Milnor 300 Lb. Tunnel Dryer Model 6464TGIL Quarterly.pdf

Chapter 3. Routine Maintenance

PELLERIN MILNOR CORPORATION

Chapter 3 Routine Maintenance

BIUUUM09 (Published) Book specs- Dates: 20170719 / 20170719 / 20170719 Lang: ENG01 Applic: PDG

3.1. Routine Maintenance—Gas Dryer

This document uses Simplified Technical English. Learn more at http://www.asd-ste100.org.

Do the maintenance in Section 3.1.2 “Maintenance Summary” to make sure that the machine is safe, keeps the warranty, and operates correctly. This will also decrease repair work and unwanted shutdowns. Speak to your dealer or Milnor if repairs are necessary.

WARNING 27 : Risk of severe injury—Mechanisms can pull in and mutilate your body.

• You must be approved by your employer for this work.

• Use extreme care when you must examine components in operation. Remove power from the machine for all other work. Obey safety codes. In the USA, this is the OSHA lockout/tagout (LOTO) procedure. More local requirements can also apply.

• Replace guards and covers that you remove for maintenance.

3.1.1. How To Show the Maintenance On a Calendar

If you use software to keep the maintenance schedule for your plant, add the items in Section

3.1.2 to that schedule. If not, you can put marks on a calendar that work with the tables in Section

3.1.2. The marks are the numbers 2, 3, 4, 5, and 6. It is not necessary to show the number 1 (items you do each day) on the calendar. The number 2 = items you do each 40 to 60 hours, 3 = each 200 hours, 4 = each 600 hours, 5 = each 1200 hours, and 6 = each 2400 hours. These are the "Mark" numbers at the top of the narrow columns on the left of each table in Section 3.1.2.

Table 2 shows where to put the marks on a calendar. For example, if your machine operates between 41 and 60 hours each week, the first three marks are 2, 2, and 3. Put these marks on the first, second, and third weeks after the machine starts operation. If you do routine maintenance on a given day of the week, put the mark on that day of each week. Continue to put marks on the subsequent weeks. It can be necessary to do the 40 to 60 hour (2) maintenance more than one time each week. If the machine operates between 61 and 100 hours, put a 2 on two days of the week. If the machine operates 101 or more hours, put a 2 on three days of the week.

On each date with a 3, do the items with an x in the 3 or the 2 column of each table in Section

3.1.2. On each date with a 4, do the items with an x in the 4, 3, or 2 column. Continue this pattern.

Table 2: Where to Put Marks On a Calendar

Hours / Week

Week Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Up to 40 2 2 2 2 3 2 2 2 2 3 2 2 2 2 4 2 2 2 2 3 2 2 2 2 3 2 2 2 2 5 41 - 60 2 2 3 2 2 2 3 2 2 4 2 2 3 2 2 2 3 2 2 5 2 2 3 2 2 2 3 2 2 4 61 - 80 2 2 3 2 3 2 4 2 2 3 2 2 3 2 5 2 3 2 2 3 2 4 2 2 3 2 2 3 2 6 81 - 100 2 3 2 3 2 4 2 3 2 3 2 5 2 3 2 3 2 4 2 3 2 3 2 6 repeat 101 - 120 2 3 2 3 4 2 3 2 3 5 2 3 2 3 4 2 3 2 3 6 repeat 121 - 140 2 3 2 3 4 3 2 3 5 2 3 2 3 4 3 2 3 6 repeat Hours / Week

Week Number, continued 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Up to 40 2 2 2 2 3 2 2 2 2 3 2 2 2 2 4 2 2 2 2 3 2 2 2 2 3 2 2 2 2 6 41 - 60 2 2 3 2 2 2 3 2 2 6 repeat

3.1.2. Maintenance Summary

The tables in this section give the routine maintenance items for your machine. Each table is for one type of procedure (example: apply grease to bearings and bushings). The top of the table gives the general procedure. The "More Data" column gives special instructions if necessary.

* If the machine operates more than 12 hours each day, do the "day" items two times each day.

Do the other items at the given hours or on the days that you show on a calendar (see Section 1).

Do all items in all tables for the maintenance intervals that apply (for example, day, 40 to 60 hours, and 200 hours).

Tip: The sections that follow the maintenance summary give more data about the maintenance items.

After you know this data, it is only necessary to look at the summary to do the maintenance.

Table 3: Guards and Related Components

Examine. If a component is damaged, missing, or not set, correct this immediately to prevent injury.

Mark Do this each Component More Data 1 2 3 4 5 6 x day* guards, covers Speak to your dealer or Milnor for replacement components. x day* safety placards x 200 hours fasteners Fasteners must be tight.

x 200 hours anchor bolts and grout Grout must be good. Bolts must be tight.

x day* emergency stop mechanism See Supplement 4. Do a test of the control.

x 200 hours fire safety system (sprinkler) Do a test of the system. See the instruction on fire safety system operation and maintenance.

x day* machine area Examine this area for materials that can burn or explode. Remove them. If you smell gas, do the explosion and fire hazard procedure for your laundry. Make sure there is no gas leak or the leak is repaired before you continue operation.

Table 4: Filters, Screens, and Sensitive Components

Remove contamination from these components to prevent damage and unsatisfactory performance.

Mark Do this each Component

More Data. See also Section 3.1.3 “How to Remove Contamination” 1 2 3 4 5 6 x 40 to 60 hours inverter fans, vents, filters See Figure 9. Keep good air flow.

x 600 hours motors Keep good air flow.

x 2400 hours entire machine Remove excessive dust and dirt.

x day* self-purging filter (and regulator) for compressed air See Figure 11. Make sure the bowl drains automatically.

x 200 hours filter element for the filter (and reguator)

Replace the filter if you cannot remove contamination.

x 200 hours strainer(s) for air inlet See Figure 10 x day* photoeyes See Figure 13 x 2400 hours proximity switches See Figure 14 x 200 hours dryer basket See Supplement 5, Figure 19. Examine these components for plastic contamination. x 200 hours main blower fins x 200 hours temperature sensors x 40 to 60 hours infrared temperature sensors

(option) See Figure 20 x 2400 hours access panel under shell See Figure 19 x 200 hours air intake areas Inspect for, and remove any materials that may block air flow.

x 600 hours exhaust duct Open inspection covers. Remove any lint buildup.

x 40 to 60 hours combustion air intake screen or grill.

Air heat burners: See Supplement 5, Figure 15 Ratio air burners: See Supplement 7, Figure 16 and Figure 17 x 1200 hours burner diffuser plate and blower fins Table 5: Fluid Containers

Examine. Add fluid if necessary and keep components clean to prevent damage.

Mark Do this each Component

More Data. See also Section 3.1.4 “Lubricant Identification and Procedures” 1 2 3 4 5 6

For the next three items, see Figure 23 first 100 hours speed reducer (gear reducer)

Remove used oil. Add oil 220 (Table 11). See Section 3.1.4.3 x 1200 hours Add oil 220 (Table 11) if necessary.

x 2400 hours Remove used oil. Add oil 220 (Table 11).

COttman Text Box Preventative Maintenance Schedule

Table 6: Components that Become Worn

Examine. Tighten or replace if necessary, to prevent shutdowns and unsatisfactory performance.

Speak to your dealer for replacement parts

Mark Do this each Component More Data 1 2 3 4 5 6 x 200 hours drive belts and pulleys See Supplement 1 and Figure 8 x 200 hours air seals. These include:

• T-seal around basket

• Nomex, felt at front of basket

• felt, rubber at top of load door

• felt at bottom of load door

• felt at unload door

• rubber at access doors

Examine. See Supplement 8, Figure 21 x 200 hours support wheels (4) under basket

Examine. If wheels are worn, repairs can be necessary. Speak to your dealer or Milnor.

This is not routine maintenance.

Table 7: Bearings and Bushings. See Table 8 for Motors.

Apply grease to these components to prevent damage.

Mark Do this each Component

More Data. See also Section 3.1.4 “Lubricant Identification and Procedures” 1 2 3 4 5 6 x 200 hours support wheel bearings (4) See Figure 22. Add 0.12 oz. (3.54 mL) of grease EPLF2 (Table 11).

x 200 hours drive chain See Figure 23. Remove dirty grease with a cloth. Apply grease CG (Table 11).

none blower shaft bearings These are sealed bearings. No grease maintenance is necessary.

Table 8: Motor Grease Schedule. Use the data in Section 3.1.4.2 to complete this table.

Motor Identification (example: main drive)

Interval Quantity Dates When Grease is Added Years Hours fl oz mL

Table 9: Mechanisms and Settings

Make sure mechanisms are serviceable and settings are correct to prevent unsatisfactory performance.

Mark Do this each Component More Data 1 2 3 4 5 6 x 2400 hours controller circuitry Examine wiring and connections in electrical boxes. Look for corrosion, loose connections.

See Section 3.1.3 x 200 hours compressed air mechanisms See Supplement 3, Figure 12 x day* automatic lint removal system See Supplement 5, Figure 18.

3.1.3. How to Remove Contamination

Table 10: Contamination Types, Cleaning Agents, and Procedures

Material or Component

Usual Contamination

Example Cleaning Agent More Data machine housing dust, dirt — compressed air or shop vacuum

Air—no more than 30 psi (207 kpa). Do not push dust in mechanisms.

fins and vents on electrical components dust motors, inverters, braking resistors shop vacuum, soft bristle brush, canned air for electrical components

Do not push dust in mechanisms.

electric box interior dust all electric boxes electrical connections corrosion, varnish spade connector, molex connector, plug-in relay spray solvent for electrical components

Disconnect then connect it again. Use solvent if the bad connection continues.

electronic sensors dust photoeye lens, reflector, laser, proximity switch, temperature probe none Use a clean, soft, dry cloth.

dirt warm water with soap, then water flush Use clean, soft cloths.

stainless steel chemical spill shell, supply injector water Use a hose to flush the chemical supply from the surface fully. Do not get water on electrical components or mechanisms.

300 series stainless steel chemical corrosive attack shell interior, cylinder pickling and passivation

Speak to your dealer or Milnor.This is not routine maintenance.

painted metal, unpainted aluminum dust, dirt, grease frame members warm water with soap, then water to flush

Use clean cloths. Do not get water in electrical components.

rubber dirt, oil, grease drive belts, hoses warm water with soap, then water to flush

Use clean cloths. Flush fully. Oil or soap must not stay on drive belts. Make sure that drive belts are serviceable.

clear plastic, acrylic discoloration (yellowing) compressed air filter bowl, visual flow meter warm water with soap, then water to flush, then acrylic cleaner. Do not use ammonia.

Use only the necessary cleaning agents. Wash and rinse with clean, soft cloths. Follow instructions on acrylic cleaner.

glass discoloration (yellowing) door glass, site glass ammonia and water solution and water rinse then acetone

Use clean, soft cloths. Use only the necessary cleaning agents. If necessary, soak in cleaner.

soft air filter, lint filter, dust, lint on inverter electric box door, in air line filter bowl, in dryers shop vacuum Replace the used with a new filter when the vacuum cannot remove contamination.

rigid strainers, screens for water, steam mineral particles in water line, y-strainer water Use a rigid bristle brush. Flush with a flow of water.

rigid strainers, screens for oil metal shavings in hydraulic line carburetor cleaner or equivalent solvent

Soak. Use a rigid bristle brush.

steel drive components dirt, hardened lubricant bearings, roller chains, sprockets, gears carburetor cleaner or equivalent solvent

Soak. Use a cloth or soft bristle brush.

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1. Blow Down and Remove Contamination - Max 30 PSI

3.1.4. Lubricant Identification and Procedures

Table 11 identifies the lubricant for each lubricant code given in the maintenance summary. Get these or equivalent lubricants from from your local lubricant supplier.

When you add grease, always use the procedures given in Section 3.1.4.1. When you add grease to motors, also use the procedures given in Section 3.1.4.2.

CAUTION 28 : Risk of damage—Bad lubricant will decrease the life of components.

• Make sure that all equipment and fittings used to apply lubricants are clean.

• Use only the given lubricants or equivalent lubricants that have the same specifications.

Table 11: Lubricant Identification

Code Type Trademark Name Application Example CG grease Shell Alvania CG or equivalent

AGMA CG-1 or CG-2 drive couplings

EM grease Mobil Polyrex EM or as given on the motor nameplate motor bearings EPLF2 grease Shell Alvania EP (LF) Type 2 drive shaft bearings and bushings, ball joints, chain drives 220 oil Shell Morlina 220 small bearing housings, gear reducers, Hydrocushions™, isolators

3.1.4.1. Grease Gun Procedures

CAUTION 29 : Risk of damage—Hydraulic pressure can push out seals and push grease into unwanted areas (example: motor windings).

• Use a hand grease gun. A power grease gun gives too much pressure.

• Know the quantity of grease your grease gun gives each cycle (each stroke).

• Operate the grease gun slowly (10 to 12 seconds for one cycle).

• Add only the specified quantity. Stop if new grease come out of a drain port or other opening.

• Remove spilled grease from belts and pulleys.

The tables give grease quantities in fluid ounces (fl oz) and milliliters (mL). You can also use grease gun cycles (strokes). A cycle is each time that you pull the trigger. One cycle is usually approximately 0.06 fl oz (1.8 mL). Your grease gun can give more or less than this. Measure the output of your grease gun as follows:

1. Make sure that the grease gun operates correctly.

2. Operate the grease gun to put grease into a small container with fluid ounce or milliliter increments. Pull the trigger fully and slowly.

3. Add a sufficient quantity of grease to measure accurately. Count the number of cycles of the grease gun (the number of times that you pull the trigger).

4. Calculate the quantity for each cycle of the grease gun.

Example: 2 fl oz / 64 cycles = 0.031 fl oz for each cycle

Example: 59 mL / 64 cycles = 0.92 mL for each cycle

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2 - Lubricate all areas

3.1.4.2. Procedures for Motors—If a motor on your machine does not have grease fittings, no grease maintenance is necessary. If a motor on your machine has grease fittings, it is necessary to add grease. But the interval is usually longer than for other maintenance. Table 12 gives motor grease intervals and quantities for motors with specified frame sizes and speeds. You get this data from the motor nameplate. Use Table 8 in Section 3.1.2 to record the data for the motors on your machine.

Figure 7: Motor Grease Maintenance Conditions

Grease Fitting and Grease Relief Grease Fitting and Grease Drain

Motor Nameplate Grease Fittings, No Reliefs or Drains

Legend

1. Grease fitting

2. Grease relief. Do not remove.

3. Grease drain plug. Remove first.

4. RPM (motor speed). This example is 1465

RPM at 50 Hz and 1765 RPM at 60 Hz.

5. NEMA (IEC) frame size. Example: 256T

CAUTION 30 : Risk of damage—You can push grease into the windings and burn out the motor if you fail to remove the grease drain plugs.

• If the motor has grease drain plugs, remove them before you add grease. If the motor has grease relief fittings, it is not necessary to remove them.

Apply grease as follows:

1. Operate the machine or use manual functions to operate the motor until it is warm.

2. Remove power from the machine.

3. If the motor has grease drain plugs, remove them. See caution statement 30 .

4. Add grease EM (Table 11) with the motor stopped. If the motor with the nameplate in Figure

7 operates at 60 Hz, the specified grease quantity for each grease fitting is 0.65 fl oz (18.4 mL).

5. If the motor has a grease drain plugs, operate the machine or use manual functions to operate the motor for two hours. Replace the drain plug.

Table 12: Motor Grease Intervals and Quantities. Use grease EM (Table 11)

On Motor Nameplate (see Figure 7) Interval Quantity

NEMA (IEC)

Frame Size

RPM Less Than or Equal To

Years Hours Fluid

Ounces mL

Up to 210 (132)

900 5.5 11000

0.34 9.5 1200 4.5 9000 1800 3 6000 3600 1.5 3000

>210 to 280 (132 to 180)

900 4.5 9000

0.65 18.4 1200 3.5 7000 1800 2.5 5000 3600 1 2000

>280 to 360 (180 to 200)

900 3.5 7000

0.87 24.6 1200 3 6000 1800 2 4000 3600 0.5 1000

>360 to 5000 (200 to 300)

900 2.5 5000

2.23 63.2 1200 2 4000 1800 1 2000 3600 0.5 1000

3.1.4.3. First Time Oil Procedure for Speed Reducers (Gear Reducers)—The oil in a speed reducer can deteriorate faster when this mechanism is new. Replace the oil in the speed reducer after the first 100 hours of operation. Do this maintenance one time, in addition to the periodic oil maintenance given in the table for fluid containers in the maintenance summary.

3.1.5. Maintenance Components—Machines and Controls Group

[Document BIUUUM10]

Figure 8: Belt and Pulley Conditions To Look For. See Supplement 1.

Types of Belt Damage How to Find a Worn Pulley

1. Broken cord—damage from a sharp object.

2. Cracks—belt is too large for the pulley.

3. Shiny side walls—oil or grease on belt.

4. The belt layers disconnect—Oil or grease.

5. Bands on side walls—dirt, particles.

6. Incorrect: The pulley is too worn.

7. Correct: The belt only touches the side walls. You can put a thin strip of paper into the space between the belt and the pulley.

8. Space

Supplement 1

How to Examine Belts and Pulleys

With power removed:

• Look for dirt, dust, oil, and grease. Remove contamination.

• Look for belt damage as shown in Figure 8.

• Look for worn pulleys as shown in Figure 8.

With the machine in operation—Do not touch the machine. Look and listen:

• A belt can have some vibration and not cause damage. It is necessary to correct this condition only if the vibration is large.

• A belt must have sufficient tension that there is no slippage on the pulley during operation.

If slippage occurs, you can usually tell from the noise.

About Component Replacement and Tension Adjustment—Correct adjustment is very important to the service life of components and operation of the machine. Your Milnor dealer can do this work. If you know how to do this work (for example, correctly align belts and pulleys), and you want to do it, speak to your dealer or Milnor for part numbers. Replace worn components before you make tension adjustments.

• Machines that use rods with full threads and nuts to hold the position of the motor base—Turn the nuts on the rods as necesary to adjust tension. Tighten the nuts.

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3. Check Belts for tension and wear

• Machines that use a spring to hold tension on the motor base—Use the belt tension sleeve supplied with the machine. Put the sleeve on the rod that the spring is attached to or remove the sleeve to increase or decrease tension. Replace the spring if necessary.

Supplement 2

How to Examine Chains and Sprockets

With power removed:

• Look for contamination (examples: dirt, dust, dried grease). Remove contamination.

• Look for worn or damaged sprocket teeth. Examples are a hook shape, cracks, or corrosion.

If the sides of a sprocket are worn, this shows that the chain is incorrectly aligned.

• Look for loose chain. If the chain connects sprockets horizontally, the chain is loose if it hangs more than 0.25 inch for each foot (21 millimeters for each meter) of the span.

• If repairs are not necessary and lubricant was removed, apply new lubricant as specified in the maintenance summary.

With the machine in operation—Do not touch the machine. Look and listen. When movement starts or changes direction:

• the chain must not become tight very quickly and make a noise. If it does, the chain is too loose.

• the sprocket must not knock against the chain rollers. If it does, the rollers and/or sprocket are worn.

About Component Replacement and Tension Adjustment—Correct adjustment is very important to the service life of components and operation of the machine. Your Milnor dealer can do this work. If you know how to do this work (for example, correctly align chain and sprockets), and you want to do it, speak to your dealer or Milnor for part numbers. Replace worn components before you make tension adjustments.

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4. Check chains and sprockets for wear or mechanical issues

Figure 9: Electric Box and Inverter. These are examples. Your machine can look different.

30022X_ Washer-extractor 48040F_ Washer-extractor 76039 CBW Tunnel Washer

1. Air filter

2. Fan on elecrtric box door. Tip: Put streamers in front of the fan to make sure the fan operates.

3. Inverter cooling vanes and vents. See caution statement 31 .

4. Braking resistor, if applicable

CAUTION 31 : Risk of damage—The inverter will burn out without sufficient airflow.

• Keep fans, filter, vents, and braking resistors clean.

Figure 10: Compressed Air Inlet Strainers. These are examples. Your machine can look different.

T-Strainer. Outside machine frame on some models.

T-Strainer. Inside machine frame on some models.

Y-strainer. Used on some models

1. See caution statement 32 . Remove plug to remove strainer.

2. Compressed air in.

Figure 11: Self-purging Air Line Filter to Remove Moisture and Other Contamination. These are examples. Your machine can look different.

Filter/regulator—68036F5N Washer-extractor

Filter—5040TG2_ Dryer Legend

1. Filter bowl. See caution statement 32 . Do maintenance if water does not drain automatically.

2. Filter element

3. Pressure adjustment knob

4. Air pressure gauge

5. Drain tube

CAUTION 32 : Risks of injury and damage—

• Close the external shutoff valve and release remaining pressure before you do maintenance.

Supplement 3 How to Examine Compressed Air Mechanisms

Your machine has one or more mechanisms that use compressed air for movement. Figure 12 shows some examples. To examine a compressed air mechanism, look at the mechanism and listen to it in operation. Do not touch the mechanism or put your hand in the machine.

Usually you can see movement directly or on a position indicator. Frequently, you can hear a valve open and close. When a signal from the controller to operate the mechanism occurs, the air pressure must increase sufficiently before movement occurs. When the signal stops, the system must release the compressed air. You can usually hear the sound of the exhaust air for a short time.

When a compressed air mechanism operates correctly, its time of movement is usually less than two seconds. The movement is smooth. It does not shake, change speed, or stop in the middle of travel. A mechanism that does not operate correctly will cause unsatisfactory performance. If the mechanism does not operate correctly and you cannot repair the problem, speak to your dealer or Milnor. Possible causes are as follows:

• a blockage or a leak in the air tube,

• a worn pilot air valve,

• worn components in the mechanism,

• air pressure supplied to the machine is not sufficient,

• a component used to remove contamination from the air line is clogged,

• a quick exhaust valve or muffler is clogged,

• on machines with an air line lubricator, a malfunction or incorrect adjustment prevents sufficient lubrication.

Figure 12: Compressed Air Mechanisms. These are examples. Your machine can look different.

Air Operated Water Valves - Milnor Air Cylinder Type

Air Operated Drain Valve - Milnor Air Cylinder Type

Air Operated Band Brake - Milnor Air Cylinder Type

Air Operated Water and

Steam Valves - Angle Type Air Operated Water Valve -

Ball Valve Type

1. Factory-set needle valves to cause two air cylinders to move together. Do not adjust.

2. Quick exhaust valves

3. Position indicator. Yellow when valve is open.

4. Arrow position indicator

Figure 13: Photoeyes. These are examples. Your machine can look different.

Photoeye protected by a site glass, each side of the CBW load chute

Photoeye and reflector on extractor discharge conveyor

→. Exposed surfaces that must be clean. Remove contamination with a soft cloth. If the surface is hard to touch, use a cloth on the end of a wood dowel or metal rod. If necessary, use a safe cleaning agent.

Figure 14: Proximity Switches These are examples. Your machine can look different.

1 Station Press Centrifugal Extractor Shuttle Conveyor

Typical Proximity Switch Legend

→. Area that must be clean. Remove contamination with a soft cloth. If the area is hard to touch, use a cloth on the end of a wood dowel or metal rod. If necessary, use a safe cleaning agent.

Supplement 4 How to Do a Test of Emergency Stop Mechanisms

This test applies to machines that have one or more stop mechanisms in addition to the Stop button ( 0). Do this test at the intervals given in the maintenance summary.

Definitions:

3-wire circuit—a series electrical circuit on a Milnor machine that must close before the machine can operate. If a switch in the circuit opens, machine movement stops and the operator alarm (a buzzer and a display message) comes on. When you push the start button (

1), this closes the 3-wire circuit, which stops the operator alarm and lets the machine operate.

emergency stop mechanism—a manual control that opens the 3-wire circuit when a person or object operates the control. Examples - emergency stop button, kick plate, pull cord.

emergency stop button—a red push button on a yellow field that locks when a person pushes it (the electrical contacts stay open). It is necessary to turn the button clockwise to unlock it.

A machine can have zero or more emergency stop buttons.

kick plate—a metal plate on a shuttle conveyor that operates a switch when an object applies sufficient force to the plate. The kick plate is usually the first component of the shuttle to hit an object in the shuttle path. All Milnor shuttles that go left/right on a path have kick plates on the two sides of the machine.

WARNING 33 : You can be killed or severely injured if a shuttle strikes you even if you come in contact with the kick plate first.

• Never do a test of the kick plate when the shuttle operates.

pull cord—a wire on a conveyor that operates a switch when a person pulls the wire. All Milnor free-stand conveyors (a conveyor that is not a component of a larger machine) have pull cords on the two sides of the conveyor.

Do a test of all emergency stop mechanisms on the machine as follows:

1. Apply power to the machine ( M).

2. Push the start button ( 1). Do not cause the machine to operate. For example, do not start a formula or operate the machine manually. It is not necessary to do the test when the machine operates.

3. Operate an emergency stop mechanism (examples - button, kick plate, pull cord). If the mechanism operates correctly, the operator alarm comes on. Did this occur?

Yes—Release the emergency stop mechanism if necessary. For example, if this is an emergency stop button, turn the button clockwise to unlock it. Push the start button (

1). Do the test on a different emergency stop mechanism. Continue until you do the test on all emergency stop mechanisms on the machine.

No—An electrical component is defective. Shut down the machine. Do not let the machine operate until you correct the problem.

3.1.6. Maintenance Components—Dryer and Dryvac Group [Document

BIPDUM02]

Supplement 5

How Particle Contamination Occurs in the Dryer

The maintenance summary gives the intervals that are usually necessary to remove particle contamination from the dryer. If low air errors occur or quality decreases, shorter maintenance intervals can be necessary. Three types of particle contamination occur:

material brought in with the air—Lint and other material will collect on the screen in front of the gas burner or steam coils in the air flow. After some time, some material will get through the screen and collect in the burner or steam coils.

lint that comes out of the goods—The lint collects on the lint screens. If the dryer has the optional Milnor lint removal system, these screens are in the dryer. If not, the screens are external. With the two types, an automatic system removes the lint from the screens. If this system does not operate correctly, the air flow through the basket will quickly decrease. If this occurs, it is necessary to repair the lint removal system.

material mixed with the goods—When the goods are sorted, this material should be removed.

Plastic material that is not removed can melt in the dryer. The melted plastic can bond to the basket and decrease the flow of air. The basket surface can be stainless steel or optional Teflon. Teflon decreases this problem, but does not fully prevent it. The plastic can bond to the fins on the main blower. This can make the blower not balanced which will decrease the life of the bearings. The plastic can also bond to temperature sensors and cause the controller to read incorrect temperature values. If plastic contamination occurs quickly, examine how you sort the goods.

Supplement 6

How to Remove Lint from the Burner Assembly—Gas Models With Air Heat Burners (not applicable to ratio air burners)

In time, some lint can get through the combustion inlet screen and go into the burner assembly.

Look at Figure 15. The lint collects in the holes in the diffuser plate. If too much lint collects, the air flow can decrease below the volume necessary for combustion. The Combustion Air Low light ( !) will come on and the dryer will not operate. The lint can also collect on the leading edge of the fins in the combustion blower. Too much lint will cause vibration of the blower.

An air wand tool (Milnor part number W7 71558) was supplied with the machine. This small steel tube has a threaded connector on one end to attach to a compressed air line. Small holes on the other end blow a strong current of air. Use this tool to blow lint out of the holes in the

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5. Check Burner then Lint collector and Dry Vac System burner. Do this lint removal procedure at the intervals given in the maintenance summary.

CAUTION 34 : Strike hazard—The air current will try to pull the air wand out of your hand when the compressed air is connected.

• Hold the tool tightly.

1. Connect the air wand tool to a compressed air hose and carefully apply air.

2. Put the end of the air wand into the access hole in the burner assembly.

3. Move the wand to blow a strong current of air at all of the diffuser holes. Do this for approximately 10 minutes.

4. To remove lint from the combustion blower fins, remove the flow restrictor plate if necessary. Blow air from the center of the blower wheel on the fins. Replace the flow restrictor plate.

Figure 15: Remove Material Brought In With the Air—Gas Models wit hAir Heat Burners (not applicable to ratio air burners)

Combustion Air Inlet A Transparent View of the Burner Assembly

1. Combustion air screen

2. Burner assembly

3. Fan. Lint can collect on leading edge of fins.

4. Put the air wand through this hole.

5. Internal diffuser plate.

Holes can collect lint.

6. Flow restrictor plate used on some models

Supplement 7

How to Remove Lint from the Burner Assembly—Gas Models With Ratio Air Burners (not applicable to air heat burners)

In time, some lint can get into the burner assembly. Look at Figure 16. All models have a ratio air actuator valve and butterfly valve. Your model may or may not have a conical diffuser plate that surrounds the burner nozzle. The lint can collect in the holes in the diffuser plate and butterfly valve and cause a bad (yellow) flame. Lint can also collect on the blower side of the butterfly valve and on the inside surfaces of the burner housing. If too much lint collects, the air flow can decrease below the volume necessary for combustion. The Combustion Air Low light (

!) will come on and the dryer will not operate. The lint can also collect on the leading edge of the fins in the combustion blower. Too much lint will cause vibration of the blower. If vibration occurs, it will be necessary to remove the larger cover plate on the bottom of the blower housing and remove lint from the blower fins.

For this maintenance, it is necessary to shut down the machine when the machine status is Waiting for Load.

WARNING 35 : Explosion hazard—The main gas line can quickly flood the facility with gas. Before you begin disconnection:

• Get professional assistance if you are not qualified to work on gas appliances.

• Lockout/tagout machine power at the external disconnect switch.

• Close the main and pilot manual gas valves on the gas train.

CAUTION 36 : Risk of malfunction—The butterfly valve must be in the same position after maintenance as before maintenance. Otherwise, the ratio air will be out of adjustment and the dryer will not function correctly.

• Use extreme care when you perform the procedures given in Figure 17.

Inspect the burner and butterfly valve at the interval specified in the routine maintenance checklist. With the manual gas valves closed, as explained in warning statement 35 , remove the burner as shown in Figure 16. De-couple the butterfly valve as explained in Figure 17.

Figure 16: Gain Access to Burner for Lint Removal

Ratio Air Burner Installed Burner - No Diffuser Plate

Burner With Diffuser Plate

Removal of Burner Legend

1a. Unscrew the UV scanner and withdraw it from the pipe nipple

1b. Disconnect the spark plug cable 1c. Disconnect the pilot gas line 1d. Disconnect the main gas line 2a. Remove the four (4) mounting bolts (# 13 metric) 2b. Back this plate off to withdraw the burner from the housing 3a. Butterfly valve inside 3b. Ratio air actuator

Figure 17: De-couple Butterfly Valve for Lint Removal

Ratio Air Actuator - Cover Removed Butterfly Valve Fully Closed

1. De-coupler button. Press down and move to the right to lock the button down as shown in the inset. After maintenance, release the button and if necessary, turn the shaft slightly by hand or with a screwdriver (see item 2b) to re-couple the valve. After recoupling, the valve must be at the fully closed position (see 2a).

2a. Valve fully closed (0° position). When machine power is removed for maintenance, the machine status must be Waiting for Load to ensure the valve is in this position. After de-coupling, turn the valve by hand or with a screwdriver (see item 2b) to clean lint from behind the valve.

2b. Screwdriver slot at the bottom of the valve shaft will be in the position shown when the valve is fully closed.

Figure 18: Examine for Correct Lint Removal—Milnor lint removal system shown

View of Lint Screen Area (See Item 1) Air channel on floor of dryer

1. Examine. If lint collects in this area, repairs can be necessary.

2. Lint screen

3. Air nozzles to blow lint off of screen

4. Air comes out between this channel and the floor to blow lint in the discharge duct.

Figure 19: Remove Material Brought In With the Goods

Plastic Bonded to the Basket Blower wheel Legend

1. Remove plastic from the basket.

2. Remove plastic from the temperature sensors.

3. Remove plastic from the blower fins.

4. Remove this panel and remove collected material.

Temperature Sensors. Your machine can look different.

Access Panel Below the Shell

Figure 20: Examine the Sensors—Option for Infrared Temperature Sensing

Views of Sensor—Unload Door Legend

1. Sensor in the unload door.

One more sensor is above the load door.

2. Remove the sensor to examine it.

3. Remove particles with a clean, soft, dry cloth.

4. Examine the air tube for damage. Air must flow continuously to keep the sensor cool.

Supplement 8 The Dryer Air Seals

The air seals shown in Figure 21 are necessary for correct dryer function. Examine the seals at the intervals given in the maintenance summary. After some time, a seal can become worn or damaged. When this occurs, it is necessary to repair the seal to keep good dryer function. Speak to your dealer or Milnor. This is not routine maintenance.

You can operate the doors in the Manual mode for access to the felt seals. But do not get in the machine with power connected. If necessary, use a board to hold a door open then remove power from the machine before you examine the seal.

COttman

6. Clean out basket of debris

Figure 21: Dryer Air Seals

Seal Locations. A 6458_ model is shown. Other models use the same types of seal.

1. The plastic T-seal goes around the center of the basket. This seal causes the air to flow through the basket. Springs keep tension on the seal. If the springs are not compressed, the seal is damaged.

2. The Nomex and felt strip at the front of the basket makes a seal between the basket and the front wall.

3. The felt and rubber strips at the top of the door make a seal when the door closes.

4. The felt strip at the bottom of the door makes a seal between the door and the sill when the door closes.

5. The felt strip on the unload door makes a seal between the door and the shell when the door closes.

6. Make sure that the rubber strips on access doors (example: the doors on the lint screen chamber on dryers with the Milnor lint removal option) are in good condition.

COttman

7. Check dryer air seals

Figure 22: Grease Ports for Support Wheel Bearings

Front Support Wheel (one of two) Rear Support Wheel (one of two)

1. Grease port for routine maintenance.

2. Grease fitting on bearing housing. Internally connected to item 1.

Figure 23: Lubrication of Basket Drive Components

Views of Left and Right Configurations Legend

1. Oil fill port and vent

2. Oil level port. Capacity:

2.3 pints (1.09 liters)

3. Oil drain port. The drain port is on the base of the unit and on the opposite side from the level port.

4. Drive chain

— End of BIUUUM09 —

COttman Text Box

8. Grease ports for basket support bearings

COttman

9. Lubricate basket drive components