Staheli West DewPoint 6110 User manual

2010-2014
DewPoint 6110
Troubleshooting
Guide
R7

II
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III
2010-2014
DewPoint 6110
Troubleshooting Guide
This manual is intended to be used with soware version
2.6 or later installed on the DewPoint 6110 machine
• Operator Training
• Warranty Informaon
• Safety Informaon
• Pre-Operaon Requirements
• Operaon
• Winterizaon
• De-Winterizaon
• Maintenance Instrucons
See DewPoint 6210 Owners Manual

iv
Contents
Informaonal
Components Locaon List ............................................................... VI
Diagram 1 Full Machine................................................................... 1
Diagram 2 Boiler Components ........................................................ 2
Diagram 3 Boiler Components ........................................................ 3
Diagram 4 Burner Components....................................................... 4
Diagram 5 Burner Components....................................................... 5
Diagram 6 Panel 1 and Door............................................................ 6-12
Diagram 7 Panel 2 and 3.................................................................. 7-13
Diagram 8 Under Frame .................................................................. 14
Diagram 9 Rear door area ............................................................... 15
Diagram 10 Engine/Generator ........................................................ 16
Sensors ............................................................................................ 17-19
Burner Nozzle Sizes ......................................................................... 20
Actuators ......................................................................................... 21
Fuses................................................................................................ 22
Circuit Breakers ............................................................................... 23
Connecons..................................................................................... 24-26
Touch Screen Wiring........................................................................ 27
Relay Block Wiring........................................................................... 28
Burner Wiring 2010-2013................................................................ 29
Burner Wiring 2014 (So Start Direct Spark) .................................. 30
Burner Wiring 2014 (So Start Propane) ........................................ 31
Burner Wiring 2014 (VFD Propane)................................................. 32
Faults
Fault 1: No Purge Card..................................................................... 33
Fault 14: High Fire Switch / Purge Hold
T19 High Fire Switch (See Fault 222)................................. 33
Fault 15: Flame Detected (Standby) ................................................ 34
Fault 17: Main Flame Fail (See Fault 220)........................................ 35
Fault 18: Flame Detected (Pre-Purge) ............................................. 36
Fault 19: Main Flame Ign ................................................................. 37
Fault 20: Low Fire SW O / Purge Hold
T18 Low Fire Switch (See Fault 223).................................. 38
Fault 28: Pilot Flame Fail ................................................................. 39-40
Fault 29: Lockout ILK (Airow Switch / VFD) ................................... 41-42
Fault 45: Low Fire Switch OFF.......................................................... 42
Fault 46-127: Call Service ................................................................ 42
Fault 200: High Pressure Limit Switch (HPLS) is tripped .................. 43
Fault 201: Turn Burner Switch ON ................................................... 44
Fault 202: Operang Pressure Control
Switch (OPLS) is tripped ................................................. 44
Fault 203: Boiler Water Level is high ............................................... 45
Fault 204: Pilot Propane Level is low............................................... 45
Fault 206: Supply Water is Empty.................................................... 45
Fault 207: Pressure Dierenal Alarm............................................. 46
Fault 208: Flue Temp is High............................................................ 47
Fault 209: Feed Water and Boiler Water Temp.
Dierenal limit has been Exceeded.............................. 48
Fault 210: Ambient Temperature is High......................................... 49
Fault 211: Furnace Door Temp is High............................................. 49
Fault 212: Low Water 2 tripped....................................................... 49
Fault 213: Boiler taking longer than expected to ll ....................... 49
Fault 214: Data Logging Failed: Replace USB Drive ......................... 50
Fault 215: Manual Valve Operaon is On ........................................ 50
Fault 224: Trouble with one or more Sensors ................................. 50
Fault 225: Burner Modbus signal failure ......................................... 51
Fault 228: Steam Pressure is low..................................................... 51
Fault 229: Boiler water temp. is low and
steam pressure is normal ............................................... 51
Fault 230: Turn Water System On.................................................... 51
Fault 231: Boiler water level is too high for operaon .................... 51
Fault 232: Generator Status ............................................................ 52-53
Fault 239: Iniate Hold: AC Frequency / Noise................................ 54
Fault 240: Control Switch Relay SR-1 did not annunciate................ 54
Fault 241: Low Water 1 Relay SR-2 did not annunciate................... 54
Fault 242: Low Water 2 Relay SR-3 did not annunciate................... 54
Fault 243: High Pressure Limit Switch
Relay SR-4 did not annunciate........................................ 54
Fault 244: Operang Pressure Control Relay SR-5
did not annunciate ......................................................... 55
Fault 245: Burner Relay SR-6 did not annunciate............................ 55
Fault 246: Fan VFD SR-7 did not annunciate ................................... 55
Fault 247: Airow Switch SR-8 did not annunciate ......................... 55
Fault 248: Touch Screen Version is
incompable with this DewPoint ................................... 55
Fault 249: Check Network or Fault 214: Missing USB Drive
(PLC-015: DEV001 No Device Found) ............................. 56
Fault 400: Low Water 1 or 2 tripped ............................................... 57-58
Fault 401: Boiler not lling / slowly lling with water..................... 59

v
Test 106: Intermient Pilot Flame Test............................................ 78
Test 108: HPLS Calibraon [15 PSI].................................................. 79
Test 109: OPLS Calibraon [14.5 PSI]............................................... 80
Test 110: Boiler Water Level Sensor Tesng .................................... 80-81
Test 111: Valve Repair...................................................................... 82
Test 112: Pump Service ................................................................... 83
Test 113: Input Card Tesng ............................................................ 84
Test 114: Program the VFD (See Fault 29) ....................................... 85
Test 115: Louver Actuator adjustments........................................... 86
Test 116: Tune the burner ............................................................... 87-89
Test 117: Remove burner gun assembly.......................................... 90
Test 118: Update to new boiler water level sensor ......................... 91-92
Test 119: Flue tube cleaning............................................................ 93-95
Test 120: Remove Panel 2 TS2 Jumpers........................................... 96
Test 121: Generator End Troubleshoong....................................... 97-98
Test 122: Release wires from terminal block................................... 99
Test 123: Maxed out sensor readings.............................................. 100-101
Test 124: All sensors oine / fuse keeps blowing ........................... 102-103
Maintenance
Maintenance Checklists:
Daily .................................................................. 104
Every 50 hours .................................................. 104
Every 250 hours / Yearly ................................... 105
Every 500 hours ................................................ 105
Every 1000 hours .............................................. 106
Every 1500 hours .............................................. 106
Every 2000 hours .............................................. 106
Maintenance Schedule.................................................................... 107-109
Contents
Fault 402: Faulty PLC Input Card...................................................... 59
Fault 403: Boiler water level higher than
set point / Boiler overowing......................................... 60
Fault 404a: Boom rear work lights will not turn on ...................... 61
Fault 404b: Side and top rear work lights will not turn on .............. 61
Fault 405: Touch Screen controller will not turn on ........................ 62
Fault 406: Steam is coming out of front water tanks ...................... 62
Fault 407: Burner Smoking .............................................................. 63-64
Fault 408: Actuators/Valves not opening/closing............................ 64
Fault 409: Loss of steam pressure during operaon ....................... 65
Fault 410: Feed Water Pump not running ....................................... 66
Fault 411: Circulaon Pump not running ........................................ 67
Fault 412: Water in Steam / Bales have Water splotches /
Sudden loss of Steam Pressure and Water Level ............ 68
Fault 413: Pilot Propane Pressure low............................................. 69
Fault 414: Fuel Nozzle Pressure is low in Low Fire .......................... 69
Fault 415: Fuel Nozzle Pressure is high in Low Fire ......................... 69
Fault 416: Fuel Nozzle Pressure is low in High Fire.......................... 70
Fault 417: Fuel Nozzle Pressure is high in High Fire......................... 70
Fault 418: Purge Delay: T19 High Fire Jumpered............................. 70
Fault 419: Purge Hold: T19 High Fire Switch
(Waing for Louver to Open) (See Fault 14)................... 71
Fault 420: Purge Hold: T18 Low Fire Switch
(Waing for Louver to Close) (See Fault 20)................... 71
Fault 421: Generator will not start form Touch Screen ................... 72
Fault 422: Generator will not shut o from Touch Screen .............. 72
Fault 423: Touch Screen Problems: Frozen,
won’t respond to touch................................................. 73
Fault 424: Generator Controller not working;
“??????????” displayed on screen ................................. 73
Fault 425: Burner not going into high re / Stuck in low re .......... 74
Fault 426: Failed PTO Bearing(s)...................................................... 75
Fault 427: PTO sha slipping ........................................................... 75
Fault 428: Water coming out of steam purge valve......................... 75
Tests
Test 101: Flame Detector Tesng Procedures ................................. 76
Test 102: Fuel Solenoid Test ............................................................ 76
Test 103: Propane Solenoid Test...................................................... 76
Test 104: Ignion Transformer Test ................................................. 77
Test 105: Igniter Electrode Orientaon & Gap ................................ 77-78
• Operator Training
• Warranty Informaon
• Safety Informaon
• Pre-Operaon Requirements
• Operaon
• Winterizaon
• De-Winterizaon
• Maintenance Instrucons
See DewPoint 6210 Owners Manual

vi
Component Part # Locaon
24v Regulator 10302 Diagram 7
Airow Switch 10041 Diagram 5
Ambient Temperature Sensor 10373 Diagram 8
Blow Down Valve Actuator 10363 Diagram 2
Boiler Door Temperature Sensor 10372 Diagram 2
Boiler Drain Valve Diagram 9
Boiler Water Level Sensor update kit
Boiler Water Level Sensor
10344
11040
Diagram 2,3
Boiler Water Sight Glass (kit) 10625 Diagram 3
Boiler Water Temperature Sensor 10372 Diagram 3
Burner Cone Diagram 4
Burner Controller 10654 Diagram 6
Burner Gun Assembly … Diagram 4
Burner Nozzle Diagram 4
Circulaon Water Pump 10585 Diagram 2,9
Circulaon Water Pump Contactor 10298 Diagram 7
Control Relay (Burner Door Switch) Diagram 7
Control Switch Diagram 4
Fan Motor Three Phase 2014 VFD
Fan Motor Single Phase 2010-2014
10687
10036
Diagram 4
Feed Water Pump 10585 Diagram 2,9
Feed Water Pump Contactor 10298 Diagram 7
Feed Water Temperature Sensor 10372 Diagram 3
Feed Water Valve Actuator 10363 Diagram 2,9
Flame Amplier Card UV 10798 Diagram 6
Flame Detector UV 10047 Diagram 4,5
Flue Diagram 2
Flue Temperature Sensor 10366 Diagram 2
Front Boiler Sight Glass Diagram 5
Front Turn box Diagram 3
Fuel Filter (Burner) Diagram 8
Fuel Level Sensor 10371 Diagram 8
Fuel Pressure Gauge 10709 Diagram 5
Fuel Pump (Burner) 10045 Diagram 5
Fuel Pump PSI Sensor 10349 Diagram 5
Component Part # Locaon
Fuel Solenoid Valves 10730 Diagram 4
Generator Controller 11078 Diagram 1
High Pressure Limit Switch 10380 Diagram 3
Ignion Electrode 2010-2013: 10648
2014: 10721
Diagram 4
Ignion Transformer (Direct Spark)
Ignion Transformer (Propane)
2010-2013: 10043
2014: 10698
Diagram 4
Louver Actuator 10038 Diagram 5
Low Water 1 Relay 2014: 10352 Diagram 6
Low Water 2 Relay 2014: 10352 Diagram 6
Low Water Cut O Probe 1/A 10354-19-3-8 Diagram 2,3
Low Water Cut O Probe 2/B 10354-19-5-8 Diagram 2,3
Low Water Cut O Sensor Head 10353 Diagram 2,3
Manual Steam Pressure Gauge Diagram 3
Modbus Card 10713 Diagram 6
Operang Pressure Limit Switch 10379 Diagram 3
PLC Ethernet Card 10377 Diagram 7
PLC Ethernet Switch 10378 Diagram 7
PLC Input Card 10375 Diagram 7
PLC Logic Controller 10374 Diagram 7
PLC Output Card 10376 Diagram 7
Pressure Relief Valve 10016 Diagram 2,3
Propane PSI Sensor 10656 Diagram 4
Propane Regulator 2014 only 10693 Diagram 4
Propane Solenoid Valve 2014 only 10692 Diagram 4
Purge Card 10712 Diagram 6
Rear Furnace Sight Glass 10014 Diagram 2
Rear Furnace Door Diagram 2
Steam PSI 1 10350 Diagram 3
Steam PSI 2 10350 Diagram 3
Steam Purge Valve Actuator 10364 Diagram 2
Steam Valves 1-4 Actuator 10363 Diagram 2
Supply Water Filter / T Strainer Diagram 9
Supply Water Level Sensor 10371 Diagram 8
VFD (Variable Frequency Drive) 10714 Diagram 6
Water Purge Valve Actuator 10365 Diagram 2
Y-Strainer 10588 Diagram 3
Components Location List

1
Diagram 1
Supply Water
Tanks
Generator
Burner
Fuel Tanks
Boiler
Generator
Controller

2
Diagram 2
Flue
Feed Water
Valve Actuator
Boiler Door
Temp. Sensor
Rear Furnace Door
Flue Temp.
Sensor
Water Purge
Valve Actuator
Steam Purge
Valve Actuator
Boom Front Steam
Valve Actuator
Boom Rear Steam
Valve Actuator
Top Front Steam
Valve Actuator
Top Rear Steam
Valve Actuator
Pressure Relief
Valve
Low Water
Cuto
Boiler Water
Level Sensor
Steam Valve Actuators
Feed Water
Pump
Circulaon
Pump
Rear Furnace
Sight Glass
Blow Down
Valve Actuator

3
Diagram 3
Boiler Water
Temp. Sensor
Feed Water
Temp. Sensor
Boiler Sight Glass
Front Turn box
Y-Strainer
Pressure Relief
Valve Low Water
Cuto Boiler Water
Level Sensor Steam PSI 1 Manual Steam
Pressure Gauge
Operang Pressure
Limit Switch (OPLS)
High Pressure
Limit Switch (HPLS)
Steam PSI 2

4
Diagram 4
Airow Switch
Flame Detector
Control Switch
Propane Solenoid
Valve (2014 only)
Fuel Safety
Solenoid Valve
Propane
Regulator
(2014 only)
Low Fire
Solenoid Valve
Ignion
Transformer
Fan Motor
Burner
Nozzle
High Fire Fuel
cylinder/piston
2014 Propane Burner
Gun Assembly
2010-2014 Direct Spark
Burner Gun Assembly
Single Ignion
Electrode
Burner Nozzle
20 GPH
Propane
line
Dual Ignion
Electrodes

5
Diagram 5
Low Fire oil
regulang
valve
Front Boiler
Sight Glass
Louver
Actuator
High Fire
Solenoid
Louver (Upper)
Fuel Pump
Pressure Gauge
Flame Detector
Low Fire
Solenoid
Fuel Pump
Fuel Pump
Pressure Sensor
High Fire Fuel
cylinder/piston
Fan cleaning
compressed air
aachment and
valve
Fuel Nozzle
pressure sensor
Fuel Nozzle
pressure gauge
Louver Close
counter-weight
Louver (Lower)
Fuel Return
line
Low Fire
adjustment
bolt/nut Propane
line
Fuel Feed
line
Fuel cylinder
push tab
2014 Propane Burner
Gun Assembly
2010-2014 Direct Spark
Burner Gun Assembly
Single Ignion
Electrode
Burner Nozzle
20 GPH
Propane
line
Dual Ignion
Electrodes

6
Purge Card
Burner Controller
Flame Amplier Card
Modbus Card
Diagram 6a (2010)
Panel 1Panel 1 door
Burner
Controller
Baldor So Start
Fan Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Safety Relays
Low Water 1Low Water 2
10R

7
Diagram 7a (2010)
Panel 3Panel 2
TS1
(Terminal Strip 1)
TS2
(Terminal Strip 2)
24v Regulator
FB (Fuse Block)
FB (Fuse Block)
RB (Relay Block)
PLC (Programmable
Logic Controller)
AI1 (Input Card 1) AI2 (Input Card 2)
AO (Output Card)
Ethernet Card Ethernet Switch
Control
Relay
Circ Pump
Contactor
Feed Pump
Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Boiler Water
Level Sensor
12v Regulator

8
Diagram 6b (2011-2013)
Panel 1Panel 1 door
Baldor So Start
Fan Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Safety Relays
Low Water 1Low Water 2
Purge Card
Burner Controller
Flame Amplier Card
Modbus Card
Burner
Controller 10R

9
Diagram 7b (2011-2013)
Panel 3Panel 2
TS1
(Terminal Strip 1)
TS2
(Terminal Strip 2)
24v Regulator
FB (Fuse Block)
FB (Fuse Block)
RB (Relay Block)
PLC (Programmable
Logic Controller)
AI1 (Input Card 1) AI2 (Input Card 2)
AO (Output Card)
Ethernet Card Ethernet Switch
Control
Relay
Circ Pump
Contactor
Feed Pump
Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Boiler Water
Level Sensor
12v Regulator

10
Diagram 6c (2014-Soft Start)
Panel 1Panel 1 door
Siemens So Start
Fan Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Safety Relays
Low
Water 1
Purge Card
Burner Controller
Flame Amplier Card
Modbus Card
Burner
Controller
Low
Water 2
10R

11
Diagram 7c (2014-Soft Start)
Panel 3Panel 2
TS1
(Terminal Strip 1)
TS2
(Terminal Strip 2)
24v Regulator
FB (Fuse Block)
FB (Fuse Block)
RB (Relay Block)
PLC (Programmable
Logic Controller)
AI1 (Input Card 1) AI2 (Input Card 2)
AO (Output Card)
Ethernet Card Ethernet Switch
Control
Relay
Circ Pump
Contactor
Feed Pump
Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Boiler Water
Level Sensor
12v Regulator

12
Diagram 6d (2014-VFD)
Panel 1Panel 1 door
Low Water 1 & 2
VFD
24v Power
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Safety Relays
Purge Card
Burner Controller
Flame Amplier Card
Modbus Card
Burner
Controller
VFD
11R9R
10R

13
Diagram 7d (2014-VFD)
Panel 3Panel 2
TS1
(Terminal Strip 1)
TS2
(Terminal Strip 2)
24v Regulator
FB (Fuse Block)
FB (Fuse Block)
RB (Relay Block)
PLC (Programmable
Logic Controller)
AI1 (Input Card 1) AI2 (Input Card 2)
AO (Output Card)
Ethernet Card Ethernet Switch
Control
Relay
Circ Pump
Contactor
Feed Pump
Contactor
TS1
(Terminal Strip 1)
CB
(Circuit Breakers)
Boiler Water
Level Sensor
12v Regulator

14
Diagram 8
Fuel Level
Sensor
Supply Water
Level Sensor
Burner
Fuel Filter Low Fire oil
regulang
valve
Burner
Fuel Pump
Ambient
Temp. Sensor