GVA 5009 eco machines consist of 2 climate chambers. These chambers provide a very long “residence time” in the very controlled climate consisting of heated air and steam in a combination which provides thorough, repeatable and consistent heatsetting for the highest quality carpet and rug products. Each chamber has its own temperature controller and its own dewpoint controller. All controllers work independently of each other. Each chamber has 3 inverter-driven circulation fans. For that reason a soft-start and an exact adjustment of speed of the fans is possible. Specially designed flow guiding sheets inside the climate chamber increase the circulation speed of the super-heated steam and make the flow more uniform.
Maintenance is straightforward and easily accomplished:
…Entry window
èCheck for yarn hangs at entry curtains
è Check window for unusual exit of vapor
…Exit window
èCheck for yarn hangs at exit roller or exit curtains
èCheck window for unusual exit of vapor
…GKK compressed air service unit
The air service unit of the GKK is located at the manhole side of the GKK. It has its own air supply.
Depending on the GVA set-up (standard or optional) the following settings are used:
Steam valve 1 and 2: 6 bar (standard)
Central yarn cooling: 6 bar (optional)
Entry or exit rollers - Note not used with entry and exit curtains 3 bar (optional)
…Steam supply
The GKK has its own pressure reducing station. The pressure is set at the pressure regulator between 2 – 2.5 bar. On the circulation fan side of the GKK, the steam pressure is displayed on a manometer (pressure gauge).
…Pleva – Humidity measuring probe
The Pleva probe is mounted and sealed at the GKK-side. The pipe of the probe, which is outside the machine wall must remain free and may not be covered. The measuring probe is only removed for periodic calibration. Caution: Any shock to the tip of the probe may damage the inner components. The probe is heated in normal operation and the risk of damage is greater if the probe is not cool when it is removed.
…GKK Filter Screen
At the entry and at the exit of the GKK you’ll find the openings for the GKK filter (central screen). Always handle the filters carefully to avoid damage. They should be cleaned periodically (frequency depends upon the fiber and the amount of fiber finish and monomer which “flash off” the fiber during heatsetting) and the cover must be closed tightly. The filter screen on the inlet side of the heater can be checked when the machine is hot (Caution: Heat-resistant gloves are required to allow the hot filter screen to be handled without getting burned) and replaced with a second one. No yarn should be processed during the inspection.
Below channel 6 (bottom right, of the entrance end, bottom left of the exit end) of the heatsetting chamber is a narrow screen cover which can be opened using a square key, giving a half turn anti-clockwise (some machines have the cover held in place by 4 bolts which require a wrench instead of the key) .
If the screen needs to be cleaned, a clean replacement screen can be put in its place to promote continued production. The filter screen can be cleaned with a steam jet or pressure washer. When closing the screen cover, make sure that the seal sits correctly and that the cover closes properly. If the screen cover does not close correctly, cold air can be drawn in from outside and higher energy consumption will be required to reach the set temperature.
We recommend checking and cleaning the chamber as follows:
Every Week
èCheck and clean the exhaust air system (exhaust zones at entry and exit ends and exhaust fan screens)
èCheck condensate lines to ensure proper drainage
èCheck the air circulation and exhaust motors
èRemove traces of oil and condensate from the conditioning chamber
èCheck for condensate and steam leakage
èClean main control panel
Every half year
èOpen the top and bottom access hatches to inspect the inside
èCheck the bottom for traces of condensate collecting, and for chemical and thread accumulation
èCheck the PT 100 temperature sensor for chemical accumulation on the tubes
èCheck the ventilation barriers: take out the top perforated screen and remove fouling. If necessary, check the flow monthly.
èCheck the sealing of the chamber (make sure that outside air is not getting in)
Once a year
è Check the heating elements for fibers or other blockage (disassemble as necessary)
èUse an ohm meter to check the resistance of the heating elements
èClean all perforations
èCheck steam valve for wear
èCheck all electrical components
Operation of the GKK
Filter (central) screen
If you’ll need any future information regarding the maintenance of the climate chamber please feel free to contact us.