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Chicago Dryer AIR CHICAGO EXPRESS Instruction Manual

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AIR CHICAGO
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EXPRESS
Towel Folder

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Summary of Contents for Chicago Dryer AIR CHICAGO EXPRESS

  • Page 1 AIR CHICAGO ® EXPRESS Towel Folder...
  • Page 2 Chicago Dryer Company © Instruction Manual #3019-120 CHICAGO DRYER COMPANY 2200 N. Pulaski Road, Chicago, Illinois USA 60639-3737 Telephone: (773) 235-4430 Fax: (773) 235-4439 www.chidry.com...

  • Page 3: Table Of Contents

    Air Chicago Express Table of Contents 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...

  • Page 4: Chapter 1 Introduction

    Table of Contents Air Chicago Express CHAPTER 1 INTRODUCTION Warranty ....................1-2 Scope of Manual ..................1-2 Safety ...................... 1-3 Safe Work Habits ..................1-3 Safety Features ..................1-4 Optional Equipment ................. 1-6 INDEX...

  • Page 5: Chapter 2 Installation

    Air Chicago Express Table of Contents CHAPTER 2 INSTALLATION Site and Utility Requirements ..............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 Pre-Operational Checkout ...............

  • Page 6: Chapter 3 Operating Guidelines

    Table of Contents Air Chicago Express CHAPTER 3 OPERATING GUIDELINES 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 Operating Controls ..................

  • Page 7: Chapter 4 Preventive Maintenance

    Air Chicago Express Table of Contents CHAPTER 4 PREVENTIVE MAINTENANCE PM Task Table ....................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 Weekly PM (50 Hours) ................

  • Page 8: Chapter 5 - Operating Principles

    Table of Contents Air Chicago Express CHAPTER 5 OPERATING PRINCIPLES Safety ........................ 5-2 Electrical System ..................5-2 Power System ..................5-2 Control System ..................5-6 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...

  • Page 9: Chapter 6 Troubleshooting

    Air Chicago Express Table of Contents CHAPTER 6 TROUBLESHOOTING Troubleshooting Symptoms ................6-2 LED Diagnostics ..................6-4 Electrical ....................6-6 Mechanical .................... 6-10 Primary Folding ..................6-12 First Crossfold ..................6-14 Second Crossfold .................. 6-15 Stacker ....................6-16 Exit Conveyor ..................6-17 Sensor Function ..................

  • Page 10: Chapter 7 Repair

    Table of Contents Air Chicago Express CHAPTER 7 REPAIR Safety Considerations ................7-2 Parts Availability ..................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 ........
  • Page 11 Air Chicago Express Operating Principles 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:...
  • Page 12 Questions about the operation of the unit can be decides when all these activities should occur. answered by your local authorized CHICAGO ® dealer, or by the Chicago Dryer Company service Power System department. Components in the power system are located in the several places.
  • Page 13 Air Chicago Express Operating Principles 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.
  • Page 14 Operating Principles Air Chicago Express 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.
  • Page 15 Air Chicago Express Operating Principles ELECTRICAL PANEL COMPONENTS Schematic Description Circuit Breaker - Stacker Motor Inverter Circuit Breaker - T3 (24VAC Control Circuit) Circuit Breaker - DC Power supplies (PWS2/PWS3/PWS4) CB10 Circuit Breaker - 24VAC Control Circuit CON1F/R Contactor - Main Drive Motor/JOG Forward/Reverse...
  • Page 16 Operating Principles Air Chicago Express Control System All the input signals from the sensors go through the I/O control panel, which also powers Control of the machine is done in two areas. the sensors. When the appropriate LED on the...
  • Page 17 Air Chicago Express Operating Principles 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.
  • Page 18 Operating Principles Air Chicago Express Photosensors Proximity Sensors The photosensors use a high-powered LED The proximity sensors use a magnetic field to pulse output to detect items. When an item detect the movement of machine components and is present, this beam is reflected back into a send signals to the I/O control panel.
  • Page 19 Air Chicago Express Operating Principles PHOTOSENSORS I/O Module LED Sensor Name Function Type & Setting (Sensor NOT triggered) Feed Table Center Detect items on the feed table. Dark Operate For hand towels, helps determine whether left or right primary fold air...

  • Page 20: Compressed Air System

    Operating Principles Air Chicago Express Air Filter/Regulators 5.2 Compressed Air Because the condition of the compressed air System is so important, the machine includes a filter It is important that the supply of compressed unit equipped with a drain (Figure 5-9, A). This air be clean and dry and at 80 psi (550 kPa).

  • Page 21: Air Valves/Air Valve Solenoids

    Air Chicago Express Operating Principles Air Valves/Air Valve Solenoids The machine uses a number of air valves which are actuated electronically by signals from the CHI•Touch control system. These valves and solenoids (Figure 5-11) control the flow of compressed air to the various air components incorporated into the unit.

  • Page 22: 5.3 Mechanical System

    Operating Principles Air Chicago Express Main Drive System 5.3 Mechanical System Use the illustration below (Figure 5-14) to Components that make up the mechanical identify the mechanical components of the system include the following: folder’s main drive system. • Main Drive System A shaft from the main drive motor extends •...

  • Page 23: Second Crossfold Drive System

    Air Chicago Express Operating Principles Second Crossfold Drive System Stacker Drive System Use the illustration below (Figure 5-15) to Use the illustration on the previous page (Figure identify the mechanical components of the second 5-14) to identify the mechanical components of crossfold drive system.

  • Page 24: Ribbon Sets

    Operating Principles Air Chicago Express Ribbon Sets Flatwork is then carried between the first crossfold ribbons (F) and the transfer ribbons (I). Five sets of ribbons are used in folding As the piece travels between the first crossfold flatwork: One set is involved in primary folding, idler (H) and transfer ribbon idler (K) rolls, one three in crossfolding and one for stacking.

  • Page 25: 5.4 Sequence Of Operation

    Air Chicago Express Operating Principles Stand-by Phase 5.4 Sequence of Operation During this phase, the incoming power The unit has 6 phases of operation. In addition, is connected to the unit, but the unit is not it will react to various error conditions.

  • Page 26: Start-Up Phase

    Operating Principles Air Chicago Express Start-up Phase Primary Fold Phase This phase begins when an operator pushes The unit’s control system uses input from and holds the green START button. photosensors to automatically operate the folder. • The coil of CR0 is energized, closing its...

  • Page 27: Crossfold Phrase

    Air Chicago Express Operating Principles Crossfold Phrase Stacking Phase After primary folding, the piece travels to the After the second crossfold, the piece is carried rear of the unit. under the stacker ribbons and onto the stacker doors. When PE15 is activated, a timing sequence is...
  • Page 30 10/04/10 Air Chicago Express TECHNICAL SPECIFICATIONS 6500-449 App:GW Folder Production Speed Drive Output Feet per Minute (m/min) (49.1) Motors Total (1.5) Main Drive , HP (kW) (0.75) Discharge Drive , HP (kW) ½ (0.375) Conveyor Drive 1 , HP (kW) (0.125)
  • Page 32 3010-025 GENERAL TORQUE SPECIFICATION CHART These torque values are approximate and should not be accepted as accurate limits. Indeterminate factors (surface finish, type of plating and lubrication) in specific applications preclude the publication of accurate values for universal use. DO NOT USE the below values for gasketed joints or joints of soft materials. DO NOT USE your torque wrench for values greater than its maximum scale reading.
  • Page 34 Air Chicago Express Index INDEX Adjustment, CHI•Touch 3-11, C-10 Categories, General Operating Techniques 3-13 Adjusting Program Parameters C-10 Chains and Belts 7-16 Using the Autotune Feature C-12 Drive Belt, Stacker Air Bar Alignment Condition and Tension Check 4-5 Crossfold 7-25...
  • Page 35 Index Air Chicago Express Clean Air Filter/Auto Drain 4-14 Daily Operating Procedures 3-7 Clean and Lubricate Fold Operation 3-9 Drive Chains 4-11 Handling Jams and Misfeeds Safely 3-9 Communications and the I/O Panel, Control System Interconnected Stop Circuit (option) Operation...
  • Page 36 Air Chicago Express Index Exit Conveyor Drive System 5-13 Jams and Misfeeds, Handling Safely 3-9 Ribbon Jam Detection, CHI•Touch C-7 Drive and Idler Roll Tracking Tape Replacement 7-13 Tension Adjustment 7-9 Troubleshooting 6-17 LED Diagnostics, Troubleshooting 6-4 Exit Phase, Sequence of Operation 5-17...
  • Page 37 Index Air Chicago Express Primary Fold Air Bar Alignment 7-24 Operating Controls 3-4 Operation Checkout 2-14 CHI•Touch 3-6, C-3 Phase, Sequence of Operation 5-16 Operating Techniques 3-13 Ribbon Tension Adjustment 7-5 Processing Standards 3-13 Work Habits 3-14 Air Cylinder Air Flow Adjustment 7-26 Operation, CHI•Touch C-3...
  • Page 38 Air Chicago Express Index Setscrews, Check 4-10 Setting the Access Level, CHI•Touch C-5 Safety 1-3, 5-2 Setting the Data Display Time Frame, CHI•Touch Repair Safety Considerations 7-2 Safety Features 1-4 Setting the Program/Operator/Account, CHI•Touch Safe Work Habits 1-3, 3-14 Safety Considerations, Repair 7-2...
  • Page 39 Index Air Chicago Express Troubleshooting Compressed Air System 6-19 Electrical 6-6 Exit Conveyor 6-17 First Crossfold 6-14 LED Diagnostics 6-4 Mechanical 6-10 Primary Folding 6-12 Second Crossfold 6-15 Sensor Function 6-18 Stacker 6-16 Symptoms 6-2 Uncrating and Positioning 2-4 Using the CHI•Touch Screen C-4 Viewing Machine Status Information, CHI•Touch...

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