Chicago Dryer King Edge VAc User manual

KING EDGE VACTM
Large Piece
Spreader/Feeder with
Vacuum Laydown
and Air Assist
INSTRUCTION MANUAL

©Chicago Dryer Company
Instruction Manual #3018-041b
CHICAGO DRYER COMPANY
2200 N. Pulaski, Chicago, Illinois USA 60639-3737
Telephone: [phone] Fax: [phone] www.chidry.com

King Edge Vac 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 PANEL BULLETIN
PICTURE PARTS LIST
SCHEMATIC PARTS LIST
APPENDIX
Floor Plans
Technical Specifications
Torque Specifications
INDEX
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INDEX

Table of Contents King Edge Vac
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
Machine Widths ....................................................................................... 1-6
Optional Equipment ................................................................................. 1-6
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King Edge Vac 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, Placement and Alignment ...................................................... 2-4
Discharge Conveyor Attachments ........................................................... 2-6
Floor Trough Installation .......................................................................... 2-7
Inlet Conveyor Upper Pulley Installation ................................................. 2-7
Compressed Air Supply Connection ....................................................... 2-8
Electrical Connection .............................................................................. 2-9
2.3 Pre-Operational Checkout ..................................................................... 2-14
Final Protective Wrapper Removal ........................................................ 2-14
Security of Hardware ............................................................................. 2-14
Clean the Corner Photosensors ............................................................ 2-15
Compressed Air Supply Checkout ........................................................ 2-15
Blower Rotation Checkout ..................................................................... 2-17
Safety Device and Control Function Checkout ..................................... 2-18
Spread/Feed Function Check ............................................................... 2-20
Checkout Completion ............................................................................ 2-21
Cleaning the Unit ................................................................................... 2-21
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Table of Contents King Edge Vac
iv
CHAPTER 3 OPERATING GUIDELINES
3.1 Safety Features ....................................................................................... 3-2
Main Disconnect Switch .......................................................................... 3-2
Safety Guards ......................................................................................... 3-2
Safety STOP Buttons .............................................................................. 3-2
Safety Interlock Switches ........................................................................ 3-3
Safety Labels .......................................................................................... 3-3
3.2 Operating Controls .................................................................................. 3-4
CHI Panel Controls and Indicators .......................................................... 3-6
3.3 Daily Operating Procedures .................................................................... 3-7
Start-Up ................................................................................................... 3-7
Interconnected Stop Circuit (Option) Operation Notes ............................ 3-8
Flatwork Handling ................................................................................... 3-9
Handling Jams and Misfeeds Safely ..................................................... 3-12
Shut-Down ............................................................................................ 3-13
3.4 Operating Techniques ........................................................................... 3-13
Maximum Efficiency .............................................................................. 3-13
Maximum Feeding Speed ..................................................................... 3-13
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King Edge Vac 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
Clean Lint Bags and Exhaust Blower Ports ............................................ 4-3
Check Safety Equipment ......................................................................... 4-3
4.2 Weekly PM (50 Hours) ............................................................................ 4-4
Check and Clean Photosensors and Reflectors ..................................... 4-4
Check and Clean Inverters ...................................................................... 4-5
Check For String Accumulation ............................................................... 4-5
Check Rodless Air Cylinder Bearings ..................................................... 4-5
Inspect Inlet Transfer Rodless Air Cylinder ............................................. 4-6
Check Pneumatic Clutch/Brake Roller Alignment ................................... 4-8
Check Spreader Clamp Linear Bearing Assemblies ............................... 4-8
Check Carriage Rail Bearings and Lubricate Upper Spreader Rail,
Carriage Rails and Rail Bearings ............................................................ 4-9
Inspect Air Filter/Auto Drain .................................................................. 4-10
Check Air Pressure Settings ................................................................. 4-10
Check Belt and Ribbon Condition and Tension ..................................... 4-12
4.3 Monthly PM (200 Hours) ....................................................................... 4-13
Clean and Lubricate Drive Chains and Friction Roll Hinge ................... 4-13
Check Upper and Lower Spreader Belt Condition and Tension ............ 4-14
Inspect Drive Belt Condition .................................................................. 4-15
Check Setscrews................................................................................... 4-15
Clean Vacuum System .......................................................................... 4-15
4.4 Semi-Annual PM (1000 Hours) ............................................................. 4-16
Clean Air Filter/Auto Drain ..................................................................... 4-17
Check and Grease Bearings ................................................................. 4-18
Replace Rodless Air Cylinder Bearings ................................................ 4-20
4.5 Annual PM (2000 Hours) ....................................................................... 4-22
Check All Electrical Connections ........................................................... 4-23
Check Insulation Resistance to Earth Ground ...................................... 4-23
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Table of Contents King Edge Vac
vi
CHAPTER 5 OPERATING PRINCIPLES
Safety ................................................................................................................ 5-2
5.1 Electrical System ..................................................................................... 5-2
Power System ......................................................................................... 5-2
Control System ........................................................................................ 5-9
5.2 Compressed Air System ........................................................................ 5-16
Air Filter/Regulators............................................................................... 5-16
Air Pressure Switch ............................................................................... 5-16
Air Reservoir .......................................................................................... 5-16
Air Valves/Air Valve Solenoids .............................................................. 5-16
Air Cylinders .......................................................................................... 5-17
Flow Controls ........................................................................................ 5-17
Air Bars .................................................................................................. 5-17
Pneumatic Clutch/Brake ........................................................................ 5-17
5.3 Mechanical System ............................................................................... 5-18
Prefeed Drive System ........................................................................... 5-18
Inlet Drive System ................................................................................. 5-19
Spread Drive System ............................................................................ 5-20
Discharge Drive System ........................................................................ 5-21
ByPass Drive System ............................................................................ 5-21
5.4 Sequence of Operation ......................................................................... 5-22
Stand-by Phase ..................................................................................... 5-23
Start-up Phase ...................................................................................... 5-23
Prefeed/Input Phase ............................................................................. 5-24
Transfer Phrase ..................................................................................... 5-24
Spread Phase ....................................................................................... 5-25
Large Piece Discharge Phase ............................................................... 5-25
Small Piece (ByPass Conveyor) Discharge Phase ............................... 5-26
Error Conditions .................................................................................... 5-26
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King Edge Vac 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 ............................................................................................ 6-14
6.5 Prefeed/Inlet Section ............................................................................. 6-15
6.6 Transfer Section .................................................................................... 6-18
6.7 Spread Section ...................................................................................... 6-20
6.8 Discharge Section ................................................................................. 6-24
6.9 Sensor Function .................................................................................... 6-27
6.10 CHI Panel .............................................................................................. 6-28
6.11 Compressed Air System ........................................................................ 6-29
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Table of Contents King Edge Vac
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CHAPTER 7 REPAIR
7.1 Safety Considerations ............................................................................. 7-2
7.2 Parts Availability ...................................................................................... 7-3
7.3 Prefeed/Inlet Section ............................................................................... 7-3
Prefeeder Carriage Eccentric Grooved Bearing Adjustment ................... 7-4
Prefeeder Carriage Grooved Bearing Replacement ............................... 7-5
Prefeeder Carriage Belt Tension Adjustment .......................................... 7-6
Prefeeder Carriage Belt Replacement .................................................... 7-7
Pneumatic Clutch/Brake Roller Alignment .............................................. 7-8
Pneumatic Cutch/Brake Roller Drive Belt Tension Adjustment ............... 7-9
Inlet Conveyor Drive Belt Tension Adjustment ...................................... 7-10
Enabling/Disabling Automatic Misfeed Reject ....................................... 7-10
7.4 Transfer Section .....................................................................................7-11
Transfer Clamp Check and Adjustment ..................................................7-11
Transfer Clamp Assembly Replacement ............................................... 7-14
Transfer Clamp Roller Adjustment ........................................................ 7-16
Rodless Air Cylinder Carrier Bracket Tension Adjustment ..................... 7-17
7.5 Spread Section ...................................................................................... 7-17
Spreader Clamp Mechanical Adjustment .............................................. 7-18
Upper Spreader Belt Tension Adjustment ............................................. 7-18
Upper Spreader Belt Replacement ....................................................... 7-19
Upper Spreader Clamp Grooved Bearing Replacement ....................... 7-20
Lower Spreader Drive Belt Tension Adjustment .................................... 7-22
Lower Spreader Drive Belt Replacement .............................................. 7-23
Lower Spreader Belt Tension Check/ Replacement .............................. 7-23
Lower Spreader Belt Gap Adjustment ................................................... 7-24
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Repair topics continued on the next page...

King Edge Vac Table of Contents
ix
7.6 Discharge/ByPass Section .................................................................... 7-26
Discharge/ByPass Conveyors Ribbon Tension Adjustment .................. 7-26
Discharge/ByPass Conveyors Ribbon Replacement ............................ 7-27
Discharge Conveyor Guide Ribbon Tension Adjustment/Replacement 7-30
Discharge Conveyor Drive Belt Tension Adjustment ............................. 7-31
ByPass Conveyors Drive Belt Tension Adjustment ............................... 7-31
Discharge/ByPass Conveyor Drive Roll Tracking Tape Replacement .. 7-32
Discharge Conveyor Doffer Roll Pressure Adjustment .......................... 7-36
Discharge Conveyor Doffer Roll Cover Replacement ........................... 7-37
7.7 Sensors ................................................................................................. 7-39
Corner Photosensors Alignment ........................................................... 7-40
Roll Photosensors Alignment ................................................................ 7-41
Taut Photosensors Alignment ................................................................ 7-42
General Photosensor Sensitivity Adjustment ........................................ 7-43
Roll Photosensors Sensitivity Adjustment ............................................. 7-44
Photosensor Replacement .................................................................... 7-45
Proximity Sensor Positioning Adjustment .............................................. 7-46
Proximity Sensor Replacement ............................................................. 7-47
7.8 Compressed Air System ........................................................................ 7-47
Air Cylinder Air Flow Adjustment ........................................................... 7-48
Inlet Clamps Air Pressure Adjustment ................................................... 7-51
Roller Counterpoint Air Pressure Adjustment ........................................ 7-52
Inlet Transfer Rodless Air Cylinder Service ........................................... 7-53
Left Spreader Clamp Air Pressure Adjustment ...................................... 7-60
Air Bar Alignment .................................................................................. 7-61
Finger Assist Air Pressure Adjustment .................................................. 7-62
Air Foil Adjustment ................................................................................ 7-63
Air Laydown Assist Air Pressure Adjustment ......................................... 7-64
Blower Gate Air Cylinder Adjustment .................................................... 7-65
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King Edge Vac Introduction
1-1
Figure 1-1: The King Edge Vac provides high quality spreading and feeding.
Chapter 1
INTRODUCTION
This chapter includes the following sections:
1.1 Warranty 1.3 Safety
1.2 Scope of Manual 1.4 Equipment Description
The King Edge VacTM automatic cornerless spreader/feeder allows operators to feed sheets or other
large pieces of flatwork into a flatwork ironer or automatic folder from two stations. A built-in bypass
conveyor allows feeding of small pieces through the King Edge Vac without altering the position of
the feeder or its discharge conveyor. It uses a vacuum box for laydown with a rear air bar and brush to
help ensure the highest quality of flatwork finishing.
Like the rest of the CHICAGO® product line, the King Edge Vac (Figure 1-1) is designed, manufactured,
and assembled in Chicago, Illinois. Before the CHICAGO® nameplate is affixed to any machine, a final
inspection is performed, including thorough testing under load conditions.
Any questions concerning the installation, operation, or repair of the unit should be directed to a local
authorized CHICAGO® dealer or the Chicago Dryer Company factory Service Department at:
 Chicago Dryer Company  [phone]
2200 North Pulaski Fax [phone]
Chicago, Illinois USA 60639-3737 Email [e-mail]
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Introduction King Edge Vac
1-2
1.1 Warranty
A full page warranty statement is located at
the front of this instruction manual. Please take
the time to review this warranty and understand
its provisions.
1.2 Scope of Manual
This instruction manual will help you keep
your CHICAGO® product operating safely,
efficiently and with minimum expense. Individual
chapters in this manual provide the necessary
information required for safe installation,
operation, maintenance, troubleshooting, and
repair of the unit.
Updates
Occasionally, new information about the
unit becomes available after publication of this
manual. If you receive a CHICAGO® FYI Service
Bulletin pertaining to our unit, insert the bulletin
in the front of the manual.
Chapter 1 - Introduction
Provides an overview of the unit and its key
features, of this manual, and of important safety
features.
Chapter 2 - Installation
Describes recommended procedures for
determining a suitable location for the unit and
connecting the electrical and the compressed air
supplies. This chapter also includes checkout
procedures to ensure all systems are working
properly. Local requirements often vary, so follow
local codes at all times.
Chapter 3 - Operating Guidelines
Gives recommendations for operating the unit
at maximum efficiency. This chapter also includes
instructions for the operators and suggestions for
work organization.
Chapter 4 - Preventive Maintenance
Contains procedures for Daily, Weekly,
Monthly, Semi-Annual, and Annual
maintenance. Follow these procedures to keep the
unit operating safely and at maximum efficiency.
A Preventive Maintenance schedule is located at
the front of the chapter.
Chapter 5 - Operating Principles
Describes the operation of the unit in detail. A
good understanding of this chapter will help avoid
operation errors and assist with trouble shooting
and maintenance.
Chapter 6 - Troubleshooting
Contains issues, possible causes, and solutions
in all areas of operation.
Chapter 7 - Repair
Contains procedures for making adjustments,
repairs and parts replacement for the unit. Please
follow all safety recommendations carefully.
CHI Panel Operation Bulletin
Describes in detail the operation of the
CHI Panel spreading/feeding control system.
Programming, adjustment and test modes are
detailed in this bulletin.
Parts List
Contains detailed drawings and part
specifications to assist in ordering replacement
parts. It is divided into views in which the parts
are grouped by function.
Schematics
Contains electrical drawings showing power
and motor circuits, control circuits and interlock
circuits, and other relevant drawings.
Appendix
Contains Technical Specifications, a Floor
Plan, and other relevant information for the
unit.
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King Edge Vac Introduction
1-3
1.3 Safety
Safe operation and maintenance of the unit
must be the first priority of all supervisors,
operators and maintenance personnel. Safety
begins with safe work habits. In addition, the
unit is equipped with built-in features to promote
safety.
Safe Work Habits
During Daily Operation
Take the flatwork only after it has
cleared the unit. Do not pull on the
flatwork while it is still in the machine.
Post the “Operator Safety” reminders
in a place where everyone will see it.
Read these reminders and follow the
recommendations.
Read and follow all safety labels.
Keep hands and clothing away from
the moving parts of the spreader/feeder
while it is operating.
Always turn off the unit before clearing
a jam.
Operate the unit only with all guards and
endframe doors in place and all safety
features operating correctly. Never
operate the unit with any safety features
bypassed.
•
•
•
•
•
•
Maintenance and Repair
WARNING
Always use extreme caution
when performing any repair
procedure that requires the
unit to be operating.
Keep hands and loose
clothing from coming into
contact with any of the
moving parts.
Serious Injury Could Result.
When the unit is running, one
person should be ready at a
red safety STOP button
at all times.
Before attempting any repair work, review
these safety steps and precautions to protect
yourself and the unit.
Safety should be the primary concern
of anyone performing corrective
maintenance.
Except where specifically directed, make
sure that the main disconnect switch to
incoming power is OFF.
It is recommended that all maintenance
procedures be handled by at least two
qualified persons. Using the “buddy
system” decreases the risk of an
accident.
Your site should have procedures that
comply with government regulations and
standards for equipment lockout/tagout
during maintenance and repair. Ask your
supervisor for specific information. It
is the users’ responsibility to make sure
they comply with all safety procedures.
•
•
•
•
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Introduction King Edge Vac
1-4
WARNING
Know the proper procedure
for locking out and tagging
equipment during repair
procedures.
Follow the rules of your work
site. Failure to do so could
result in serious injury.
Make sure the power
is disconnected before
servicing the unit.
Do not repair or correct any
condition without reading
and understanding the
REPAIR chapter.
Only qualified personnel
should troubleshoot and
repair this unit.
Safety Features
There are several general categories of safety
features:
Main Disconnect Switch
Safety Guards
Safety Interlock Switches
Safety STOP Buttons
Safety Labels
Safety Messages in the Manual
Main Disconnect Switch
The main disconnect switch is located on the
outside of the main electrical box. When turned
to OFF, this switch shuts off incoming electrical
power to the unit.
Unless otherwise indicated, turn the main
disconnect switch to OFF before performing any
maintenance or repair work.
For more information on operating the main
disconnect switch, refer to the INSTALLATION
chapter, Installation Procedures section,
Electrical Connection procedure.
Safety Guards
A front safety guard runs the entire length of
the unit’s working area and physically restricts
hands from coming into contact with moving
parts.
Both endframes and other appropriate areas
of the unit are covered with protective panels to
prevent fingers or hands from coming into contact
with moving parts. The guards and panels also
serve to keep foreign objects from entering the
unit and damaging components.
When a panel is removed or the front guard is
raised, all rotating parts stop moving.
•
•
•
•
•
•
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King Edge Vac Introduction
1-5
Figure 1-2: Safety labels remind operators and
maintenance personnel that care must
be taken when working near these
areas.
Safety Interlock Switches
Safety interlock switches are located behind
each endframe panel and the front guard.
Whenever any of these components is opened or
removed, its associated interlock switch is opened
and all rotating parts stop moving.
The safety interlock switches are not intended
to lockout the unit. Site management is responsible
for developing and implementing lockout/tagout
procedures that comply with government
standards for use when servicing the unit.
Safety STOP Buttons
There are six red safety STOP buttons arrayed
around the unit, one at each corner and one at each
operator station. Pressing any of these buttons
immediately stops all rotating and moving parts,
releases compressed air pressure, and shuts down
the machine. To reset a pressed red safety STOP
button, twist it.
The preferred method of stopping the operation
of the unit is by pressing one of the square red
Stop buttons located at each operator station.
Safety Labels
Orange Warning and yellow Caution labels
(Figure 1-2) are placed at locations around the
unit to keep operators and maintenance personnel
alert in particular areas.
WARNING message labels alert personnel that
personal injury may result from not following
recommended procedures.
CAUTION message labels alert personnel that
the machine may be damaged if conditions,
practices, or procedures are not observed.
When training operators, take the time to
review, understand, and locate all areas where
labels are posted.
NOTE: Do not remove safety
labels at any time. If a label
needs to be replaced, contact
Chicago Dryer Company for free
replacements.
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Introduction King Edge Vac
1-6
Safety Messages in this Manual
WARNING and CAUTION messages also
appear in this manual to highlight essential safety
information.
WARNING messages alert personnel that
personal injury may result from not following
recommended procedures.
WARNING
Never bypass any of the
safety devices. This could
result in serious injury.
BLACK BOX WARNING messages alert
personnel of the operating condition a unit
must be in before performing any procedure.
Personal injury may result from not following
recommended procedures.
Perform only when the unit is OFF
with power disconnected.
CAUTION messages alert personnel that the
unit may be damaged if conditions, practices,
or procedures are not observed.
CAUTION
The incoming electric power
must match the electrical
requirements as shown on
the nameplate.
1.4 Equipment Description
A general overview of the King Edge Vac
spreader/feeder includes:
Machine Widths
Optional Equipment
Machine Widths
The King Edge Vac comes in a standard 120”
(3050 mm) width. Extra wide models including
130” (3300 mm), 136” (3455 mm) and wider are
also available for processing California kings,
banquet cloths or other oversized items.
Optional Equipment
The following optional equipment is available
on all models:
Interconnected Stop Circuit: Pressing a red
safety STOP button on the feeder, ironer or folder
stops the entire finishing line.
Variable Speed Interconnect: The speeds of
each machine in a finishing line are automatically
coordinated for maximum efficiency.
Single Point Electrical Connection: Allows
the unit to receive its electrical supply from the
ironer.
Chicago Automatic Reject Processor:
Allows operator to press a stain or tear reject
button after a piece is fed into the unit for
automatic handling by the Chicago® folder at the
end of the finishing line.
Pacing Lights: Allows operating standards
to be set and provides a visual signal to indicate
whether operators are reaching target production
rates.
Lifting Conveyor: Uses compressed air to
raise and position the discharge conveyor.
ChiLinc: Production data collection and
reporting system for archiving and analysis of
production and efficiency information.
•
•
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King Edge Vac Installation
2-1
Chapter 2
INSTALLATION
This chapter contains installation instructions for the King Edge VacTM spreader/feeder and includes
the following sections:
2.1 Site and Utility Requirements
2.2 Installation Procedures
2.3 Pre-Operational Checkout
The spreader/feeder is tested under load conditions at the factory and inspected to ensure proper
operation. It is shipped in working condition and is completely assembled, requiring only setup of the
exit conveyors. Sufficient strapping, blocking, and bracing were provided to give reasonable assurance
that no shipping damage would occur.
NOTE: If the spreader/feeder is received in damaged condition, notify the carrier
at once.
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.
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Installation King Edge Vac
2-2
2.1 Site and Utility
Requirements
Figure 2-1 shows the clearances required for
the spreader/feeder. The dimensions noted are the
minimums recommended for efficient production
and service, as well as maintenance access. It is
strongly recommended that enough clear space
be provided around the spreader/feeder to allow
for efficient access.
NOTE: The correct location of
the spreader/feeder is of extreme
importance.
The site must have a level, sturdy floor capable
of supporting the spreader/feeder’s weight without
significant flexing. For weight specifications
and other technical information refer to the
APPENDIX, Technical Specifications.
No special foundation, floor grouting, or
installation of anchors is required. Generally,
the locking wheels will hold the spreader/feeder
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.
Figure 2-1: Recommended clearances for installation of the King Edge.
36”
(915 mm)
36”
(915 mm)
72” (1830 mm)
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