisture retention, use the following formulas:

Moisture Retention (%) before ironing = (W1-W3)/ W3

Moisture Retention (%) after ironing = (W2-W3)/ W3

As a general guide: The Moisture Retention before ironing should be 30% to 50%. The Moisture Retention 5 minutes after ironing should be 2% to 4%.

Fabric Weight is a major factor needed to determine the actual practical work rate for flat goods. Fabric weight is typically expressed as g/m2 (grams per square meter), lbs/yd2 (lbs per square yard), or oz/yd2 (ounces per square yard). The fabric weight for the goods must be known to find the proper ironing speed in the Work Rate Chart. The weight of the flatwork can be determined easily by:

1.Measure the Length and Width of each of the 10 sample pieces used above. Multiply the measurements for each sheet to find the total area of each piece (Area = Length x width).

2.Add the calculated area for all 10 pieces.

3.If the sheets are measured in inches, divide the sum by 1296 to convert to square yards (yd2).

4.Divide the total dry weight (W3 from above) by the area in square yards from step 3 to calculate the weight.

Fabric weight = Total Weight (lbs) / Total Area(yd2)

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Figure 3.1: Machine Clearances

3.4Site Requirements

3.4.1 Service Clearance

Figure 3.1 shows the recommended minimum service clearances. The dimensions shown are needed to adequately service and operate the machine with maximum efficiency. Reducing this clearance is not recommended. You must allow space around the machine for maintenance.

3.4.2 Floor Requirements

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

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3.4.3 Gas Requirements

The ironer requires a significant gas service capable of providing the volume and pressure needed to achieve the BTU rating of the particular machine. Typical gas pressure ranges from 1/2 to 2 PSI with ratings up to 2.5 million BTU. Refer to the previous section for gas connection sizing, gas pressure requirements and BTU ratings.

3.4.4 Thermal Fluid Requirements

The ironer is shipped with a minimal amount of thermal fluid. Before commissioning, the machine must be properly filled with thermal fluid. Follow the procedure outlined in the Maintenance section of this manual for specific procedures for filling and purging the system.

3.4.5 Exhaust Duct Requirements

A short run of pressurized gas flue vent ducting and a short run of exhaust vent ducting is required and must be procured locally. Adequate ventilation is required and must meet all local codes. Refer to the previous section for airflows and other pertinent information.

Important: Do not interrupt the flow of make-up air or the exhaust!

Use the shortest possible path with the fewest number of bends to connect to the outlet ductwork. Measured back pressure should not exceed 0.3 inches of water column pressure for reliable ignition and best results.

Note: Check for proper exhaust fan rotation direction before placing the equipment into service. If the rotation is incorrect, remove power from the machine and exchange any two incoming power leads.

3.4.6 Compressed Air Requirements

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

3.4.7 Electrical Requirements

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

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Note! Do not use phase adders (roto-phase) on inverter driven equipment!

The machine should be connected to an individual branch circuit not shared with lighting or other equipment.

A lockable, load break rated, visible break disconnect switch with safe working clearances is required for all installations. A disconnect plug is also acceptable, so long as it is able to safely break the load, is in an accessible location, and can be locked.

The connection should be shielded in a liquid tight or approved flexible conduit with proper conductor of correct size installed in accordance with National Electric Code (USA) or other applicable codes. The connection must be made by a qualified electrician using the wiring diagram provided with the machine.

For personal safety and for proper operation, the machine must be grounded in accordance with state and local codes and in the USA in accordance with the National Electric Code, article 250-96.

The ground connection must be to a proven earth ground, not to conduit or water pipes.

Do not connect the ground to the neutral (N) leg at the terminal strip.

If a DELTA supply system is used, the high leg should be connected to T or L3, as control power is derived from L1 & L2.

3.5Machine Placement

3.5.1 Uncrating

Prior to removing the packaging from the machine, ensure that the installation site is acceptable and any necessary floor or foundation improvements or modifications have been made.

Remove all packaging materials from the machine including bagging, crating, straps and any other materials while leaving the machine attached to the pallet.

Remove these and move to a safe place until called for:

Optional canopies

Optional railing

All end frame panels

Boiler ductwork

Carefully check all enclosures and remove any other materials shipped with the machine. These items will be used later in the installation process, so move to a convenient place.

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3.5.2 Clean Gap Pieces

Before placing the ironing modules, the gap piece(s) must be cleaned. There is a protective coating applied during the manufacturing process that protects the finely polished surface during shipping.

Carefully remove the plastic covering, making sure that all plastic covering has been completely removed.

Thoroughly wipe down the entire gap piece using a clean, dry lint-free cloth. Do not use solvents or abrasives during this process. Make sure the entire surface is cleaned of protectant.

3.5.3 Placement and Alignment

WARNING! Modules are heavy. Ensure that proper equipment and personnel are available to prevent injury or damage. Modules should only be moved by qualified machinery riggers using correct equipment.

Each module section has a chest and roll arrangement and up to 4 modules can be combined. Keep in mind the following terminology:

The front module contains the controls and electrical connection.

The center module(s), if necessary, include no extra equipment.

The rear module contains the boiler, gas connection and compressed air connection.

Place the sections beginning with the rear module, then the center modules if so equipped and finally the front module. Once the rear module is placed, the position of the ironer becomes fixed.

3.5.4 Moving the Ironer to Location

a) General

The modules can be moved by using a fork lift or a crane with an appropriate sling system. The weight of the modules can be found in the technical data of the ironer. The minimum required entrance dimensions are:

Type 800: 71 x 71in (1800 x 1800mm)

Type 1200: 87 x 71in (2200 x 1800mm)

For single roller ironers the minimum required entrance dimensions are:

Type 800: 83 x 71in (2100 x 1800mm)

Type 1200: 99 x 71in (2500 x 1800mm)

b) Using a Fork Lift

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Figure 3.2: Module Bolting

NOTE: The fork lift used must have the required capacity and be fitted with appropriate forks.

The modules can be picked up at the I-Beams at the front side. If using a fork lift, then one side of the ironer is to be lifted and skid rollers are to be used for the opposite side. Lift the ironer and move it slowly to its destination. The passage of the load should be clear of any obstruction on the floor or overhead, such as power lines, ceiling beams and others.

c) Using a Crane

The transport brackets must be in position before attempting to move the modules with a crane.

NOTE: The crane used must have the required capacity and be fitted with appropriate slings and a spreader frame.

The modules are to be moved in a horizontal position only. After the modules are in position, remove the transport brackets before mounting the modules together.

3.5.5 Positioning and Leveling

The ironer should be positioned as per installation drawing. The minimum required side distance to walls or other obstructions or equipment is 36 inches (915mm).

NOTE: The module number can be found at the top of the side frame beside the connecting bracket (see figure 3.2).

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Figure 3.3: Flange Cover Detail

3.5.6 Center/Front Module Placement

With the module still on its skid, move it near its final position, about 12 inches (300mm) from the already placed module and remove the skid bolts.

Place drip pans under the flange shipping covers (painted red).

Note: Thermal Fluid may cause a skin reaction in sensitive individuals. Wear protective clothing. Refer to the Material Safety Data Sheet in the Appendix of this manual.

Remove the flange shipping covers from the thermal fluid supply and return connections. A small amount of fluid will drain out. Wait until the flow completely stops before continuing.

Note: Follow local codes for handling the disposal of the thermal fluid collected in the drip pans. Do not attempt to reuse this fluid!

Carefully clean the flanges and any additional spilled thermal fluid. Carefully dispose of the thermal fluid and cleaning materials according to local codes.

Using a crane or forklift, lift the module straight up and carefully remove the skid. Do not drop or twist the module.

Move the module until it is directly above its final location. The endframes of the modules will be in contact with one another. Carefully lower the section to its final position. Ensure that the gap piece is aligned with the chest of the previously placed module.

The gap piece should be slightly above the mating chest and extend just beyond the surface

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Figure 3.4: Thermal Fluid Flange Bolt Tightening

edge of the chest. The endframes must rest firmly on the floor.

After the modules are set in location, bolt the lower I-Beams together using the hex bolts (M20 x 50). Do not tighten the bolts yet.

Bolt the upper connecting brackets between the modules using the hex bolts (M8 x 35). Do not tighten the bolts yet.

Level the modules by using sheet metal shims. The shims are to be used only under I-Beam at the chest support. The modules are to be leveled horizontally in two directions and must be parallel to each other.

The holes for the roll pins (8 x 25) are drilled while the ironer is preassembled at the factory. Now tighten all bolts using the following torque values: (M8 = 16 ft-lb / 22 Nm) (M20 = 300 ft-lb / 420 Nm)

3.5.7 Internal Piping Connections

Once all modules are aligned, secured, and bolted together, the thermal fluid piping must be connected.

Starting at the rear module, connect the thermal fluid piping to the next module using the gaskets and bolts provided. Use care to avoid damaging the gaskets during installation.

Tighten the nuts and bolts by hand, then follow the crisscross pattern shown in figure 3.4.

Repeat these steps for each additional module.

After all internal thermal fluid piping has been connected, recheck for level on all modules using a large carpenters level.

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