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: (773) 235-4430 Fax: (773) 235-4439 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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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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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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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
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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
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INDEX
PL-TOC
3039-034 Air Chicago Express
PL-2
Front View
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2
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11 12
15 16 17
7
13 14
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1818 19
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25
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27 26
29
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24
30
31
35 35 35
32
34 33
19
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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)
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PL-TOC
3039-034 Air Chicago Express
PL-4
Rear View
1
2
3
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1818
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1
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13 15
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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
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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
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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*
*
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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
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PL-TOC
3039-034 Air Chicago Express
PL-10
Primary Fold Detail
12
3
4
5
11
12
15
16 17
13
14
10
1818 19 20
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24 25
22 26
21
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7
77
19
7
7
7
10
13
14 8
69
8
7
7
7
79
9
97
10
11
10
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INDEX
PL-TOC
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