Chicago Dryer AIR CHICAGO EXPRESS User manual

AIR CHICAGO®
EXPRESS
Towel Folder
INSTRUCTION MANUAL

©Chicago Dryer Company
Instruction Manual #3019-120
CHICAGO DRYER COMPANY
2200 N. Pulaski Road, Chicago, Illinois USA 60639-3737
Telephone: [phone] Fax: [phone] www.chidry.com

Air Chicago Express Table of Contents
i
TABLE OF CONTENTS
MANUAL
Chapter 1 - Introduction
Chapter 2 - Installation
Chapter 3 - Operating Guidelines
Chapter 4 - Preventive Maintenance
Chapter 5 - Operating Principles
Chapter 6 - Troubleshooting
Chapter 7 - Repair
CHI•TOUCH BULLETIN
PARTS LIST
SCHEMATICS
APPENDIX
Floor Plans
Technical Specifications
Torque Specifications
INDEX
TOC
INDEX

Table of Contents Air Chicago Express
ii
CHAPTER 1 INTRODUCTION
1.1 Warranty .................................................................................................. 1-2
1.2 Scope of Manual ..................................................................................... 1-2
1.3 Safety ...................................................................................................... 1-3
Safe Work Habits .................................................................................... 1-3
Safety Features ....................................................................................... 1-4
1.4 Optional Equipment ................................................................................. 1-6
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INDEX

Air Chicago Express Table of Contents
iii
CHAPTER 2 INSTALLATION
2.1 Site and Utility Requirements .................................................................. 2-2
2.2 Installation Procedures ............................................................................ 2-3
Inspection ................................................................................................ 2-3
Uncrating and Positioning ....................................................................... 2-4
Compressed Air Supply Connection ....................................................... 2-5
Electrical Connection .............................................................................. 2-6
Final Protective Wrapper Removal .......................................................... 2-8
2.3 Pre-Operational Checkout ....................................................................... 2-8
Security of Hardware ............................................................................... 2-9
Compressed Air Supply Checkout .......................................................... 2-9
Ribbon Rotation Checkout .....................................................................2-11
Safety Device Checkout ........................................................................ 2-12
Primary Fold Operation Checkout ......................................................... 2-14
Crossfold Operation Checkout .............................................................. 2-15
Checkout Completion ............................................................................ 2-15
Cleaning the Unit ................................................................................... 2-15
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INDEX

Table of Contents Air Chicago Express
iv
CHAPTER 3 OPERATING GUIDELINES
3.1 Safety Features ....................................................................................... 3-2
Main Disconnect Switch .......................................................................... 3-2
Safety STOP Buttons .............................................................................. 3-2
Air Permeable Barriers (Safety Guards) ................................................. 3-2
Safety Interlock Switches ........................................................................ 3-3
Safety Labels .......................................................................................... 3-3
3.2 Operating Controls .................................................................................. 3-4
3.3 Daily Operating Procedures .................................................................... 3-7
Start-Up ................................................................................................... 3-7
Handling Jams and Misfeeds Safely ....................................................... 3-9
Fold Operation ........................................................................................ 3-9
Interconnected Stop Circuit (Option) Operation Notes .......................... 3-12
Shut-Down ............................................................................................ 3-12
3.4 Operating Techniques ........................................................................... 3-13
Processing Standards ........................................................................... 3-13
Work Habits ........................................................................................... 3-14
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INDEX

Air Chicago Express Table of Contents
v
CHAPTER 4 PREVENTIVE MAINTENANCE
PM Task Table .................................................................................................... 4-1
4.1 Daily PM (8 Hours) .................................................................................. 4-2
Watch and Listen for Anything Abnormal ................................................ 4-2
General Cleanliness ................................................................................ 4-2
Check and Clean Photosensors .............................................................. 4-3
Check Safety Equipment ......................................................................... 4-3
4.2 Weekly PM (50 Hours) ............................................................................ 4-4
Check and Clean Inverter ....................................................................... 4-4
Polish Metal Surfaces ............................................................................. 4-5
Check Stacker Drive Belt Condition and Tension .................................... 4-5
Check and Grease Stacker Door Bearings ............................................. 4-6
Inspect Air Filter/Auto Drain .................................................................... 4-7
Check Air Pressure Settings ................................................................... 4-7
Check Ribbon Condition and Tension ..................................................... 4-9
4.3 Monthly PM (200 Hours) ......................................................................... 4-9
Check Setscrews................................................................................... 4-10
Check and Clean Main Drive Motor ...................................................... 4-10
Clean and Lubricate Drive Chains .........................................................4-11
Lubricate Primary Fold Ski Bearings and Linkages .............................. 4-12
Check and Grease Bearings ................................................................. 4-13
4.4 Semi-Annual PM (1000 Hours) ............................................................. 4-14
Clean Air Filter/Auto Drain ..................................................................... 4-14
4.5 Annual PM (2000 Hours) ....................................................................... 4-15
Check All Electrical Connections ........................................................... 4-16
Check Insulation Resistance to Earth Ground ...................................... 4-16
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INDEX

Table of Contents Air Chicago Express
vi
CHAPTER 5 OPERATING PRINCIPLES
Safety ................................................................................................................ 5-2
5.1 Electrical System ..................................................................................... 5-2
Power System ......................................................................................... 5-2
Control System ........................................................................................ 5-6
5.2 Compressed Air System ........................................................................ 5-10
Air Filter/Regulators............................................................................... 5-10
Air Pressure Switch ............................................................................... 5-10
Air Reservoirs ........................................................................................ 5-10
Air Valves/Air Valve Solenoids ...............................................................5-11
Air Cylinders ...........................................................................................5-11
Air Bars ...................................................................................................5-11
5.3 Mechanical System ............................................................................... 5-12
Main Drive System ................................................................................ 5-12
Second Crossfold Drive System ........................................................... 5-13
Stacker Drive System ............................................................................ 5-13
Exit Drive System .................................................................................. 5-13
Ribbon Sets ........................................................................................... 5-14
5.4 Sequence of Operation ......................................................................... 5-15
Stand-by Phase ..................................................................................... 5-15
Start-up Phase ...................................................................................... 5-16
Primary Fold Phase ............................................................................... 5-16
Crossfold Phrase ................................................................................... 5-17
Stacking Phase ..................................................................................... 5-17
Exit Phase ............................................................................................. 5-17
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INDEX

Air Chicago Express Table of Contents
vii
CHAPTER 6 TROUBLESHOOTING
Troubleshooting Symptoms ............................................................................... 6-2
6.1 LED Diagnostics ...................................................................................... 6-4
6.2 Electrical .................................................................................................. 6-6
6.3 Mechanical ............................................................................................ 6-10
6.4 Primary Folding ..................................................................................... 6-12
6.5 First Crossfold ....................................................................................... 6-14
6.6 Second Crossfold .................................................................................. 6-15
6.7 Stacker .................................................................................................. 6-16
6.8 Exit Conveyor ........................................................................................ 6-17
6.9 Sensor Function .................................................................................... 6-18
6.10 Compressed Air System ........................................................................ 6-19
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INDEX

Table of Contents Air Chicago Express
viii
CHAPTER 7 REPAIR
7.1 Safety Considerations ............................................................................. 7-2
7.2 Parts Availability ...................................................................................... 7-3
7.3 Ribbons and Rolls ................................................................................... 7-4
Primary Fold Ribbon Tension Adjustment ............................................... 7-5
First Crossfold Ribbon Tension Adjustment ............................................. 7-6
Transfer Ribbon Tension Adjustment ...................................................... 7-7
Second Crossfold Ribbon Tension Adjustment ....................................... 7-8
Stacker Ribbon Tension Adjustment ........................................................ 7-9
Exit Conveyor Ribbon Tension Adjustment ............................................. 7-9
Ribbon Replacement ............................................................................. 7-10
Tracking Tape Overview ........................................................................ 7-12
Exit Conveyor Ribbon Idler Roll Tracking Tape Replacement ............... 7-13
Riveted Tracking Tape Replacement ..................................................... 7-14
7.4 Chains and Belts ................................................................................... 7-16
Main Drive Chain Tension Adjustment ................................................... 7-17
Second Crossfold Ribbon Drive Chain Tension Adjustment .................. 7-18
Stacker Ribbon Drive Belt Tension Adjustment ..................................... 7-19
7.5 Sensors ................................................................................................. 7-20
Photosensor Replacement .................................................................... 7-20
Primary Fold Ski Position Detect Proximity Sensor Adjustment ............ 7-21
Primary Fold Ski Position Detect Proximity Sensor Replacement ........ 7-22
7.6 Compressed Air System ........................................................................ 7-23
Primary Fold Air Bar Alignment ............................................................. 7-24
Crossfold Air Bar Alignment .................................................................. 7-25
Primary Fold Ski Air Cylinder Air Flow Adjustment ................................ 7-26
Stacker Door Air Cylinder Air Flow Adjustment ..................................... 7-27
Air Valve Repair ..................................................................................... 7-28
TOC
INDEX

Air Chicago Express 3039-034
PL-1
Air Chicago Express
Picture Parts List
NOTE: When ordering parts, please provide the serial number and a
complete description of the Air Chicago Express, including any
non-standard features. Electrical part numbers can be found in
the SCHEMATICS section (when available).
Content
General Components
Front View..................................................................................................................................PL-2
Rear View...................................................................................................................................PL-4
Rolls & Ribbons .........................................................................................................................PL-6
Input Mechanism Detail .............................................................................................................PL-8
Primary Fold Detail ..................................................................................................................PL-10
Rear Detail...............................................................................................................................PL-12
Stacker Door Assy....................................................................................................................PL-14
Left Endframe Components
Drive Detail L/H........................................................................................................................PL-16
Left Side Bearings....................................................................................................................PL-17
L/H Misc. Parts.........................................................................................................................PL-19
Right Endframe Components
Drive Detail R/H.......................................................................................................................PL-20
Right Side Bearings.................................................................................................................PL-22
R/H Misc. Parts........................................................................................................................PL-23
Pneumatic Components
Incoming Air Regulator Assy. ...................................................................................................PL-24
Speedaire Air Tank Assy...........................................................................................................PL-26
Primary Fold Regulator Assy....................................................................................................PL-28
Second Cross Air Valve Assy...................................................................................................PL-30
Stacker Exit Conveyor Equipment
Stacker Conveyor Assy............................................................................................................PL-32
TOC
INDEX
PL-TOC

3039-034 Air Chicago Express
PL-2
Front View
1
2
3
4
5
6
9
8
11 12
15 16 17
7
13 14
10
1818 19
20
21
22
23
24
20
20
21
20
21
21
25
23
24
27 26
29
28
24
30
31
35 35 35
32
34 33
19
TOC
INDEX
PL-TOC

Air Chicago Express 3039-034
PL-3
Front View continued...
ID Part Number Qty Description
1 3418-500 1 SWIVEL CASTER W/2” BRAKE KITASSY
2 1402-651 1 HANDLE OPERATING
3 2010-488 1 LH INPUTARM 20” x 5-5/8” x 7 GA
4 3209-670 1 FEED RIBBON DRIVE ROLL 3-1/2”x6”
5 3401-090 1 FEED TABLE 36” WIDE
6 0607-480 1 LH INPUT ROLL BRACKET
7 0607-481 1 RH INPUT ROLL BRACKET
8 0609-240 1 INPUT GUIDE 6” ROLL SUPPORT BRKT 36”
9 1411-020 1 RED STOP BUTTON TURN REL’SE 1 N/C SEALED
10 1418-075 1 PLATE YELLOW
11 2001-912 1 FRONT CONTROL PANEL 16-1/2”x36-1/2”x14 G
12 3006-079 1 PANEL FRONTAIR CHICAGO EXPRESS
13 1417-550 1 ALARM AUDIBLE
14 1411-003 1 ILL START SWITCH GREEN 2 N/O CONTACTS
15 1411-560-01 1 SWITCH STOP 30 MM W/1 N/C CONTACT BLOCK
16 1414-486 1 SWITCH STAIN/TEAR REJECT
17 1402-675 1 SWITCH ADVANCE CONVEYOR
18 1402-579 1 SWITCH JOG REVERSE
19 0210-100 2 AIR PERMEABLE BARRIER 41” x 37-1/2”
20 S07-150 4 STEEL HINGE .120 x 2 x 2.50 x 2.50
21 0609-124 4 AIR BARRIER MOUNTING BRKT HINGE SIDE
22 2001-887 1 END FRAME DOOR 19-1/4” x 52” x 16 GA
23 4019-014 2 BUMPER 50-1/2” 3 HOLES 1 END CAP
24 2001-995 3 LOCK, LIFT & TURN NON LOCKING
25 2001-908 1 RH FRONT END FRAME DOOR
26 3006-175 1 “AIR CHICAGO EXPRESS” BEAUTY PLATE
27 1409-073 1 TOUCH SCREEN FRONT ENCLOSURE WELDMENT
28 0609-084 1 TOUCH SCREEN TILT W/WIRE ACCESS
29 2605-400 1 TOUCHSCREEN DISPLAY
30 2010-496 1 TOUCH SCREEN SPACER
31 1416-555 1 INDICATOR LIGHT GREEN 24 VDC
32 3418-510 2 SWIVEL CASTER
33 1414-492 1 PUSHBUTTON MULTI COLOR 22 MM
34 2010-487 1 RH INPUTARM 20” x 5-5/8” x 7 GA
35 1607-405 3 100 mm FIXED FOCUS D.O. (DBSP)
TOC
INDEX
PL-TOC

3039-034 Air Chicago Express
PL-4
Rear View
1
2
3
4
5
6
9
8
11
12
15
16
17
7
13
14
10
1818
34
1
3
4
9
8
6
14
14
13
13
13 15
TOC
INDEX
PL-TOC

Air Chicago Express 3039-034
PL-5
Rear View continued...
ID Part Number Qty Description
1 3418-500 2 SWIVEL CASTER W/2” BRAKE KITASSY
2 2003-138 1 LEG MOTOR GUARD
3 3004-314 3 ARROW LABEL
4 3004-315 3 BILINGUAL METAL PLATE “KEEP HANDS OUT...
5 3210-231 1 REAR COVER PLEXI GUARD
6 1411-020 2 RED STOP BUTTON TURN REL’SE 1 N/C SEALED
7 3403-302 1 HINGED REAR ACCESS COVER ASSEMBLY
8 3006-175 2 “AIR CHICAGO EXPRESS” BEAUTY PLATE
9 0210-100 2 AIR PERMEABLE BARRIER 41” x 37-1/2”
10 0609-119 1 RH CONTROL PANEL MOUNT
11 1409-071 1 TOUCH SCREEN REAR ENCLOSURE COVER
12 0609-120 1 LH CONTROL PANEL MOUNT
13 0609-123 4 AIR BARRIER MOUNTING BRKT REST SIDE
14 2001-995 3 LOCK, LIFT & TURN NON LOCKING
15 4019-014 2 BUMPER 50-1/2” 3 HOLES 1 END CAP
16 2001-909 1 LH FRONT END FRAME DOOR
17 2001-887 1 END FRAME DOOR 19-1/4” x 52” x 16 GA
18 3418-510 2 SWIVEL CASTER
TOC
INDEX
PL-TOC

3039-034 Air Chicago Express
PL-6
Rolls & Ribbons
1234569
811 12 15 16 17
713 14
10 1818
19
20
21
22
23
24
25
TOC
INDEX
PL-TOC

Air Chicago Express 3039-034
PL-7
Rolls & Ribbons continued...
ID Part Number Qty Description
1 3204-059 1 IDLER ROLL 3-1/2”x34”x11 GAW/6 RINGS
2 3209-670 1 FEED RIBBON DRIVE ROLL 3-1/2”x6”
3 3203-414 1 IDLER ROLL 3-1/2” x 14-1/2” x 11 GA
4 1003-430 1 SNOWFLAKE RIBBON 4” x 215” W/PIN
5 1003-431 1 TEV TEX RIBBON 2” x 215” W/PIN
6 3203-415 1 RAW IDLER ROLL 3-1/2” x 29-1/2” x 11 GA
7 3209-599 1 DRIVE ROLL 2-1/4”x22”x11 GAW/2 RINGS
8 3203-414 1 IDLER ROLL 3-1/2” x 14-1/2” x 11 GA
9 1003-434 1 POLYFLAKE RIBBON 3” x 109” W/PIN
10 3203-418 1 IDLER ROLL 2-1/4” x 22” x 11 GA
11 3204-043 1 IDLER ROLL 2-1/4”x22”x11 GAW/4 RINGS
12 1003-433 1 SNOWFLAKE RIBBON 3” x 17” W/PIN
13 3209-601 1 DRIVE ROLL 3” x 22” x 11 GAW/4 RINGS
14 3204-044 1 IDLER ROLL 2-1/4”x22”x11 GAW/2 RINGS
15 0209-076 1 2ND CROSS FOLD ASSISTAIR BAR 32” LONG
16 3204-039 1 IDLER ROLL 3”x22”x11 GAW/12 RINGS
17 0209-075 1 2ND CROSS FOLD AIR BAR 32” LONG
18 3204-043 1 IDLER ROLL 2-1/4”x22”x11 GAW/4 RINGS
19 0609-082 1 2ND X-FOLD PHOTO SENSOR MOUNT
20 3209-598 1 DRIVE ROLL 2-1/4”x22”x11 GAW/4 RINGS
21 0209-074 1 1ST CROSS FOLDAIR BAR 32” LONG
22 3209-596 1 DRIVE ROLL 3-1/2”x22”x11 GA W/12 RINGS
23 0603-097 1 RIBBON SPACER 1” x 1” x 31-3/4” x 1/8”
24 1003-432 1 SNOWFLAKE RIBBON 8” x 25” W/PIN
25 3209-594 1 DRIVE ROLL 2-1/4”x29-1/2”x11 GAW/6 RING
TOC
INDEX
PL-TOC

3039-034 Air Chicago Express
PL-8
Input Mechanism Detail
*= SPECIFY LEFT OR RIGHT
123456
9
8
11 12
15
16
17
7
13
14
10
1818
19
20
21
22
20
16
43
6*
*
TOC
INDEX
PL-TOC

Air Chicago Express 3039-034
PL-9
Input Mechanism Detail continued...
ID Part Number Qty Description
1 0607-482 1 LH CONTROL PANEL MOUNTASSEMBLY
2 1210-219 1 SHAFT 1” DIAx 36-3/8” LONG
3 0614-300 2 COLLAR 1” ID LOCKING
4 0401-825 2 BEARING 1” SUPER PILLOW BLOCK
5 0607-473 1 LH SKI MOUNTASSEMBLY
6 1819-148 2 RUNNER 95-1/2” x 2” (SPECIFY LH OR RH)
7 0609-087 1 INPUT MECHANISM SENSOR BRACKET
8 1607-405 1 100 mm FIXED FOCUS D.O. (DBSP)
9 0410-138 1 SENSOR BRKT BUSHING 1” x 2-1/4” x 2-3/4”
10 0607-472 1 RH SKI MOUNTASSEMBLY
11 0405-125 1 BEARING ROD END 7/16” FEMALE
12 0208-270 1 AIR CYLINDER 1-1/2” BORE 3” STROKE
13 0208-412 1 BRKT PIVOTAIR CYLINDER 2” BORE
14 0607-483 1 RH CONTROL PANEL MOUNTASSEMBLY
15 0205-250 2 ELBOW 1/8” NPT x 1/4” OD
16 0203-200 2 ELBOW FLOW CONTROL 1/8” NPT
17 0609-089 1 SKI PROXY TRIGGER 1-7/8” x 6” x 14 GA
18 0609-174 1 SKI POSITION SENSOR BRKT 2ND GEN
19 1607-430 4 12mm N.C. PROX (XNC)
20 0405-100 4 BEARING ROD END 3/8” FEMALE
21 2007-244 1 INLET REAR CROSS BRACEASSEMBLY 36-1/4”
22 0607-484 1 INPUT MECHANISM BRKTASSY FOR 36” FEED
TOC
INDEX
PL-TOC