Chicago Dryer Air Chicago Standard User manual

AIR CHICAGO®
(STANDARD/XW/XL/XXL)
Towel Folder
INSTRUCTION MANUAL

©Chicago Dryer Company
Instruction Manual #3019-105b
CHICAGO DRYER COMPANY
2200 N. Pulaski, Chicago, Illinois USA 60639-3737
Telephone: [phone] Fax: [phone] www.chidry.com

Air Chicago (Standard/XW/XL/XXL) Table of Contents
i
TABLE OF CONTENTS
MANUAL
Updates
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 PANEL BULLETIN
PICTURE PARTS LIST
SCHEMATIC PARTS LIST
APPENDIX
Floor Plans
Technical Specifications
Torque Specifications
INDEX

Table of Contents Air Chicago (Standard/XW/XL/XXL)
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 Equipment Description ............................................................................ 1-6
Models and Model Designations ............................................................. 1-6
Optional Equipment ................................................................................. 1-6

Air Chicago (Standard/XW/XL/XXL) Table of Contents
iii
CHAPTER 2 INSTALLATION
2.1 Site and Utility Requirements .................................................................. 2-2
2.2 Installation Procedures ............................................................................ 2-4
Inspection ................................................................................................ 2-4
Uncrating and Positioning ....................................................................... 2-5
Compressed Air Supply Connection ....................................................... 2-6
Electrical Connection .............................................................................. 2-7
Final Protective Wrapper Removal .......................................................... 2-9
2.3 Pre-Operational Checkout ..................................................................... 2-10
Security of Hardware ............................................................................. 2-10
Compressed Air Supply Checkout .........................................................2-11
Ribbon Rotation Checkout .................................................................... 2-12
Safety Device and CHI Panel Function Checkout ................................. 2-13
Primary Fold Operation Checkout ......................................................... 2-15
Crossfold Operation Checkout .............................................................. 2-16
Checkout Completion ............................................................................ 2-16
Cleaning the Unit ................................................................................... 2-16

Table of Contents Air Chicago (Standard/XW/XL/XXL)
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
CHI Panel ................................................................................................ 3-6
3.3 Daily Operating Procedures .................................................................... 3-7
Start-Up ................................................................................................... 3-7
Handling Jams and Misfeeds Safely ....................................................... 3-8
Fold Operation ........................................................................................ 3-8
Shut-Down ............................................................................................ 3-12
3.4 Operating Techniques ........................................................................... 3-12
Processing Standards ........................................................................... 3-13
Work Habits ........................................................................................... 3-14

Air Chicago (Standard/XW/XL/XXL) 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
Inspect Air Filter/Drain ............................................................................. 4-5
Check Air Pressure Settings ................................................................... 4-6
Check and Grease Stacker Door Bearings ............................................. 4-7
Lubricate Stacker Door Linkages ............................................................ 4-8
Check Belt and Ribbon Condition and Tension ....................................... 4-8
4.3 Monthly PM (200 Hours) ......................................................................... 4-9
Check Setscrews..................................................................................... 4-9
Clean and Lubricate Drive Chains ........................................................ 4-10
4.4 Semi-Annual PM (1000 Hours) ..............................................................4-11
Clean and Lubricate Threaded Rods .....................................................4-11
Clean Air Filter/Auto Drain ..................................................................... 4-13
Inspect Gear Reduction Unit ................................................................. 4-14
4.5 Annual PM (2000 Hours) ....................................................................... 4-15
Check All Electrical Connections ........................................................... 4-15
Check Insulation Resistance to Earth Ground ...................................... 4-16

Table of Contents Air Chicago (Standard/XW/XL/XXL)
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 Reservoir .......................................................................................... 5-10
Air Valves/Air Valve Solenoids ...............................................................5-11
Air Cylinder .............................................................................................5-11
Air Manifolds (Air Bars/Air Jets) .............................................................5-11
Pneumatic Clutch/Brake .........................................................................5-11
5.3 Mechanical System ............................................................................... 5-12
Main Drive System ................................................................................ 5-12
Primary Fold Ski Drive System .............................................................. 5-12
Stacker Drive System ............................................................................ 5-13
Exit and Return Drive Systems ............................................................. 5-13
Ribbon Sets ........................................................................................... 5-14
5.4 Sequence of Operation ......................................................................... 5-15
Stand-by Phase ..................................................................................... 5-15
Start-up Phase ...................................................................................... 5-15
Primary Fold Phase ............................................................................... 5-16
Crossfold Phrase ................................................................................... 5-16
Stacking Phase ..................................................................................... 5-16

Air Chicago (Standard/XW/XL/XXL) Table of Contents
vii
CHAPTER 6 TROUBLESHOOTING
Troubleshooting Symptoms ............................................................................... 6-2
6.1 CHI Diagnostic Message Index ............................................................... 6-6
6.2 LED Diagnostics ...................................................................................... 6-8
6.3 Electrical ................................................................................................ 6-10
6.4 Mechanical ............................................................................................ 6-13
6.5 Primary Folding ..................................................................................... 6-14
6.6 First Crossfold ....................................................................................... 6-17
6.7 Second Crossfold .................................................................................. 6-19
6.8 Stacker .................................................................................................. 6-20
6.9 Exit/Return Conveyors .......................................................................... 6-21
6.10 Sensor Function .................................................................................... 6-22
6.11 CHI Panel .............................................................................................. 6-23
6.12 Compressed Air System ........................................................................ 6-24

Table of Contents Air Chicago (Standard/XW/XL/XXL)
viii
CHAPTER 7 REPAIR
7.1 Safety Considerations ............................................................................. 7-2
7.2 Parts Availability ...................................................................................... 7-3
7.3 Ribbons ................................................................................................... 7-3
Inlet Ribbon Tension Adjustment ............................................................. 7-4
Primary Fold Ribbon Tension Adjustment ............................................... 7-4
Intermediate Ribbon Tension Adjustment ................................................ 7-5
Transfer Ribbon Tension Adjustment ...................................................... 7-6
Stacker Ribbon Tension Adjustment ........................................................ 7-7
Exit Conveyor Ribbon Tension Adjustment ............................................. 7-8
Return Conveyor Ribbon Tension Adjustment ......................................... 7-9
Ribbon Replacement ............................................................................. 7-10
7.4 Rolls ...................................................................................................... 7-12
First Crossfold Pinch Point Gap Adjustment ......................................... 7-12
Tracking Tape Overview ........................................................................ 7-14
White Tracking Tape Replacement ........................................................ 7-15
Grey Tracking Tape Replacement ......................................................... 7-16
Riveted Tracking Tape Replacement ..................................................... 7-17
7.5 Chains and Belts ................................................................................... 7-19
Main Drive Chain Tension Adjustment ................................................... 7-19
Primary Fold Ski Drive Chain Tension Adjustment ................................ 7-20
Primary Fold Ribbon Drive Chain Tension Adjustment .......................... 7-21
Transfer Ribbon Drive Chain Tension Adjustment ................................. 7-22
Inlet Ribbon Drive Belt Tension Adjustment .......................................... 7-23
Stacker Ribbon Drive Belt Tension Adjustment ..................................... 7-24
Primary Fold Ski Position Adjustment ................................................... 7-25
7.6 Mechanical Adjustments ....................................................................... 7-28
Primary Fold Conveyor Stop Position Adjustment ................................ 7-28
Clutch Adjustment ................................................................................. 7-29
Second Crossfold Steel Fingers Adjustment ......................................... 7-30
Stacker Door Mechanical Adjustments ................................................. 7-31

Air Chicago (Standard/XW/XL/XXL) Table of Contents
ix
7.7 Sensors ................................................................................................. 7-32
Photosensor Replacement .................................................................... 7-32
Primary Fold Ski Position Detect Proximity Sensor Adjustment ............ 7-34
Primary Fold Ski Position Detect Proximity Sensor Replacement ........ 7-35
Stacker Proximity Sensor Adjustment ................................................... 7-36
Stacker Proximity Sensor Replacement ................................................ 7-38
Primary Fold Skis Limit Switch Adjustment ........................................... 7-39
7.8 Compressed Air System ........................................................................ 7-41
Primary Fold Air Manifold Alignment ..................................................... 7-41
Crossfold Air Manifold Alignment .......................................................... 7-42
Stacker Door Air Cylinder Air Flow Adjustment ..................................... 7-43
Air Valve Repair ..................................................................................... 7-44

Air Chicago (Standard/XW/XL/XXL) Installation
2-1
Chapter 2
INSTALLATION
This chapter contains installation instructions for the Air Chicago® which are in the below listed
sections.
2.1 Site and Utility Requirements
2.2 Installation Procedures
2.3 Pre-Operational Checkouts
The unit was tested under load conditions at the factory and inspected to ensure proper operation.
It was shipped in working condition and is completely assembled. Sufficient strapping, blocking, and
bracing were provided to give reasonable assurance that no shipping damage would occur.
NOTE: Notify the carrier at once if the unit is received in damaged condition.
Chicago Dryer Company’s responsibility for shipping damage, other than the standard warranty,
ceases upon delivery to the carrier. For more information on the warranty, see the full page warranty
statement at the front of this manual.

Installation Air Chicago (Standard/XW/XL/XXL)
2-2
2.1 Site and Utility
Requirements
See Figure 2-1 for the clearances required by
the Air Chicago. As the figures show, the unit
can be set up for left return, right return or rear
discharge.
The clearance dimensions noted are the
minimums recommended for efficient production
and service, as well as for maintenance access.
Provide enough room at the discharge end of the
machine to receive finished items.
NOTE: The correct location of the
unit is of extreme importance.
The site should have a relatively level,
sturdy floor capable of supporting the unit’s
weight without significant flexing. For weight
specifications, refer to the APPENDIX, Technical
Specifications.
No special foundation, floor grouting, or
installation of anchors is required. Generally,
the locking wheels will hold the unit in position
and still allow for repositioning when necessary.
Floor grouting or installation of anchors may be
required to comply with local codes or conditions,
or aboard a ship.
Compressed air that is clean and dry must
be provided for the unit. This is very important
because the air will blow directly on the flatwork.
The compressed air supply must meet the
pressure and air flow requirements noted in the
APPENDIX, Technical Specifications.
The electrical requirements of the folder are
shown on the nameplate (Figure 2-2), located on
the right side of the inlet conveyor. Additional
information can be found in the APPENDIX,
Technical Specifications.
Wiring and a separate, fused disconnect
switch of suitable size must be locally supplied
if local codes require one. Check local codes for
clearance requirements to any electrical box.
Figure 2-2: The nameplate contains important
information.

Air Chicago (Standard/XW/XL/XXL) Installation
2-3
Figure 2-1: Recommended clearances for Air Chicago installation.
24" 24"
24"
24"
24"
24"
24"
24" 24"

Installation Air Chicago (Standard/XW/XL/XXL)
2-4
2.2 Installation
Procedures
Installation of the unit includes:
Inspection
Uncrating and Positioning
Compressed Air Supply Connection
Electrical Connection
Final Protective Wrapper Removal
•
•
•
•
•
Inspection
Carefully inspect all shipments before they
are accepted from the carrier. Upon delivery,
make sure all items listed on the bill have been
received.
Any shortage, breakage, or damage noticed at
the time of delivery should be indicated on the
carrier’s freight bill and signed by the driver or
carrier’s representative.
Damage noticed after delivery should be
reported to the carrier at once. Request their
inspection of the shipment and fill out a concealed
damage inspection report.
NOTE: N o t i f y t h e c a r r i e r
immediately if any damage has
been done to the unit during
shipment.

Air Chicago (Standard/XW/XL/XXL) Installation
2-5
Uncrating and Positioning
Required Tools
forklift, crowbar, sledgehammer, wire
cutters/knife, wrench
Before unpacking the unit, make sure that
the proposed site is acceptable and any nec-
essary foundations have been prepared.
Remove the crating, strapping, and other
packaging materials except the protective
plastic cover.
Open both endframe doors and remove any
materials shipped with the unit. Close and
secure the doors.
Remove the exit conveyor from the skids.
Set this aside. Remove the return conveyor
from its separate crate. Set it aside.
CAUTION
Do not drop or twist the unit.
Carefully remove the machine from the
skids. Be careful not to drop or twist the
unit.
1.
2.
3.
4.
5.
Move the unit into final position and lock
the casters. The endframes of the machine
should rest firmly on the floor. Secure the
unit to its foundation if required by local
code or conditions.
Determine how the exit and return convey-
ors are to be set up. See Figure 2-1 for il-
lustrations. Choose one of the following:
For left discharge, place the exit con-
veyor under the unit with the motor
toward the front of the unit. Place the
return conveyor on the left side of the
unit.
For right discharge, place the exit
conveyor under the unit with the motor
toward the rear of the unit. The motor
will protrude slightly beyond the rear
of the machine. Place the return con-
veyor on the right side of the unit.
For rear discharge, place the return
conveyor directly under the stacker
doors. Position it so that folded pieces
will drop directly onto it from the trap
doors. The exit conveyor is not used
for rear discharge.
Set the return conveyor to match up with
the discharge of the exit conveyor.
6.
7.
•
•
•
8.

Installation Air Chicago (Standard/XW/XL/XXL)
2-6
Compressed Air Supply Connection
The folder requires a compressed air supply
to fold the flatwork. The air must be clean and
dry. This is very important because air will blow
directly on the flatwork.
The compressed air supply must meet the
pressure and airflow requirements noted in the
APPENDIX, Technical Specifications.
The connection is made to the filter/drain/
regulator unit at the right front of the unit (Figure
2-3). The compressed air supply should be
equipped with a separate shut-off valve and a dirt
leg with a drain cock, supplied locally.
Required Tools
wrench, Teflon tape/pipe compound
NOTE: The compressed air
supply hose must be at least 1/2”
in diameter.
Run copper tubing, or a sturdy flexible
hose, if preferred, from the external source
to the 1/2” inlet fitting (Figure 2-3, A).
Use Teflon tape or pipe joint compound
to assure leakproof connections.
Run tubing from the 1/4” drain fitting
(Figure 2-3, B) to an open drain, such
as a floor drain. Use Teflon tape or pipe
joint compound to assure leakproof con-
nections.
CAUTION
Do NOT turn on the
compressed air supply at
this time.
1.
2.
Figure 2-3: The compressed air supply connection
at the right front of the unit.
A
B

Air Chicago (Standard/XW/XL/XXL) Installation
2-7
Exit and Return Conveyors Power
Connections
On the outer wall of the left endframe near
the front of the unit, is a pair of electrical
outlets (Figure 2-5). One of these is for the
exit conveyor motor and the other is for
the return conveyor motor.
Plug each motor into one of the outlets.
They are interchangeable so it does not
matter which plug goes into which out-
let.
Give each plug about a 1/8 clockwise twist
to lock it in place.
1.
2.
3.
Electrical Connection
The nameplate (Figure 2-2), located on
the right side of the inlet conveyor, shows the
electrical requirements of the folder. All labor and
materials required to bring the electrical service
to the unit are a local responsibility.
All electrical wiring must comply with local
codes and a qualified electrician must size and
connect the wiring.
CAUTION
The incoming electric
power service must match
the specific electrical
requirements as shown on
the nameplate.
See the unit’s nameplate to determine the
power supply requirements. If high or low voltage
is suspected, check the electrical service to
determine the actual voltage conditions. Improper
or fluctuating voltage may damage motors and
other electrical system components, and void the
factory warranty.
NOTE: A fused disconnect
switch is incorporated into the
electrical connection box (Figure
2-4, A). Check local regulations
to determine whether a separate
external fused disconnect switch
is also required. Follow local
codes at all times.
Figure 2-4: Electrical connection box at the left
front of the unit.
A
B
Figure 2-5: Power connections for the exit and
return conveyors are simple plugs.

Installation Air Chicago (Standard/XW/XL/XXL)
2-8
Pacing Light (Option) Attachment
The pacing light is shipped protective wrapper
inside the front right endframe.
Remove the pacing light from its protec-
tive wrapper.
At the left front of the unit, align the white
arrow on the light with the black arrow on
the base (Figure 2-6).
Twist about 1/8 turn clockwise to lock
into position.
1.
2.
3.
Figure 2-7: Rotate the yellow lever on the main
disconnect switch before attempting to
open or close the electrical connection
box.
Main Power Connection
Required Tools
screwdriver
WARNING
Only a qualified electrician
should make the electrical
connections to the unit.
Improper installation could
result in serious injury.
The main disconnect switch is located on
the electrical connection box at the left
front of the unit (Figure 2-4, A). Turn it
to the OFF position.
Turn the door latch (Figure 2-4, B) on the
electrical connection box counterclock-
wise.
Rotate and hold the yellow lever while
holding the main disconnect switch in the
OFF position (Figure 2-7), then open the
electrical connection box door.
Bring the electrical supply lines to the
electrical connection box. Use three wires
for the power supply and a green fourth
wire for ground.
1.
2.
3.
4.
Figure 2-6: The pacing light is fixed in position
with a twist.

Air Chicago (Standard/XW/XL/XXL) Installation
2-9
Extend the wires through conduit or
greenfield. If it will be necessary to move
the folder, leave plenty of slack in the
greenfield for this purpose.
Temporary wires can be seen extending
from the fused disconnect switch and out
through the box. Pull these temporary
wires into the box and remove them.
Pull the external wiring through the hole in
the electrical box and secure the conduit or
greenfield to the box. Follow local codes
at all times.
Connect the three incoming power wires to
the fused terminals of the main disconnect
switch (Figure 2-8, A).
Connect the ground wire to the grounding
lug, (Figure 2-8, B).
WARNING
The unit must be properly
grounded to ensure operator
safety in case of
electrical malfunction.
Make sure the other end of the ground wire
is connected to a proper earth ground.
Close and latch the electrical connection
box after all electrical connections have
been made.
CAUTION
Do not attempt to start the
unit at this time. Leave the
disconnect switch set to OFF.
5.
6.
7.
8.
9.
10.
11.
Final Protective Wrapper Removal
After the unit is positioned, secured and
connected, remove the protective plastic covers.
Make sure that all brown paper, plastic and tape
have been completely removed. Remove the
protective plastic covers from the controls.
Figure 2-8: Electrical connections are made in
the electrical connection box near the
front left of the unit.
B
A