OPERATING INSTRUCTIONS
for
CTPR
Topper For Jeans
( prepared pursuant to Section 6.5 of Standard EN ISO 12100-2 )
DEAR EQUIPMENT OWNER,
Let us congratulate you on occasion of purchasing your new equipment. It
is our firm conviction that you have chosen correctly when deciding on
purchasing a Concorde-Machines equipment.
Prior to commissioning, a careful studying of and adherence to the
Operating Instructions and to the conditions of handling, operation and
maintenance is needed since safe, energy-saving, long-lasting, reliable
and environment protecting operation of the equipment can be achieved in
this manner only.
Our product has been manufactured on basis of the standard specifications
of the European Community, as well as by means of the ISO 9001 quality
assurance system functioning and certified at our firm.
2
Table of Contents
a)
b)
c)
d)
e)
f)
g)
h)
Information relating to transportation, handling and storing of the equipment
Information relating to commissioning of the equipment
Data relating to the machine itself
Data relating to usage of the machine
Data relating to maintenance
Information relating to putting the machine out of operation
Data relating to emergency situation
Troubleshooting
3
ANNEXES
Guarantee conditions
CE declaration of conformity
Pneumatic circuit diagrams
Electric circuit diagrams
Main structural elements, installation and list of parts
FOR THE MACHINE SAFETY AND YOUR SAFETY IS
SEVERELY PROHIBITED:
- TO REMOVE
- TO MODIFY
- TO REPLACE THE ELECTRIC AND STEAM CONTROL AND
SAFETY UNITS WITH NOT ORIGINAL SPARE PARTS.
Address the Selling Firm for any maintenance and control
operation asking for specialized staff.
4
The trouser topper machine is suitable for all clothing asking for ironing characteristics
corresponding to those offered by the machine itself.
It is forbidden the use of the machine for clothes, which cannot be steam, pressed thus keep to
the labels placed on the items themselves.
ATTENTION: According to the characteristics required for the garment, check the exact setting
of the machine.
a)
Information relating to transportation, handling and storing of the equipment
Conditions of the equipment storing
Warehousing, storing of the equipment is permissible only in premises free of dust and
moisture, where it is assured that the temperature may never decrease below 1 oC.
Conditions of transportation of the equipment
Normally the equipment is delivered with foil packing. On special request resp. in case of export
delivery each unit is delivered on euro-pallets, with foil packing, fixed by band and provided with
edge-protection.
Hoisting of the packed equipment is possible only from the bottom (depending on the mass by
hand up to 50 kg or by a dolly or fork-lift truck over that weight).
ATTENTION!
The parts and fittings outreaching from the covering are not suitable for
grasping and hoisting during the transportation.
Dimensions of the equipment
WIDTH
mm
DEPTH
mm
HEIGHT
mm
MASS
kg
800
800
1990
215
b) Information relating to commissioning of the equipment
Prior to commissioning the equipment, make sure that:
• the designed place of erection of the equipment is in compliance with the environmental
conditions;
• sufficient electric energy is available and that the cross section of the conductors is sufficient;
• steam of proper quality is available;
• the steam connection is solved.
ATTENTION!
You should sign the sheet certifying the commissioning only when the fitter
performing the setting up operations has:
- completed the commissioning and setting up of the equipment and you
tested the device, and
- taught you for the usage thereof.
5
Foundation
The equipment may be erected on a horizontal floor of smooth surface, made of noncombustible material.
The legs of the equipment are of screw-type design enabling tilt-free leveling.
The connections should be flexible.
Floor area demand
The equipment has to be accommodated as near as possible to the steam consumer (max. 2.5
m) so as to ensure a free place of about 0.8 m around the equipment for handling and
maintenance.
Recommended positions
Environmental conditions
The equipment has to be erected in a "temporarily wet premise"1. For example, it may not be
operated in a washing or drying room.
The equipment performs the specified parameters under ambient temperature ranging between
+20 and +40 oC.
ATTENTION!
Below +1 oC freezing of the water to be found in the steam tank and in the
fittings may cause damage to the equipment.
Grade of electric protection of the equipment: IP 23, resp. "protected against drip water".
Due to the steam escaping to the air space of the room (flowing out from the trouser) an
adequate air exchange or individual exhaustion equipment has to be provided.
Data of connection to the energy supply system
ATTENTION!
Installation of the equipment, its connection to the electric- and steam networks
may be performed by a specialist fitter of the given area.
Connection of the networks
POWER SUPPLY
1
CONNECTION
VALUE
CONSUMPTION
UNIT
Temporarily wet is a premise where in case designed usage the moisture content of the air exceeds
75 % only for a short time resp. periodically vapour or steam develops resp. moisture condensation
occurs, however, the premise quickly dries out.
6
POWER SUPPLY
CONNECTION
VALUE
CONSUMPTION
UNIT
Electric
400/230/115 V
50/60Hz
2,2 kW
Steam
4 – 5 bar
10 - 20 kg/h
2 x 3/8”
Air
6 – 7 bar
5,5 l
¼” gas
5 x 1,5 mm2 *
* - Wired shock protection according to EN 60204-1 (6.3.3.; 8.)
The equipment is delivered complete with wiring prepared for connection. After being connected
to the mains the equipment is serviceable.
Electric connection
• Is effected with use of connecting cable provided with protection contact; with use of
conductor power cable
5-
• The voltage drop on the mains installed for the connector plug should not exceed
+/- 10 %;
ATTENTION!
The electric connections have to be established according to the schematic
circuit diagram.
Should the equipment get faulty due to being operated from a mains not
provided with adequate grounding then the resulting damages will be born by
the operator.
The connection and wiring has to be made in a fully de-energized state of the
equipment.
Steam connection
• For steam conduction only a hose or pipe complying durably with the set working pressure
and temperature (Teflon pipe with metal braiding) may be used.
• Prior to commissioning, do not forget checking the other end of the steam-hose, too!
ATTENTION!
Always make sure to tighten the connections correctly.
Air connection
• Connect the 1/4"gas thread inlet of the reduction filter with a RYLSAN tube for compressed
air.
• Make sure a steady airflow rate of 5,5 litres per minute at minimum 6-bar pressure is
provided.
ATTENTION!
Always make sure to tighten the connections correctly.
Preventive measures required on behalf of the operator:
• Checking the shock protection system of the equipment after commissioning, resp. repairs.
• Checking the pipe joints for tightness.
7
• Removing combustible-inflammable materials from the vicinity of the equipment.
• Providing individual protection devices (gloves) for controls of the equipment (fittings outside
the cover) whose operating temperature may exceed 50 ºC.
• DO NOT leave the equipment unattended during its operation!
c)
Data relating to the machine itself
Power
consumption,
kW
Steam
consumption,
kg/h
Steam pressure,
bar
Air pressure,
bar
Max.
Recomm.
Max.
Recomm.
Engine
power,
HP
2,2
10-20
6
4…5
8
6…7
2
The working noise level of the equipment does not exceed 70 dBA sound pressure level in open
surroundings from 1 meter distance.
d) Data relating to usage of the machine
Description of operation of the equipment:
Structural construction:
The topper main parts, as follows:
- Base-plate, machine base with foot switch (8, 9)
- Blowing unit
- Ventilator house with the fan and motor inside (20)
- built-in steam heating (radiator hot air) (21)
- Steam circuit
- Stainless steam tank (19)
- Solenoid steam valve (18)
- Manometer (4)
- Superheater (27) unit with electric tubular heater (28) and thermostat (3)
- Steam dispenser (31)
- Pneumatic circuit
- Filter – pressure reducer – pressure gauge (13, 14, 15, 16)
- Pistons with flow restrictor
- Trolley slider (43)
- Turnbuckle for pelvis (33)
- Trouser fixing (37)
- Left pliers (23)
- Right pliers (23)
- Solenoid valves 5/2 (39, 40)
- Program control unit (12)
Distinctive feature of TOPPER
- Pneumatic leg clamping unit,
- Connecting to the central steam network,
- Front pressing,
- Pneumatic transversal stretching,
8
-
Separate leg and pelvis stretching,
Adjustable air volume,
Device preventing over-stretching, automatic stretching,
Superheater unit (with 1000W electric heating element) with perfectly dry steam,
100 programme storage places, timers for steaming steam/air mixture and hot air supply,
Adjustable head for different trouser leg lengths,
The main controls are easy to access and handle and the structural elements can be easily
maintained.
9
Control and signal elements:
On the front panel:
Pressure reducer
(turnbuckle for
pelvis) (1a)
Pressure reducer
(trolley) (1b)
Pressure gauge
(turnbuckle for
pelvis) (2a)
Pressure gauge
(trolley) (2b)
Manometer (steam
tank pressure) (4)
Thermostat (3)
Main switch (5)
Knobs for adjustable
trolley (6)
Knob for adjustable
pliers (left) (7)
Knob for adjustable
pliers (right) (7)
Pedal (right) (9)
Pedal (left) (8)
10
Program control unit
Program control unit (12)
Display
Steaming time
(0 – 999 sec)
Steam/air mixture blowing
time (0 – 999 sec)
Program number (up – down)
Display – show the blowing times in seconds
and the actual program number.
Air blowing time (0 – 999 sec)
Programs save
The program settings:
- Choosing of the program number (⊕ or Θ) /10 up to 1000, hundred positions/;
- Setting the time of
o steaming period (in sec) /⊕ or Θ/;
o
o
-
steaming and of air-blowing in (in sec) /⊕ or Θ/;
air-blowing in (in sec) /⊕ or Θ/;
If the needed periods are already adjusted, the ℗ MEMO button shall be pushed over about
5 sec. On display appears: PROGRAMMED. On this way all the set times are fixed at 10, 20,
30 etc. depending on materials of the trousers.
Possibility of manual control:
o Setting the manual switch: put below number 10 by button PROGR Θ;
o Putting on the trousers (it counts the single steps up to 7);
o Function of the 3 buttons: for the needed activity push the relevant button ⊕, as
long as it is necessary.
On the right side
11
Knob for pressure
reducer (13)
Pressure reducer (14)
Pressure gauge (15)
Air filter (16)
12
Bellow the rear panel:
Solenoid valve (steam) (18)
Ball journal (steam quantity
control) (17)
Steam inlet
Steam tank (stainless) (19)
+ insulating cover (19a)
Condensate outlet
Starting sequence:
Make sure all connections are correct and check ironing cycle times. At this point, you can start ironing.
• Turn the main switch (5) of the equipment to position “I” ON.
• Move the top of trousers to trousers top stretcher (turnbuckle for pelvis) (38)
• Press pedal right (12)
• Close the piston for trouser fixing (37)
• Press pedal right (12) again
• Stretch the pelvis trousers – adjust the volume of stretch (Pressure reducer (1a))
• Insert the trousers right leg into the right pliers
• Press pedal right (12) again
• Close the right leg pliers
• Insert the trousers left leg into the left pliers
• Press pedal right (12) again
• Close the left leg pliers
• Press pedal right (12) again
13
• the trolley move down and automatically stop
• adjust the length of the trouser legs – (Knobs for adjustable trolley (6))
• adjust the optimal trolley speed – (Pressure reducer (1b))
• adjust the optimal stretch of the trouser legs:
• adjust the stretch of the lower spring (22b) on the middle position;
• adjust the stretch of the upper spring (22a) is required degree;
• fine adjust the lower spring (22b) for optimal stretch of the trouser legs
• Press pedal right (12) again
• Start the program (the ironing cycle /steam – air/steam – air/ pre-set using the timer) – for the
programming, see the “The program settings” chapter!
• If the pre-set ironing cycle is completed, both clamps will open thus releasing the trouser legs
• Press pedal right (12) again to release the top of trouser with your hands
• If press the pedal left (11) anytime, the machine step back to the previous position
• Increasing of the steam pressure can be observed on the manometer (4) and the value of the
pressure may not exceed the red mark.
Halting takes place in a sequence reverse to that of the starting:
• Turn main switch (5) of the equipment to position "0" OFF.
• Close the steam and air supply.
• Wait until the equipment cools down to the ambient temperature.
Tasks of the operator during operation:
• Attending the operation of the equipment (manometer (2, 4,),
Risks prevailing during the course of the operation of the equipment:
• Burning injuries occurring during the course of unintended touching of high-temperature
machine parts, fittings or their handling.
• Scalding by unexpected blow-out of steam (pipe rupture, slackening)
• Touching of the moving machine parts (clamps, pliers)
Individual protection appliances:
• Protective gloves for usage of controls of hot surface.
Breakdown remedy:
• Touching the machine on observation of a breakdown is PROHIBITED!
• Do not remove the covers of the equipment.
• In certain cases the faulty operation is indicated by the control (the program control unit
display goes dark)
• If the reason of the breakdown is not unambiguous, then restarting of the equipment may
take place only after a decision taken by the person responsible for the operation, resp. after
rectification of the fault by a professional service.
• In case of electric power failure the equipment switches off.
14
e)
Data relating to maintenance
ANY MAINTENANCE WORK MAY BE PERFORMED ONLY ON EQUIPMENT ISOLATED
FROM THE ENERGY SOURCE AND COOLED DOWN TO THE AMBIENT TEMPERATURE
Maintenance tasks of the operating staff:
Inspection- and maintenance plan
Interval Part of machine in question
Work to be carried out
Remarks
8h
Safety features
Check correct functioning
40 h
Complete machine
Clean
See chapter d) USAGE
OF THE MACHINE
Dry wipe with a clean,
lint-free cloth
Maintenance tasks of the specialized staff:
Maintenance of the equipment, e.g. that of the items listed below may be performed only by a
skilled mechanic-, and electric fitter, resp. professional service:
• Cleaning of switch contacts,
• Checking, replacement of electric parts,
• Checking of electric control, operation of the regulation circuit
For location of an electric failure only a measuring instrument of high internal resistance may be
used.
Inspection- and maintenance plan
Interval Part of machine in question
Work to be carried out
Remarks
160 h
Check for leaks
Check and replace if
necessary
Check correct functioning
Check and replace if
necessary.
Water drain
Check and replace if
necessary
2000 h
Hoses, pipe systems and screw
connections;
Signal elements (manometer,
pressure gauges) (4, 2);
Seal (29).
Main switch (5);
Switch and switch attachments
Pressure reducer filter (16)
Thermostat (3)
Heating element (28);
Steam tank (19);
Blowing motor (20);
Pressure reducer (1, 13);
Steam valve (18).
Cleaning
Check for leaks
(Call the THEOBALD
service!)
For the maintenance only original, factory made or equivalent parts may be used. When
ordering spare parts, in addition to the numbers indicated on the parts list, the type and
year of production of the equipment have also to be indicated.
15
f)
Information relating to putting the machine out of operation
In case of a durable halting of the equipment the water has to be drained from the boiler space
and from the pipes and preferably the structure has to be dried out.
Separate the equipment durably from the energy sources.
Take care on protection against dust and corrosion.
g) Data relating to emergency situation
When unexpectedly a large quantity of steam blows out accessing to controls of the equipment
is risky. In a case of this kind interrupt the energy supply (steam, air, and electric) and
remove all persons from the vicinity of the equipment until the emergency situation ceases.
h) Troubleshooting:
FAULT
PROCEDURE
No steam output
- Check that steam pressure (4,5 bar min) is available at
pressure gauge 8, page 4;
Wet steam
- Make sure the temperature of the steam superheater
thermostat is correct about 250°C;
- Check the
operation;
condensate
drainage
system
for
correct
Machine puts out - Make sure the temperature of the steam superheater
steam instead of
thermostat is correct about 250°C;
water
- Check the condensate drainage system for correct
operation;
- Check superheater resistor;
Automation system - Because of their complexity, we recommended to contact
problems
the installation engineer;
Weak air blow
- Make sure the direction of rotation of the motor is correct;
No compressed air - Make sure air pressure is available at pressure gauge;
drive
- Contact installation engineer;
16
Warranty conditions
Dear Equipment Owner,
For perfect operation of the equipment and to obtain your full satisfaction we want to provide
some help by familiarizing you with the warranty conditions. You are kindly requested to check
verification of the date of the purchasing on the Letter of warranty, since this is one of the
conditions of our warranty.
The manufacturer undertakes a 12-month warranty (guarantee) for its type TPR ironing tables
sold, reckoned from the date of the purchasing, under conditions as follows:
During the warranty period the service provider, assigned by the manufacturer as
indicated below, provides free-of-charge replacement for returned faulty parts, if default
in manufacture can be stated and performs repairs within 1 year free-of-charge at his site
or, against payment of the travelling cost an board, during the reparation work in your
premises: within 8 working days reckoned from the reception of the fault notice at the site of
the operation.
The natural tear and wear and contamination occurring during the course of normal usage of
the equipment necessitate certain repairs, readjustments, cleaning operations according to the
Operating Instructions (e.g. scale removing of the boiler space and the heater units, removal of
the deposits, re-tightening of the connections, cleaning of the electric appliances, checking of
the control, replacement of parts, etc.) also during the guarantee period, which do not belong to
the sphere of our warranty obligation.
No warranty is undertaken by the manufacturer for the electric bulbs, switches assembled with
lamps, magnetic switches, heater units, solenoid valves, electric pump, water pump.
In respect of warranty the parts can not be considered faulty if their failure was caused by nondesigned usage, calamity or other reason (e.g. ignorance to specifications of the Operating
Instructions, negligence in maintenance or inadequate water quality) occurring subsequent to
the hand-over, provided that evidence of this is given by the manufacturer or its assigned
service provider commissioned to perform the repair. In a case of this kind the repair costs will
be born by the operator, during the warranty period, too.
We want to provide facilities for maintenance of our product both within and beyond the
warranty period. Please, if you have maintenance problem within the warranty period or
maintenance or repair problems beyond the warranty period, contact the manufacturer with
confidence. Within the frame of our service facilities we are readily at your disposal, against
payment. The commissioning, repairing and maintenance works performed on special orders
are carried out by the manufacturer and the expenses thereof invoiced for the operator.
Should commissioning or annual checking maintenance of the equipment be performed by a
fitter not authorized for this job by the Concorde Machines. then no further warranty can
be undertaken for that equipment by us. Restoration of the warranty is possible only on basis of
individual consideration, after a paid repair.
17
Pneumatic circuit diagram
18
Electric circuit diagram
R,S,T,
Live wires
M
Blowing motor
N
Neutral wire
Gsz
Solenoid valve (steam)
PE
Earth wire
Hsz
Thermostat
FK
Main switch
HK
Heat break off
MK
Solenoid switch
FB
Heating element
LK1
Foot switch
LK2
Foot switch
19
Main structural elements, installation and list of parts
Radiator hot air (behind the
cover) (21)
Air inlet
Blowing motor (20)
Solenoid valve (steam) (18)
Ball journal (steam quantity
control) (17)
Steam tank (stainless) (19)
+ insulating cover (19a)
20
Spring (trolley) (22a)
(pre-adjusting)
Micro-switch (10)
Spring (trolley) (22b)
(fine adjusting)
Knob for adjustable
trolley (6)
Spiral pipe (26)
Pliers (23)
Pliers deposit (24)
Piston for pliers (25)
21
Superheater (27)
Heating element (28)
Seal (29)
Heat break off (30)
Steam dispenser (31)
Geared lath (32)
Piston turnbuckle for
pelvis (33)
Gear (34)
Track guides (35)
Staying roller (36)
Piston for trouser
fixing (37)
Turnbuckle for pelvis
(38)
22
Solenoid valve (40)
Solenoid valve (double
control) (39)
Electric control panel (41)
Connection to the
programming unit
Main switch (5)
Solenoid switch (42)
Connection to the electric
cable
23
Installation
Air inlet fitting
(6-7 bar, ¼”)
Steam inlet fitting
(4-5 bar, 3/8”)
Electric power
connection:
400 V, 50 Hz with
earthed net
(Max. 16 A)
Condense outlet
fitting
(4-5 bar, 3/8”)
24
TOPPER list of parts
Ordering
No.
1
1a
2
2a
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19a
20
21
22a
22b
23
24
25
26
27
28
29
Title
Pressure reducer (turnbuckle for
pelvis)
Pressure reducer (trolley)
Pressure gauge (turnbuckle for
120.002 pelvis)
Pressure gauge (trolley)
120.003 Thermostat
120.004 Manometer (steam tank pressure)
120.005 Main switch
120.006 Knob for adjustable trolley
120.007 Knob for adjustable pliers (left –
right)
120.008 Pedal (left)
120.009 Pedal (right)
120.010 Micro-switch
120.011 Spring for pedals
120.012 Programming unit
120.013 Pressure reducer
120.014 Knob for pressure reducer
120.015 Pressure gauge
120.016 Air filter
120.017 Ball journal (steam quantity control)
120.018 Solenoid valve (steam)
120.019 Steam tank (stainless)
120.019a Insulating cover
120.020 Blowing motor
120.021 Radiator hot air
120.022a Spring (trolley) (pre-adjusting)
120.022b Spring (trolley) (fine adjusting)
120.023 Pliers
120.024 Pliers deposit
120.025 Piston for pliers
120.026 Spiral pipe
120.027 Superheater
120.028 Heating element
120.029 Seal
Sign by
electric
circuit
diagram
Type
Note
120.001
HK
FK
LK1, LK2
Gsz
M
2 in 1
ISO 20x50
FB
1000 W
Ordering
No.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
120.030
120.031
120.032
120.033
120.034
120.035
120.036
120.037
120.038
120.039
120.040
120.041
120.042
120.043
Title
Heat break off
Steam dispenser
Geared lath
Piston turnbuckle for pelvis
Gear
Track guides
Staying roller
Piston for trouser fixing
Turnbuckle for pelvis
Solenoid valve (double control)
Solenoid valve
Electric control panel
Solenoid switch
Piston for trolley slider
Sign by
electric
circuit
diagram
HK
Type
Note
ISO 20x200
ISO 20x50
SY 3360
SY 3160
5/2
5/2
MK
ISO 32x600
When ordering spare parts, in addition to the numbers indicated on the parts list, the type and
year of production of the equipment have also to be indicated.