Related Manuals for Staheli West DewPoint 6110 2010
Summary of Contents for Staheli West DewPoint 6110 2010
- Page 1 DewPoint 6110 Owner's Manual 2010 DewPoint 6110 2011 DewPoint 6110 2012 DewPoint 6110 2013 DewPoint 6110 2014 DewPoint 6110 R8.5: 12.1.21...
- Page 2 Quick Navigation Buttons...
- Page 3 RAISING INDIVIDUAL, FAMILY, AND COMMUNITY STANDARDS WHILE REVOLUTIONIZING THE AGRICULTURAL INDUSTRY. FOR THE MOST UP-TO-DATE SERVICE INFORMATION DOWNLOAD THE STAHELI WEST APP: Download the App When you see a QR code in this handbook, scan the code with your smart phone or tablet to see the associated video or content.
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Page 4: Table Of Contents
Contents Foreword Operation DewPoint Machine Operator Training ....8 Common Operating Times........58 Warranty Information ..........10 How to Start Steaming ...........59 Common Valve Settings ..........61 Simple Operation ............ 62 Safety Steam Rate Adjustment With a Gazeeka ....63 Steam Rate Adjustment Without a Gazeeka ..64 Safety Decals ............ - Page 5 Contents Technical Information Troubleshooting Diagram 1 ............... 94 Fault 1: No Purge Card ..........134 Diagram 2 ............... 94 Fault 14: High Fire Switch / Purge Hold Diagram 3 ............... 95 T19 High Fire Switch ........134 Diagram 4 ............... 95 Fault 15: Flame Detected (Standby) .......135 Diagram 5 ...............
- Page 6 Contents Fault 242: Low Water 2 Relay SR-3 Fault 420: Purge Hold: T18 Low Fire Switch Did Not Annunciate ........155 (Waiting for Louver to Close) ......175 Fault 243: High Pressure Limit Switch Relay SR-4 Fault 421: Generator Will Not Start Did Not Annunciate ........155 From Touch Screen ........176 Fault 244: Operating Pressure Control Relay SR-5...
- Page 7 Contents Tests Maintenance Test 101: Flame Detector Testing Procedures ..186 Winterize ..............218 Test 102: Fuel Solenoid Test ........186 De-Winterize ............227 Test 103: Propane Solenoid Test ......186 Daily Maintenance ..........231 Test 104: Ignition Transformer Test ......187 Pre-Operation ..........232 Test 105.A: Igniter Electrode Orientation & Gap Post-Operation ..........234 (Direct Spark) ..........187 50 Hour Maintenance..........235...
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Page 8: Dewpoint Machine Operator Training
Ideal conditions (all sliders 100%). Changing dew conditions. Adverse conditions (hot and windy). Turn steam off when turning around. Blowdown (what it is and what to do about it). Teach what to do when there is a fault. © 2022 Staheli West... - Page 9 I understand that operating, testing, and servicing may only be performed by a qualified individual that has received the instructions contained in this manual. Print:__________________________________________ Signature: ______________________________________ Date: ___________________ Trainer Name:___________________________________ Trainer Signature:________________________________ Date: ___________________ © 2022 Staheli West...
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Page 10: Warranty Information
The warranty period for the DewPoint machine starts from the date of first use. Staheli West Parts offers a 1-year warranty on all parts from the date of purchase. Staheli West Parts does not cover labor costs of replacing a warrantied part. -
Page 11: Safety
Safety Safety Safety Decals ............13 Tractor Requirements ..........15 Safety Warnings ............16 Boiler Jurisdiction ........... 18 Boiler Safety Test ............ 19 © 2022 Staheli West... - Page 12 This Page Intentionally Left Blank © 2022 Staheli West...
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Page 13: Safety Decals
CALDERA BAJO PRESIÓN Hot Surfaces Inside Do Not Superficies Climb Calientes Adentro No Subir Watch Your Step Subir con Cuidado Tener Cuidado Use Caution Mientras When Servicing Mantener el Engine and Motor y el Generator Generador © 2022 Staheli West... - Page 14 * Véase la sección de toma de fuerza en el “In- * Véase la sección de toma de fuerza en el “In- struction Manual” para más detalles struction Manual” para más detalles. struction Manual” para más detalles © 2022 Staheli West...
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Page 15: Tractor Requirements
Adjust the amount the hydraulic trailer brakes engage by moving these pins to meet your needs. Rear Front More More Less Less DO NOT OPERATE THE DEWPOINT MACHINE WITH A TRACTOR THAT LACKS THE NECESSARY HORSEPOWER OR HYDRAULIC BRAKING SYSTEM. SERIOUS DEATH OR INJURY MAY OCCUR. © 2022 Staheli West... -
Page 16: Safety Warnings
When traveling on public roads, obey all local traffic laws. Before traveling on any public road (or any road when you will be traveling at higher rates of speed) make sure that steering is locked and trailer brakes are working properly. © 2022 Staheli West... - Page 17 If propane smell is detected, shut down and find the leak. • Check hoses to ensure they are not cracked and/or leaking. • Check propane tanks for damage. Replace if damaged. • Keep the dust covers over the filling valves when the machine is in use. © 2022 Staheli West...
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Page 18: Boiler Jurisdiction
Boiler Jurisdiction It is your responsibility to make sure your boiler is up to code and meets the legal requirements in your area. For boiler jurisdiction information in your area, navigate to: https://www.nationalboard.org/PrintAllSynopsis.aspx?Jurisdiction=Select © 2022 Staheli West... -
Page 19: Boiler Safety Test
Press Low Water 1. Control Power on the left of the screen off (RED) and Press and hold Manual Test. on (GREEN). When the indicator on the right turns green it means that the system is functioning properly. © 2022 Staheli West... - Page 20 Press the Operating Pressure button. Fill the boiler pressure (Opens steam purge valve). again with compressed air until the Operating Reset the HPLS by pressing down on the Reset button. Pressure Limit Switch trips (Trips around 14.5 psi). © 2022 Staheli West...
- Page 21 Ensure that boiler psi 1 & 2 match the manual gauge. You have successfully completed the Boiler Safety Test. You can now Power Down or Continue Running. © 2022 Staheli West...
- Page 22 This Page Intentionally Left Blank © 2022 Staheli West...
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Page 23: Pre-Operation Requirements
DewPoint Hookup to Tractor ........44 DewPoint Hookup to Baler ........45 Fill Fuel Tanks............46 Fill Water Tanks ............47 Start DewPoint ............48 Burner Tune ............49 Gazeeka Calibration ..........53 Gazeeka Screen ............54 Brake Adjustments ..........55 © 2022 Staheli West... -
Page 24: Water
● The test lab will analyze your water sample(s) and send a report to Staheli West. ● Staheli West will send their recommended water treatment method to your dealer. Your dealer will help you select the appropriate water softener, RO unit, or other necessary equipment available through Staheli West Parts. -
Page 25: System Equipment Setup
Test the operation of the float valve to be sure it will stop the water flow when the bulk water storage tank is full. ● You should leave your water system active during the season to keep the bulk water storage tank(s) full and ready for harvest operations. © 2022 Staheli West... -
Page 26: Transportation
A 2-inch engine driven transfer pump is normally used to transfer water from the water transport vehicle into the DewPoint machine. ● Tailor your water/service transport vehicle to your own needs. Bulk Water Storage Tank Water Softener Unit Reverse Osmosis (RO) Unit Water Transfer Pump © 2022 Staheli West... -
Page 27: Water Softener
Water Softener © 2022 Staheli West... -
Page 28: Reverse Osmosis Unit
Reverse Osmosis Unit © 2022 Staheli West... -
Page 29: Setup
Water Setup Water Softener Unit Reverse Osmosis (RO) Unit Water Treatment Bulk Water Storage Tank Chemical 55 Gallon 1 Gallon Container Light restricting to prevent algae growth 1 Gallon Chemical Water Transfer Pump Ratio 1:1000 Chemical:Water © 2022 Staheli West... -
Page 30: Water Equipment Selection
Parts Per Million (PPM) of Source Water Run Time Loss Amount of Water Expelled in Blowdown Carry (Reduction in Over Run Time) Will Occur 1100- Blowdown open 100% of time Parts Per Million (PPM) of Feed Water © 2022 Staheli West... - Page 31 600 PPM <50 PPM Reverse Osmosis Cons: Hard Water RO Water • Higher initial cost • Higher operating cost • Non-Toxic waste water created ○ Irrigation -Requires 240v ○ Dust abatement • Needs 240v power © 2022 Staheli West...
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Page 32: Water Treatment Chemical
Organic Part #11634 Part #10034 55 Gallon Organic Part #11635 Part #10790 15 Gallon Boiler Guard™ has 3 purposes: 1. Scale Prevention 2. Rust Prevention 3. Foam Prevention Mix with supply water at a 1:1000 ratio. © 2022 Staheli West... -
Page 33: Water Quality/Blowdown Principles
Surface tension is increased because of high concentrations of contaminants left behind in the boiler water as steam is produced and discharged. • The blowdown process removes some of the contaminated water in a controlled manner and allows new clean supply water to replace the old. © 2022 Staheli West... - Page 34 • Observe all local regulations regarding the discharge of boiler water. ALWAYS USE A WATER SOFTENER OR A REVERSE OSMOSIS SYSTEM ALWAYS USE WATER TREATMENT CHEMICAL BOILER DAMAGE WILL OCCUR IF THESE STEPS ARE NOT TAKEN © 2022 Staheli West...
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Page 35: Water Quality Settings
3. Enter the PPM (Parts per Million) for that particular source. Failure to enter an accurate PPM will result in blowdown cycles being too short, or too long. To ensure maximum efficiency, enter the appropriate PPM whenever changing water sources. © 2022 Staheli West... -
Page 36: Baler Preparation
INSTALL GAZEEKA moisture gauge as instructed in the Gazeeka instruction manual. • CALIBRATE prior to putting hay in the baler the first time. Follow all directions with the GAZEEKA instrument to calibrate and establish proper settings for safe and reliable operation. © 2022 Staheli West... -
Page 37: Dewpoint Machine Preparation
CONNECT the end of each camera cable to the camera extension cables which are just inside and below the rear door. □ Use cable zip ties to secure all camera cables to the wire harnesses that run to the tail/work light assemblies. Pickup Pickup PSI Gauge / Knotters Bale Chute © 2022 Staheli West... -
Page 38: Valve Inspection
Hot Water Boiler Drain Feed Water Mixed Water Circulation Valve Drain Valve Isolation Valve Cold Water Feed Water Actuator Supply Water Supply Water Circulation Feed Water Isolation Valve Fill Valve Pump Pump Supply Water Filter (T-Strainer) Y-Strainer © 2022 Staheli West... -
Page 39: Generator Inspection
Generator Inspection Remove tie downs from flue caps before starting the Check engine radiator coolant. generator. Check engine oil (use SAE 15W-40 rated for heavy Ensure main circuit breaker is turned on. duty diesel engine use). © 2022 Staheli West... -
Page 40: Electrical Panel Inspection
Make sure all circuit breakers are turned “ON”. Make sure the “Run/Test” switch on the Honeywell Burner Controller is in the “Run” position. Make sure the toggle switch on the bottom of the PLC is set to “RUN”. © 2022 Staheli West... -
Page 41: Actuator Inspection
Go to “Operations”. Go to “Manual Mode”. Open and close all 8 valves one at a time. Listen to be Activate “Manual Mode”. sure you hear each one. Generator does not need to be running. © 2022 Staheli West... - Page 42 Actuator Inspection Visually inspect valves and actuators for damage. 6: Water Purge Valve. 1-4: Steam Valves. 7: Feed Water Valve. 5: Steam Purge Valve. 8: Blowdown Valve. © 2022 Staheli West...
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Page 43: Wheel Inspection
Wheel Inspection Make sure all lug nuts are tightened to 260 ft-lbs. Inflate tires to proper pressure. Tires: BKT 628 16-Ply Flotations Size: 550/45 R22.5 Wheels: Custom Built Silver Tire pressure: 52 psi © 2022 Staheli West... -
Page 44: Dewpoint Hookup To Tractor
Connect chains in crossing pattern shown above. Connect hydraulic trailer brakes and light harness. This prevents the chains from dragging in the windrow while still allowing you to turn. Connect hydraulic steering. Connect PTO. Secure anti-rotating shield clip as shown. © 2022 Staheli West... -
Page 45: Dewpoint Hookup To Baler
Be sure to adjust hitch height for optimal PTO angles. Make sure the PTO knuckles are lined up on both the Never operate with harsh PTO angles. DewPoint machine and the baler. Failure to do so will result in heavy vibrations and excessive wear. © 2022 Staheli West... -
Page 46: Fill Fuel Tanks
Fill the fuel tanks with #2 Diesel. The tanks are connected so you only need to fill from one side. You need to give the fuel a little time to equalize after filling one tank and then add more. Leave 4” of space in the top of the tanks. © 2022 Staheli West... -
Page 47: Fill Water Tanks
Always add 1 gallon of chemical for every 1000 *Tip: Fill the boiler with water and then top off the gallons of water. supply tanks for longer operating time. © 2022 Staheli West... -
Page 48: Start Dewpoint
The burner ignites and begins heating boiler water the burner fan. (10-20 min). Proceed to Burner Tune (Should be A 30 second purge occurs before the burner ignites. tuned once a year or anytime it blows black smoke). © 2022 Staheli West... -
Page 49: Burner Tune
Check louver position (Should be about 1/4 inch Turn on the touch screen press “Start All” and open; adjust the top bolt as needed). “Confirm Start”. Press “Menu”. Press “Tune Burner”. © 2022 Staheli West... - Page 50 80- 90 psi using a flat head screwdriver. Reinstall when Decrease the louver position by loosening the top bolt done. Use the physical gauge and the digital gauge on until dark smoke appears. the touch screen. © 2022 Staheli West...
- Page 51 Nozzle pressure = 80-90 psi, System does not blow black/white smoke). Increase psi Decrease psi Once the boiler reaches 180° F, make sure the fuel Make sure the fuel pump pressure is still between 280- pump pressure is still between 280-300 psi. 300 psi. © 2022 Staheli West...
- Page 52 Burner Tune Make sure the air louver is 100% open. The burner should burn clean when properly tuned. (No white/black smoke) Press “Finished”. *Note: Nozzle pressure should automatically scale to 160-190 psi during high fire. © 2022 Staheli West...
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Page 53: Gazeeka Calibration
If no error message displayed, the air path standard- Power the Gazeeka off then on again. ization has been completed OK. The instrument is now ready to start measuring bales. Press (ENT) to go back to the Setup Menu. © 2022 Staheli West... -
Page 54: Gazeeka Screen
If the Gazeeka 870 is on the ISObus reading the star wheel and knotter signals, then the peak and average will not be time based, but bale by bale. © 2022 Staheli West... -
Page 55: Brake Adjustments
Move pin IN on brake lever for LESS braking power. Check brake action after adjustment. Rear Front More More Less Less DO NOT OPERATE DEWPOINT MACHINE WITH A TRACTOR THAT LACKS THE NECESSARY HORSEPOWER OR HYDRAULIC BRAKING SYSTEM. SERIOUS INJURY OR DEATH MAY OCCUR. © 2022 Staheli West... - Page 56 © 2022 Staheli West...
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Page 57: Operation
Judging Bale Moisture After Baling ......90 Judging Bale Temperature ........91 Hauling, Stacking, and Storage of Steam Treated Hay ........92 Hauling and Stacking Steamed Hay during Normal Harvest Operations ......92 Stacking High Temperature Steamed Hay when Weather is a threat ......92 © 2022 Staheli West... -
Page 58: Common Operating Times
135° F. They often bale into the evening until the windrows become too saturated with dew. 10 11 12 10 11 12 Often too wet 10 11 12 10 11 12 Often too wet Not enough dew / moisture © 2022 Staheli West... -
Page 59: How To Start Steaming
The operator then has to agree with the Owner/ Operator Agreement before he can move on to the You have arrived at the Field Work screen! Field Work screen. © 2022 Staheli West... - Page 60 Adjust the master steam Turn on the master steam steam sliders to where valves by pressing them. slider to a good starting button and steam will you want them. point. (We suggest 60%) start coming out. © 2022 Staheli West...
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Page 61: Common Valve Settings
When baling in hot and dry conditions, adjust than on top, start with the bottom steam valves the front steam valves to around 70% and the rear around 70% and the top steam valves at 100%. steam valves to 100%. © 2022 Staheli West... -
Page 62: Simple Operation
#5 - Adjust Steam Rate 5-10% If Necessary #6 - Repeat Steps 4-5 Until Optimum Bale Moisture is Reached Make steam rate changes based on the average (Avg) reading *The steam ratio should not be changed unless the windrow condition changes © 2022 Staheli West... -
Page 63: Steam Rate Adjustment With A Gazeeka
(Avg) reading #4 - Wait for at least two bales before making more steam rate changes Wait 2 Bales Steam Rate Change Gazeeka Reading REMEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS © 2022 Staheli West... -
Page 64: Steam Rate Adjustment Without A Gazeeka
Wait 24-72 hours to obtain a precise reading. #3 - Wait for at least two bales before making more steam rate changes Wait 2 Bales Steam Rate Change Steamed Bale REMEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS © 2022 Staheli West... -
Page 65: Common Operation
Common Operation Turn steam off when: Turning around at the end of windrows Slowing down Light/Absent windrow spots © 2022 Staheli West... -
Page 66: Short Term Storage (Wet Layup)
As soon as water comes out, shut down the machine. The machine is now ready for short term storage. Having the boiler completely full of water prevents rust and corrosion inside the boiler. Days of Storage Storage Recommendations None Short Term Storage 3-30 (Wet Layup) >30 Winterize © 2022 Staheli West... -
Page 67: Keep Hot
60 minutes. It will cycle like this until the machine is turned off. Leave the steamer in keep hot mode the entire time the machine will be subjected to below freezing temperatures. Using keep hot will prevent sensors, plumbing, and other components on the steamer from freezing. © 2022 Staheli West... -
Page 68: Blowdown System
The surface blowdown that the operator performs while running the machine removes highly concentrated water from the surface of the boiling water. Behind baler pickup Not spraying tires © 2022 Staheli West... - Page 69 The blowdown can last several minutes. Always the blowdown hose is not kinked. A kinked allow the blowdown to finish its cycle to maintain blowdown hose will cause foaming and water to water quality. enter the bales. © 2022 Staheli West...
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Page 70: Water Purge System
Menu > Settings > Water System. The “Water Purge Valve Open Time” setting loses its value each time the touch screen is turned off. The water purge valve is open when the “Water Purge” indicator is green. © 2022 Staheli West... -
Page 71: Steam Purge System
The steam purge system turns on automatically at 50% and above. It turns off automatically at 49% and below. The steam purge system can be manually activated and deactivated. When active, it will open the steam purge valve when the boiler reaches 12 psi. © 2022 Staheli West... -
Page 72: Irrigation
Since Natural Dew tends to form more heavily in low areas of a field it is a good practice to water the low side of the field first and the high side last during the final rotation before your hay harvest. This will make your dry-down more consistent across the entire field. © 2022 Staheli West... -
Page 73: Cutting
Simply decide how many acres you want to bale each day and go ahead and cut that many acres each day. □ Each DewPoint/Baler combo can typically bale 200-250 acres in 8-10 hours, depending on yield. © 2022 Staheli West... -
Page 74: Raking
Moisture from the soil will percolate up into the bottom of a double windrow particularly when yields are heavy. • In this case it may be necessary to “flip” the double windrow to get sufficient dry-down for baling. © 2022 Staheli West... - Page 75 If rake teeth are set too high you will leave valuable crop tonnage on the ground in the field. □ Maintaining rake teeth and the rake in general, and careful daily adjustment are worth the effort. © 2022 Staheli West...
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Page 76: Dewpoint Machines
Hydraulic GPM • 1 Set SCV • Hydraulic Trailer Brake Hydraulics • 3/8” Direct Return to Valve Hydraulic Tank • 12 Volt Auxillary Port • SW Harness 11546 Electrical • SW Harness 11547 • Trailer Brake Controller © 2022 Staheli West... -
Page 77: Baling With Steam
Condition of Alfalfa Fully Cured (6-10%) Before Steaming Fully Cured (6-10%) Condition of Cereal Grain Don’t be tricked by green nodes on plants that Before Steaming appear dry Condition of Mixed Grass/Alfalfa Before Fully Cured (6-10%) Steaming © 2022 Staheli West... -
Page 78: Suggested Moisture With Steam
Suggested Moisture With Steam Large Square Bales Small Square Bales Legumes Alfalfa 12-14% 14-22% Alfalfa/Grass Grasses Forage Grasses Timothy Wheat Cereal Triticale Grains Beardless Barley Straw © 2022 Staheli West... -
Page 79: Steaming Different Crops
“springy” characteristics of bales, better effects with hay press machinery. Timothy Wheat Higher density, more weight, less dust, consistent bales, Cereal Triticale reduces “springy” characteristics of bales, better effects Grains with hay press machinery. Beardless Barley Straw © 2022 Staheli West... -
Page 80: Steam Effects In Different Temperatures
The higher the temperature and the steam rate, the more cohesive the flakes will be. This is one reason why operators may choose to bale during cooler temperatures. © 2022 Staheli West... -
Page 81: Judging Bale Moisture
We also recommend that you watch bale chamber pressure readings and visually observe the bales you are making as you pass by them on the next windrow. These redundant observations will help assure that you are making the best hay possible. © 2022 Staheli West... -
Page 82: Moisture Sensors
(for dispersion dispersion experienced balers only) 3 day Reading Accurate Initial Reads low Reads low Reading Accurate Accuracy varies 3-5% 3-5% with steam 3 day Accurate Reading It is NEVER recommended to bale with stem moisture © 2022 Staheli West... -
Page 83: Judging Bale Moisture With The Gazeeka Moisture Gauge
8-10% moisture in the windrow. ▫ In these climates you will normally be able to make bales with very good leaf retention and density by applying enough steam to bring the bale moisture up to 12-14%. © 2022 Staheli West... - Page 84 WATCH the moisture reading on the GAZEEKA monitor. • ADJUST the steam injection rate over the first 5 to 10 bales. • MONITOR and make adjustments throughout the operating time to keep the bale moisture at the desired level. © 2022 Staheli West...
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Page 85: Judging Bale Moisture By
WATCH Bale Chamber pressure readings on baler monitor. • ADJUST the steam injection rate over the first 5 to 10 bales. • INCREASE steam injection rate to lower bale chamber pressure readings. • DECREASE steam injection rate to raise bale chamber pressure readings. © 2022 Staheli West... -
Page 86: Judging Bale Moisture Visually
NOTE: There is an acceptable range of moisture where bale density, flake wafering and other characteristics can be manipulated and controlled according to the demands of your hay market. You should become familiar with these characteristics. © 2022 Staheli West... -
Page 87: Judging Bale Moisture With A Hand Held Moisture Probe
If the windrow is very dry, requiring a higher rate of steam to bring the bale moisture to an optimum level there will be a much larger offset in the moisture reading compared to the actual moisture in the bale. © 2022 Staheli West... - Page 88 • This type of moisture probe is effective several hours after the hay has been baled as the applied moisture diffuses throughout the plant tissue more completely. © 2022 Staheli West...
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Page 89: Judging Bale Moisture With A Baler Mounted Contact Moisture Sensor
• WATCH moisture sensor readings. • ADJUST the steam injection rate over the first 5 to 10 bales to achieve the desired moisture level in your bale. © 2022 Staheli West... -
Page 90: Judging Bale Moisture After Baling
The beauty of DewPoint technology is that you can choose the way you want to bale your hay and the bale formation characteristics you and your market want in the finished product. © 2022 Staheli West... -
Page 91: Judging Bale Temperature
LEARN YOUR OWN LIMITS Some types of hay may be more sensitive to heat than others. We recommend that you define temperature levels that are acceptable for your operation. Temperature Probe (Large Square Bales) Part # 11345 © 2022 Staheli West... -
Page 92: Hauling, Stacking, And Storage Of Steam Treated Hay
This allows heat dissipation through all four sides of each bale. ▫ Allow the stack to remain in this configuration for a few days to cool. ▫ Re-stack the hay in a tight stack when bales have cooled enough to stack conventionally (below 115° F). © 2022 Staheli West... -
Page 93: Technical Information
Panel 2 Relay Block Wiring ........123 Burner Wiring 2010-2013 ........124 Burner Wiring 2014 (SS Direct Spark) .....125 Burner Wiring 2014 (SS Propane) ......126 Burner Wiring 2014 (VFD Propane) ......127 Fuel Pump .............. 128 Fan Motor ............... 129 Fuel Nozzles ............130 © 2022 Staheli West... -
Page 94: Diagram 1
Steam Valve Actuators Flue Steam Purge Valve Actuator Water Purge Valve Actuator Flue Temp. Sensor Boiler Door Blowdown Temp. Sensor Rear Furnace Door Valve Actuator Rear Furnace Feed Water Sight Glass Valve Actuator Feed Water Circulation Pump Pump © 2022 Staheli West... -
Page 95: Diagram 3
Dual Ignition Motor Electrodes 2010-2014 Direct Burner Nozzle Spark Burner Gun Propane Regulator 20 GPH Assembly (2014 only) 2014 Propane Propane Burner Gun Line Assembly Single Ignition Main Fuel Fuel Safety Electrode Solenoid Valve Solenoid Valve © 2022 Staheli West... -
Page 96: Diagram 5
Diagram 6a (2010) Panel 1 door Panel 1 Burner Controller (Terminal Strip 1) (Circuit Breakers) Purge Card Burner Controller Modbus Card Flame Amplifier Card Fan Contactor Baldor Soft Start Safety Relays Low Water 2 Low Water 1 © 2022 Staheli West... -
Page 97: Diagram 7A (2010)
Diagram 6b (2011-2013) Panel 1 door Panel 1 Burner Controller (Terminal Strip 1) (Circuit Breakers) Purge Card Burner Controller Modbus Card Flame Amplifier Card Safety Relays Low Water 2 Low Water 1 Fan Contactor Baldor Soft Start © 2022 Staheli West... -
Page 98: Diagram 7B (2011-2013)
Diagram 6c (2014-Soft Start) Panel 1 door Panel 1 (Terminal Strip 1) (Circuit Breakers) Burner Controller Safety Relays Burner Controller Fan Contactor Siemens Soft Start Water 1 Water 2 Purge Card Modbus Card Flame Amplifier Card © 2022 Staheli West... -
Page 99: Diagram 7C (2014-Soft Start)
Level Sensor Diagram 6d (2014-VFD) Panel 1 door Panel 1 Burner Controller (Terminal Strip 1) (Circuit Breakers) Purge Card Burner Controller Modbus Card Flame Amplifier Card Safety Relays Low Water 1 & 2 24 V Power © 2022 Staheli West... -
Page 100: Diagram 7D (2014-Vfd)
RB (Relay Block) FB (Fuse Block) (Terminal Strip 2) Boiler Water Level Sensor Diagram 8 Burner Fuel Pump Fuel Level Sensor Burner Fuel Filter Low Fire oil Ambient Supply Water regulating Temp. Sensor Level Sensor valve © 2022 Staheli West... -
Page 101: Diagram 9
Filter (T-Strainer) *All valves are shown in normal operating positions Diagram 10 Water Temperature Switch Glow Plugs Air Filter Radiator Oil Cap Generator End Oil Filter Oil Dipstick Fuel Fuel / Water Oil Pressure Solenoid Separator Switch © 2022 Staheli West... -
Page 102: Diagram 11
Circulation Water Sparge Tube Temp Sensor Sparge Tube Y-Strainer Feed Water Drain Valve Circulation Isolation Valve Check Valve 2 Check Valve 3 Feed Water Circulation Drain Valve Feed Water Pump Pump Circulation Feed Water Isolation Valve Actuator © 2022 Staheli West... -
Page 103: Diagram 15
(Discontinued 2010-13) Steam Purge See Test 120 Actuator Water Purge Actuator Water Purge Steam Purge Hose Hose Diagram 16 Feed Water Pump Bypass Hose Circulation Water Pump Bypass Hose Blowdown Actuator Circulation Isolation Valve Check Valve 1 © 2022 Staheli West... -
Page 104: Diagram 17 Low Fire Fuel Path
Return Fuel Nozzle psi Gauge High Fire Fuel Nozzle psi Sensor cylinder/piston High Fire Solenoid Fuel Safety Solenoid Valve Orifice #1 Main Fuel Fuel Pump psi Gauge Solenoid Valve Supply Fuel (From Tank) Return Fuel (To Tank) © 2022 Staheli West... -
Page 105: Diagram 19 Soft Line Fuel Path (Update)
Diagram 19 Soft Line Fuel Path (Update) 25” 36” 36” Fuel Return Diagram 20 Soft Line Fuel Wiring (Update) © 2022 Staheli West... -
Page 106: Diagram 21 Propane System (2014 Only)
Diagram 21 Propane System (2014 Only) Burner Regulator Tank Regulator Adjustable 4-7 WC Propane Solenoid Propane Tank 10 PSI 10 PSI 4-7 WC (0.15-0.25 PSI) © 2022 Staheli West... -
Page 107: Field Work Screen
Field Work Screen Operation Indicators Steam Valve Controls Master Steam ON/OFF Button Individual Steam Menu Controls ON/OFF Buttons Master Steam Slider Master Steam Slider Percentage Open Burner State Steam Purge Active/Inactive © 2022 Staheli West... -
Page 108: How The Dewpoint 6110 Works
• Added Value • Risk Mitigation Steam rate and distribution is controlled by • Increased Annual Yield the machine operator from the touch screen • Dew More With Less located in the tractor cab. • Better Lifestyle © 2022 Staheli West... -
Page 109: Machine Specifications
300 Gal. 360-600 Tons / Load Fuel / Diesel 9-18 Hours 1,100 L 330-540 Metric Tons / Load Tractor Requirements Minimum Recommended Engine Horsepower Engine Horsepower 0-2% Slopes 0-5% Slopes 0-10% Slopes Hydraulic Trailer Brake Valve Required © 2022 Staheli West... - Page 110 0-5% Slopes 240 Recommended Horsepower 0-10% Slopes 275 Recommended Horsepower > 10% Slopes Contact Staheli West for detailed tractor assessment > 20% Slopes Not recommended for field operation of the DewPoint 1 3/4 Inch 1,000 RPM Hydraulics Steering Axle Lock Cylinders...
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Page 111: Sensors
Automatically resets Set at 14.5 psi Limit Switch ≥14.5 psi once pressure drops Below 4 New/Updated Level adjustable in inches Boiler Water Level 0-12 inches Settings > Water inches Above 10 4-20mA (See Test 118) System inches © 2022 Staheli West... - Page 112 24 V 250 psi Fuel Pump psi 0-500 psi 280-300 psi during purge Fault 250 4-20mA Fuel Pump 0-1000 psi 280-300 psi Gauge Low Fire Fuel Nozzle 80-90 psi 0-1000 psi Gauge High Fire 160-190 psi © 2022 Staheli West...
- Page 113 120 V clockwise Airflow Detects airflow = ON 120 V will increase Switch Does not detect airflow = OFF sensitivity. Clockwise adjustment will decrease sensitivity 0-15 V Flame (Screen 3-15 V Detector Reading) © 2022 Staheli West...
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Page 114: Actuators
Steam Purge Valve Actuator B. 24 V C. 12 V Actuators are not interchangeable Connections are interchangeable A. GND Water Purge Valve Actuator B. 24 V C. 12 V See Test 115 for Louver Actuator details © 2022 Staheli West... -
Page 115: Generator Controller
ENGINE RUNNING LED will be lit. Removing power while the controller is in the RUN mode may corrupt the EEPROM. If this occurs, the GSC300 will have to be reprogrammed. 3.2 General Failure Conditions © 2022 Staheli West The following conditions can cause the GSC300 controller to shutdown the engine-generator system unexpectedly. -
Page 116: Fuses
24 V to Ethernet Switch 24 V to Touch Screen 12 V to Red Rocker Switch Generator Controller Engine Component Glow Plugs Crank Back Front Fuel Battery Battery Component Power to Panel 2 Work Lights Panel 2 WorkLights © 2022 Staheli West... -
Page 117: Circuit Breakers
ON to be able to operate the machine. 60amp Panel 1 Circuit Breakers 2010 2011-2013 2014 Panel 2 Circuit Breakers 2010 2011-2013 2014 Feed Circ Feed Circ Feed Circ Pump Pump Pump Pump Pump Pump © 2022 Staheli West... -
Page 118: Connections
Valve Actuators Tail Light Assembly 12 V Work Turn 4-20mA Tail Temp Sensors Fuel/Water Level Sensors Pres Sensors 4-20mA 4-20mA 24 V 24 V 24 V 4-20mA DIN 4 Pin Steam psi Sensors 4-20mA 24 V © 2022 Staheli West... - Page 119 Connections Note: 2014 machines only © 2022 Staheli West...
- Page 120 Connections © 2022 Staheli West...
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Page 121: 120 V Control Power
24 V signal from SR1 telling the PLC that Control Power is ON 24 V 120 V 120 V Panel 1 Door Panel 1 120 V 120 V 120 V 120 V Soft Starter Generator Plug © 2022 Staheli West... -
Page 122: Touch Screen Wiring
30-AMP Fuse 12 V 24 V 24 V 12 V 12 V 12 V 24 V 12 V 12 V 24 V 12 V 12 V Panel 3 Panel 2 24 V 12 V 12 V © 2022 Staheli West... -
Page 123: Panel 2 Relay Block Wiring
Panel 2 Relay Block Wiring 24 V Signal from PLC Red LED “On” when active © 2022 Staheli West... -
Page 124: Burner Wiring 2010-2013
Burner Wiring 2010-2013 © 2022 Staheli West... -
Page 125: Burner Wiring 2014 (Ss Direct Spark)
Burner Wiring 2014 (SS Direct Spark) © 2022 Staheli West... -
Page 126: Burner Wiring 2014 (Ss Propane)
Burner Wiring 2014 (SS Propane) © 2022 Staheli West... -
Page 127: Burner Wiring 2014 (Vfd Propane)
Burner Wiring 2014 (VFD Propane) © 2022 Staheli West... -
Page 128: Fuel Pump
Make sure the manual gauge and the touch screen readings match up when adjusting pressure. Fuel Pump Pressure 280-300 psi Increase Pressure Decrease Pressure 80-90 psi Nozzle Pressure (Low Fire) 160-190 psi Nozzle Pressure (High Fire) © 2022 Staheli West... -
Page 129: Fan Motor
Load = 25-50% Load = 25-50% Soft Start Settings Time = 5-10 sec Time = 5-10 sec Wiring 1 Phase Wiring 3 Phase Wiring Typical Amp Draw ~12 amps Low Fire ~15 amps High Fire ~19 amps Purge © 2022 Staheli West... -
Page 130: Fuel Nozzles
The higher the elevation, the smaller the nozzle size should be. The number relates to how many gallons per hour the nozzle sprays. Less More Steam Output © 2022 Staheli West... - Page 131 © 2022 Staheli West...
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Page 132: Troubleshooting
Fault 240: Control Switch Relay SR-1 Did Not Annunciate ........154 Fault 241: Low Water 1 Relay SR-2 Did Not Annunciate ........154 Fault 242: Low Water 2 Relay SR-3 Did Not Annunciate ........155 Fault 243: High Pressure Limit Switch Relay SR-4 © 2022 Staheli West... - Page 133 Fault 425: Burner Not Going Into High Fire / Stuck in Low Fire ...........177 Fault 426: Failed PTO Bearing(s) ......178 Fault 427: PTO Shaft Slipping ........178 Fault 428: Water Coming Out of Steam Purge Valve (See Fault 403) ......178 © 2022 Staheli West...
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Page 134: Fault 1: No Purge Card
• Lubricate the bushings. obstructions. • Inspect wiring for continuity, • Faulty wiring. • Repair/Replace faulty wiring. voltage, and ground. • Faulty burner controller. • Check for 120 V on T19. • Replace burner controller. © 2022 Staheli West... -
Page 135: Fault 15: Flame Detected (Standby)
• Wait for flame to burn out. • Faulty flame detector or • Replace flame detector or • Perform Test 101. amplifier card. amplifier card. • Inspect the wiring for • Faulty wiring. continuity, ground, and proper • Repair/Replace wiring. voltage. © 2022 Staheli West... -
Page 136: Fault 17: Main Flame Fail
• This will also cause a Fault 28. • Turn propane valve on. • Pilot flame lost just before main Check your propane valve and ignition. • Refill/Replace propane tank. pressure. © 2022 Staheli West... -
Page 137: Fault 18: Flame Detected (Pre-Purge)
• Wait for flame to burn out. • Faulty flame detector or • Replace flame detector or • Perform Test 101. amplifier card. amplifier card. • Inspect the wiring for • Faulty wiring. continuity, ground, and proper • Repair/Replace wiring. voltage. © 2022 Staheli West... -
Page 138: Fault 19: Main Flame Ign
• No fuel pump pressure. • Check that the fan/pump shaft • Repair/Replace the fan/pump coupler is in place. shaft coupler. • Inspect the wiring for continuity, • Faulty wiring. • Repair/Replace wiring. ground, and proper voltage. © 2022 Staheli West... -
Page 139: Fault 20: Low Fire Sw Off / Purge Hold T18 Low Fire Switch
• Faulty louver actuator. returns to the closed position other causes before buying a new after the 30 second purge. component). • Inspect wiring for continuity, • Faulty wiring. • Repair/Replace faulty wiring. voltage, and ground. © 2022 Staheli West... -
Page 140: Fault 28: Pilot Flame Fail
• Check propane tank. • Refill propane tank. • Replace burner regulator. • Test that propane is passing • To prevent future clogs, clean • Clogged burner regulator. through the burner regulator. propane hoses using compressed air. © 2022 Staheli West... - Page 141 • Louver not closing enough ignition to see if it closes as shown for ignition. • Perform Test 116. in Test 116 step 3. • Inspect the wiring for continuity, • Faulty wiring. • Repair/Replace wiring. ground, and proper voltage. © 2022 Staheli West...
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Page 142: Fault 29: Lockout Ilk (Airflow Switch / Vfd) (Page 1 Of 2
0-60 over 15 seconds. • Replace VFD. • Low supply voltage to VFD • Check for 120 V on L1 and L2 of • Repair faulty wiring or cause of (some 2014’s). VFD. low voltage. © 2022 Staheli West... -
Page 143: Fault 30-44
• Lubricate the bearings. obstructions. • Inspect wiring for continuity, • Faulty wiring. • Repair/Replace faulty wiring. voltage, and ground. Fault 46-127: Call Service • Check wiring behind the burner controller. • Replace the burner controller if fault persists. © 2022 Staheli West... -
Page 144: Fault 200: High Pressure Limit Switch (Hpls) Is Tripped
• See Test 121. • Check both circ and feed pump • Faulty pump contactor. • Replace pump contactor. contactors for functionality. • Inspect the wiring for • Faulty wiring. continuity, ground, and proper • Repair/Replace wiring. voltage. © 2022 Staheli West... -
Page 145: Fault 202: Operating Pressure Control Switch (Opls) Is Tripped
• Propane level is low. • Check propane level. • Refill propane tank. • Propane lighting count is not • Refill propane tank & reset propane light count (Menu > Settings > accurate. Pilot Propane > Reset Pilot Propane Gauge). © 2022 Staheli West... -
Page 146: Fault 206: Supply Water Is Empty
• Faulty input card 1 in the PLC. • Perform Test 113. Test 113). • If after replacing the sensor and the input card 1 there is still an • Faulty PLC. • Replace PLC. abnormal reading this indicates a faulty PLC. © 2022 Staheli West... -
Page 147: Fault 208: Flue Temp Is High
PLC. • Use REDEW boiler de-scaler • Remove a hand-hole cover and (Part # 11194). • Scale has built up in the boiler. inspect boiler tubes for scale. • Use Boiler Guard (preventative). © 2022 Staheli West... -
Page 148: Fault 209: Feed Water And Boiler Water Temp. Differential Limit Has Exceeded
• PLC output not sending “Y5” (Menu > Diagnostics > • Replace PLC. signal. Inputs/Outputs > Discrete Outputs > Y5). • Inspect the wiring for continuity, • Faulty wiring. • Repair/Replace wiring. ground, and proper voltage. © 2022 Staheli West... -
Page 149: Fault 210: Ambient Temperature Is High
250° F). Fault 212: Low Water 2 Tripped • See “Fault 400: Low Water 1 or 2 Tripped”. Fault 213: Boiler Taking Longer Than Expected to Fill • See “Fault 400: Low Water 1 or 2 Tripped”. © 2022 Staheli West... -
Page 150: Fault 214: Data Logging Failed: Replace Usb Drive
• 2010-2013 machines See Test • Replace 24 V regulator. 120. -Faulty 24 V regulator. • Repair/Replace damaged wire harness. -Faulty wire harness. • Inspect wiring for continuity, • Faulty wiring. • Repair/Replace faulty wiring. voltage, and ground. © 2022 Staheli West... -
Page 151: Fault 225: Burner Modbus Signal Failure
• Field mode is active and the • Turn water system on. water system is off. Fault 231: Boiler Water Level Is Too High for Operation • See “Fault 403: Boiler Water Level Higher Than Set Point / Boiler Overflowing”. © 2022 Staheli West... -
Page 152: Fault 232: Generator Status
• Voltage between L1 and L2 should be 240 V. • Check and adjust the generator automatic voltage regulator (See Test 121). • There is less voltage than • AC Under Voltage. normal. • Voltage between L1 and L2 should be 240 V. © 2022 Staheli West... - Page 153 • Replace 12 V relay in generator end box or located in wire harness • Faulty 12 V relay. somewhere. • Check if there is a green light on the 12 • Faulty 12 V regulator. • Replace 12 V regulator. V regulator (Panel 3 diagram 7). © 2022 Staheli West...
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Page 154: Fault 239: Initiate Hold: Ac Frequency / Noise
• Replace SR-2 relay in panel 1. 1 for a temporary fix. • If the relay is lit up green and • Faulty PLC input. voltage is making it to the PLC, • Replace PLC this indicates a faulty PLC input. © 2022 Staheli West... -
Page 155: Fault 242: Low Water 2 Relay Sr-3 Did Not Annunciate
• Replace SR-5 relay in panel 1. 1 for a temporary fix. • If the relay is lit up green and • Faulty PLC input. voltage is making it to the PLC, • Replace PLC. this indicates a faulty PLC input. © 2022 Staheli West... -
Page 156: Fault 245: Burner Relay Sr-6 Did Not Annunciate
• Replace SR-8 relay in panel 1. 1 for a temporary fix. • If the relay is lit up green and • Faulty PLC input. voltage is making it to the PLC, • Replace PLC. this indicates a faulty PLC input. © 2022 Staheli West... -
Page 157: Fault 248: Touch Screen Version Is Incompatible With This Dewpoint
2.x. touch screen and PLC. • 2017 and newer should be version 3.x. • Update to the latest version of • PLC lost the version #. • Ignore the fault. touch screen and PLC. © 2022 Staheli West... -
Page 158: Fault 249: Check Network Cable Or Fault 214: Missing Usb Drive (Plc-015: Dev001 No Device Found)
• Faulty PLC network card. • Replace network card: Part #10377. • Reprogram PLC. • Faulty PLC. • Replace PLC: Part#10374. • Faulty touch screen. • Replace touch screen: Part #10370. • Fault 214. • See Fault 214. © 2022 Staheli West... -
Page 159: Fault 250: Fuel Pump Pressure Low
• Burner fuel filter clogged. • Inspect burner fuel filter. (Napa 4006). • Fuel manifold clogged. • Inspect fuel manifold. • Clean out fuel manifold. • Fuel lines clogged. • Inspect fuel lines. • Clean out fuel lines. © 2022 Staheli West... -
Page 160: Fault 400: Low Water 1 Or 2 Tripped
• 2014 machines. • Replace 24 V relay. • Test boiler water ppm • Bad water (water level drops • Drain boiler and refill with and trips LWCO 1 while turning). fresh water. >3500ppm = foaming. © 2022 Staheli West... - Page 161 • Plugged/Blocked sparge tubes. • Inspect sparge tube holes. • Re-drill holes in sparge tubes. • Inspect feedwater system (See • Blockage in feedwater system. • Remove blockage. diagrams 12 and 13). © 2022 Staheli West...
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Page 162: Fault 401: Boiler Not Filling / Slowly Filling With Water (See Fault 400)
• Faulty check valve. valve may cause the circ pump • Replace the faulty check valve. to spin backwards during the fill stage. • Clean/Re-drill holes in sparge • Plugged/Blocked sparge tubes. • Inspect sparge tube holes. tubes. © 2022 Staheli West... -
Page 163: Fault 402: Faulty Plc Input Card (See Test 113)
• All other analog input sensors. input readings return to normal. off and be gentle (input cards are • After replacing the faulty delicate). sensor, a faulty input card will still give you abnormal readings on one or more inputs. © 2022 Staheli West... -
Page 164: Fault 403: Boiler Water Level Higher Than Set Point / Boiler Overflowing
• Faulty wiring. continuity, ground, and proper • Repair/Replace wiring. voltage. • 70 Pin connector pins are • Disconnect 70 pin connector • Repair/Replace bad pins in 70 damaged. from panel 2 and inspect pins. pin connector. © 2022 Staheli West... -
Page 165: Fault 404.A: Bottom Rear Work Lights Will Not Turn On (All Work Lights Not Working 2010-2012 Machines)
• Check in-line 30A fuse from • Replace in-line 30A battery battery. fuse. • Blown in-line battery fuse. • Check for break in the wire • Repair in-line wire splice (See harness where the in-line fuse is Fuses page). spliced in. © 2022 Staheli West... -
Page 166: Fault 405: Touch Screen Controller Will Not Turn On
Then it closes for 30 seconds. • Test in manual mode: Menu > Operations > Manual mode: • Faulty water purge valve Open and close the water purge • Replace actuator. actuator. actuator making sure it rotates a full 90°. © 2022 Staheli West... -
Page 167: Fault 407: Burner Smoking / Pulsing
• Louver not closing during • Install second louver closing open and close freely. transition from high to low fire. weight. • Check fuel cylinder to see if it is • Replace fuel cylinder. closing. © 2022 Staheli West... -
Page 168: Fault 408: Actuators/Valves Not Opening/Closing
• Bottom right of the PLC ensure that the toggle switch is set to “Run”. • Faulty 12 V regulator. • Check for 12 V output. • Replace 12 V regulator. • Inspect the wiring for • Faulty wiring. continuity, ground, and proper • Repair/Replace wiring. voltage. © 2022 Staheli West... -
Page 169: Fault 409: Loss Of Steam Pressure During Operation
• Faulty high fire relay 10r. • Burner won’t go into high fire. • See Fault 425. • Faulty boiler water circulation • See “Fault 209”. system. © 2022 Staheli West... -
Page 170: Fault 410: Feed Water Pump Not Running
“Y4” (Menu > Diagnostics > • PLC output not sending signal. • Replace PLC. Inputs/Outputs > Discrete Outputs > Y4). • Inspect entire wiring path • Repair/Replace faulty wiring • Faulty wiring. checking for continuity, ground, section. and proper voltage. © 2022 Staheli West... -
Page 171: Fault 411: Circulation Pump Not Running
“Y5” (Menu > Diagnostics > • PLC output not sending signal. • Replace PLC. Inputs/Outputs > Discrete Outputs > Y5). • Inspect entire wiring path • Repair/Replace faulty wiring • Faulty wiring. checking for continuity, ground, section. and proper voltage. © 2022 Staheli West... -
Page 172: Fault 412: Water In Steam / Bales Have Water Splotches / Sudden Loss Of Steam Pressure And Water Level
• Faulty supply water level blowdown is based on the • Replace supply water level sensor. amount of water used. If the sensor. supply water level sensor is not working, the machine will not prompt for blowdowns. © 2022 Staheli West... -
Page 173: Fault 413: Pilot Propane Pressure Low
• Remove burner gun and inspect • Faulty fuel nozzle. • Repair/Replace nozzle. nozzle. • Faulty sensor (fuel pump or • Swap sensors to identify faulty • Replace faulty sensor. nozzle). sensor. © 2022 Staheli West... -
Page 174: Fault 416: Fuel Nozzle Pressure Is Low In High Fire
• Faulty louver actuator. returns to the closed position other causes before buying a new after the 30 second purge. component). • Inspect wiring for continuity, • Faulty wiring. • Repair/Replace faulty wiring. voltage, and ground. © 2022 Staheli West... -
Page 175: Fault 419: Purge Hold: T19 High Fire Switch (Waiting For Louver To Open)
• Inspect wiring for continuity, voltage, and ground. • Trace the 120 V wires. When • Faulty wiring. • Repair/Replace faulty wiring. the louver is closed T18 on the burner controller should have 120 V. © 2022 Staheli West... -
Page 176: Fault 421: Generator Will Not Start From Touch Screen
• Replace PLC. Manual Mode. • Factory reset screen then program screen (new screen). • No system found. • Send to Staheli West to be reprogrammed (old touch screen). • Upgrade to new touch screen (old touch screen). © 2022 Staheli West... -
Page 177: Fault 424: Generator Controller Not Working; "????????" Displayed On Screen
• Check for 24 V on PLC output “Y10” (Menu > Diagnostics • PLC output not sending signal. • Replace PLC. > Inputs/Outputs > Discrete Outputs > Y10). • Inspect wiring for continuity, • Faulty wiring. • Repair/Replace faulty wiring. voltage, and ground. © 2022 Staheli West... -
Page 178: Fault 426: Failed Pto Bearing(S)
• Faulty water purge actuator. • Replace water purge actuator. manual mode for function. Fault 429: PLC NAK Error Causes Troubleshooting Fixes • Faulty/corrupted PLC • Reload PLC program. Programming. • Faulty PLC. • Replace PLC. © 2022 Staheli West... -
Page 179: Fault 430: Water In Furnace / Steam Coming Out Of Flue Exhaust / Leaky Flue Tube(S)
• Water will be leaking where the • Plug flue tube on both ends. burner mounts to the boiler, or Contact Staheli West for repair • Leaky flue tube. on the rear boiler door, or at the options. (A boiler repair shop will front turn box. -
Page 180: Fault 434: Main Wire Harness Damage / 70 Pin Connector Damaged
Fault 437: Blown Fuse Panel 3: F1 (15 Amp) Causes Troubleshooting Fixes • Faulty actuator. • See faults 321-322. • Replace faulty actuator. • Inspect entire wiring path • Repair/Replace faulty wiring • Faulty wiring. checking for continuity, ground, section. and proper voltage. © 2022 Staheli West... -
Page 181: Fault 438: Blown Fuse Panel 3: F2 (15 Amp)
Fault 442: Blown Fuse Panel 3: F6 (1.5 Amp) Causes Troubleshooting Fixes • Faulty PLC. • Test for ground short. • Replace PLC. • Inspect entire wiring path • Repair/Replace faulty wiring • Faulty wiring. checking for continuity, ground, section. and proper voltage. © 2022 Staheli West... -
Page 182: Fault 443: Blown Fuse Panel 3: F7 (2 Amp)
Causes Troubleshooting Fixes • Faulty control relay. • Test for ground short. • Replace control relay. • Inspect entire wiring path • Repair/Replace faulty wiring • Faulty wiring. checking for continuity, ground, section. and proper voltage. © 2022 Staheli West... -
Page 183: Fault 449: Algae In Supply Tanks
• Charge/Replace battery. • Loose connection on 12 V inline • Inspect/Tighten connection. fuse. • Check battery ground to engine • Loose ground connection. • Tighten ground. frame. • Faulty 24 V regulator. • Replace 24 V regulator. © 2022 Staheli West... -
Page 184: Fault 453: Boiler Taking Longer Than Normal To Heat Up
• Restriction in fuel path. • Inspect fuel path. path. • Use REDEW boiler de-scaler • Severe scale on water side of (Part # 11194). • Inspect boiler tubes. boiler tubes. • Use Boiler Guard (preventative). © 2022 Staheli West... - Page 185 Test 124: All Sensors Offline / Fuse Keeps Blowing 213 Test 124.A: Faulty Wire Harness Test (Multimeter Required) ........213 Test 124.B: Faulty Sensor Test (No Multimeter Required) ......214 Test 125: Touch Screen Calibration (Updated Touch Screens) ......215 Test 126: Setting Modbus Address ......216 © 2022 Staheli West...
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Page 186: Test 101: Flame Detector Testing Procedures
You should hear and feel an audible click as it opens. If it hums or buzzes, this indicates a faulty solenoid valve that needs cleaning or replacement. See Fault: 28 Propane Solenoid Safety Main Fuel Solenoid Solenoid © 2022 Staheli West... -
Page 187: Test 104: Ignition Transformer Test
3. The gap between the nozzle and the diffuser cone should be 5/16”. Note 1: Adjust the electrode depth with Allen wrench. Note 2: Adjust the electrode gap with pliers. See Fault: 28 5/16 inch 1/16 5/16 inch inch inch Note 2 Note 1 © 2022 Staheli West... -
Page 188: Test 105.B: Igniter Electrode Orientation & Gap (Propane: 2014)
3. Remove top cap on the propane regulator with a flat head screwdriver. 4. While observing the pilot flame through the sight glass, adjust the regulator to stabilize the flame. See Fault: 28 *Propane Pressure at pilot: 4-7 in WC (inches Water Column) 0.14 - 0.25 psi © 2022 Staheli West... -
Page 189: Test 108: Hpls Calibration [15 Psi]
5. After the HPLS trips, release pressure to adjust HPLS by opening one of the pigtail valves and reset the sensor (releasing only a few psi is necessary). 6. Loosen the set screw (5/64” Allen), and then increase HPLS psi by rotating the bolt clockwise in the bottom of the housing. See Fault: 200 © 2022 Staheli West... -
Page 190: Test 109: Opls Calibration [14.5 Psi]
2 & 3. 2. Remove boiler water level sensor (6 bolts 7/16”). 3. Move the float in increments of 1” and verify that the touch screen reading reflects accurately. © 2022 Staheli West... -
Page 191: Test 110.B: Boiler Water Level Sensor Testing
18. Connect between the red and yellow wires. 19. The resistance should be between 600-750 ohms, moving the float should not effect the resistance. *The resistance must never go above 900 ohms. **Replace the sensor if any of the tests fail. © 2022 Staheli West... -
Page 192: Test 111: Valve Repair
3. Remove the stud and the inner seal by pressing the stud down into the valve and out the end. 4. Remove the outer seal. 5. Remove the inner seat. *To reassemble, repeat these steps in reverse with the new parts. © 2022 Staheli West... -
Page 193: Test 112: Pump Service
(see Figure 5B). Remove excess soapy water. and move the sealing washer face up against seat facing. Reinstall impeller screw (if used). © 2022 Staheli West... -
Page 194: Test 113: Input Card Testing (See Fault 402)
6. A functioning channel reads about 100 Ω. 7. A non functioning channel will read some other amount (see below 33.68 Ω). 8. A functioning COM port will read about 0 Ω. © 2022 Staheli West... -
Page 195: Test 114.A: Program The Vfd (See Fault 29)
18. Use up arrow to advance to 60 and press “M”. 19. With “Stop” displayed, press “M”. 20. Use up arrow to advance to P132 and press “M”. 21. Use up arrow to advance to 60 and press “M”. 22. “Stop” should be displayed. © 2022 Staheli West... -
Page 196: Test 115: Louver Actuator Adjusting (See Fault 14)
9. Ensure the louvers move freely and that the bushings are lubricated with a greaseless lubricant. The counterweight(s) should not be so heavy to where the louver actuator cannot lift the louvers, but they should be heavy enough that the louvers return to closed position when the burner is off. © 2022 Staheli West... -
Page 197: Test 116: Tune The Burner
3. Check louver position (Should be about 1/4” open; adjust the top bolt as needed). 4. Turn on the touch screen press “Start All” and “Confirm Start”. 5. Press “Menu”. 6. Press “Tune Burner”. 7. Press “Low Tune”. 8. Wait for the burner to reach “Low Fire”. © 2022 Staheli West... - Page 198 Increase the louver position an additional 1/16”. 10. Turn off burner and relight to confirm everything is working properly (Pump pressure = 280-300 psi, low fire nozzle pressure = 80-90 psi, system does not blow black/white smoke). © 2022 Staheli West...
- Page 199 Make sure the air louver is 100% open. c. The burner should burn clean when properly tuned (no white/black smoke). 13. Press “Finished”. Note: Nozzle pressure should automatically scale to 160-190 psi during high fire. © 2022 Staheli West...
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Page 200: Test 117: Remove The Burner Gun Assembly
4. Remove the fuel line pass-through plate and bolt. 5. Disconnect the ignition electrode wire (two wires and electrodes on 2010-2013 machines). 6. Plug the fuel lines and remove the gun assembly. 7. Drain the excess fuel into a bucket. © 2022 Staheli West... -
Page 201: Test 118: Update To New Boiler Water Level Sensor Part # 10344
5. In Panel 2, locate the first blue terminal strip section on TS1. 6. (2010-2013 DewPoint machines) release the Red and Black wires shown. 7. (2014 DewPoint machines) release the Red and Black wires shown. 8. In Panel 2, locate the first white terminal strip section on TS1. © 2022 Staheli West... - Page 202 12. (2014 DewPoint machines) Put the Red wire from step 7 into the top open hole created in step 10; Also, put the Black wire from step 6 into the lower open hole created in step 9. 13. Remove the boiler water level sensor signal conditioner on panel 3. © 2022 Staheli West...
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Page 203: Test 119: Fire Tube Cleaning
5. Remove the blowdown hose and the water purge hose. 6. Remove the left and right heat shields. 7. Remove the rear flue box cover to expose the upper tubes. 8. Disconnect the rear door temperature sensor wire harness. © 2022 Staheli West... - Page 204 Remove the insulation by pulling the bottom down and out, the top is held in place internally (inspect rope gaskets and insulation; replace as needed). 13. Remove all top heat diffusing rods from the top flue tubes. © 2022 Staheli West...
- Page 205 Note: Reinstalling the insulation board; orient properly (flat edge) and put top in first then the bottom. 19. Re-Tune the burner (See Burner Tune). © 2022 Staheli West...
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Page 206: Test 120: Remove Panel 2 Ts2 Jumpers (2010-2013 Machines Only)
4. Remove the three green jumpers shown. Note: This update should be done to all 2010-2013 DewPoint 6110 machines. These extra jumpers are sending 24 V power to disconnected sensors and can cause fuses to blow. © 2022 Staheli West... -
Page 207: Test 121: Generator End Troubleshooting
4 grounding bolts. The meter should show an open. If the resistance is low (less than 10kΩ) then the exciter is shorted and the generator end will need to be replaced. Use a flat head screwdriver to adjust voltage © 2022 Staheli West... -
Page 208: B: Main Stator Test
*Voltage regulator can be model 440 or 460 Service Feed Circulation Burner Outlet Pump Pump Motor Use a flat head screwdriver to adjust voltage © 2022 Staheli West... -
Page 209: D: Surge Suppressor Test
0.5VDC now. Repeat for the other side. * If any diode has a short or has an open in both directions, then all the diodes and the surge suppressor should be replaced. © 2022 Staheli West... -
Page 210: Test 122: Release Wires From Terminal Block
Tests Test 122: Release Wires From Terminal Block Use a flat head screwdriver to open spring Wire is Wire is locked in inserted © 2022 Staheli West... -
Page 211: Test 123: Maxed Out Sensor Readings
**If replacing the faulty sensor does not fix the problem and you have a good input card (Test 113), replace the PLC. 4-20mA wires 24 V wire Card 1 Card 2 Faulty Sensor Faulty Wire Harness © 2022 Staheli West... -
Page 212: Test 123.B: Faulty Sensor Test (No Multimeter Required)
Limit Switch (HPLS) Pressure Relief Boiler Water Valve Level Sensor Low Water Cutoff Steam psi 1 Steam psi 2 Boiler Sight Glass Manual Steam Pressure Gauge Front Turn box Boiler Water Temp. Sensor Y-Strainer Feed Water Temp. Sensor © 2022 Staheli West... -
Page 213: Test 124: All Sensors Offline / Fuse Keeps Blowing
*If no faulty sensors or faulty wiring is found, replace the 24 V regulator (Part# 10302). See Test 122 for how to release a wire from a terminal block Card 1 Card 2 24 V wires GND block Faulty Sensor Faulty Wire Harness © 2022 Staheli West... -
Page 214: Test 124.B: Faulty Sensor Test (No Multimeter Required)
Boiler Sight Glass Boiler Sight Glass Manual Steam Manual Steam Pressure Gauge Pressure Gauge Front Turn box Front Turn box Boiler Water Boiler Water Temp. Sensor Y-Strainer Temp. Sensor Y-Strainer Feed Water Feed Water Temp. Sensor Temp. Sensor © 2022 Staheli West... -
Page 215: Test 125: Touch Screen Calibration (Updated Touch Screens)
1. With the touch screen on, press and hold the top left corner of the screen for 5 seconds. 2. Press OK 3. Press Settings 4. Press Adjust Touch Panel 5. Press Start Calibration 6. Complete the calibration 7. Press Menu 8. Press Exit *Calibration can be done on any page. © 2022 Staheli West... -
Page 216: Test 126: Setting Modbus Address
1. Unplug the modbus cable and remove any tape holding the modbus card in place. 2. Remove the modbus card pulling out from the bottom. 3. On the bottom of the modbus card set the 10’s pot to 7. 4. Set the 1’s pot to 8. © 2022 Staheli West... - Page 217 Daily Maintenance ..........231 Pre-Operation ..........232 Post-Operation ..........234 50 Hour Maintenance..........235 250 Hour Maintenance / Yearly ......241 500 Hour Maintenance...........249 1000 Hour Maintenance ........253 1500 Hour Maintenance ........255 2000 Hour Maintenance ........258 Maintenance Schedule ...........260 Notes..............262 © 2022 Staheli West...
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Page 218: Winterize
Winterize Tools Needed: • Phillips Screwdriver • Crescent Wrench • Shop Vac / 2 large pipe wrenches (depending on method) • 9/16” End Wrench • Air Compressor • Hammer Failure to winterize will hurt your wallet © 2022 Staheli West... - Page 219 To speed up the drying process, start the boiler and during long term storage. Re-input the numbers heat up the water to around 120° F. during de-winterization. From the Menu: Go to Operations > Manual Mode. Activate “Manual Mode”. © 2022 Staheli West...
- Page 220 7: Feed Water Valve. 8: Blowdown Valve. While still in the “Manual Mode” screen, turn off the Disconnect touch screen and store in safe dry place screen with the red rocker switch. that is between 0-140° F. © 2022 Staheli West...
- Page 221 After boiler has drained, disconnect boiler drain hot water drain on your feet. camlock and remove boiler drain assembly to allow complete drainage of the boiler. Unscrew and remove supply water filter housing and Supply water filter shown removed. filter. © 2022 Staheli West...
- Page 222 Remove the boiler drain hose and attach vacuum hose. Turn on the vacuum and allow air to be pulled Close boiler drain valve and open feed water drain in through the pump plugs, through the feed water valve. system, and into the vacuum. © 2022 Staheli West...
- Page 223 Position valve so water can drain completely. Push check valve open to drain water from back side of valve. Open feed water system drain valve (boiler right Open feed water system “Y” strainer flush valve front). (boiler left front). © 2022 Staheli West...
- Page 224 Store the sensor where it won’t freeze. Place tie-down straps on flue exhaust caps to prevent *Dry out the pressure transducers and the water level water, birds or rodents from entering the flue. sensor with a rag or compressed air. © 2022 Staheli West...
- Page 225 Check all camlocks and fittings for corrosion and/or other damage. the plug and remove the gasket. Then turn the plug and remove it. Check and manually actuate all hand valves. Turn the battery disconnect switch to “OFF” (Update Kit Part #11062). © 2022 Staheli West...
- Page 226 If your fire tubes are in bad condition, consider and weather out. purchasing ReDew boiler de-scaler to increase the Store your DewPoint under a shed, hay barn or in a efficiency and life of your DewPoint machine. shop all winter if possible. © 2022 Staheli West...
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Page 227: De-Winterize
When should you de-winterize your DewPoint machine? • Anytime you plan on operating your machine after it has been winterized Tools Needed: • Phillips Screwdriver • Crescent Wrench • 9/16” End Wrench © 2022 Staheli West... - Page 228 Ensure all hand hole plugs are tightened and secure. Install the supply water level sensor (under the right front water tank). Install the steam pressure sensors on the front of the Close all 5 pigtail valves. boiler. © 2022 Staheli West...
- Page 229 Close the feed water system drain valve (boiler front Connect the touch screen and go to Menu > right) and the Y-Strainer (boiler front left). Operations > Manual mode and test all valves for functionality. © 2022 Staheli West...
- Page 230 De-Winterize Inspect all 8 valves for frost damage. Test the pressure relief valve by lifting up the lever fully several times. Check flue caps for free operation. Tune the burner before operating. (See Burner Tune). © 2022 Staheli West...
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Page 231: Daily Maintenance
1st OPERATION Wheel nut torque check (see 500 hour maintenance step 9) Steering hinge gap check/adjustments (see 1500 hour maintenance step 2) Check/Adjust engine speed so that frequency is 61-62.5hz (see 250 hour maintenance steps 5-7) © 2022 Staheli West... - Page 232 Daily Maintenance (Pre-Operation) Grease PTO anti-rotating shield. Check engine coolant level. Check engine oil level. Check water separator. Close the supply water isolation valve. Unscrew the supply water filter. Remove the internal mesh filter. © 2022 Staheli West...
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Page 233: Pre-Operation
This helps prevent boil-over by reducing the for damage. amount of dissolved solids in the boiler. Purge steam through all baler hardware nozzles to clear condensed water and debris. Ensure nozzles are not plugged. © 2022 Staheli West... -
Page 234: Post-Operation
Hook up and blow compressed air in short quick bursts until the fan blades are free of debris. *Blowing a constant stream of compressed air will spin the fan but will not clean it properly. © 2022 Staheli West... -
Page 235: Hour Maintenance
Inspect front and rear of boiler. Look for any potential hot spots on the boiler doors. Inspect baler hardware 31-32 1st 50 HOUR MAINTENANCE Check/Adjust generator cooling fan v-belt (see 250 hour maintenance steps 8-9). Change oil and oil filter (see 250 hour maintenance steps 10-13). © 2022 Staheli West... - Page 236 For machines without the update, the grease zerks are directly on the middle bearings. Grease every 50 hours. Grease every 50 hours. Check the battery and recharge if necessary. Close the fuel valve. Unscrew the retaining ring. © 2022 Staheli West...
- Page 237 Use detergent and rinse with tap water if needed. Press “Auto” to return controller to auto state. Pop these two tabs to clean the inner and outer air Remove end cap. filters. Remove the outer air filter. © 2022 Staheli West...
- Page 238 90° bend if necessary. Clean the rest of the burner blast tube area with Clean the flame detector lens and inspect the o-ring compressed air. to make sure it is not damaged. When reinstalling, hand tighten only. © 2022 Staheli West...
- Page 239 Stick a long screwdriver or rod up through the Verify that water is coming out of the blowdown hose water purge valve to ensure there are no blockages. when the DewPoint performs a blowdown. Caution! Hot water has been known to scald! © 2022 Staheli West...
- Page 240 Inspect front and rear of boiler. Look for any potential hotspots on the boiler doors. Contact your dealer if any hotspots are found. Inspect all nozzles and ensure they are clean and Inspect steam hoses and ensure there are no kinks or functioning properly. holes. © 2022 Staheli West...
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Page 241: Hour Maintenance / Yearly
Clean low water 1 & 2 probes and boiler water level sensor. 29-35 Rotate tires (front to rear). Inspect boiler tubes for scale. Boiler Safety Test. 1st 250 HOUR MAINTENANCE see 1500 hour maintenance step 3 Check/Adjust wheel bearing gap ( © 2022 Staheli West... - Page 242 3.5 LED Layout Front View of GSC300 Front View of GSC300 Figure 4 Figure 4 Start the generator. After the generator starts, the generator controller will cycle through screens. Ensure that the AC frequency is between 61-62.5 Hz. © 2022 Staheli West...
- Page 243 Install the new oil and tighten to 40-47 ft-lb. Dispose of oil properly. filter and tighten to 14-17 ft-lb. © 2022 Staheli West...
- Page 244 Mark the burner gun assembly depth. Loosen sight tube locking bolt; remove the flame Lift up then out to remove the cover. detector, cover bolts, nozzle pressure sensor M12 plug, fuel lines and propane line (2014 only). © 2022 Staheli West...
- Page 245 Drain the excess fuel into a bucket. Then clean the nozzle with denatured alcohol. Unscrew the bottom portion of the Y-Strainer. Ensure Remove the Y-Strainer filter and clean. Reinstall the the boiler is empty and not under pressure. filter and reassemble the Y-Strainer. © 2022 Staheli West...
- Page 246 Remove the cap of the low water cutoff by removing Remove the wires by loosening the top nuts with a the 4 screws on top with a Phillips screwdriver. 3/16” socket. © 2022 Staheli West...
- Page 247 Only the tip of the probe is used for sensing. Remove the 6 bolts on the boiler water level sensor Rotate tires (front to rear). and disconnect the wires. Remove the sensor and clean the probe. © 2022 Staheli West...
- Page 248 Perform a boiler safety test. Instructions are located in fire tubes for scale. If a lot of scale is present, contact the front of this manual in the “Safety” section. your dealer (Tubes in picture are in good condition). © 2022 Staheli West...
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Page 249: Hour Maintenance
Inspect boiler rear door “L” brackets for tightness. Inspect boiler front smoke turn box insulation. Check torque on wheel nuts. Check brake gasket. Check/Adjust brake lever stroke. Grease central joints. Grease brake cam supports and levers. Grease steering rod joints. Grease steering hinges. © 2022 Staheli West... - Page 250 Tighten the Clean the boiler flue tubes. See Test 119. new filter with a filter wrench to 14-17 ft-lb. Be sure to prime the diesel fuel system afterwards. (50 hour maintenance step 9) © 2022 Staheli West...
- Page 251 Adjust the brake lever stroke. After 500 hours it is thickness outside the reference line. Replace when likely that more braking power will be needed. material thickness is less than 2mm outside the line. © 2022 Staheli West...
- Page 252 Grease the central joints below both sets of leaf Grease the brake cam supports and the brake levers springs (2 zerks total). on both axles (8 zerks total). Grease steering rod joints (2 zerks total). Grease steering hinges (4 zerks total). © 2022 Staheli West...
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Page 253: 1000 Hour Maintenance
Perform 250 hour maintenance (Not included in 6 hour time estimate above). hour See 500 Perform 500 hour maintenance (Not included in 6 hour time estimate above). hour Flush and replace coolant. Adjust intake / exhaust valve clearance. Clean out water side of the boiler. © 2022 Staheli West... - Page 254 Pressure wash as much of the internals of the boiler as opening and closing the valves. possible. Use a shop vac to vacuum everything out of the Standard valve clearance: 0.15 ~ 0.25 mm. bottom of the boiler. © 2022 Staheli West...
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Page 255: 1500 Hour Maintenance
Perform 500 hour maintenance (Not included in 2 hour time estimate above). hour Inspect, clean and test fuel injection nozzle, if necessary. Inspect crankcase breather system. Check/Adjust steering hinge gap. Check/Adjust wheel bearing gap. Check torque on steering rod end screw. © 2022 Staheli West... - Page 256 ADR original spare part. wheel is off the ground and rotates freely. Insert a 6) Reassemble the hub cap and tighten the 6 screws. lever between the ground and tire and force the wheel up to find any gaps. © 2022 Staheli West...
- Page 257 1500 Hour Maintenance Check screw torque indicated in the illustration with a torque wrench. Torque should be between 290 - 325 ft-lb. © 2022 Staheli West...
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Page 258: 2000 Hour Maintenance
Perform 500 hour maintenance (Not included in 2 hour time estimate above). hour See 1000 Perform 1000 hour maintenance (Not included in 2 hour time estimate above). hour Replace fuel hoses and coolant hoses (Not included in 2 hour time estimate above). © 2022 Staheli West... - Page 259 2000 Hour Maintenance Replace all fuel hoses and coolant hoses on the generator. © 2022 Staheli West...
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Page 260: Maintenance Schedule
Grease PTO anti-rotating shields Grease and lubricate axles and PTO bearings Grease fan motor (1 pump) (DO NOT OVER GREASE) Grease/Lube Grease central joints Grease brake cam supports and levers Grease steering rod joints Grease steering hinges © 2022 Staheli West... - Page 261 Check/Adjust steering hinge gap Rotate tires (front to rear) (1st) Check/Adjust wheel bearing gap Frame/Axles Check brake gasket Check/Adjust brake lever stroke Check torque on steering rod end screw (290- 325 lb-ft) Other Inspect baler hardware © 2022 Staheli West...
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Page 262: Notes
Notes © 2022 Staheli West... - Page 263 Notes © 2022 Staheli West...
- Page 264 © 2022 Staheli West...
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