Staheli West DewPoint 6210 2015 Manuel utilisateur

DewPoint 6210

Owner's Manual

R7.1: 12.1.21

2015 DewPoint 6210

2016 DewPoint 6210

2017 DewPoint 6210

2018 DewPoint 6210

2019 DewPoint 6210

2020 DewPoint 6210

2021 DewPoint 6210

2022 DewPoint 6210

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Contents

Foreword

DewPoint Machine Operator Training....................8

Warranty Informaon.............................................10

Safety

Safety Decals ..........................................................13

Tractor Requirements.............................................15

Safe Procedures...................................................... 16

Boiler Jurisdicon ...................................................18

Boiler Safety Test ....................................................19

Pre-Operaon Requirements

Water...... ................................................................ 24

Source Selecon and Water Sampling ..........24

Analysis and Treatment

Equipment Specicaon ..........................24

System Equipment Setup ..............................25

Transportaon ..............................................26

Water Soener..............................................27

Reverse Osmosis Unit....................................28

Setup............................................................. 29

Water Equipment Selecon ..........................30

Water Treatment Chemical ...........................32

Quality/Blow-Down Principles .....................33

Quality Sengs .............................................35

Baler Preparaon ...................................................36

Install Baler Hardware...................................36

Install Cameras on Baler ...............................36

Install Bale Moisture Monitor on Baler.........36

DewPoint Machine Preparaon .............................37

Install Oponal/Custom Equipment..............37

Install Cameras on DewPoint Machine .........37

Install Air Hose Coupler.................................38

Valve Inspecon ............................................39

Generator Inspecon ....................................40

Electrical Panel Inspecon ............................41

Actuator Inspecon.......................................42

Wheel Inspecon ..........................................44

DewPoint Hookup to Tractor ..................................45

DewPoint Hookup to Baler .....................................46

Fill Fuel Tanks..........................................................47

Fill Water Tanks ......................................................48

Start DewPoint .......................................................49

Burner Tune............................................................50

Gazeeka Calibraon................................................51

Gazeeka Screen ......................................................52

Brake Adjustments .................................................53

Operaon

Common Operang Times......................................56

How to Start Steaming ...........................................57

Common Valve Sengs..........................................59

Simple Operaon....................................................60

Steam Rate Adjustment With a Gazeeka................61

Steam Rate Adjustment Without a Gazeeka ..........62

Common Operaon................................................63

Short Term Storage (Wet Layup) ............................64

Keep Hot.................................................................65

Blowdown System ..................................................66

Water Purge System ...............................................68

Steam Purge System...............................................69

Irrigaon.................................................................70

Cung.... ................................................................71

Raking.....................................................................72

DewPoint Machines................................................74

Baling With Steam..................................................75

Suggested Moisture With Steam............................76

Steaming Dierent Crops .......................................77

Steam Eects in Dierent Temperatures................78

Judging Bale Moisture............................................79

Moisture Sensors....................................................80

Judging Bale Moisture with the

Gazeeka Moisture Gauge .............................81

Judging Bale Moisture by

Bale Chamber Pressure ................................83

Judging Bale Moisture Visually...............................84

Judging Bale Moisture with a

Handheld Moisture Probe ............................85

Judging Bale Moisture with a

Baler-Mounted Contact Moisture Sensor ....87

Judging Bale Moisture Aer Baling ........................88

Judging Bale Temperature......................................89

Hauling, Stacking, and Storage of

Steam-Treated-Hay ......................................90

Hauling and Stacking Steamed Hay During

Normal Harvest Operaons ..........................90

Stacking High-Temperature Steamed Hay

When Weather Is a Threat............................90

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Contents

Technical Informaon

Components Locaon List ...................................... 93

Diagram 1 ...............................................................94

Diagram 2 ...............................................................94

Diagram 3 ...............................................................95

Diagram 4a (2017-2022).........................................95

Diagram 4b (2015-2016).........................................96

Diagram 5a (2016-2022).........................................96

Diagram 5b (2015)..................................................97

Diagram 6a (2017-2022).........................................97

Diagram 6b (2015-2016).........................................98

Diagram 7a (2017-2022).........................................98

Diagram 7b (2015-2016).........................................99

Diagram 8 ...............................................................99

Diagram 9 ...............................................................100

Diagram 10 .............................................................100

Diagram 11 .............................................................101

Diagram 12 .............................................................101

Diagram 13 .............................................................101

Diagram 14 .............................................................101

Diagram 15 .............................................................102

Diagram 16 .............................................................102

Diagram 17 Propane System ..................................103

Field Work Screen...................................................104

How the 6210 Works..............................................105

Sensors.... ...............................................................108

Actuators ................................................................111

Generator Controller (2017-2022) .........................112

Generator Controller (2015-2016) .........................113

Fuses....................................................................... 114

Circuit Breakers ......................................................116

Connecons............................................................ 117

120 V Control Power...............................................121

Touch Screen Wiring (2017-2022) ..........................122

Panel 2 Relay Block Wiring (2017-2022).................124

Burner Wiring (2016-2022) ....................................126

Fuel Pump .............................................................. 128

Fan Motor...............................................................129

Fuel Nozzles............................................................130

Troubleshoong

Fault 1: No Purge Card............................................ 134

Fault 14: High Fire Switch / Purge Hold

T19 High Fire Switch (See Fault 222).............134

Fault 15: Flame Detected (Standby) .......................135

Fault 17: Main Flame Fail (see Fault 220) ...............135

Fault 18: Flame Detected (Pre-Purge) ....................136

Fault 19: Main Flame Ign........................................137

Fault 20: Low Fire SW O / Purge Hold

T18 Low Fire Switch (See Fault 223)..............138

Fault 28: Pilot Flame Fail ........................................139

Fault 29: Lockout ILK (Airow Switch / VFD) ..........140

Fault 30-44 ............................................................. 140

Fault 45: Low Fire Switch O / Louver Low

Fire Posion Is Set Abnormally High .............141

Fault 46-127: Call Service .......................................141

Fault 200: High Pressure Limit Switch

(HPLS) Is Tripped ...........................................142

Fault 201: Turn Burner Switch ON..........................143

Fault 202: Operang Pressure Control Switch

(OPLS) Is Tripped ...........................................144

Fault 203: Boiler Water Level Is High......................144

Fault 204: Pilot Propane Level Is Low .....................144

Fault 205: Pilot Propane Pressure Low...................145

Fault 206: Supply Water Is Empty...........................145

Fault 207: Pressure Dierenal Alarm....................146

Fault 208: Flue Temp Is High...................................147

Fault 209: Feed Water and Boiler Water

Temp. Dierenal Limit Has Exceeded..........148

Fault 210: Ambient Temperature Is High................149

Fault 211: Furnace Door Temp Is High....................149

Fault 212: Low Water 2 Tripped .............................149

Fault 213: Boiler Taking Longer Than

Expected to Fill..............................................149

Fault 214: Data Logging Failed: Replace USB Drive 150

Fault 215: Manual Valve Operaon Is ON ..............150

Fault 216: Pressure Detected on

Fuel Nozzle 2 in Low Fire...............................150

Fault 217: Fuel Nozzle 1 Pressure Is

Low in Low Fire .............................................151

Fault 218: Fuel Nozzle 1 Pressure Is

Low in High Fire.............................................151

Fault 219: Fuel Nozzle 2 Pressure Is

Low in High Fire.............................................151

Fault 220: Fuel Was Not Detected

During Main Oil Ignion (See Fault 17).........152

Fault 221: Burner Louver Not Closed in Standby....153

Fault 222: Burner Louver Did Not

Open for Purge (See Fault 14).......................154

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Contents

Fault 223: Burner Louver Did Not

Close for Pilot Ignion (See Fault 20) ............155

Fault 224: Trouble with One or More Sensors........156

Fault 225: Burner Modbus Signal Failure ...............157

Fault 226: Burner Controller Did Not

Detect That the Louver Actuator Closed.......157

Fault 227: Burner Controller Did Not

Detect That Louver Actuator Opened ...........158

Fault 228: Steam Pressure Is Low...........................158

Fault 229: Boiler Water Temp. Is Low and

Steam Pressure Is Normal.............................158

Fault 230: Turn Water System On...........................158

Fault 231: Boiler Water Level Is Too

High for Operaon ........................................ 158

Fault 232: Generator Status (Page 1 of 3)...............159

Fault 233: Generator Modbus Signal Failure..........162

Fault 234: Generator Started Manually

from Generator Controller ............................162

Fault 235: Generator Is in Warning ........................163

Fault 236: Generator Is in Failure (Page 1 of 2) ......164

Fault 237: Feed Pump Overload .............................166

Fault 238: Circulaon Pump Overload....................166

Fault 239: Iniate Hold: AC Frequency / Noise.......167

Fault 240: Control Switch Relay SR-1

Did Not Annunciate.......................................167

Fault 241: Low Water 1 Relay SR-2

Did Not Annunciate.......................................167

Fault 242: Low Water 2 Relay SR-3

Did Not Annunciate.......................................168

Fault 243: High Pressure Limit Switch Relay SR-4

Did Not Annunciate.......................................168

Fault 244: Operang Pressure Control Relay SR-5

Did Not Annunciate.......................................168

Fault 245: Burner Relay SR-6 Did Not Annunciate..169

Fault 246: Fan VFD SR-7 Did Not Annunciate .........169

Fault 247: Airow Switch SR-8

Did Not Annunciate.......................................169

Fault 248: Touch Screen Version Is

Incompable with This DewPoint .................170

Fault 249: Check Network Cable or

Fault 214: Missing USB Drive

(PLC-015: DEV001 No Device Found) ............171

Fault 250: Fuel Pump Pressure LOW ......................172

Fault 251: Propane Pressure HIGH .........................172

Fault 300: Low Water 1 or 2 Tripped ......................173

Fault 301: Boiler Not Filling /

Slowly Filling with Water (See Fault 300)......176

Fault 302: Faulty PLC Input Card (See Test 13) .......177

Fault 303: Boiler Water Level Higher

Than Set Point / Boiler Overowing..............178

Fault 304.A: Work Lights Will Not Turn On.............178

Fault 304.B: Side and Top Rear Work Lights Will

Not Turn On (2015-2016 Machines Only) .....179

Fault 305: Touch Screen Controller

Will Not Turn On ...........................................180

Fault 306: Steam Coming out of

Water Supply Tanks ......................................181

Fault 307: Burner Smoking / Pulsing ......................182

Fault 308: Actuators/Valves Not Opening/Closing .183

Fault 309: Loss of Steam

Pressure During Operaon............................184

Fault 310: Feed Water Pump Not Running.............185

Fault 311: Circulaon Pump Not Running ..............186

Fault 312: Water in Steam / Bales Have Water

Splotches / Sudden Loss of Steam

Pressure and Water Level .............................187

Fault 313: Touch Screen Problems: Frozen,

Won’t Respond to Touch...............................188

Fault 314: Failed PTO Bearing(s).............................188

Fault 315: PTO Sha Slipping..................................189

Fault 316: Water Coming out of

Steam Purge Valve ........................................189

Fault 317: Water in Furnace / Steam Coming out of

Flue Exhaust / Leaky Flue Tube(s) .................189

Fault 318: Camera problems ..................................189

Fault 319: Boiler Building Pressure

During Fill Stage ............................................190

Fault 320: PLC NAK Error ........................................190

Fault 321: Blown Valve Actuator Fuses

Panel 2: F1-F7 (5 amp) ..................................190

Fault 322: Blown Louver Actuator Fuse

Panel 2: F8 (5 amp) .......................................190

Fault 323: Blown Fuse Panel 3: F1 (15 amp)...........191

Fault 324: Blown Fuse Panel 3: F2 (15 amp)...........191

Fault 325: Blown Fuse Panel 3: F3 (5 amp).............191

Fault 326: Blown Fuse Panel 3: F4 (1.5 amp)..........191

Fault 327: Blown Fuse Panel 3: F5 (2 amp).............191

Fault 328: Blown Fuse Panel 3: F6 (2 amp).............192

Fault 329: Blown Fuse Panel 3: F7 (2 amp).............192

Fault 330: Blown Fuse Panel 3: F8 (1.5 amp)..........192

Fault 331: Blown Fuse Panel 3: F9 (0.5 amp)..........192

Fault 332: Blown Fuse Panel 3: F10 (1.5 amp)........192

Fault 333: 2015-2016’s ONLY -

Blown Fuse Panel 3: F1 (15 amp) ..................193

Fault 334: 2015-2016’s ONLY -

Blown Fuse Panel 3: F2 (15 amp) ..................193

Fault 335: 2015-2016’s ONLY -

Blown Fuse Panel 3: F3 (2 amp) ....................193

Fault 336: 2015-2016’s ONLY -

Blown Fuse Panel 3: F4 (15 amp) ..................193

Fault 337: 2015-2016’s ONLY -

Blown Fuse Panel 3: F5 (5 amp) ....................193

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Contents

Fault 338: 2015-2016’s ONLY -

Blown Fuse Panel 3: F6 (1.5 amp) .................194

Fault 339: 2015-2016’s ONLY -

Blown Fuse Panel 3: F7 (2 amp) ....................194

Fault 340: 2015-2016’s ONLY -

Blown Fuse Panel 3: F8 (2 amp) ....................194

Fault 341: 2015-2016’s ONLY -

Blown Fuse Panel 3: F9 (2 amp) ....................194

Fault 342: 2015-2016’s ONLY -

Blown Fuse Panel 3: F10 (1.5 amp) ...............194

Fault 343: 2015-2016’s ONLY -

Blown Fuse Panel 3: F11 (0.5 amp) ...............195

Fault 344: 2015-2016’s ONLY -

Blown Fuse Panel 3: F12 (1.5 amp) ...............195

Fault 345: Algae in Supply Tanks.............................195

Fault 346: Burner Stuck in Purge............................195

Fault 347: Trouble Reinstalling Sparge Tube...........196

Fault 348: Touch Screen Reboong

When Generator Starng..............................196

Fault 349: Boiler Taking Longer Than

Normal to Heat Up........................................196

Fault 397: Purge Delay: T19 High

Fire Jumpered (See Fault 221).......................196

Fault 398: Purge Hold: T18 Low Fire Switch

(Waing for Louver to Close)(See Fault 20) ..197

Fault 399: Purge Hold: T19 High Fire Switch

(Waing for Louver to Open)(See Fault 14) ..198

Fault 421: Generator Will Not

Start from Touch Screen................................199

Fault 422: Generator Will Not

Shut o from Touch Screen...........................199

Fault 424: Generator Controller Not Working;

“????????” Displayed on Screen...................199

Tests

Test 1: Flame Detector Test ....................................203

Test 2: Fuel Solenoid Test .......................................203

Test 3: Propane Solenoid Test.................................204

Test 4: Ignion Transformer Test ............................204

Test 5: Igniter Electrode Orientaon & Gap ...........204

Test 6: Intermient Pilot Flame Test.......................205

Test 7: Leaky Igniter Test.........................................205

Test 8: HPLS Calibraon [15 psi] .............................206

Test 9: OPLS Calibraon [14.5 psi]..........................207

Test 10.A: Boiler Water Level Sensor Tesng..........207

Test 10.B: Boiler Water Level Sensor Tesng

(2015 Machines Only) ...................................208

Test 11: Valve Repair...............................................209

Test 12: Pump Service ............................................210

Test 13: Input Card Tesng (See Fault 302).............211

Test 14.A: Program the VFD (AB 156 - AB 458).......212

Test 14.B: Program the VFD (AB 459+) ...................212

Test 15: Fire Tube Cleaning.....................................213

Test 16: Generator End Troubleshoong................216

A: Exciter Wire Test .......................................216

B: Main Stator Test........................................217

C: Voltage Regulator Test ..............................217

D: Surge Suppressor Test...............................218

E: Diodes Test ................................................218

Test 17: Release Wires from Terminal Block...........219

Test 18: Maxed out Sensor Readings......................220

Test 18.A: Faulty Sensor /

Faulty Wire Harness Test ..............................220

Test 18.B: Faulty Sensor Test

(No Mulmeter Required) ............................221

Test 19: All Sensors Oine / Fuse Keeps Blowing ..222

Test 19.A: Faulty Wire Harness Test

(Mulmeter Required)..................................222

Test 19.B: Faulty Sensor Test

(No Mulmeter Required) ............................223

Test 20: Burner Tune...............................................223

Test 21: Touch Screen Calibraon...........................224

Test 22: Burner Gun Assembly Instrucons............225

Test 23: Seng Modbus Address ...........................226

Test 98: CR-2 Bypass and Removal .........................228

Test 99: Update to New Boiler Water

Level Sensor (Update Kit Part # 10344).........229

Maintenance

Winterize ................................................................232

De-Winterize ..........................................................241

Daily Maintenance .................................................245

Pre-Operaon ...............................................246

Post-Operaon..............................................248

50 Hour Maintenance.............................................249

250 Hour Maintenance / Yearly..............................257

500 Hour Maintenance...........................................265

1000 Hour Maintenance ........................................269

1500 Hour Maintenance ........................................271

2000 Hour Maintenance ........................................274

Maintenance Schedule...........................................276

Notes..... .................................................................278

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Preparaon

Open the “Owner’s Manual”

Read the “Owner’s Manual” before operang the DewPoint machine

Train on where resources are found (Customer Portal, Support Tab, Owner’s Manual)

Train on local boiler requirements

Safety

Show where emergency shut-os are located

Never remove any boiler component while under pressure

Always make sure hydraulic brakes are hooked up and funconing properly

Always lock the steering axles on the steamer and baler when traveling on roadways, operang on

hillsides, or backing up

Operaon

Use only so water or reverse-osmosis-treated water in the DewPoint machine

Fill the supply tanks and add Boiler Guard (water treatment chemical)

Set up your tractor steering stops

Set up your moisture sensor

Teach the dierences between microwave and contact moisture sensors with steam

Teach the basics of the Touch Screen

Turn on the steamer

Shut o the steamer

The importance of the PPM seng and how to set it based on your water test

Dierent start opons (basic overview)

Start All

Start Fill

Keep Hot

Wet Layup

Tune the burner (low and high re)

Field work screen (overview)

Seng the steam valve proporons (4 individual sliders)

Ideal condions (all sliders 100%)

Changing dew condions

Adverse condions (hot and windy)

Turn steam o when turning around

Blowdown (what it is and what to do about it)

Teach what to do when there is a fault

DewPoint Machine Operator Training

Scan to watch the “Operator Training” video in order to learn the following topics:

TestsTests

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Technical

Informaon

Technical

Informaon

OperaonOperaon

Pre-Operaon

Requirements

Pre-Operaon

Requirements

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Operaon

Teach that ideal baling moisture, with steam, is 11-15%

Steamed bales should be ghtly packed with good leaf paern. Sides of bales should be

smooth but not smeared.

Never exceed 135° F (57° C) internal bale temperature

Never stack hay if internal bale temperature exceeds 115° F (45° C)

High-temperature stacking method

Train on what to do if dark spots or wet akes appear

General baling with steam guidelines

Baling speed

Ideal steaming condions

Baling in hot/dry condions

Baling in moderate humidity condions

Avoid baling with stem moisture

Baling in high-humidity condions with stem moisture

You are responsible for how your bales turn out

Service & Cleaning

Train how to perform Daily Maintenance

Show where to nd the Maintenance Schedule

Train how to conrm Blowdown is working

Train how to conrm Water Purge is working

Explain crackling noise in rear supply tank

Train how to perform the Yearly Boiler Safety Test

Safety devices (what they do and where they are located)

Call dealer if more service is required

I ______________________________ have received instrucons on how to properly operate,

test, service, and clean the boiler. I understand that the operang, tesng, and servicing may

only be performed by a qualied individual that has received the instrucons contained in this

handbook.

Print:__________________________________________

Signature: ______________________________________ Date: ___________________

Trainer Name:___________________________________

Trainer Signature:________________________________ Date: ___________________

DewPoint Machine Operator Training

Tests

Maintenance

Troubleshoong

Technical

Informaon

Operaon

Pre-Operaon

Requirements

Safety

(customer / operator)

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Informaon

OperaonOperaon

Pre-Operaon

Requirements

Pre-Operaon

Requirements

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Warranty Information

All DewPoint machines come with a 1-Year Limited Warranty. This voluntary manufacturer’s warranty covers

everything on the machine against manufacturing defects. Normal wear-and-tear items and problems caused

by operator negligence or operator error are not covered.

The warranty period for the DewPoint machine starts from the date of rst use.

Staheli West Parts oers a 1-year warranty on all parts from the date of purchase. Staheli West Parts does not

cover labor costs of replacing a warraned part.

Warranty items will not be honored if roune maintenance has not been performed.

To ensure warranty coverage, use only OEM parts.

DewPoint Machine

Warranty Period Coverage

Months Hours Parts Labor

0-12 Unlimited 100% 100%

Tests

Maintenance

Troubleshoong

Technical

Informaon

Operaon

Pre-Operaon

Requirements

Safety

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