W150180 Vol1 e

#
W150180
USE AND MAINTENANCE

MANUAL
ENGLISH
file: WAman1_e
codice: XT040089 rev. C 29.12.14 i #2 § 0- 4 / 5

#
W150180
BIANCALANI S. r. l. textile machinery

via Menichetti 28, 59100 Prato (PO), ITALY .
tel.: 0574 - 54871 http: / / www.biancalani.com
fax: 0574 - 633491 e - mail: contacts@biancalani.com
BIANCALANI
ITALIA
ENGLISH
file: WAman1_e
codice: XT040089 rev. C 29.12.14 ii #2 § 0- 4 / 5

manual

AIRO 24
USE AND MAINTENANCE

MANUAL
BOOK 1 INDEX
§1.0 OVERVIEW
1.1 PRODUCER’S DATA
1.2 HOW TO USE THE HANDBOOK
1.3 MACHINE IDENTIFICATION
1.4 CE MARK
1.5 THIRD--PARTY PRODUCT LIABILITY
1.6 GUARANTEE REGULATIONS
1.7 ASSISTANCE
file: indice1_e
codice: XT040089 rev. C 19.12.14 1 English §0
manual
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AIRO 24
§2.0 DESCRIPTION
2.1 MACHINE CONFIGURATION
2.2 MECHANICS
2.3 SYSTEMS
§3.0 USE
3.1 OPERATING LIMITS OF THE MACHINE
3.2 INSTRUCTIONS FOR THE OPERATOR
3.2.1 RESIDUAL RISKS
3.2.2 NOISE LEVEL DECLARATION
3.2.3 DANGER WARNING LABELS
3.3 COMMANDS AND CONTROLS
3.3.1 MAIN CONTROL PANEL
3.3.2 TOUCH--SCREEN CONTROLS
3.3.3 SECONDARY CONTROLS
3.4 INTRODUCTION TO FABRIC TREATMENTS
3.5 THE FABRIC ROUTE
§4.0 MAINTENANCE
4.1 INSTRUCTIONS FOR THE MAINTENANCE MEN
4.2 ORDINARY MAINTENANCE
4.2.1 CLEANING AT THE END OF A PROCESS
4.2.2 RECURSIVE MAINTENANCE
4.3 EXTRAORDINARY MAINTENANCE
4.3.1 WARNINGS IN CASE OF FAILURE
4.3.2 SEARCHING FOR FAULTS
4.4 LUBRICANT TABLE
4.5 SPARE PARTS
4.6 DISPOSAL PROCEDURES
4.7 PRESSURE EQUIPMENTS SPECIFIC MANUALS
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AIRO 24
§1
OVERVIEW
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AIRO 24
1.1 PRODUCER’S DATA
Company style
BIANCALANI S. r. l.
Purpose:
The production of textile machines
Street:
Menichetti
Street number:
28
Zip code:
59100
City:
Prato
State:
Italy
Telephone:
0574 -- 54871
Fax:
0574--633491
E--mail code:
contacts@biancalani.com
Internet site:
http://www.biancalani.com
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AIRO 24
1.2 HOW TO USE THE MANUAL
The manual is divided up into five chapters, the first three of which are devoted to
operators, and the last two to maintenance men and fitters.
The first book contains of the first four chapters, the second book contains the chapter
five only.
The contents may be summarized as follows:
1) GENERAL
Chapter containing information on the use of the manual, the manufacturer,
servicing and the guarantee.
2) DESCRIPTION
This chapter described the machine in its entirety in order to identify its parts and
functions. It is indispensable to read and/or consult this chapter in order to
understand subsequent chapters.
3) USE
Chapter focusing on operators who must have in--depth knowledge. It contains a
detailed description of all the machine’s controls, their appropriate use and their
repercussions.
Naturally the chapter is also an indispensable guide to maintenance operators in
order to know the machine’s working logic.
A special paragraph is dedicated to the residual risks to which the machine’s
operators and maintenance are subjected and it is an indispensable reference
for persons in charge of safety at the factory.
4) MAINTENANCE
This chapter describes indispensable machine maintenance criteria and
concerns both the operator who is directly responsible for small daily and weekly
maintenance and those called upon to carry out ordinary and extraordinary
large--scale maintenance.
5) INSTALLATION
Chapter entirely reserved for the machine’s installers and technicians studying
its placing. It contains indications on the transport, dimensions, foundation,
assembly operations and hook--up of units.
Furthermore, this chapter contains all specifications, diagrams, drawings and
calibrations that configure the machine in the version in which it was actually
supplied (i.e. with the same serial number indicated on the cover of this manual).
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AIRO 24
1.3 MACHINE IDENTIFICATION
The specifications and data discussed in paragraphs 5.1 and 5.2 fully identify the
version and registration of the machine actually supplied.
The machine registration which, by definition, identifies one and only one machine, is
also shown on the cover of this manual which is, therefore, valid for that machine alone.
The front of the machine has a nameplate, like in fig. 1.3#1, which showis besides the
registration number, also the model and the type indicated by an alphanumeric imprint.
1.3#1 Producer’s nameplate with the CE mark (example)
S.r.l.
AIRO 24
WA18VBCF
W080047
2008
400
50
6 - 10
100 - 200
6 - 12
1- 3
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AIRO 24
1.4 CE MARK
The machine is designed and built according to the provisions of European EEC
89/392 standards known as the Machine Directive and its subsequent updates.
A Technical File of all machines produced is deposited at the BIANCALANI factories at
the disposal of European Standardization Bodies.
CE marking placed on the machine and its ”Compliance Statement”, supplied on
delivery, testify to its compliance with European Economic Community provisions
Figure 1.4#1 gives an example of the compliance certificate supplied with the
machine and figure 1.3#1 the CE plate fixed onto the machine itself.
1.4#1 An example of the Compliance Statement
r l
2 W07
2007
r l
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AIRO 24
1.5 THIRD--PARTY PRODUCT LIABILITY
The machine does not jeopardise operators if the instructions provided by BIANCALANI
are always scrupulously observed and if safety devices are always kept active and
efficient.
In the event of offence to operators chargeable to faulty working of the machine

supplied, BIANCALANI underwrote an insurance policy valid for Italy and abroad.
The foregoing is in agreement with what was established by Italian legislation with the
Presidential Decree N5224 of 24 May 1988 that, in agreement with European
legislation, resumes the EEC 85/374 directive on product liability.
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AIRO 24
1.6 GUARANTEE REGULATIONS
DURATION
The commencement of the guarantee period coincides with the day on which the
machine is set on stream in accordance with the date shown on the Start--up Report
countersigned by the purchaser. The length of the period is as follows:
-- 12 months for mechanical parts and, in all events, for not more than 15 months from
the delivery date;
-- 6 months for electrical and electromechanical components and, in all events, for not
more than 9 months from the date of delivery.
CONDITIONS
The terms of the guarantee include the replacement of defective material with shipment
chargeable to BIANCALANI and customs tariffs to the purchaser and any intervention
on the part of a technician at the purchaser’s workplace for the purpose of solving
operating problems which have been unequivocally shown to be due to defects leading
back to defective manufacturing.
When a part included in the guarantee has to be replaced, the purchaser must return it
to BIANCALANI according to the procedure to be established from time to time with
BIANCALANI personnel.
The guarantee also doesn’t included damage caused by the failure by to do
maintenance work as provided for in the User Manual accompanying the machine.
Moreover, the guarantee does not cover caused by the lack of expertise on the part of
the customer or damage resulting from the improper use of the machine.
The guarantee also doesn’t cover any damage caused by the disrespect of the
specification required for the installation and connection of the units (electrical, gas,
steam, compressed air, water and discharges) shown in the User Manual and those
attached to the order conformation.
PRECAUTIONS
If any parts have to be replaced, only those of the type originally supplied must be used.
Spare parts that are not original and that have not been checked and approved by
BIANCALANI, may reveal chemical and physical properties and dimensional
characteristics which do not meet those specified at the time the machines were being
planned. The use of such parts may give rise during operation to serious mishaps.
We strongly recommend that the machine be put through the breaking--in procedure
described in paragraph 3.5 before placing it on stream in the full production cycle.
Finally, it should also be remembered that during long periods when the machine
remains idle, deterioration can set in and this can be avoided only by having recourse to
the maintenance tips set down in chapter 4.
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AIRO 24
1.7 ASSISTANCE
BIANCALANI has a world--wide sales network.

Assistance is provided, depending on the circumstances, directly by the parent
company or by on--site collaborators who are connected to the sales network.
There, to get the best assistance, either contact BIANCALANI directly by fax, phone
or E--mail, or its local agent.
In the requests for assistance it is indispensable to specify:

-- The registration number of the machine as shown on the producer’s nameplate;
-- The machine type as shown on the producer’s nameplate;
-- The factory where the machine has been installed;
-- Telephone number
-- Fax number or E--mail address;
-- The person to contact;
-- A detailed description what’s wrong;
-- The operating conditions of the machine at the time the problem cropped up and/ or
recurred;
-- Any tests made and their outcome;
-- Should spare parts be required, identify them exactly as specified in chapter 4.
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AIRO 24
§2
DESCRIPTION
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AIRO 24
2.1 MACHINE CONFIGURATION
Paragraphs 5.1 and 5.2 provide technical specifications and configuration

of your machine, whose serial number can be found on the cover of the
manual.
AIRO 24 is a special finishing machine which, in continuous and open width, can
treat by drying without tension any kind of fabric to give greater softness, volume
with dimensional shrinkage and stability.
The treatment can be performed with both wet and dry fabric, which, by moving
alternately inside the machine, is submitted to the tumbler effect while the
machine itself is working in continuous.
The finishing done by this machine improves the hand and look of the final textile
product with considerable effect on its quality.
The exclusive air--driven dragging system prevents any mechanical crushing or
abrasion of the fabric and allows for both robust and delicate handling all at the
same time.
By acting on various processing parameters, such as air volume and
temperature, humidity and fabric speed, etc. the machine offers a great variety
of treatments covering a wide range of fabrics.
The simplified machine set--up allows for the excellent reproduction of the final
effect obtained.
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AIRO 24
2.2 MECHANICS
Machine Composition.
The machine is basically composed of 3 essential elements:

-- A storage chamber for incoming fabric
-- A storage chamber for outcoming fabric
-- A two--way ejector, with rectangular cross--section and horizontal
development, which connects the two storage chambers.
Additionally to the above--listed devices, others are also very important, that is:
-- Inlet devices for fabric from either a folded or rolled state.
-- Outlet devices, such as the folder and/or coiler.
-- Process air filtration and heating systems
-- Incoming fabric steam--treatment.
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AIRO 24
2.2#1 AIRO 24: overall view
10 9 8
1 2 3 4 5 6 7
1) Inlet frame with end--of--fabric stop photocell.
2) Load cells for weighing the incoming fabric storage.
3) Access doors to the inlet storage chamber.
4) Main control panel with touch--screen.
5) Electrical power cabinet.
6) Electrical cabinet conditioner
7) Access doors to the outlet storage chamber.
8) Folder for outcoming fabric.
9) Centring and widening device for outcoming fabric.
10) Pipe for connecting the exhaust fan to the hoods.
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AIRO 24
2.2#2 AIRO 24: inner parts seen from the left side
4 3 2 1
1) Fabric steamer.
2) Chute which forms the basket that collects the incoming fabric.
3) Exhaust air fan.
4) Automatic rotating filter and fuzz compactor.
5) Gas burner to heat the air or, alternatively in the same position, thermal
exchange battery.
6) Chute which forms the basket that collects the outcoming fabric.
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AIRO 24
2.2#3 AIRO 24: inner parts seen from the right side
2 3
1) Exhaust fan to expel the air from the steamer.

2) Pneumatic control feathering valves to inspect the operation of the ejector
duct.
3) Fan of the duct lower ejector.
4) Fan of the duct upper ejector.
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AIRO 24
2.3 SYSTEMS
The fabric--feeding and treatment ejector is fed by two fans: one blows air on the
fabric and the other under the fabric.
The air used by these fans is brought up to the process temperature by a proper
heating system.
Another exhaust fan, downstream a proper filter, sucks the air out of the machine,
by maintaining the two storage chambers under light vacuum conditions.
The upper and lower ejector fans (the lower fan is smaller than the upper one) are
controlled by two inverters, which allow to change speed and consequently
flow--rate so as to meet all fabric--feeding needs.
The air filter is an automatic--type rotating disk device with fuzz compaction
system.
The air heating system can be indifferently provided to be gas, steam or
diathermic oil fired.
The fabric movement reversal, inside ejectors, takes place automatically by
processing all information coming from the load cells to which fabric collection
chutes are hung.
A touch--screen control panel allows to check all machine functions, whose
functional logic is managed by a programmable processor called PLC.
On request, the machine can be equipped with a steam--treatment system located
at the fabric entrance
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AIRO 24
2.3#1 Exhaust air rotating filter
5
3 6
2 1
The rotating--disc filter sees to the removal of fuzz from the air.
1) Air--outlet opening
2) Compacted fuzz discharge.
3) Upper inspection door
4) Transparent window for filter inspection
5) Air--inlet opening
6) Chain transmission for rotating the filter
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AIRO 24
2.3#2 Gas burner designed to meet European standards
16 15
14
17 13
18
19 12
1 11
2 10
9
6 7 8
3 4 5
The gas burner produces an adjustable flame placed directly in the path of the air
flowing to the ejector fans.
A small fan blows the comburent air required for gas combustion into the front of the
burner.
Fueling can be done with methane or evaporated liquid gas (propane and/or butane) at
pressures of between 100 and 200 millibars by having the burner adjusted accordingly
by authorized personnel.
In order to gain a more in--depth knowledge of the burner the manual provided by the
burner manufacturer should be consulted.
1) Ball cock serving to rapidly cut off the gas supply

2) Flexible supply tube (it allows for the absorption of vibrations and expansion
caused by heat) (present only on European standard burners)
3) Supply pressure regulator (it allows for the adjustment and constancy of the gas
pressure at the level required by the burner head for the particular type of gas
being supplied)
(European--standard burners must also have gas filters)
4) Burner head
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AIRO 24
5) Minimum gas--pressure pressure switch
6) Safety shut--off solenoid valves
7) Gas control valve
8) Electric servocontrol for the positioning of the butterfly valve regulating the gas
flowrate
9) Maximum gas--pressure pressure switch
10) Peepsight
11) Ignition electrode
12) Minimum comburent--air pressure switch
13) 3 ways solenoid valve
14) Combustion air manual adjuster
15) Fan eletric motor
16) Comurent--air fan
17) Junction box
18) Flame programming relay
19) Ignition transformer
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AIRO 24
2.3#3 Heat exchanger for air
4
3
2
1
1) Heat exchange battery
2) Condensate outlet flange or diathermic oil inlet flange
3) Steam inlet flange or diathermic oil outlet flange
4) Inspection door
5) Air manifold
6) Sliding and removable air filters
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AIRO 24
2.3#4 Fabric steamer
5 6
4 7
3 2
1) Steam supply connection used for steaming the fabric.

2) Condensate collection tank drain pipe.
3) Steamer radiator condensate outlet flange connection.
4) Air intake duct inspection door.
5) Exhaust fan discharge--to--the--atmosphere pipe flange.
6) Butterfly valve to manually adjust the air suction.
7) Steamer radiator steam supply connection.
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AIRO 24
§3
USE
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AIRO 24
3.1 OPERATING LIMITS OF THE MACHINE
The definition of the limitations of use of the machine is a recall to the

correct use of this last in order to avoid causing damages to work
processes, but mostly to the personnel involved in the use of the machine
itself.
Further explanations about the practical use of the machine to perform all
possible different types of treatment are provided in Paragraph 3.5.
Other types of treatment, different from those mentioned above, shall necessarily
result from a modified combination of these last and not from the improper use
of the machine itself.
The use of the machine must, in any case, fall under the limitations provided
in the technical specifications contained in Chapter 5 and meet all safety
requirements described in Paragraph 3.2.
If you are in doubt, the BIANCALANI company is always at your disposal to
provide more information and all necessary explanations.
Moreover, when fabrics have been effectively treated on AIRO (registered trade
mark) patented machines, according to the instructions of this manual and in
conformity with a good textile technology, users are authorized to apply a mark
to fabrics which guarantees the originality of the particular treatment to which they
have been submitted.
For this purpose BIANCALANI has conceived and made available the label here
represented and usable for fabrics treated on AIRO.
3.1#1 Label: “AIRO hand”
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AIRO 24
3.2 INSTRUCTIONS FOR THE OPERATOR
The machine must be used by qualified and properly trained personnel.
By the term ”operator” is meant the person who, at that moment, has
authorization and responsibility to use the machine.
The use of the machine, in conformity with regulations and laws in force,
must always fall within the ”scope of allowed use” as specified in Paragraph
3.1.
The machine has been designed so as to guarantee safe conditions of use to the
personnel involved in all phases of the working process: from setting and
production to recovery and maintenance operations.
CAUTION: read carefully Paragraphs 3.2.1 and 3.2.3 where all dangerous
zones and operations are identified and described as well as the
protections adopted and the relative ”residual risks” (not completely
eliminated to avoid compromising the normal functioning of the machine)
CAUTION: in the areas and during the operations subject to residual risk all
behaviours, safety precautions and individual protection means required
in Paragraph 3.2.1 must be adopted.
The operator must in any case respect the main safety requirements listed
here below:
-- Respect the dispositions and instructions given by the authorized person and
those prescribed by the work safety rules in force.
-- Use properly machine, tools, substances, work equipment and safety devices
and, in any case, all warnings contained in this manual or on the machine itself.
-- Use, if required, all necessary individual protections.
-- Signal immediately all possible defects, directly related to the machine or its
equipments, and dangerous situations.
-- Do not remove or modifiy the safety devices, warning signals or control
systems of the machine.
-- Do not perform by yourself any operations or manoeuvres which do not fall
within your competence and responsibility.
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AIRO 24
3.2.1 RESIDUAL RISKS
The machine has been designed using safety criteria. To this end a large part of the
machine, with particular regard to its moving parts, is opportunely equipped with active
and/or passive safety devices and materials.
However, the total elimination of risks is not always possible, sometimes owing to
construction limitations, but more often to the necessity of not compromising the normal
running of a machine.
As a consequence, there still remain the so--called “RESIDUAL RISKS” that must be
immediately apparent to all machine operators.
In the areas where such risks are found, the greatest care must be taken and all the
information and suggestions contained in the manual strictly followed.
For a better understanding of what is to follow. We have listed here the definitions
contained in EEC “Machine Directives” 89/392 and its subsequent amendments:
-- DANGER ZONE:
Any area inside or in the proximity of the machine where there is a person exposed to
risk, constitutes a danger to the safety and well--being of that person.
-- PERSON EXPOSED TO RISK:

Any person found in or nearby a danger zone.
-- OPERATOR:
The person or persons entrusted with the installation, operation, adjustment,
maintenance, cleaning, repairing or transporting the machine.
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AIRO 24
3.2.1#1 RESIDUAL ERGONOMIC RISK
This type of risk is defined as those deriving from postures or the
exercise of excessive force outside the limits of human anatomy, the
failure to use safety devices and supports and insufficient lighting
Access to the upper parts of the machine

During the fabric feeding operations on the inlet and outlet arms use safe
ladders and make sure that the machine is not powered during these
operations.
Same attention must be paid during cleaning operations in such areas.
3.2.1#2 MECHANICAL RISKS

Such risks are defined as those where there is a danger of getting
crushed, dragged or struck.
Movement of the ejector pipe feathering valves

These valves are protected by locked doors.
De--energize completely the machine before opening these doors.
Fan inspection doors
De--energize completely the machine and wait for the complete impeller
stop before opening these doors.
Automatic rotating filter
De--energize completely the machine before opening its covers.
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AIRO 24
3.2.1#3 ELECTRICAL RISKS
Such risks are defined as being those that may occur during direct
or indirect contact with electrical equipment.
Electrical cabinet
The electrical cabinet is equipped with high--voltage energized
electro--mechanical and electronic devices.
Opening the main switch of the electrical cabinet, power bus bars and
terminals, upstream the main switch, remain in any case energized.
Moreover, the condensers placed inside the inverters maintain their
circuits energized for a few tenths of seconds after they have been
de--energized.
Therefore, it is necessary to act with great care even after cutting the power
off.
Maintenance technicians, qualified and authorized to operate on powered
machinery, are the only ones who can access the electrical cabinet.
Junction boxes
All junction boxes of the machine are closed and mechanically sealed. A
rating plate indicates the presence of a dangerous voltage inside them.
In any case, they can only be opened by the qualified maintenance
personnel who, when necessary, shall open the main switch placed on the
electrical cabinet.
3.2.1#4 RISK CAUSED BY NOISE

Such risk is due to the dangers which may occur with damages to
hearing and/or psychological effects and interferences on verbal
communication.
Prolonged exposure to the machine noise.

Refer to the machine noise data, provided in the following paragraph, and
to those strictly related to the environment where the machine is located.
The inspection of a technician responsible for the overall assessment shall
provide indications about the necessity, or not, of suitable protection
means.
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AIRO 24
3.2.1#5 HIGH HEAT
This risk of course concerns the danger of injuring oneself by getting
burned or scalded thereby damaging the health of the operators.
Fans and hot air ducts and the relevant heating systems.
Some surfaces of the gas burner combustion chamber or alternatively the
heat exchanger to heat the air reach dangerous contact temperatures.
The same danger is present on ventilation ducts and on the fans.
These surfaces cannot be normally accessible, but when, for cleaning or
maintenance, you gain access to these areas, ensure that parts are
sufficiently cooled.
Fabric storage chambers.
Some surfaces of the two fabric storage chambers reach dangerous
temperatures only as a result of a prolonged contact.
Also the hot air flowing out of the ejector channel is dangerous, but only in
case of prolonged contact.
Avoid being exposed for too long to such temperatures.
Fabric steamer.
Steam feed pipes, condensate drain pipes, radiator and steaming vats
reach dangerous temperatures.
These are placed at heights which are out of the operator’s reach; however,
during fabric drawing--in operations it is possible to come into contact with
such parts.
Always stop the steam flow, use proper gloves and clothing or use tools
capable of preventing you from coming into contact with these surfaces.
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AIRO 24
3.2.2 NOISE LEVEL DECLARATION
Machine noise level declaration according to the requirements of Machine

Directive 89/392/EEC of 6/14/1989 and subsequent modifications, all taken in
to account in Italy in Presidential Decree 459/96.
With the machine running continuously under the normal working conditions,
unfavorable against the noise, the following values are obtained:
Continuous equivalent sound--pressure level at the workplace

L eq (A) < 83.0 dB(A).
Level of sound produced by the machine
L w (A) = 109.3 dB(A).
Instant peak sound pressure level at the workplace
L pc (C) < 130 dB(C).
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AIRO 24
3.2.3 WARNING LABELS
DANGER OF ELECTRIC SHOCK

On electrical cabinet doors.
On the antistatic bars.
DANGER TO MOVING MECHANICAL PARTS

On all access doors to the inner zones where the ejector duct is
located.
On all fan inspection doors
On the automatic rotating filter.
DANGER DUE TO HIGH TEMPERATURE

On all access doors to the inner zones where the ejector duct is
located.
On the side of the combustion chamber opposite the gas burner.
On three sides of the steamer radiator.
DO NOT POUR OIL INTO THE PRESSURE REDUCER FILTER

Close the compressed air pressure regulator.
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AIRO 24
3.3 COMMANDS AND CONTROLS
3.3.1 MAIN CONTROL PANEL

Explanation of symbols and functions
(The numbers correspond to those shown in the previous illustrations)
3.3.1#1 Main control panel
6 5 4 3 2
1) Touch--screen display panel

(for these panel commands see the following list of touch--screen controls)
2) Machine stop push--button
3) Machine start push--button
4) Burner flame control reset push--button
5) Reset push--button to exit from emergency or alarm conditions
6) Emergency stop button
(all controls are deactivated and all engines are de--energized and to
restart it is necessary to reset the emergency push--button and push the
appropriate reset button)
(CAUTION: the pneumatic system remains in any case pressurized)
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AIRO 24
3.3.2 TOUCH--SCREEN CONTROLS

(Referring to the correspondent figures)
3.3.2#1 Main control page

Includes the main controls of the machine.
1) Date and time.
2) Name of the running program (if any).
Go to the program screen.
Ventilation System ON
Setting of the fabric entry speed in m/1’

(3 -- 50 m/1’).
Setting of the % air flow in the ejectors

(10% to 100%)
Setting of the % excess air flow of the exhaust fan

(+0 to +30%)
Air heating ON.

(the heating action shall then be applied and stopped according to
fabric start/stop).
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AIRO 24
Setting and indication of temperature in C of the process air
(up to 170 C with air heating by gas or diathermic oil)
(up to 150 C with air heating by steam)
Fabric introduction roller OFF.
Fabric extraction roller OFF.
Twin fabric feeding operation mode.
Unidirectional transfer of the fabric to the entry

(the movement is controlled by the start/stop of the machine).
Unidirectional transfer of the fabric to the exit

(the movement is controlled by the start/stop of the machine).
Supply of the steamer radiator.

(this control is useful to pre--heat the radiator steamer before use)
(Steaming activation control automatically activates as well
radiator supply)
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AIRO 24
Fabric steaming system ON
(if the light is ON that means that the control is active)
(the radiator inside the steaming field and the aspiration fan
immediately activate; steam issue occurs only when the fabric entry
roller is running)
(in order to drain supply tubes, keeping this button pressed, when
the fabric entry roller is stopped and the machine run is ON, steam
is issued as well)
(when the system is switched OFF, steam issue immediately stops;
the radiator and the aspiration fan are switched off with a 5 minute
delay).
Setting and indication of the minimum basket emptying level.
Duct lower air to both directions.
Duct air to both directions.
Duct air flow % to reverse fabric direction

(from 10% to 40%).
Setting and indication of the time range between two consecutive

inversions of the movement of the fabric
(when set to a level different from zero, it disables the function which
maintains the maximum level of basket filling and forces the
machine to progressively set to such inversion times, automatically
decreasing or increasing the reserve of fabric inside the machine).
Fabric at entry check enabling.
Fabric at exit check enabling.
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Operation in line with upstream and/or downstream machines ON.
Increase of maximum ventilation limit.
Go to the configuration screens.
Go to the information screens.
Alarm display
(to be used to display the alarms)
(when a new alarm occurs, it is automatically displayed).
Activation of the HELP mode to get the description of the of the

controls in the screen.
Go to the secondary screen.
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3.3.2#2 Secondary control page
It includes information about the operation of the machine.
Date and time
Graphs indicating the trend of the process dimensions.
Indication, non resettable, of the total number of

meters of fabric entered.
Indication, non resettable, of the total number of

meters of fabric out.
Indication, non resettable, of the total hours worked.
Indication of the average number of hits to which the fabric has been
subjected.
Indications of the total meters of fabric which have crossed the

machine and reset control.
Indication of the temperature of exhausted air.
Setting of the meters of fabric build--up in the machine

(it has no effect on the operation of the machine, its purpose is to
calculate the number of hits to the fabric before it leaves the
machine).
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Indication, non resettable, of the total forward--backward
movements of the fabric
(the precision of this value is strictly dependent by the precision of
the fabric accumulation meters set).
Setting the % air suction flow from steamer device

(from 50% to 100%)
Maximum C air temperature when machine is on stand--by

condition
(up to 170 C with heating by gas or diathermic oil).
(When set to zero the stand--by temperature will be the same of the
process one)
The action is opportunely delayed.
Indication of the % residual humidity of the fabric on exit.
Indication of the pressure of the steam supply for the air heating
bar
Indication of the temperature of the steam supply for the air heating
oC
Go to the information screens.
Alarm display
(to be used to display the alarms)
(when a new alarm occurs, it is automatically displayed).

Return to the main screen.
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3.3.2#3 Screen to select and store the
automatic operation programs
It is recalled by the specific button on the main page.
It enables to create or recall the process programs.
Name of the program to be recalled or added.

To see the list press on the right arrow, to get the
keyboard press on the name.

Select the control just after this button.
Program storage.
Program deletion.
Exit from the loaded program.
Recall of the program setting screen.
Creation of a new program.
Recall of the keyboard to enter the password to access program

configuration.
Activation of the program execution mode

and light indicating automatic process running
(the actual execution of the program starts when the machine run
button is pressed).
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3.3.2#4 Screen to set a program
to be stored.
It includes the controls which can be stored in the programs for the automatic
control of the machine.
It is recalled by the specific buttons in the program selection and storage screen.
Controls which can be selected: see main screen.
Take the data from the main screen.
Return to the program selection, storage and execution screen.
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3.3.2#5 Screen in HELP mode
Screen set to display the information on the functions of the controls it contains.
Display area of the description of a selected control in

the screen.

Select the control just after this button.
Exit from the HELP mode.
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3.3.2#6 Parameters configuration pages.
They permit setting the parameters of configuration and installation.
Displaying the keys to insert the password for accessing the programs
configurations.
Go to the previous screen.
Go to the following screen.
LOAD CELLS SETTING

For setting the load cell unload the fabric from the bascules on the entrance and
the exit, open the doors and cut--out the ventilation.
Push the help key on the main page, then the key for going to the configuration
screens.. Enter the password for accessing the machine configuration
parameters (852).
Scroll the pages until the parameter 13 is shown.
Enter in the lower cases (grey) the actual values shown in the respective upper
cases (yellow).
Exit from the configuration pages.
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3.3.2#7 Pop - up windows.
They are windows superimposed to the current screens to set and/or display
Numeric keypad
Alphanumeric keyboard.
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3.3.2#8 Alarm displaying page.
It indicates the alarms and the actions to be taken.
Description displaying area for alarms and correction

actions.
Return to the main screen
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List of alarms:
The list of the alarm messages may be displayed are the following:
1) Emergency intervention
Disable the command and press
the reset pushbutton
2) Compressed air lack
Cut in the supply, check
pressure switch: SP
11) Fault on feeding roller
motor inverter UF202
See inverter manual instructions
12) Fault on extraction roller
motor inverter UF235.
Check FR235 and/or FR236
13) Fault on upper air fan
14) Fault on lower air fan
15) Fault on exhaust air fan
16) Thermal protection of the air filter
motors QM218 / QM219
Check motors and protections
18) Thermal protection of the scroll
roller motors QM230--1/--2
Check motors and protections
20) Thermal protection of steamer
fan motor QM225
Check motor and protection
30) Absence of fabric in entrance:
photocell SQ535
Check fabric
31) Absence of fabric on exit:
photocell SQ536
Check fabric
32) Limit switch for fabric on feeding roller
Reset the limit switch SQ515
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33) Thermal protection of scroll
roller motor on entrance QM204
Check motor and protection
34) Fault on centering device
35) Fault on plaiter arms
40) Butterfly valve for upper ejector
is locked
Check actuator JVF210
50) or:
Fault on load cells of entrance
side bascule
Check load cells B545--1/2
or:
Fault on load cell of entrance left
side bascule
Check load cell B545--1
51) or:
Fault on load cells of exit
side bascule
Check load cells B550--1/2
or:
Fault on load cell of exit left
side bascule
52) Fault on load cell of entrance right
side bascule
53) Fault on load cell of exit right
side bascule
54) Fault on photo--cell
of entrance bascule
Check the photo--cell BF511
55) Fault on photo--cell
of exit bascule
Check the photo--cell BF512
65) Rolling--up device arms lowered
Rise the arms
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66) Safety limit switch intervention of rolling--up device
Reset limit switch SQ562
and press reset pushbutton
67) Maximum roll diameter
Change A--frame
68) Plaiter arms are not in proper position
out of interference
Move those on limit switch
69) Tubular knitted fabric guiding rings rised
Move the rings to lowered position
71) Fault of process air temperature
sensor
Check BT159 e ST159
72) Lack of consent for
burner firing
Insufficient ventilation
73) Thermal protection of combustion
air fan QM216
Check and then reset
74) Gas pressure too low
Open gas supply valve
Check pressure regulator
75) Gas pressure too high
Check pressure regulator
76) Gus burner air temperature
too high
Check BT155 and ST155
77) Combustion air insufficient
Check combustion air filter
cleaning and pressure switch
78) Exhaust air insufficient
pressure switch tripped SP164
Clean process air filters
79) Stop of the burner firing cycle
Press the burner reset
pushbutton, clean electrodes
80) Exhaust air temperature
sensor fault
Check BT158 e ST158
81) Heat exchanger air temperature
too high
Check valve JV75 and transducer BP75
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82) Lack of the alternate movement
of the fabric
Unblock or seam the fabric
90) Fault on preceding machine
Look for troubles
on previous machine
91) Fault on succeeding machine
Look for troubles
on following machine
92) Lack of consent by
preceding machine
Check previous machine
93) Lack of consent by
succeeding machine
Check following machine
96) Voltage loss for air conditioner
of the electric power cabinet
Check supply and protection QF250
97) Alarm on electric cabinet conditioner
Check conditioner display
99) ETHERNET communication fault
Try to reset the system
Check PLC and its connections
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3.3.3 SECONDARY CONTROLS
(Referring to the numbers shown on the figures)
3.3.3#1 Entry main control panels alternatives.
1 2 3 4 5 6
1 7 8 4 5 6
1 7 9 4 5 6
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2) Cut--off push--button for fabric entry rollers
3) Cut--off push--button for fabric exit rollers
4) Temporary run selector backward--0--forward of the fabric driving rollers
(it acts as well when the machine is stopped and the entry roller is
disabled).
7) Cut--off push--button for all fabric feeding rollers
8) Cut--off selector switch for fabric scroll roller on entrance (when it is present)
9) Temporary running roller enabling selector:
left--both--right.
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3.3.3#2 Exit main control panel
1 2 3 4 5 6

2) Rotation cut--out switch for fabric widening rollers
3) Cut--off push--button for fabric driving rollers
4) Temporary run selector backward--0--forward of the fabric driving rollers
(it acts as well when the machine is stopped or the exit roller is disabled).
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3.3.3#3 Exit optional secondary control panel
1 2 3 4 5 6
8 9 10 4 5 6
7 11
1) Rolling--up arms rising/stop/lowering selector

2) Plaiting/rolling--up selector
3) Fabric braking adjusting
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7) Fabric rolling up roller lightening enabling button
(it can be enabled when the selector switch 1 is in central position only)
(the lightening intensity may be adjusted by the proper pressure regulator close
this push--button board)
8) Reset button for convex fabric fold increment
9) Selector switch for plait / convex fold
10) Convex fabric fold amplitude adjusting
11) Selector switch for up / down positioning of tubular knitted fabric guiding rings
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3.3.3#4 Entry and exit secondary control panels
1 2 3

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3.3.3#5 Electrical cabinet main switch.
ON
OFF
1) Control lever of the main switch of the electrical cabinet.

Such lever is interlocked with door opening.
This switch cuts off the electric supply to the whole machine, including the
equipment located behind the electrical cabinet, except for the switch itself
and the connection terminals to the supply line.
CAUTION:
The other doors of the electrical cabinets have no interlock and/or limit
switch which automatically open the main switch.
Only maintenance technicians are allowed to open and work inside the
electrical cabinet.
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3.3.2#6 Compressed air supply
5 1
1) Pneumatic pressure main cut--out valve of the machine

2) Compressed air supply pressure gage for machine pneumatic system
3) Pressure regulator for the pneumatic system system
4) Minimum pressure switch for compressed air
5) Drain cock
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3.4 THE FABRIC ROUTE
The fabric from a folded or rolled state, but also from another in--line machine,
such as for example a squeezer, enters the machine and accumulates in a tilting
chute equipped with load cells.
The load cells send to the electronic Programmable Logic Controller (PLC) the
information about the amount of fabric which has accumulated on the slide, thus
allowing the machine to adjust the fabric pick--up so as to keep the fabric storage
within pre--established limits.
The fabric, taken from the inlet chute, travels through an horizontal duct, with
rectangular flattened cross--section, where a suitable ventilation system blows
air at high speed tangentially to the fabric itself with a considerable drive effect.
At the other end of the duct there is another chute, the outlet chute, which is
perfectly equal and symmetrical with respect to the previous one, where the fabric
is temporarily transferred.
From this second tilting chute the fabric repeats the previous path, by reversing
the direction, and most of it comes back into the previous chute.
The portion of the fabric which does not come back is removed from the machine,
at constant speed, through its outlet devices.
Therefore, the fabric makes a forward--backward path at very high speed, driven
by the air flow, and a constant forward movement, at low speed, from the entrance
to the exit.
A fabric extraction system, with centering and widening device and exit in folded
or rolled state, takes automatically the fabric from the inside of the machine by
keeping into account the set treatment speed, that is the speed at which the fabric
enters the machine and the amount of fabric accumulated in the two chutes.
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3.5 TREATMENTS
One of the most representative processes which is normally adopted by the

finisher to ennoble fabrics is that of performing in integrated form
drying--softening--shrinkage to compact textile structures, increase volume and
consequently obtain the soft hand of the substrate
It is possible to achieve with optimum repeatability:
natural shrinkage, softening and increase in volume for each type of fabric, with
particular attention to twelling, wool fabric and rubber--proofed sheating;
lamb--skin effect on synthetic furs and polar fleece;
preparation for shearing: pile fabrics.
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§4
MAINTENANCE
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4.1 INSTRUCTIONS FOR THE
MAINTENACE MEN
Any maintenance work on the machine must be done by qualified and especially trained
personnel.
A maintenance man is defined as anyone who at the time is authorized to do
maintenance work and takes responsibility for carrying out maintenance work,
repairs and tests on the machine.
In accordance with the rules and regulations currently in force, the machine’s
use must always remain within “the allowable limits” specified in chapter 3.
The machine has been designed to safeguard the personnel assigned to all its
operational phases from tuning, adjustment and production to resetting and
maintenance. To this end all the danger spots in the machine and particularly its moving
parts are opportunely protected. These safeguards are equipped, when necessary,
with interlocks and/or limit switches which must be kept serviceable at all time.
WARNING: Carefully read chapter 3 which points out dangerous areas and
operations, the type of protection required and the risks that can be run owing to
the presence of residual matter whose complete removal would compromise the
machine’s normal operations.
The operator must , in any case, observe the following main safety regulations:
-- Comply with the instructions given by the supervisor in charge and those imposed by
the current safety standards governing the workplace.
-- Correctly use the machine and the tools, substances, equipment and safety devices
that are made available and observe all the directions given in this manual or on the
machine itself.
-- When required, take any personal precautions that may be deemed necessary.
-- Quickly find and eliminate any and all faults and dangerous situations that are come
across in the machine and its equipment.
-- Do not remove or modify the safety devices, signals or control systems of the
machine.
-- Do not take or carry out on your own initiatives, operations or maneuvers that are not
a part of the duties to which you have been assigned.
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4.2 ROUTINE MAINTENANCE
All operations of preventive maintenance and interventions allowing the

periodical replacement of those parts which are normally subject to wear and tear
fall within this definition.
For this purpose, Paragraph 4.5 provides a list of spare parts you can refer to for
ordinary maintenance needs.
CAUTION: unless otherwise specified, all operations must be performed
with the machine stopped and all plants de - energized (main electrical
switch open, compressed air cut - off, cut - out of steam and any other
heating fluids)
4.2.1 CLEANING AT THE END OF THE

WORKING PROCESS
There are no particular operations to carry out at the end of a working process,
the machine can switch directly from the treatment of a given fabric to another
without interruptions and the neccesity of cleaning operations.
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4.2.2 PERIODICAL MAINTENANCE
OPERATIONS
DAILY MAINTENANCE
CAUTION: unless otherwise specified, all operations must be performed
with the machine stopped.
1) Heat exchanger filters for air heating

(if any)
Extract the filters and clean them on both sides with compressed--air jets.
2) Air rotating filter
Check the filling level of the bag used to collect the fuzz extracted from the
automatic air filter.
3) Fabric treatment grid
Remove any residual yarns from grilles.
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WEEKLY MAINTENANCE
1) All daily maintenance operations
2) Process air inlet grille upstream the gas burner
(if any)
Extract the filter and clean it on both sides with compressed--air jets.
3) Gas burner combustion air grille (if any)
Remove fuzz from the grille by preventing it from penetrating into the fan.
4) Pneumatic system
The condensate contained in the separation filter bowl, on the main
pressure regulator, shall be discharged by opening and closing the proper
drain placed on the bottom.
5) Radiant unit heat exchanger for heating the air (if any)
With fans in operation, remove the inspection door located on the air outlet
manifold and filters, then clean the radiant group with compressed air jets
first of all from the filters side, then from the opposite side.
6) Air rotating filter
Check that the filtering surface is free from fuzz and threads remained
attached; remove them, if any.
7) Electrical switchboard conditioner
Extract and clean the cooling air inlet filter of the conditioner located on the
electrical switchboard.
Verify that the condensate discharge is unclogged, otherwise clean it.
CAUTION
At the end of the first week of productive working of the machine an accurate
inspection of this last must be made. During this inspection all bolts and
nuts fastening and connecting rotating component parts shall be
retightened as well as the bolts and nuts of those parts which are subject
to strong vibration and those whose loosening is source of great danger.
Refer to the list of controls of this type provided in this Chapter for the
annual maintenance.
QUARTERLY MAINTENANCE
1) Lubrication
Lubricate as required in the table in paragraph 4.4
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ANNUAL MAINTENANCE
PAY ATTENTION TO PREVENTIVE MAINTENANCE ACTIONS:
the components for which the periodical preventive replacement is
required must always be replaced although they appear undamaged; if you
omit to do so, the safety of operators and the machine itself may be even
seriously compromised.
1) All weekly maintenance operations

2) Ejector fans
With the machine stopped and after waiting for the complete stop of fan
impellers, open the fan inspection doors and clean by means of
compressed--air jets.
Close the doors.
3) Exhaust fan
With the machine stopped and after waiting for the complete fan impeller
stop, open the fan inspection door and clean by means of compressed air
jets.
It is possible that is not enough to use compressed air. In this case, use a
high--pressure water jet lance.
Reclose the door.
4) Air pipes
Disassemble the straight lengths of pipe connecting the suction hoods.
Clean the inside of both the disassembled pipes and those remained on the
machine.
Reinstall the components.
5) Electric engines
Clean electric engine cooling grills and fans by means of compressed--air
jets.
Execute this operation by preventing dirt and fuzz, contained in the air flow,
from penetrating into the engines.
6) Supports and bearings
Verify the condition of the bearings of the moving parts of the machine. With
the machine off, let rotating parts run at idle manually, verifying that there
is no excessive clearance or noise on bearings: if it is the case, replace
bearings.
Lubricate, by means of proper lubricators, support bearings by using the
lubricants specified in the table of Paragraph 4.4.
Lubricate, by means of proper lubricators, also the bearings of the motors
of the main fans by using the lubricants specified in the table of paragraph
4.4.
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7) Gearmotors
The machine is equipped with low--power gearmotors. For these last a
lifetime lubrication with grease is adopted. Therefore, these gearmotors
are maintenance--free.
Nevertheless you are advised to check the absence of leaks of lubricants
and of strange clearances or noises. In this case, replace the gearmotor.
8) Ejector duct control feathering valve sealing gaskets.

Check if they show signs of wear and aging. If necessary, replace gaskets.
9) Ejector duct control feathering valve pneumatic cylinders.
Check the mechanical integrity of cylinders and the state of wear of
gaskets. If necessary, replace gaskets or cylinders.
Check the ball joint connecting the control cylinders of the feathering
valves. If necessary, replace them.
10) Door sealing gaskets.
Check them to verify if they show signs of wear or aging. If necessary,
replace rubber gaskets.
11) Fabric dragging rollers.
Check them to verify if they show signs of wear or aging. If necessary,
replace the rubber belt.
12) Tightening of critical bolts and nuts
Check and if necessary retighten the bolts and nuts which fasten the
following component parts, whose loosening may seriously compromise
the safety of people and the machine itself:
-- all fans and their engines
-- heat exchanger manifold for heating the air
-- gas burner manifold for heating the air
-- steam, diathermic oil piping connecting flanges,
overheated water, burner gas
-- all roller supports
-- fabric dragging roller control engines
-- feathering valve control lever locking sets
(tightening torque for 17 Nm screws)
-- ejector duct assembly and connecting flanges
-- fabric impact grills
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13) Check the integrity of limit switches
Verify efficiency, integrity and fastening of all limit switches, as well as their
actuation cams
If these devices do not work, this may create a severe danger for the safety
of the workers and of the machine itself.
If you are unsure, replace the device.
CAUTION (preventive maintenance action):
every five years replace all the limit switches of the machine. Do it
even if they appear to be integer.
14) Warning labels check

Check the presence, the integrity, and the legibleness of all the “warning
labels” should be present on the machine as shown on the proper list in
chapter 3.
WARNING :
The loss of this labels, in addition to violate the safety rules, may be
a very high risk for the personnel which sometime approach to the
machine and so they do not know it.
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4.3 EXTRAORDINARY MAINTENANCE.
All maintenance operations which are necessary to solve an expected or

unexpeected machine malfunction and in any case to cope with situations of
abnormal wear, here included those covered by the warranty conditions, fall
within this definition.
To perform maintenance operations, which involve the disassembly and
reassembly of substantial parts of the machine, refer to the explanations provided
in Chapter 5 on Installation and to the paragraphs on trasport, assembly and
disassembly, start--up and testing.
This Chapter provides a collection of all plant diagrams, which are essential in the
case you need to act on these last.
Chapter 2 and 3 will be useful to learn how to assemble and operate both
mechanical parts and systems.
Remember to reset the machine to the default working and safety conditions, by
making explicit reference to the instructions in Chapter 3 on risks and Chapter 5
on calibrations.
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4.3.1 WARNINGS IN CASE OF FAILURE.
The machine is equipped with an automatic failure and malfunction warning

system.
Naturally this system cannot detect all failures, but also those which can be
identified by the electronic control system of the machine.
You can see the complete list of all types of failures, which the electronic control
system can detect and signal, in Chapter 3 where the alarm messages displayed
by the touch--screen are listed.
CAUTION:
If the machine stops or electrical, electro--mechanical or mechanical failures are
detected you are advised to apply the general safety rules listed here below:
-- allow only qualified personnel to operate the machine;
-- to perform the repair operation verify if it is necessary to cut the power to the
machine. In such case, open the main switch, lock it, or make sure that no one
recloses it unexpectedly;
-- to perform the repair operation verify if it is necessary to release the pneumatic
pressure. In such case, close the manual feed valve of the machine and lock
it, or make sure that no one re--opens it unexpectedly;
-- operate with extreme caution if you need to act in the powered electrical
cabinet or in energized control panels;
-- do not deactivate safety devices during repair operations;
-- make sure that the personnel uses, when necessary, proper personal
protections;
-- if you need to disassemble large and heavy component parts ensure that lifting
machineries as well as harness belts are capable of hoisting the pieces to be
moved and provide personnel to signal the displacement of hoisting
machineries and the movements of suspended loads.
-- for interventions which require to operate on the upper part of the machine use
safety ladders.
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4.3.2 SEARCHING FOR FAULTS.
The machine has a failure and malfuncion warning system that usses the operator’s
panel screen to provide indications about the problems detected, the causes and where
and/or how to intervene.
In paragraph 3.3 is enclosed a complete list of all alarm and/or failure messages that
may be shown on the operator’s touch--screen panel.
As to the terminology used and the location of the various devices, consult the
descriptions made in chapter 2.
For any information regarding the code names, location and adjustments of the
components, refer to the diagrams and lists in paragraph 5.10.
For information regarding the functional limits of the machine, consult the chapter 3.
For spare parts, refer to paragraph 4.5.
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4.4 LUBRICANT TABLE
RECOMMENDED LUBRICANTS
LUBRICATION
LUBRICATION POINTS FORM SUPPLIER TYPE
INTERVALS
Support bearings of fabric 12 months grease SHELL ALVANIA

feeding rollers. GREASE EP 2
KLUBER Centoplex 2EP
AGIP GR MU EP 2
ESSO GP GREASE
Bearings of the three main 3 months grease SHELL ALBIDA
fan motors GREASE RL 2
and KLUBER PETAMO
feathering valve bearings. GHY 133 N
AREXONS GC 300
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4.5 SPARE PARTS
In ordering spare parts the model and registration number of the machine (found on the
identification plate) should always be indicated.
The machine mechanical parts that are subject to a normal wearing, are listed in
this paragraph.
The mechanical parts, not included in the above mentioned list, but singularly
should be replaced, may be found in the figures and related comments in chapter
2.
The components of the systems are instead listed and identified in the proper lists
attached to the schematic diagrams enclosed in chapter 5.
4.5#1 Spare parts for consumables

Chute for:
-- work height 180 cm
Feathering valves compact silicone rubber profile for:

-- work height 180--280 cm
Feathering valves compact silicone rubber side gasket
Bottom feathering valve expanded silicone rubber profile

for:
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Feathering valves teflon profile
for:
Door rubber gasket

(available in roll form to be cut to length)
Rubber tape for covering the fabric entrance and exit rollers
(available as a rool to be cut to the measure)
Heat exchanger process air filter
Gas burner process air filter
Electrical switchboard conditioner filter
Gas burner hose
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4.6 DISPOSAL PROCEDURES
The Italian and EEC regulations impose precise procedures when it comes to the
disposal of industrial products.
Everybody shall refer to theese and/or to those of his country of belonging
For the disassembly and the transport of the various parts of the machine refer
respectively to paragraphes 5.7 and 5.6.
DISPOSING OF THE MACHINE

It should be remembered that the machine, once it is no longer serviceable, must be
disposed of as industrial waste and, as a consequence, the collection, sorting, transport
and treatment of this waste and its storage must be carried out in accordance with EEC
European Directive 75/442 dated July 15, 1975 and its subsequent amendments.
DISPOSING OF OIL
Whether it be in the form of lubricants, grease or whatever, the oil used during the
machine’s processing cycles and/or maintenance must be disposed of as provided for
in EEC European Directive 75/439 dated July 16, 1975 which orders any and all
enterprises making use of such substances to notify the competent authorities how
exhausted oil and its residues have been destroyed or stored. It should be pointed out
that in Italy it is obligatory to notify the CONSORZIO DEGLI OLI USATI (The Exhausted
Oil Consortium)
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4.7 PRESSURE EQUIPMENTS
SPECIFIC MANUALS
For reasons of information fullness, on previous paragraphs, concerning the

periodic maintenance operations, and in the following chapter, concernig the
transport and installation of themselves, we refer directly to the consulting of
theese manuals for any operation related to those equipments.
BEWARE OF PREVENTIVE MAINTENANCE ACTIONS:

the safety components of the pressure equipments require ever a
preventive replacement, their change shall be done before their integrity is
compromized; the omission of that action should compromized, also
critically, the safety of the machine operators.
file: cap4_i
manual

AIRO 24
MANUAL FOR THE HEAT EXCHANGER
OF AIR HEATING
HANDLING.
For the handling, just use the special lifting points foreseen on the exchanger.
taking into consideration that such points were dimensioned so as to hold up only
the empty exchanger weight.
For the exchanger handling and lifting do not use the bends, the pipes and the
connections.
Lift the exchanger with suitable devices according to the weight and sizes.
During handling, be very careful of the sharp corners on the exchanger as well
as of the heat exchange fins, since they are sharp.The use of safety gloves is
recommended during handling.
Do not stop near and/or pass under the exchanger during handling operations.
During the exchanger positioning, make sure it is well fixed to the lifting devices
and avoid possible overturning
INSTALLATION.
All installation operations shall be carried out wearing safety gloves.
During installation, there can be high pressure as well as high temperature fluid
jets and therefore take the necessary precautions.
The safety auxiliary equipment shall be provided for in compliance with the
regulations in force. They shall prevent from exceeding the acceptable limits of
the pressure equipment and in particular:
-- Pressure limiting devices( PED All ”I“ 2.11.2)
-- Temperature control devices ( PED All ”I” 2.11.3)
-- Damage limiting devices in case of fire breaking out outside the premises
( PED All ”I” 2.12).
Leave enough space to allow access to the exchanger and to remove it if needed.
The piping system shall be supplied with valves and bypasses to shut off feeding
in case of inspections and/or repairs.
Provide suitable air exhaust taps in order to eliminate gas formation in the pipe
lines.
All supporting structure shall be arranged in order to prevent the exchanger from
lowering with resulting pipe deformations.
Level the exchangers and square up so as to carry out the pipe connections
without forcing them.
file: cap4_i
manual

AIRO 24
Prevent the vibrations produced by moving parts such as fans, compressors,
gates etc. from being released on the exchanger through pipes or common
supporting structures.
Before installation, remove the plugs and/or protections provided for handling
and transport. After removing the plugs, do not expose the equipment to bad
weather in order to avoid rain water penetrations which could cause oxidation or
pipes breaking in case of frost.
Do not tighten the bolts without making sure that the gaskets are fully in place.
Make sure that the whole installation is clean before operation and that the pipes
do not carry foreign matters, (sediments, weeds, sand) which could block the
exchanger pipes.
Provide a suitable expansion means at the pipes inlet and outlet connections in
order to avoid breaking during operation due to thermal expansions.
Start operation gradually and do not abruptly let hot fluid into the exchanger when
it is empty or cold.
Open the exhaust vents of the pipe side circulation and let the internal fluid
circulate up to complete filling.Then close the exhaust vents and slowly bring the
exchanger up to the temperature level.
Give pressure to the installation gradually and carefully control if irregularities are
present.
In order to stop the installation it is necessary to block the hot fluid flux.
Do not make the exchangers operate under conditions different from those stated
in the label.
If after operating the exchanger, there should be leaks between the
connecting flanges, tighten the bolts as much as required to stop the leaks
paying attention to possible pipe extreme temperatures.
In case of accidental breaks during operation there can be gas, fluid and fragment
emissions; therefore take the necessary precautions in order to avoid the
damage caused by those phenomena.
MAINTENANCE.
All maintenance operations shall be carried out wearing safety gloves.
During maintenance, there can be high pressure as well as high temperature fluid
jets and therefore take the necessary precautions.
All maintenance operations on the heat exchanger shall be carried out with the
installation off.
When the exchanger is stopped for maintenance it is absolutely necessary to
exhaust all internal fluids and not to loosen any screw or bolt until the internal
pressure has decreased and the temperature of the parts is the same as the room
temperature.
file: cap4_i
manual

AIRO 24
Check the connection seals with gasket every time the exchanger is restarted
after having been stopped.
Make sure that all installation parts are clean and under perfect operating
conditions.
Carry out a periodical draining if the air tends to accumulate in the pipe side
circulation.
Never leave the exchanger off when it is full of fluid on the pipe side if there is a
possibility of freezing since the fluid freezing would cause irreparable damage to
the exchanger. Foresee total emptying in order to avoid such a problem.
When the heat exchanger is disassembled, it is recommended to use new gaskets
for reassembling it; this will prevent possible future leaks since the gasket
compounds become fragile and dry and their reuse does not guarantee a good
seal.To remove or prevent the formation of rust on the steel surfaces, dry the area,
use a steel brush to clean it and spray it with cold zinc paint.
file: cap4_i

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#

USE AND MAINTENANCE

codice: XT040089 rev. C 29.12.14 i #2 § 0- 4 / 5

BIANCALANI S. r. l. textile machinery

tel.: 0574 - 54871 http: / / www.biancalani.com

fax: 0574 - 633491 e - mail: contacts@biancalani.com

codice: XT040089 rev. C 29.12.14 ii #2 § 0- 4 / 5

USE AND MAINTENANCE

1.3#1 Producer’s nameplate with the CE mark (example)

1.4#1 An example of the Compliance Statement

In the event of offence to operators chargeable to faulty working of the machine

BIANCALANI has a world--wide sales network.

In the requests for assistance it is indispensable to specify:

Paragraphs 5.1 and 5.2 provide technical specifications and configuration

The machine is basically composed of 3 essential elements:

1) Exhaust fan to expel the air from the steamer.

1) Ball cock serving to rapidly cut off the gas supply

1) Steam supply connection used for steaming the fabric.

The definition of the limitations of use of the machine is a recall to the

3.1#1 Label: “AIRO hand”

-- PERSON EXPOSED TO RISK:

Access to the upper parts of the machine

3.2.1#2 MECHANICAL RISKS

Movement of the ejector pipe feathering valves

3.2.1#4 RISK CAUSED BY NOISE

Prolonged exposure to the machine noise.

Machine noise level declaration according to the requirements of Machine

Continuous equivalent sound--pressure level at the workplace

DANGER OF ELECTRIC SHOCK

DANGER TO MOVING MECHANICAL PARTS

On all fan inspection doors

On the automatic rotating filter.

DANGER DUE TO HIGH TEMPERATURE

On the side of the combustion chamber opposite the gas burner.

On three sides of the steamer radiator.

DO NOT POUR OIL INTO THE PRESSURE REDUCER FILTER

3.3.1 MAIN CONTROL PANEL

3.3.1#1 Main control panel

1) Touch--screen display panel

Explanation of symbols and functions

3.3.2#1 Main control page

1) Date and time.

2) Name of the running program (if any).

Go to the program screen.

Setting of the fabric entry speed in m/1’

Setting of the % air flow in the ejectors

Setting of the % excess air flow of the exhaust fan

Air heating ON.

Fabric introduction roller OFF.

Fabric extraction roller OFF.

Twin fabric feeding operation mode.

Unidirectional transfer of the fabric to the entry

Unidirectional transfer of the fabric to the exit

Supply of the steamer radiator.

Setting and indication of the minimum basket emptying level.

Duct lower air to both directions.

Duct air to both directions.

Duct air flow % to reverse fabric direction

Setting and indication of the time range between two consecutive

Fabric at entry check enabling.

Fabric at exit check enabling.

Increase of maximum ventilation limit.

Go to the configuration screens.