Staheli West DewPoint 6110 2010 User manual

DewPoint 6110
Owner's Manual
R8.5: 12.1.21
2010 DewPoint 6110
2011 DewPoint 6110
2012 DewPoint 6110
2013 DewPoint 6110
2014 DewPoint 6110
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Contents
Foreword
DewPoint Machine Operator Training....................8
Warranty Informaon.............................................10
Safety
Safety Decals ..........................................................13
Tractor Requirements.............................................15
Safety Warnings......................................................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
Water Quality/Blowdown Principles ............33
Water 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
Valve Inspecon............................................38
Generator Inspecon .................................... 39
Electrical Panel Inspecon ............................40
Actuator Inspecon.......................................41
Wheel Inspecon ..........................................43
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 Calibraon................................................53
Gazeeka Screen ......................................................54
Brake Adjustments .................................................55
Operaon
Common Operang Times......................................58
How to Start Steaming ...........................................59
Common Valve Sengs..........................................61
Simple Operaon....................................................62
Steam Rate Adjustment With a Gazeeka................63
Steam Rate Adjustment Without a Gazeeka ..........64
Common Operaon................................................ 65
Short Term Storage (Wet Layup) ............................66
Keep Hot.................................................................67
Blowdown System ..................................................68
Water Purge System ...............................................70
Steam Purge System...............................................71
Irrigaon................................................................. 72
Cung... .................................................................73
Raking..................................................................... 74
DewPoint Machines................................................76
Baling With Steam..................................................77
Suggested Moisture With Steam............................78
Steaming Dierent Crops .......................................79
Steam Eects in Dierent Temperatures................80
Judging Bale Moisture ............................................81
Moisture Sensors....................................................82
Judging Bale Moisture with the
Gazeeka Moisture Gauge .............................83
Judging Bale Moisture by
Bale Chamber Pressure ................................85
Judging Bale Moisture Visually...............................86
Judging Bale Moisture with a
Hand Held Moisture Probe ...........................87
Judging Bale Moisture with a
Baler Mounted Contact Moisture Sensor .....89
Judging Bale Moisture Aer Baling ........................90
Judging Bale Temperature......................................91
Hauling, Stacking, and Storage of
Steam Treated Hay .......................................92
Hauling and Stacking Steamed Hay during
Normal Harvest Operaons ..........................92
Stacking High Temperature Steamed
Hay when Weather is a threat ......................92
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Contents
Technical Informaon
Diagram 1 ...............................................................94
Diagram 2 ...............................................................94
Diagram 3 ...............................................................95
Diagram 4 ...............................................................95
Diagram 5 ...............................................................96
Diagram 6a (2010)..................................................96
Diagram 7a (2010)..................................................97
Diagram 6b (2011-2013).........................................97
Diagram 7b (2011-2013).........................................98
Diagram 6c (2014-So Start) ..................................98
Diagram 7c (2014-So Start) ..................................99
Diagram 6d (2014-VFD)..........................................99
Diagram 7d (2014-VFD)..........................................100
Diagram 8 ...............................................................100
Diagram 9 ...............................................................101
Diagram 10 .............................................................101
Diagram 11 .............................................................102
Diagram 12 .............................................................102
Diagram 13 .............................................................102
Diagram 14 .............................................................102
Diagram 15 .............................................................103
Diagram 16 .............................................................103
Diagram 17 Low Fire Fuel Path...............................104
Diagram 18 High Fire Fuel Path ..............................104
Diagram 19 So Line Fuel Path (Update) ...............105
Diagram 20 So Line Fuel Wiring (Update) ............105
Diagram 21 Propane System (2014 Only)...............106
Field Work Screen................................................... 107
How The DewPoint 6110 Works.............................108
Machine Specicaons........................................... 109
Sensors... ................................................................111
Actuators ................................................................114
Generator Controller ..............................................115
Fuses..... .................................................................116
Circuit Breakers ......................................................117
Connecons............................................................ 118
120 V Control Power...............................................121
Touch Screen Wiring............................................... 122
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
Troubleshoong
Fault 1: No Purge Card............................................ 134
Fault 14: High Fire Switch / Purge Hold
T19 High Fire Switch...................................... 134
Fault 15: Flame Detected (Standby) .......................135
Fault 17: Main Flame Fail .......................................136
Fault 18: Flame Detected (Pre-Purge) ....................137
Fault 19: Main Flame Ign ........................................138
Fault 20: Low Fire SW O / Purge Hold
T18 Low Fire Switch ......................................139
Fault 28: Pilot Flame Fail ........................................140
Fault 29: Lockout ILK (Airow Switch / VFD) ..........142
Fault 30-44 ............................................................. 143
Fault 45: Low Fire Switch O..................................143
Fault 46-127: Call Service ....................................... 143
Fault 200: High Pressure Limit Switch
(HPLS) Is Tripped ........................................... 144
Fault 201: Turn Burner Switch ON..........................144
Fault 202: Operang Pressure Control Switch
(OPLS) Is Tripped ...........................................145
Fault 203: Boiler Water Level Is High......................145
Fault 204: Pilot Propane Level Is Low .....................145
Fault 206: Supply Water Is Empty...........................146
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 224: Trouble with One or More Sensors........150
Fault 225: Burner Modbus Signal Failure ...............151
Fault 228: Steam Pressure Is Low...........................151
Fault 229: Boiler Water Temp. Is Low and
Steam Pressure Is Normal.............................151
Fault 230: Turn Water System On...........................151
Fault 231: Boiler Water Level Is Too
High for Operaon ........................................151
Fault 232: Generator Status ...................................152
Fault 239: Iniate Hold: AC Frequency / Noise.......154
Fault 240: Control Switch Relay SR-1
Did Not Annunciate.......................................154
Fault 241: Low Water 1 Relay SR-2
Did Not Annunciate.......................................154
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Fault 242: Low Water 2 Relay SR-3
Did Not Annunciate.......................................155
Fault 243: High Pressure Limit Switch Relay SR-4
Did Not Annunciate.......................................155
Fault 244: Operang Pressure Control Relay SR-5
Did Not Annunciate.......................................155
Fault 245: Burner Relay SR-6 Did Not Annunciate..156
Fault 246: Fan VFD SR-7 Did Not Annunciate .........156
Fault 247: Airow Switch SR-8
Did Not Annunciate.......................................156
Fault 248: Touch Screen Version Is
Incompable With This DewPoint.................157
Fault 249: Check Network Cable or
Fault 214: Missing USB Drive
(PLC-015: DEV001 No Device Found) ............158
Fault 250: Fuel Pump Pressure LOW ......................159
Fault 400: Low Water 1 or 2 tripped ......................160
Fault 401: Boiler Not Filling /
Slowly Filling with Water (See Fault 400)......162
Fault 402: Faulty PLC Input Card (See Test 113) .....163
Fault 403: Boiler Water Level Higher Than
Set Point / Boiler Overowing.......................164
Fault 404.A: Boom Rear Work Lights Will
Not Turn On (All Work Lights Not
Working 2010-2012 Machines).....................165
Fault 404.B: Side and Top Rear Work
Lights Will Not Turn On .................................165
Fault 405: Touch Screen Controller Will
Not Turn On .................................................. 166
Fault 406: Steam Coming Out of
Water Supply Tanks ......................................166
Fault 407: Burner Smoking / Pulsing ......................167
Fault 408: Actuators/Valves Not Opening/Closing .168
Fault 409: Loss of Steam
Pressure During Operaon............................169
Fault 410: Feed Water Pump Not Running.............170
Fault 411: Circulaon Pump Not Running ..............171
Fault 412: Water In Steam / Bales Have Water
Splotches / Sudden Loss of Steam
Pressure and Water Level .............................172
Fault 413: Pilot Propane Pressure Low...................173
Fault 414: Fuel Nozzle Pressure Is Low in Low Fire.173
Fault 415: Fuel Nozzle Pressure Is High in Low Fire 173
Fault 416: Fuel Nozzle Pressure Is Low in High Fire 174
Fault 417: Fuel Nozzle Pressure Is
High in High Fire............................................174
Fault 418: Purge Delay: T19 High Fire Jumpered....174
Fault 419: Purge Hold: T19 High Fire Switch
(Waing for Louver to Open) ........................175
Fault 420: Purge Hold: T18 Low Fire Switch
(Waing for Louver to Close) ........................175
Fault 421: Generator Will Not Start
From Touch Screen........................................ 176
Fault 422: Generator Will Not Shut O
From Touch Screen........................................ 176
Fault 423: Touch Screen Problems:
Frozen, Won’t Respond To Touch..................176
Fault 424: Generator Controller Not Working;
“????????” Displayed On Screen ..................177
Fault 425: Burner Not Going Into High Fire /
Stuck in Low Fire ...........................................177
Fault 426: Failed PTO Bearing(s).............................178
Fault 427: PTO Sha Slipping..................................178
Fault 428: Water Coming Out of Steam
Purge Valve (See Fault 403)...........................178
Fault 429: PLC NAK Error ........................................ 178
Fault 430: Water in Furnace / Steam Coming
Out of Flue Exhaust / Leaky Flue Tube(s) ......179
Fault 431: Camera Problems ..................................179
Fault 432: Boiler Building Pressure
During Fill Stage ............................................179
Fault 433: Burner Switching From High to
Low Fire Frequently ......................................179
Fault 434: Main Wire Harness Damage /
70 Pin Connector Damaged ..........................180
Fault 435: Melted Igniter Wires..............................180
Fault 436: Blown Valve Actuator Fuses
Panel 2: F1-F7 (5 Amp)..................................180
Fault 437: Blown Fuse Panel 3: F1 (15 Amp) ..........180
Fault 438: Blown Fuse Panel 3: F2 (15 Amp) ..........181
Fault 439: Blown Fuse Panel 3: F3 (2 Amp) ............181
Fault 440: Blown Fuse Panel 3: F4 (15 Amp) ..........181
Fault 441: Blown Fuse Panel 3: F5 (5 Amp) ............181
Fault 442: Blown Fuse Panel 3: F6 (1.5 Amp) .........181
Fault 443: Blown Fuse Panel 3: F7 (2 Amp) ............182
Fault 444: Blown Fuse Panel 3: F8 (2 Amp) ............182
Fault 445: Blown Fuse Panel 3: F9 (2 Amp) ............182
Fault 446: Blown Fuse Panel 3: F10 (1.5 Amp) .......182
Fault 447: Blown Fuse Panel 3: F11 (0.5 Amp) .......182
Fault 448: Blown Fuse Panel 3: F12 (1.5 Amp) .......182
Fault 449: Algae in Supply Tanks.............................183
Fault 450: Burner Stuck in Purge............................183
Fault 451: Trouble Reinstalling Sparge Tube...........183
Fault 452: Touch Screen Reboong
When Generator Starng..............................183
Fault 453: Boiler Taking Longer Than
Normal to Heat Up........................................184
Contents
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Requirements
Pre-Operaon
Requirements
SafetySafety

Tests
Test 101: Flame Detector Tesng Procedures ........186
Test 102: Fuel Solenoid Test ................................... 186
Test 103: Propane Solenoid Test.............................186
Test 104: Ignion Transformer Test ........................187
Test 105.A: Igniter Electrode Orientaon & Gap
(Direct Spark) ................................................ 187
Test 105.B: Igniter Electrode Orientaon & Gap
(Propane: 2014) ............................................ 188
Test 106: Intermient Pilot Flame Test
(2014 machines only).................................... 188
Test 108: HPLS Calibraon [15 psi] .........................189
Test 109: OPLS Calibraon [14.5 psi] ......................190
Test 110.A: Boiler Water Level Sensor Tesng........190
Test 110.B: Boiler Water Level Sensor Tesng........191
Test 111: Valve Repair.............................................192
Test 112: Pump Service ..........................................193
Test 113: Input Card Tesng (See Fault 402) ..........194
Test 114.A: Program the VFD (See Fault 29)...........195
Test 114.B: Program the VFD (New) .......................195
Test 115: Louver Actuator adjusng (See Fault 14) 196
Test 116: Tune the burner ......................................197
Test 117: Remove the burner gun assembly ..........200
Test 118: Update to new boiler water
level sensor Part # 10344..............................201
Test 119: Fire Tube Cleaning...................................203
Test 120: Remove panel 2 TS2 jumpers
(2010-2013 machines only)...........................206
Test 121: Generator End Troubleshoong..............207
A: Exciter Wire Test .......................................207
B: Main Stator Test........................................208
C: Voltage Regulator Test ..............................208
D: Surge Suppressor Test...............................209
E: Diodes Test ................................................209
Test 122: Release Wires From Terminal Block ........210
Test 123: Maxed Out Sensor Readings ...................211
Test 123.A: Faulty Sensor /
Faulty Wire Harness Test...............................211
Test 123.B: Faulty Sensor Test
(No Mulmeter Required) ............................212
Test 124: All Sensors Oine / Fuse Keeps Blowing 213
Test 124.A: Faulty Wire Harness Test
(Mulmeter Required) ..................................213
Test 124.B: Faulty Sensor Test
(No Mulmeter Required) ............................214
Test 125: Touch Screen Calibraon
(Updated Touch Screens) ..............................215
Test 126: Seng Modbus Address .........................216
Maintenance
Winterize ................................................................218
De-Winterize ..........................................................227
Daily Maintenance .................................................231
Pre-Operaon ...............................................232
Post-Operaon..............................................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
Contents
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Requirements
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Requirements
SafetySafety

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Preparation
Open the “Owner’s Manual”.
Read the “Owner’s Manual” before operating 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 functioning properly.
Always lock the steering axles on the steamer and baler when traveling on roadways, operating on
hillsides, or backing up.
Operation
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 .
e importance of the PPM setting and how to set it based on your water test.
Dierent start options (basic overview).
Start All.
Start Fill.
Keep Hot.
Wet Layup.
Tune the burner (low and high re).
Field work screen (overview).
Setting the steam valve proportions (4 individual sliders).
Ideal conditions (all sliders 100%).
Changing dew conditions.
Adverse conditions (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:

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Operation
Teach that ideal baling moisture, with steam, is 12-14%.
Steamed bales should be tightly packed with good leaf pattern. 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 conditions.
Baling in hot/dry conditions.
Baling in moderate humidity conditions.
Avoid baling with stem moisture.
Baling in high-humidity conditions 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 instructions on how to properly operate,
test, service, and clean the boiler. I understand that operating, testing, and servicing may only be
performed by a qualied individual that has received the instructions contained in this manual.
Print:__________________________________________
Signature: ______________________________________ Date: ___________________
Trainer Name:___________________________________
Trainer Signature:________________________________ Date: ___________________
DewPoint Machine Operator Training
(customer / operator)
Tests
Maintenance
Troubleshoong
Technical
Informaon
Operaon
Pre-Operaon
Requirements
Safety

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Warranty Information
All DewPoint machines come with a 1-Year Limited Warranty. is 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.
e 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 warrantied part.
Warranty will not be honored if routine 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%
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11 © 2022 Staheli West
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Safety
Safety
Safety Decals ..........................................................13
Tractor Requirements.............................................15
Safety Warnings......................................................16
Boiler Jurisdicon ................................................... 18
Boiler Safety Test ....................................................19

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This Page Intenonally Le Blank

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e DewPoint machine has many safety decals to help ensure operator safety. Pay attention to the decals
and their warnings to avoid serious injury. ey range from red DANGER (most dangerous) to the yellow
CAUTION (less dangerous... but still dangerous)
Keep All Shields
in Place
No Retirar las
Tapas
Mecánicas
Hot Surfaces
in Area
Superficies
Calientes
Cercanas
Do Not
Climb
No Subir
Use a Safe
Ladder or Steps
to Service
Upper
Components
Use una
Escalera
Segura para
Mantener los
Componentes
Superiores
Hot Surfaces
Inside
Superficies
Calientes
Adentro
Never Fire Boiler in
Enclosed Area
Nunca Prender la
Caldera Adentro
Safety Decals
DO NOT REMOVE ANY
BOILER COMPONENT
UNDER PRESSURE
NO RETIRE NINGUN
COMPONENTE DE LA
CALDERA BAJO
PRESIÓN
240 Volts
240 Voltios
Watch Your
Step
Subir con
Cuidado
Use Caution
When Servicing
Engine and
Generator
Tener Cuidado
Mientras
Mantener el
Motor y el
Generador

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Safety Decals
To avoid excessive driveline wear, please refer to
your baler Operator’s Manuals regarding proper
hitch and PTO shaft operating angle adjustments.
*See PTO section of the Instruction Manual for
further detail.
Para evitar el desgaste excesivo de toma de
fuerza, consulte los manuales del operador de su
empacadora en relación con el enganche adecua-
do y ajustes del ángulo de funcionamiento de la
toma de fuerza .
* Véase la sección de toma de fuerza en el “In-
struction Manual” para más detalles
When connecting PTO drivelines between this ma-
chine and the baler, be sure the front connecting
yoke of the driveline on each machine holds the
same rotation angle.
*See PTO section of the Instruction Manual for
further detail.
Al conectar la toma de fuerza entre esta máquina y
la empacadora , asegúrese de que la conexión
frontal yugo de la línea de conducción en cada
máquina tiene el mismo ángulo de rotación.
* Véase la sección de toma de fuerza en el “In-
struction Manual” para más detalles.
To avoid excessive driveline wear, adjust hitch
height so that the machine runs level.
*See PTO section of the Instruction Manual for
further detail.
Para evitar el desgaste excesivo de toma de
fuerza, adjuste la altura del enganche de modo que
la máquina funciona nivel.
* Véase la sección de toma de fuerza en el “In-
struction Manual” para más detalles
To Prevent Serious Injury or death:
1. Read the Instruction Manual before operating
the machine
2. Keep all shields in place
3. No Riders
4. Make certain everyone is clear of machine
before starting engine or operation
5. Stop engine and operation before adjusting,
lubricating, or cleaning
6. Use the flashing warning lights and slow moving
vehicle emblem when transporting on highways.
Para evitar lesiones graves o la muerte:
1. Lea el “Instruction Manual” antes de hacer fun-
cionar la máquina
2. Mantenga todos las tapas mecánicas en su lugar
3. No Pasajeros
4. Asegúrese de que todos estén lejos de la máqui-
na antes de arrancar el motor o la operación
5. Apague el motor y la operación antes de ajustar,
lubricar, o limpiar la máquina
6. Use las luces intermitentes de advertencia y de
vehículo lento durante el transporte en las carret-
eras
ere are also many lengthy warnings and words of advice. Read all of them and know what they refer to.

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Tractor Requirements
In order to pull the DewPoint machine ≈ 30,000 lbs (when fully loaded) and a big baler ≈ 20,000
lbs, you will need a tractor with the following horsepower.
In order to safely stop the DewPoint machine and a big baler you will need a tractor equipped with a hydraulic
trailer brake valve.
Adjust the amount the hydraulic trailer brakes engage by moving these pins to meet your needs.
DO NOT OPERATE THE DEWPOINT MACHINE WITH A TRACTOR THAT LACKS THE NECESSARY
HORSEPOWER OR HYDRAULIC BRAKING SYSTEM. SERIOUS DEATH OR INJURY MAY OCCUR.
Hydraulic Trailer
Brake Valve Required
More
More
FrontRear
Less
Less
Minimum
Engine Horsepower
Recommended
Engine Horsepower
0-2% Slopes 200 225
0-5% Slopes 240 265
0-10% Slopes 275 300

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Operating on Hillsides
• Operating on side slopes can cause water to get into your steam.
• e DewPoint is a heavy machine, and signicant side slopes could cause the machine to slide or tip.
• Ensure that brakes are functioning properly before taking the DewPoint up or down steep slopes.
Safety Lighting
e DewPoint has all proper safety, hazard, and signal lighting installed. Check that all lights are functioning
properly before each use.
Electricity Overhead
Ensure that the DewPoint will not interfere with overhead power lines. Hitting power lines with the DewPoint
can cause serious damage to you, your equipment, and/or others.
Personal Protective Equipment
When operating or servicing the DewPoint, ensure that you use all proper Personal Protective Equipment (PPE).
PPE includes, but is not limited to, proper footwear, gloves, eye protection, and ear protection.
Persons on DewPoint
• NEVER operate the DewPoint while others are on or under the machine.
• Ensure that stepping and standing only happens in designated safe areas.
• DO NOT step or climb areas specically marked prohibited. Doing so can cause serious injury or death.
• Use caution when standing on the deck of the machine - especially if deck is wet.
• DO NOT operate with children near the machine. Ensure that all children are kept at a safe distance.
Shields, Guards, and Door
• All shields and guards are in place for a reason. Never operate the machine with shields or guards displaced
or removed.
• Never attempt to operate the machine with the boiler door removed.
Exhaust and Fumes
Never operate the DewPoint in conned spaces. e generator and burner generate toxic gases. Operation and
maintenance should only happen in well-ventilated areas.
Handrails
Some service and maintenance procedures on the DewPoint require climbing around the top of the machine.
Step ladders and handrails have been specically put in place and designed with your safety in mind. Use caution
and common sense when climbing on top of the DewPoint machine.
Chemicals
Use chemicals according to instructions attached to their containers. Using them improperly can be very
dangerous. If no longer needed, ensure that excess chemicals are disposed of properly.
Traveling on Public Roads
When traveling on public roads, obey all local trac 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.
Safety Warnings

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Safety Chains
Ensure that safety chains are connected and free from defect before operating the DewPoint.
Faulty/Broken/Worn Out Components
• Replace all lters according to maintenance schedule.
• Repair/Replace any faulty components as soon as they fail to function properly. Using defective components
(especially sensors) can be a hazard to you and those around you.
• Periodically check bolts to ensure that they are properly tightened.
• Do not operate the DewPoint if any components are leaking or will not hold pressure.
Burner Safety System
• NEVER bypass burner safeties.
• Keep hands away from the louver. Hands and/or ngers can be pinched and lacerated by the fan.
• Keep debris away from the louver to avoid pulling debris into the burner.
Fire Safety
• Check the re extinguisher according to the maintenance schedule attached to the extinguisher.
• If re does occur, use the re extinguisher as directed.
• Always stand upwind of ames.
Safety Warnings
Opening Valves/Drains Under Pressure
• Use extreme caution when opening/ushing any valve that is under pressure. Hot steam and/or water can
cause harm to you and others.
• Do not operate the blowdown valve or baler steam valves without all hardware properly installed.
• Stand clear when draining hot water from the boiler.
Electrical/Battery Safety
Use caution when working:
1) near the ignition transformer.
2) in the electrical panel.
3) around any loose electrical wires.
4) near pump & generator plugs.
5) near the battery.
Sight Glass
Remember that the sight glass is actually GLASS, not plastic or rubber. It can break and can cut you.
Propane
• Close valve on propane tanks when the DewPoint is not in use.
• If propane smell is detected, shut down and nd 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 lling valves when the machine is in use.

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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

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Boiler Safety Test
1
3
5
2
4
6
Press Menu.
*e DewPoint machine needs to be full of fuel and
water before the boiler safety test can occur.
Press Test Now.
Press Conrm Test Now.
*Generator will start aer this step.
Following the instructions on the screen, press
Control Power on the le of the screen o (RED) and
on (GREEN). When the indicator on the right turns
green it means that the system is functioning properly.
Press Maintenance.
Press Boiler Safety Test.
Press Control Power button on the right.
Press Low Water 1.
Press and hold Manual Test.

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7
9
11
8
10
12
Press Reset.
Press High Pressure Limit.
Press and hold the Pressure Relief button to relieve
pressure (Opens steam purge valve).
Reset the HPLS by pressing down on the Reset button.
e indicator turning green indicates proper function
of Low Water 1.
Repeat these steps for Low Water 2.
Attach air compressor tting to the pressure test hose.
Begin lling with air slowly until the High Pressure
Limit Switch trips (Trips around 15 psi).
Press the Operating Pressure button. Fill the boiler
again with compressed air until the Operating
Pressure Limit Switch trips (Trips around 14.5 psi).
Boiler Safety Test