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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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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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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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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Air Chicago Express Operating Principles
5-1
Chapter 5
OPERATING PRINCIPLES
In order to maintain and troubleshoot the Air Chicago® Express towel folder safely and effectively, it
is necessary to understand how the unit works. This chapter is divided into three operating systems and
a review of how these systems are controlled in order to fold flatwork:
5.1 Electrical System
5.2 Compressed Air System
5.3 Mechanical System
5.4 Sequence of Operation
Electrical System: This section reviews incoming power requirements, how power is
distributed throughout the unit, the controls, sensors and switches
used to operate the unit, and the safety buttons and switches used
to provide a safe system.
Compressed Air System: This section reviews compressed air requirements, how air is
distributed throughout the unit, and the controls and mechanisms
operating the pneumatic system.
Mechanical System: This section reviews the drive mechanisms which power all rotating
and moving parts, how they move items through the unit to fold
towels and other small items.
Sequence of Operation: This section provides a step-by-step guide to the unit’s 6 phases of
operation: Stand-By, Start-Up, Primary Fold, Crossfold, Stacking,
and Exit.
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Operating Principles Air Chicago Express
5-2
Safety
The equipment described here has been
designed to work together to provide a safe and
reliable machine. Changing the equipment or
controls may cause a malfunction that could
injure someone. Do not bypass any of the safety
features or controls. Do not replace components
except with factory-approved repair parts.
Questions about the operation of the unit can be
answered by your local authorized CHICAGO®
dealer, or by the Chicago Dryer Company service
department.
5.1 Electrical System
The electrical components of the unit are
divided into two areas:
Power System
Control System
The power system moves the rolls and ribbons,
activates the air valves, etc. The control system
decides when all these activities should occur.
Power System
Components in the power system are located in
the several places. The fused disconnect switch is
incorporated into the electrical panel box door. If
a line voltage transformer is required, it is located
on the back of the electrical panel box.
The power system includes:
Disconnect Switch and Fuses
Step-Down Transformers
Electrical Panel
•
•
•
•
•
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Air Chicago Express Operating Principles
5-3
Disconnect Switch and Fuses
The unit comes equipped with a disconnect
switch (DDS). This switch (Figure 5-1, A) is
located in the electrical box attached at the front
of the machine.
Included as a part of the disconnect switch
are a set of fuses (B), which will isolate the unit
from the mains if necessary. See the schematics
for the rating of these fuses, which is dependent
on line voltage.
NOTE: The power supplied to the
unit must match the requirements
listed on the nameplate.
Figure 5-1: The disconnect switch (A) and fuses
(B) provide isolation from the mains.
B
A
Step-Down Transformers
If the unit is installed in a property with line
voltage higher than 240 VAC, transformers T1
and T2 are provided (Figure 5-2) in the machine’s
interior near the air tanks. These adjust the voltage
to 240 VAC, which is used throughout the unit.
Figure 5-2: Step-down transformers are mounted
on the back of the electrical box.
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Operating Principles Air Chicago Express
5-4
Electrical Panel
All power system components are located
in the electrical box at the front of the machine
(Figure 5-3). The table on the next page provides
an explanation of each item indicated in the
picture.
INV2
PWS2
PWS3
CB1
PWS4
CON1F/R
CB6DSC1
T3
CON2
CON3
MP1
MP3
CB10CB5
Figure 5-3: Components in the electrical panel.
FILT1
CR2
CR0B
CR1A
CR6 CR4
CR5B
CR3
CR5A
CR5C CR0C
CR0A
CR1B
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Air Chicago Express Operating Principles
5-5
ELECTRICAL PANEL COMPONENTS
Schematic Description
CB1 Circuit Breaker - Stacker Motor Inverter
CB5 Circuit Breaker - T3 (24VAC Control Circuit)
CB6 Circuit Breaker - DC Power supplies (PWS2/PWS3/PWS4)
CB10 Circuit Breaker - 24VAC Control Circuit
CON1F/R Contactor - Main Drive Motor/JOG Forward/Reverse
CON2 Contactor - Inverter2/Stacker Motor
CON3 Contactor - Exit Conveyor Motor
CR0 (A/B/C) Control Relays - Start Circuit
CR1 (A/B) Control Relays - Control Power Latch
CR2 Control Relay - E-Stops
CR3 Control Relay - Door Switches
CR4 Control Relay - Motor/Inverter Faults
CR5 (A/B/C) Control Relays - Run
CR6 Control Relay - Run Latch
DSC1 Main Disconnect Switch
FILT1 Filter - Incoming Power
INV2 Inverter - Stacker Motor
MP1 Motor Protector - Main Drive Motor
MP3 Motor Protector - Exit Conveyor Motor
PWS2 Power Supply - 24VDCI Control Circuit
PWS3 Power Supply - 24VDCO Control Circuit
PWS4 Power Supply - 12VDC Display
T3 Transformer - 24VAC Control Circuit
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Operating Principles Air Chicago Express
5-6
Control System
Control of the machine is done in two areas.
Input from the operator takes place at the
CHI•Touch screen, located on the outside of the
unit. These commands are combined with internal
signals in microprocessor unit.
CHI•Touch Screen
Operators control the folder with the Chicago
High Intelligence (CHI) touch screen located
at the right front of the unit (Figure 5-4). The
CHI•TOUCH OPERATION bulletin discusses
the use of this screen.
The touch screen accepts the operator touch
and sends them to the microprocessor unit, which
in turn sends operation and diagnostic messages
to the screen for display.
Communication between the CHI•Touch
screen and the microprocessor unit is handled
via a USB connection.
Communications and the I/O Panel
Inside the electrical panel box is the I/O control
panel. A serial cable provides communication
between the microprocessor and the I/O control
panel. Two LED’s on the communications head
of the control panel show when it is receiving
information from the microprocessor (RX) and
sending data to it (TX).
All the input signals from the sensors go
through the I/O control panel, which also powers
the sensors. When the appropriate LED on the
I/O control panel come on, it means that a signal
has been received from a sensor. Each LED is
numbered for easy identification.
Output signals from the I/O control panel go
directly to the output devices. These devices are
also powered via the I/O control panel.
Most output devices like air valves, relays, and
indicators run on the 24 VDC that comes right
from the I/O control panel. For other devices that
require a different voltage, the I/O control panel
sends an open collector output signal to drive the
logic input on a separate driver board.
When the appropriate LED on the I/O control
panel comes on, it shows that a signal has been
sent to a device. The LED on the I/O control panel
comes on to show that the panel is functioning
properly.
For open collector output, the LED means that
the I/O control panel is sending the signal to the
output device. Each LED is numbered for easy
identification.
Microprocessor
The microprocessor, located in the right
endframe (Figure 5-5) provides all of the control
logic for operating the unit.
Figure 5-5: The microprocessor unit controls all
machine operations.
Figure 5-4: CHI•Touch screen.
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Air Chicago Express Operating Principles
5-7
Electrical Panel I/O Control Panel
All control components are located in the
I/O control panel (Figure 5-6) in the electrical
box at the front of the machine. The table below
provides an explanation of each item indicated in
the picture. For details about each component’s
function, refer to schematic 6270406.
ELECTRICAL PANEL CONTROL COMPONENTS
Module Description
COMM Communications Head - CHI•Touch Interface
DEMO Feeder E-Stop (Option)/Manual Program Select
INT Interlock Inputs
MOTION Motion Control Outputs
OUT Outputs (Control/Run Latch, Alarm, Pacing Lights, Manual Program Indicator)
PNEUMATIC Pneumatic Control
P01A/P02/P03 DC Power Supplies
SENSORS Sensor Input
TERM Terminator Block
Figure 5-6: Control components in the electrical panel.
COMM
PNEUMATIC
P02
TERM
P01A
INT
OUT
SENSORS
P03
MOTION
DEMO
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Operating Principles Air Chicago Express
5-8
Photosensors
The photosensors use a high-powered LED
pulse output to detect items. When an item
is present, this beam is reflected back into a
sensitive detector built into the photosensor.
A signal is then sent to the CHI•Touch control
system.
There are seven photosensor located at various
places around the unit (Figure 5-7). The table on
the next page provides information about each
photosensor.
Proximity Sensors
The proximity sensors use a magnetic field to
detect the movement of machine components and
send signals to the I/O control panel.
There are four proximity sensors (Figure 5-8),
which detect the position of the primary fold skis.
The table on the next page provides additional
information about the proximity sensors.
Figure 5-8: Primary fold skis position detect
sensors under the front control panel.
PX5 PX7
PX6 PX8
Figure 5-7: Photosensor locations.
PE1
PE2
PE3
PE4 PE13 PE12
PE15
PE9/9A
PE10
PE11
PE10 PE11PE9
PE1
PE2
PE3
PE15
PE9A
PX9
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Air Chicago Express Operating Principles
5-9
PHOTOSENSORS
Sensor Name Function Type & Setting
I/O Module LED
(Sensor NOT
triggered)
PE1 Feed Table Center Detect items on the feed table.
For hand towels, helps determine
whether left or right primary fold air
bar blasts first depending on which
sensors are triggered.
Dark Operate ON
PE2 Feed Table Left Dark Operate ON
PE3 Feed Table Right Dark Operate ON
PE4 Primary Measure Detects leading edge of flatwork
as it enters primary fold section.
Control logic determines timing of
air blast(s).
Dark Operate ON
PE9/9A First Crossfold Detect leading edge of flatwork
as it enters crossfold section
(both sensors must be triggered).
Working with PE12, control logic
determines timing of air blasts for
two crossfolds, either in quarters or
French style.
Dark Operate ON
PE10/11 Crossfold Overwidth Detect when piece is too large
for crossfolding. Causes piece to
drop onto exit conveyor without
crossfolding.
Dark Operate ON
PE12 Second Crossfold Detects leading edge of flatwork.
Working with PE9/9A, control logic
determines timing of air blast(s)
for the second crossfold, either in
quarters or French style.
Dark Operate ON
PE13 Stack Entry Detects lead edge of flatwork as it
moves over stacker doors. Dark Operate ON
PE15 First Crossfold Low Detects leading edge of flatwork.
Control logic determines timing of air
blasts for one crossfold.
Dark Operate ON
PROXIMITY SENSOR
Sensor Name Function Type & Setting
I/O Module LED
(Sensor NOT
triggered)
PX5 (Narrow)
Primary Fold Skis
Position Detect
Determine the width of the primary
fold skis by detecting a metal plate
attached to the ski assembly.
8 mm OFF
PX6
PX7
PX8
PX9 (Wide)
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Operating Principles Air Chicago Express
5-10
5.2 Compressed Air
System
It is important that the supply of compressed
air be clean and dry and at 80 psi (550 kPa). All air
is filtered before it is used. The major components
of the pneumatic system are:
Air Filter/Regulators
Air Pressure Switch
Air Reservoirs
Air Valves/Air Valve Solenoids
Air Cylinders
Air Bars
•
•
•
•
•
•
Air Filter/Regulators
Because the condition of the compressed air
is so important, the machine includes a filter
unit equipped with a drain (Figure 5-9, A). This
helps keep the air clean and dry. This unit must
be serviced weekly for peak efficiency.
Air pressure regulators (Figure 5-10, A) are
used to control the air pressure used to perform
various functions.
Air Pressure Switch
The air pressure switch (Figure 5-9, B), located
near front of the machine at the left endframe,
ensures that the unit has air supplied at an
adequate pressure to operate properly.
If air pressure supplied to the unit falls below
60 psi (415 kPa), the switch closes and a “low
air pressure” message displays in the CHI•Touch
screen.
Air Reservoirs
An air tank (Figure 5-10, B) is mounted ahead
of the incoming air connection. In addition,
crossbeams running across the machine (Figure
5-10, C) are sealed and used as air reservoirs.
These hold a supply of compressed air for use in
various parts of the machine as required.
Figure 5-9: An air filter helps ensure a clean, dry
air supply within the folder.
AB
Figure 5-10: Regulators control the air pressure
used to perform various tasks.
C
B
A
A
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