Maxi Comet Executive Exec-56-G User manual

INSTRUCTION MANUAL
COMET EXECUTIVE™
Gas Heated
Flatwork Ironer

Instruction Manual #3011-102f
MAXI Companies
4317 E. Genessee Street, Dewitt, New York 13214 USA
Phone: [phone] Fax: [phone]
E-mail: [email protected]

Comet Executive Gas 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
PICTURE PARTS LIST
SCHEMATIC PARTS LIST
APPENDIX
Floor Plans
Technical Specications
Manufacturer’s Bulletins
Torque Specications
Operating Standard
INDEX
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INDEX

Table of Contents Comet Executive Gas
ii
CHAPTER 1 INTRODUCTION
1.1 Warranty.................................................................................................. 1-2
1.2 Scope of the Manual ............................................................................... 1-2
1.3 Safety ...................................................................................................... 1-3
Safe Work Habits .................................................................................... 1-3
Safety Features....................................................................................... 1-4
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Comet Executive Gas 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
Exhaust Blower Installation ..................................................................... 2-5
Electrical Connection............................................................................... 2-8
Gas Connection..................................................................................... 2-12
Receiving Shelf Set-Up ......................................................................... 2-14
Final Protective Wrapper Removal........................................................ 2-15
2.3 Pre-Operational Checkout..................................................................... 2-15
Security of Hardware............................................................................. 2-16
Exhaust Blower Motor Rotation Checkout............................................. 2-17
Safety Device and Control Function Checkout...................................... 2-18
Ironing Cylinder Paper Removal ........................................................... 2-19
Gas Connection Checkout .................................................................... 2-20
Checkout Completion............................................................................ 2-25
Cleaning the Unit................................................................................... 2-25
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Table of Contents Comet Executive Gas
iv
CHAPTER 3 OPERATING GUIDELINES
3.1 Safety Features....................................................................................... 3-2
Main Disconnect Switch .......................................................................... 3-2
Safety Stop Buttons................................................................................. 3-2
Safety Guards ......................................................................................... 3-2
Safety Interlock Switch............................................................................ 3-3
Safety Labels........................................................................................... 3-3
3.2 Operating Controls .................................................................................. 3-4
Right Endframe Controls......................................................................... 3-4
Left Endframe Controls ........................................................................... 3-5
3.3 Standard Operating Procedures.............................................................. 3-6
Start-Up................................................................................................... 3-6
Waxing .................................................................................................... 3-7
Flatwork Handling.................................................................................... 3-9
Clearing a Jam Safely ........................................................................... 3-10
Shut-Down..............................................................................................3-11
3.4 Operating Techniques ........................................................................... 3-12
Conditioning Flatwork Before Ironing .................................................... 3-12
Unit Settings.......................................................................................... 3-14
Processing Standards ........................................................................... 3-15
Maximum Productivity ........................................................................... 3-15
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Comet Executive Gas Table of Contents
v
CHAPTER 4 PREVENTIVE MAINTENANCE
PM Task Tables .................................................................................................. 4-1
Daily, Weekly Tasks................................................................................. 4-1
Monthly, Semi-Annual Tasks ................................................................... 4-2
4.1 Daily PM (8 Hours).................................................................................. 4-3
Watch and Listen for Anything Abnormal ................................................ 4-3
General Cleanliness................................................................................ 4-3
Check and Clean Temperature Sensor Contact Shoes........................... 4-4
Check Guide Tapes ................................................................................. 4-4
Check Safety Equipment......................................................................... 4-5
Wax Ironing Cylinder ............................................................................... 4-5
4.2 Weekly PM (50 Hours) ............................................................................ 4-6
Clean Behind Service Panels.................................................................. 4-6
Check Ironing Cylinder............................................................................ 4-7
Check and Clean Inverter........................................................................ 4-7
Grease “Weekly” Bearings ...................................................................... 4-8
Oil Roll Bearing Pivots........................................................................... 4-10
Check and Clean Motors........................................................................4-11
Check and Clean Sail Switch and Exhaust Blower Wheel.....................4-11
Check Ribbon Condition and Tension ................................................... 4-12
4.3 Monthly PM (200 Hours) ....................................................................... 4-13
Check Setscrews................................................................................... 4-13
Grease Bearings ................................................................................... 4-14
Oil Drive Chain and Tension Springs..................................................... 4-14
Check Compression Roll Pressure and Padding Condition.................. 4-15
4.4 Semi-Annual PM (1000 Hours) ............................................................. 4-15
Check Gas Pressure ............................................................................. 4-16
Check Mechanical and Electrical Connections ..................................... 4-16
4.5 Annual PM (2000 Hours)....................................................................... 4-17
Check and Clean Pilot Assembly .......................................................... 4-18
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Table of Contents Comet Executive Gas
vi
CHAPTER 5 OPERATING PRINCIPLES
Safety ................................................................................................................ 5-2
5.1 Electrical System..................................................................................... 5-2
Disconnect Switch and Fuses ................................................................. 5-3
Step-Down Transformer .......................................................................... 5-3
Electrical Panel........................................................................................ 5-4
5.2 Mechanical System ................................................................................. 5-5
Drive System........................................................................................... 5-5
Ribbon Sets............................................................................................. 5-6
5.3 Exhaust System ...................................................................................... 5-7
Exhaust Blower ....................................................................................... 5-7
Sail Switch............................................................................................... 5-7
5.4 Heating System....................................................................................... 5-7
Burner System......................................................................................... 5-9
Temperature Control.............................................................................. 5-10
Temperature Sensor Contact Shoes ..................................................... 5-10
5.5 Sequence of Operation ..........................................................................5-11
Stand-By Stage ......................................................................................5-11
JOG REVERSE Operation Stage...........................................................5-11
Mechanical Start-Up Stage ................................................................... 5-12
Burner Operation Stage ........................................................................ 5-12
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Comet Executive Gas Table of Contents
vii
CHAPTER 5 TROUBLESHOOTING
Troubleshooting Symptoms ............................................................................... 6-2
6.1 Electrical.................................................................................................. 6-4
6.2 Mechanical System ................................................................................. 6-6
6.3 Ironing Quality ......................................................................................... 6-9
6.4 Heating System..................................................................................... 6-12
Pilot Ignition........................................................................................... 6-12
Burner Ignition....................................................................................... 6-13
Burner Operation................................................................................... 6-14
6.5 Exhaust System .................................................................................... 6-16
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Table of Contents Comet Executive Gas
viii
CHAPTER 7 REPAIR
7.1 Safety Considerations ............................................................................. 7-2
7.2 Parts Availability ...................................................................................... 7-3
7.3 Feed Section ........................................................................................... 7-4
Feed Ribbon Tension Adjustment............................................................ 7-5
Feed Ribbon Replacement...................................................................... 7-6
Feed Ribbon Drive Roll Friction Material Replacement .......................... 7-8
Guide Tape Replacement...................................................................... 7-10
Feed Table Alignment and Positioning .................................................. 7-13
7.4 Compression Roll.................................................................................. 7-16
Compression Roll Pressure Check ....................................................... 7-17
Compression Roll Pressure Adjustment................................................ 7-18
Compression Roll Cover Replacement ................................................. 7-19
7.5 Ironing Section ...................................................................................... 7-23
Drive Chain Tension Adjustment ........................................................... 7-23
Ironing Cylinder Reconditioning ............................................................ 7-24
Ironing Cylinder Hardened Ring Replacement...................................... 7-27
7.6 Burner System....................................................................................... 7-29
Burner Removal/Replacement .............................................................. 7-29
Burner Tip Maintenance ........................................................................ 7-32
Temperature Sensor Contact Shoe Replacement................................. 7-33
Temperature Control or High Temperature Limit Control Replacement 7-34
7.7 Return Section....................................................................................... 7-36
Return Ribbon Tension Spring Replacement ........................................ 7-37
Return Ribbon Replacement................................................................. 7-38
Return Ribbon Drive Roll Friction Material Replacement...................... 7-40
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Comet Executive Gas Introduction
1-1
Chapter 1
INTRODUCTION
This chapter contains the following sections:
1.1 Warranty
1.2 Scope of the Manual
1.3 Safety
The Comet Executive™ Gas-Heated Flatwork Ironer (Figure 1-1) is a one-piece unit that dries and
irons sheets, pillowcases, table linen, and other types of atwork. The unit processes 100% polyester,
polyester/cotton blends or all-cotton fabrics. This unit is available with an ironing cylinder length of
56” (1400 mm), 66” (1600 mm), or 80” (2000 mm). This unit is not designed to process anything other
than atwork.
Like the rest of the CHICAGO®product line, the Comet Executive Gas is designed, manufactured,
and assembled in Chicago, Illinois. Before the CHICAGO® nameplate is axed to any machine, a nal
inspection is performed, including thorough testing under load conditions.
Any questions concerning the installation, operation, or repair of the Comet Executive Gas ironer
should be directed to your local authorized CHICAGO®dealer or:
Chicago Dryer Company  [phone]
2200 North Pulaski Road Fax [phone]
Chicago, Illinois 60639-3737 E-mail [e-mail]
Figure 1-1: The Comet Executive Gas provides high quality atwork nishing.
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Introduction Comet Executive Gas
1-2
1.1 Warranty
A full page warranty statement is included
in this Instruction Manual. Please take the
time to review this warranty and understand its
provisions.
1.2 Scope of the Manual
This instruction manual will help you keep
your CHICAGO®product operating safely,
eciently, and with minimum expense. Individual
chapters in this manual provide the necessary
information required for safe installation,
operation, maintenance, troubleshooting, and
repair of the Comet Executive Gas ironer.
Updates
Occasionally, new information about the unit
becomes available after the publication of this
manual. If you receive a CHICAGO®FYI Service
Bulletin pertaining to your 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 utilities. 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 eciency. This chapter includes
instructions for 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 eciency.
A Preventive Maintenance Schedule is located at
the front of this 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 troubleshooting
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.
Parts List
Contains detailed drawings and part
specications 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 and interlock circuits,
gas control and safety circuits, and other relevant
drawings, including part specications.
Appendix
Contains Technical Specications, a Floor
Plan, manufacturer’s bulletins, and other relevant
information for the unit.
Index
Contains an alphabetical listing/cross-
reference of all topics and procedures within
this Instruction Manual.
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Comet Executive Gas 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 safety features for
protection.
Safe Work Habits
During Daily Operation
• Take the atwork only after it has
cleared the unit. Do not pull on the
nished atwork 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 ironer while it is
operating.
• Always turn o 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.
• Never stand, sit, or kneel on a receiving
shelf.
Maintenance and Repair
WARNING
Always use extreme caution
when performing any
repairs that require 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 to
stop the unit if necessary.
Before attempting any repair work, review
these safety steps and precautions to protect
yourself and the machine.
• Safety should be the primary concern
of anyone performing corrective
maintenance.
• Except where specically directed, make
sure that the main disconnect switch to
incoming power is OFF and the machine
completely COOL.
• It is recommended that all maintenance
procedures be handled by at least two
qualied persons. Using the “buddy
system” facilitates a quicker procedure
and 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 specic information. It
is the users’ responsibility to make sure
they comply with all safety procedures.
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Introduction Comet Executive Gas
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 qualied personnel
should troubleshoot and
repair this unit.
Safety Features
There are six categories of safety features:
• Main Disconnect Switch
• Safety Stop Buttons
• Safety Guards
• Safety Interlock Switches
• Safety Labels
• Safety Messages in this Manual
Main Disconnect Switch
The main disconnect switch is located on the
outside of right endframe door. When turned to
“O” (horizontal position), the main disconnect
switch shuts o the incoming electrical power
to the unit.
Unless otherwise indicated, turn the main
disconnect switch to o before performing any
maintenance or repair work.
Safety Stop Buttons
The preferred method of stopping the operation
of the unit is by pressing any of the four red safety
STOP buttons located at each corner of the unit.
Pressing any of these buttons immediately
stops the heating system and all rotating parts.
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Comet Executive Gas Introduction
1-5
Safety Guards
A red safety nger guard covers the moving
parts at the front of the unit. It runs the entire
length of the unit’s working area and physically
restricts hands from coming into contact with
moving and heated parts. Pushing the safety
nger guard immediately stops the heating system
and all rotating parts.
Both endframes and the rear of the unit are
covered with protective doors and panels to
prevent ngers or hands from coming into contact
with moving and heated parts. Removing the rear
panel immediately stops the heating system and
all rotating parts.
Safety Interlock Switch
A safety interlock switch is located behind
the protective backplate. If it is removed, the
interlock switch is disconnected, all rotating parts
stop moving, and the heating system shuts o.
This safety interlock switch is 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.
Figure 1-2: Safety labels remind operators and maintenance personnel that care must be taken when working
near these areas.
Safety Labels
WARNING (orange) and CAUTION (yellow)
labels (Figure 1-2) are placed at locations around
the unit to keep operators and maintenance
personnel alert in particular areas.
WARNING labels alert personnel that
personal injury may result from not following
recommended procedures.
CAUTION labels alert personnel the unit
may be damaged if conditions, practices, or
procedures are not observed.
When training operators, take the time to
locate, review, and understand 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 Comet Executive Gas
1-6
Safety Messages in this Manual
WARNING and CAUTION messages 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 operate the unit
unless all safety systems
are working correctly and all
access panels are in place.
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 and COOL.
CAUTION messages alert personnel that the
unit may be damaged if conditions, practices,
or procedures are not observed.
CAUTION
Never use compressed air
on or around electronic
components. Doing so may
damage them.
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Comet Executive Gas Installation
2-1
Chapter 2
INSTALLATION
This chapter contains installation instructions for the Comet Executive™ Gas and includes the
following sections:
2.1 Site and Utility Requirements
2.2 Installation Procedures
2.3 Pre-Operational Checkout
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 except for the receiving shelves and the
exhaust blower assembly. Sucient strapping, blocking, and bracing were provided to give reasonable
assurance that no shipping damage would occur.
NOTE: If the unit 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 Comet Executive Gas
2-2
2.1 Site and Utility
Requirements
Figure 2-1 shows the clearance requirements
for the unit. These are the minimum dimensions
recommended for ecient production, service,
and maintenance access.
NOTE: The location of the unit
is extremely important.
It is strongly recommended that sufficient
clear space be provided to allow for removal of
the gas burner assembly from the left endframe
for service, if necessary. If this clearance is not
possible, additional clearance to the front or rear
of the unit should be provided so the unit can be
rotated.
The site should have a relatively level,
sturdy floor capable of supporting the unit’s
weight without signicant exing. For weight
specications, refer to APPENDIX: Technical
Specications.
Shimming of the endframes is generally
needed to level the unit. No special foundation,
floor grouting, or installation of anchors is
required. However, oor grouting or installation
of anchors may be required to comply with local
codes or aboard a ship.
A short run of 8” (203 mm) diameter vent
ducting must be supplied locally for the exhaust
blower and canopy. Adequate ventilation
is required. For more information, refer to
Ventilating the Work Area on page 2-7.
Figure 2-1: Recommended clearances for installation.
18”
(460 mm)
18”
(460 mm)
Ironing Cylinder Length
plus 24” (610 mm)
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Comet Executive Gas Installation
2-3
2.2 Installation
Procedures
Installation procedures of the unit include the
following.
• Inspection
• Uncrating and Positioning
• Exhaust Blower Installation
• Electrical Connection
• Gas Connection
• Receiving Shelf Set-Up
• 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: Notify the carrier
immediately if any damage has
been done to the unit during
shipment.
The electrical requirements of the unit are
shown on the nameplate (Figure 2-2), located
on the front of the left endframe. 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. For more information, refer
to APPENDIX: Technical Specications.
Each unit has specic gas requirements; verify
the local gas supply matches the gas requirements
specified on the unit’s nameplate. For more
information, refer to APPENDIX: Technical
Specications.
Note that the nature of the atmospheric burner
used in the machine prevents it from operating
at full capacity when in use above an altitude of
approximately 2000 feet (609 meters). For use
at higher elevations, contact the factory service
department.
Figure 2-2: The nameplate contains important
information, including information
about altitude usage.
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Installation Comet Executive Gas
2-4
Uncrating and Positioning
Required Tools
Crowbar
Forklift
Screwdriver
Sledgehammer
Wire cutter/knife
Wrenches:
9/16” or 3/4”
1. Before unpacking the unit, make sure the
proposed site is acceptable and necessary
foundations have been prepared. For more
information, refer to Site and Utility Re-
quirements on page 2-2.
2. Remove the crating, strapping, and other
packaging materials except guide tapes
(Figure 2-3), the protective plastic cover
and the brown paper on the ironing cyl-
inder. These protective coverings should
be left in place so the unit remains clean
until it is ready to use.
3. Remove the exhaust blower assembly
from the crate and set aside.
4. Open both endframe doors and remove
any materials shipped with the unit. Close
and secure the doors.
CAUTION
The unit should only be
moved by qualied riggers
using proper equipment.
5. With the unit still on its skid, move it into
approximate position. Remove the bolts
which secure the unit to the skid.
CAUTION
Do not drop or twist the unit.
6. As appropriate, using care not to drop or
twist the unit:
• If the unit is equipped with eye bolts,
lift the unit straight up using the two
eye bolts on top of each endframe and
carefully remove the skid from under it.
• OR
• Lift one endframe and carefully re-
move the skid from under it and then
repeat for the other endframe.
7. The endframes of the unit should rest
rmly on the oor. If necessary, add shims
to level the unit. Secure the unit to its
foundation, if required by local code or
conditions. For use aboard a ship, the unit
may be welded at the foot pads.
Figure 2-3: Do not remove the guide tapes when
removing the shipping materials.
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