Chicago Dryer King Edge VAc Instruction Manual

Large piece spreader/feeder with vacuum laydown and air assist

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KING EDGE VAC

Large Piece

Spreader/Feeder with

Vacuum Laydown

and Air Assist

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Chicago Dryer King Edge VAc

Page 1 KING EDGE VAC Large Piece Spreader/Feeder with Vacuum Laydown and Air Assist...
Page 2 Chicago Dryer Company © Instruction Manual #3018-041b CHICAGO DRYER COMPANY 2200 N. Pulaski, Chicago, Illinois USA 60639-3737 Telephone: (773) 235-4430 Fax: (773) 235-4439 www.chidry.com...
Page 3 King Edge Vac 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...
Page 4: Table Of Contents
Table of Contents King Edge Vac CHAPTER 1 INTRODUCTION Warranty ....................1-2 Scope of Manual ..................1-2 Safety ...................... 1-3 Safe Work Habits ..................1-3 Safety Features ..................1-4 Equipment Description ................1-6 Machine Widths ..................1-6 Optional Equipment ................. 1-6...
Page 5 King Edge Vac Table of Contents CHAPTER 2 INSTALLATION Site and Utility Requirements ..............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 ............
Page 6 Table of Contents King Edge Vac CHAPTER 3 OPERATING GUIDELINES 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 Operating Controls .................. 3-4 CHI Panel Controls and Indicators ............
Page 7 King Edge Vac 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 Clean Lint Bags and Exhaust Blower Ports ..........4-3 Check Safety Equipment .................
Page 8 Table of Contents King Edge Vac CHAPTER 5 OPERATING PRINCIPLES Safety ........................ 5-2 Electrical System ..................5-2 Power System ..................5-2 Control System ..................5-9 Compressed Air System ................ 5-16 Air Filter/Regulators................5-16 Air Pressure Switch ................5-16 Air Reservoir ..................5-16 Air Valves/Air Valve Solenoids ..............
Page 9 King Edge Vac Table of Contents CHAPTER 6 TROUBLESHOOTING Troubleshooting Symptoms ................6-2 CHI Diagnostic Message Index ............... 6-6 LED Diagnostics ..................6-8 Electrical ....................6-10 Mechanical .................... 6-14 Prefeed/Inlet Section ................6-15 Transfer Section ..................6-18 Spread Section ..................6-20 Discharge Section .................
Page 10 Table of Contents King Edge Vac CHAPTER 7 REPAIR Safety Considerations ................7-2 Parts Availability ..................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 ............
Page 11 King Edge Vac Table of Contents 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 ..
Page 13: Chapter 1 Introduction
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.
Page 14 Introduction King Edge Vac Chapter 4 - Preventive Maintenance 1.1 Warranty Contains procedures for Daily, Weekly, A full page warranty statement is located at M o n t h l y , S e m i - A n n u a l , a n d A n n u a l the front of this instruction manual.
Page 15: Safety
King Edge Vac Introduction Maintenance and Repair 1.3 Safety Safe operation and maintenance of the unit WARNING must be the first priority of all supervisors, Always use extreme caution operators and maintenance personnel. Safety when performing any repair begins with safe work habits. In addition, the...
Page 16: Safety Features
Introduction King Edge Vac Safety Features WARNING There are several general categories of safety Know the proper procedure features: for locking out and tagging equipment during repair • Main Disconnect Switch procedures. • Safety Guards Follow the rules of your work •...
Page 17 NOTE: Do not remove safety labels at any time. If a label needs to be replaced, contact Chicago Dryer Company for free replacements. Figure 1-2: Safety labels remind operators and maintenance personnel that care must be taken when working near these areas.
Page 18: Equipment Description
Optional Equipment personal injury may result from not following recommended procedures. Machine Widths The King Edge Vac comes in a standard 120” WARNING (3050 mm) width. Extra wide models including Never bypass any of the 130” (3300 mm), 136” (3455 mm) and wider are safety devices.
Page 19: Chapter 2 Installation
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.
Page 20: Site And Utility Requirements
Installation King Edge Vac 2.1 Site and Utility Requirements Figure 2-1 shows the clearances required for The site must have a level, sturdy ﬂoor capable the spreader/feeder. The dimensions noted are the of supporting the spreader/feeder’s weight without minimums recommended for efﬁcient production significant flexing.
Page 21: Installation Procedures
King Edge Vac Installation Compressed air that is clean and dry must 2.2 Installation be provided for the unit. This is very important Procedures because the air will blow directly on the ﬂatwork. The compressed air supply must meet the The spreader/feeder should be moved on pressure and air ﬂow requirements noted in the...
Page 22: Uncrating, Placement And Alignment
Installation King Edge Vac Uncrating, Placement and Alignment While either the entire unit or one side of the unit is suspended, attach the lock- ing ﬂoor castors (Figure 2-3) which were Required Tools removed for shipping. forklift, crowbar, sledgehammer, wire...
Page 23 King Edge Vac Installation Move the unit into ﬁnal position in front of the ironer. Figure 2-5 shows the desired relative positioning of the bypass conveyor and the discharge conveyor idler rolls to the ironer inlet. Ironer inlet Figure 2-5: Position the bypass exit conveyor so...
Page 24: Discharge Conveyor Attachments
Installation King Edge Vac Cut and remove the strapping holding the Discharge Conveyor Attachments vacuum hoses in position (Figure 2-8, A). The discharge conveyor lift air cylinder and the Also remove the tape securing the rear brush air cylinder are disconnected for shipping brush compressed air cylinders (B).
Page 25: Floor Trough Installation
King Edge Vac Installation Floor Trough Installation Inlet Conveyor Upper Pulley Installation Now it is time to install the ﬂoor trough which will catch wet linen which is dropped during For facilities with low clearance, the inlet processing. conveyor upper pulleys are sometimes reversed for shipping (Figure 2-13).
Page 26: Compressed Air Supply Connection
Installation King Edge Vac Compressed Air Supply Connection Run a sturdy, ﬂexible air hose from the external compressed air source to the 1/2” The unit requires a compressed air supply inlet ﬁtting (Figure 2-15, A) at the back of to drive certain parts of the machine and direct the left endframe.
Page 27: Electrical Connection
King Edge Vac Installation Electrical Connection The unit offers two different types of electrical connection: The nameplate (Figure 2-2) , located on the right rear endframe near the electrical connection • Single Point and Other Cable box shows the electrical requirements of the Connections (Options) spreader/feeder.
Page 28 Installation King Edge Vac Communications Cable Connection (Option) If the unit was shipped with the optional communications cable, locate it at the right rear of the machine (Figure 2-18, A). Uncoil the cable and connect to the communications port on the right front of the ironer (Figure 2-17, B).
Page 29 King Edge Vac Installation Standard Electrical Wiring Extend the lines through conduit or green- ﬁeld. If it will be necessary to move the unit, leave plenty of slack in the greenﬁeld WARNING for this purpose. Only a qualiﬁed electrician should make the electrical Pull the external wiring through the hole connections to the unit.
Page 30 Installation King Edge Vac Connect the ground wire to the ground- Feeder/Ironer Interlock (Option) ing lug (Figure 2-22, B) using the Allen If the unit is not equipped with the optional wrench. Interconnected Stop Circuit, follow these steps to ensure that the spreader/feeder will automatically WARNING shut down when the ironer does.
Page 31 King Edge Vac Installation Ironer Encoder Wheel (Option) Installation This option allows the spreader/feeder to get its automatic speed control signal from an encoder wheel when the unit is paired with a non-Chicago ironer. Required Tools screwdriver, 5/8” wrench, plastic wire...
Page 32: Pre-Operational Checkout
Installation King Edge Vac Security of Hardware 2.3 Pre-Operational Hardware may loosen during shipment or Checkout rigging. Make sure power is OFF at the main dis- NOTE: For more information connect switch. about the controls mentioned in the following procedures, refer to Open both endframe doors.
Page 33: Clean The Corner Photosensors
King Edge Vac Installation Clean the Corner Photosensors Compressed Air Supply Checkout Since they look up, dust can easily settle Check the primary air pressure regulators and on the corner photosensors during transit. To make sure each has the correct initial setting.
Page 34 Installation King Edge Vac Turn power ON at the main disconnect switch. WARNING Make sure all personal are clear and that no person touches any moving part of the machine. There is no reason to do so during this procedure.
Page 35: Blower Rotation Checkout
King Edge Vac Installation Blower Rotation Checkout WARNING The vacuum blowers must be checked to sure Only a qualiﬁed electrician they are turning in the proper direction; this will should make or correct any indicate the machine is properly phased.
Page 36: Safety Device And Control Function Checkout
Installation King Edge Vac Safety Device and Control Function Checkout The machine can now be checked for proper safety device and control function, and checked for correct operation. This includes: • Safety Device Check • CHI Panel Function Check NOTE: W o r k w i t h a n o t h e r person.
Page 37 King Edge Vac Installation • To test the Interconnected Stop Circuit, CHI Panel Function Check start another machine in the line and On the CHI panel, press a STATION but- press a red safety STOP button on that ton. Its indicator should light. Repeat for machine.
Page 38: Spread/Feed Function Check
Installation King Edge Vac Spread/Feed Function Check Small Piece Check Press the BYPASS button on the CHI Large Piece Check panel. Its light will illuminate. Use a sheet or similar piece of ﬂatwork to The front bypass conveyor should raise test the spreader/feeder.
Page 39: Checkout Completion
King Edge Vac Installation Checkout Completion Cleaning the Unit If any checkout step is unsuccessful, refer During shipment and installation of the to the TROUBLESHOOTING and REPAIR spreader/feeder, some dirt or other contaminants chapters of this manual. may have accumulated that will mark processed ﬂatwork.
Page 41: Chapter 3 Operating Guidelines
King Edge Vac Operating Guidelines Chapter 3 OPERATING GUIDELINES In order to operate the King Edge Vac spreader/feeder safely and with maximum efﬁciency, it is necessary to become familiar following guidelines: Safety Features Operating Controls Daily Operating Procedures Operating Techniques...
Page 42: Safety Features
Operating Guidelines King Edge Vac Safety STOP Buttons 3.1 Safety Features Pressing any of the six red safety STOP The spreader/feeder is manufactured with buttons (Figure 3-3, B) stops the spreader/feeder several built-in features to promote safety and and locks out operation of the machine. A fault proper operating procedures.
Page 43: Safety Interlock Switches
When training operators, take 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. INDEX...
Page 44: Operating Controls
Operating Guidelines King Edge Vac 3.2 Operating Controls All operating controls are externally mounted on the endframes and most are clearly marked with nameplates. References to these functions are capitalized in this instruction manual for easy identiﬁcation. Detailed descriptions are given in the following paragraphs.
Page 45 King Edge Vac Operating Guidelines STAIN/TEAR REJECT buttons (Option) CHI Panel (F): (C, D): Allows fully automatic operation of the unit Determine how stained or torn ﬂatwork are under a wide range of conditions. For a complete handled by the CHICAGO folder at the end of description of the CHI Panel’s functions, refer to...
Page 46: Chi Panel Controls And Indicators
Operating Guidelines King Edge Vac The CURSOR button (E) moves the cursor CHI Panel Controls and Indicators to various positions in the CHI panel Display in The CHI panel is the heart of the operation order to change settings. of the Edge spreader/feeder, making it easy to operate as well as to program and adjust the The “-”...
Page 47: Daily Operating Procedures
King Edge Vac Operating Guidelines Turn power ON at the main disconnect 3.3 Daily Operating switch. Procedures Press the green station Start button. The In the daily operation of the unit, it is desirable indicator lamp in the switch lights and the to follow consistent operational procedures.
Page 48: Interconnected Stop Circuit (Option) Operation Notes
Operating Guidelines King Edge Vac Restart the unit. After the CHI Panel com- Interconnected Stop Circuit (Option) pletes its diagnostics, for about 3 seconds Operation Notes the CHI Panel displays: If the unit is part of a line with the Interconnected...
Page 49: Flatwork Handling
King Edge Vac Operating Guidelines Flatwork Handling Press the CURSOR button until it is under the pace setting. The way that operators use the feeder is very important. They can increase productivity, extend Press the + or - key as appropriate to set the life of the unit, and most importantly, promote the desired hourly standard.
Page 50 Operating Guidelines King Edge Vac Feeding Small Pieces NOTE: The sheet does not Press the BYPASS button on the CHI have to be precisely centered. Panel. However, the closer to the center, the better. The sheet feeder stations shut off and the front bypass conveyor raises into posi- tion.
Page 51 King Edge Vac Operating Guidelines MANUAL Mode (PWM=1) Counter Operation The CHI Panel automatically tracks the count KING SHEET COTTON totals in each program selected. To view the SPEED XXX FPM CNT XXXXX counts for each of the two stations in any program selected: When in manual mode, press the SPEED ...
Page 52: Handling Jams And Misfeeds Safely
Operating Guidelines King Edge Vac Handling Jams and Misfeeds Safely Handling Misfeeds Safely If set to do so, the CHI control system will During normal operation, pieces of ﬂatwork automatically reject items which are not fed will occasionally feed incorrectly into the unit.
Page 53: Shut-Down
Maximum Feeding Speed Maximum speed for feeding the ﬂatwork into the King Edge Vac is achieved by placing the leading edge of the next sheet onto the sheet guide before the conveyor returns to pick it up, at both feeding stations.
Page 55: Pm Task Table
Preventive Maintenance Chapter 4 PREVENTIVE MAINTENANCE Various components and parts of the King Edge Vac spreader/feeder require scheduled attention to assure long life and trouble-free operation. The Preventive Maintenance (PM) Schedule below outlines all of the PM tasks required at regular intervals. All tasks are the responsibility of maintenance personnel unless otherwise indicated.
Page 56: Daily Pm (8 Hours)
Preventive Maintenance King Edge Vac General Cleanliness 4.1 Daily PM (8 Hours) It is important to prevent the buildup of lint, dirt, dust and foreign material in the unit. General WARNING cleanliness prevents damage to components, Do not repair or correct any jamming and soiling ﬂatwork.
Page 57: Clean Lint Bags And Exhaust Blower Ports
King Edge Vac Preventive Maintenance Clean Lint Bags and Exhaust Blower Check Safety Equipment Ports Perform only when the unit is The unit’s lint collection bags and exhaust RUNNING. blower ports must be cleaned after every eight- Use extreme caution.
Page 58 Preventive Maintenance King Edge Vac INDEX...
Page 59: Check And Clean Inverters
King Edge Vac Preventive Maintenance Check and Clean Inverters Check For String Accumulation Check and clean the inverters and their cooling Check for accumulated string and lint on the ﬁns (Figure 4-4) weekly with a vacuum cleaner. drive shaft rollers and bearings.
Page 60: Inspect Inlet Transfer Rodless Air Cylinder
Preventive Maintenance King Edge Vac Inspect Inlet Transfer Rodless Air Make sure the compressed air system is depressurized. Cylinder Raise the front access guard and secure in CAUTION position using the provided bracket arms The following procedure is (Figure 4-6).
Page 61 King Edge Vac Preventive Maintenance If the drive T is secure, check the drive If no resistance is felt, the air cushion blocks and make sure they are tight against pressure must be increased. Refer to the the drive T by moving the carriage assem- Repair section, Increase the Air Cushion bly back and forth (Figure 4-7, B).
Page 62: Check Pneumatic Clutch/Brake Roller Alignment
Preventive Maintenance King Edge Vac Check Pneumatic Clutch/Brake Roller Alignment Perform only when the unit is OFF with power disconnected. Make sure the clutch/brake rollers are seated evenly against each other (Figure 4-9). It is very important that these components are aligned parallel for proper corner clutching.
Page 63: Check Carriage Rail Bearings And Lubricate Upper Spreader Rail, Carriage Rails And Rail Bearings
King Edge Vac Preventive Maintenance Check Carriage Rail Bearings and Lubricate Upper Spreader Rail, Carriage Rails and Rail Bearings Required Tools dry silicon lubricant, clean lint-free cloth Perform only when the unit is OFF with power disconnected. Turn power OFF at the main disconnect switch.
Page 64: Inspect Air Filter/Auto Drain
Preventive Maintenance King Edge Vac Inspect Air Filter/Auto Drain Check Air Pressure Settings Maintaining proper incoming and internal air Perform only when the unit is OFF pressures helps keep the machine operating at with power disconnected. peak efﬁciency. The combination air filter with automatic...
Page 65 King Edge Vac Preventive Maintenance Press a green station Start button at either operator station. Looking in from the rear of the machine, locate the other two primary pressure gauges of the machine at the left and right center (Figure 4-16, A, B).
Page 66: Check Belt And Ribbon Condition And Tension
Preventive Maintenance King Edge Vac Figure 4-17, A, B, C, D shows the remaining air pressure valves located inside the body of the machine at the left center, at the left rear, under the right inlet station motor, and at the right front inside endframe.
Page 67: Monthly Pm (200 Hours)
King Edge Vac Preventive Maintenance Clean and Lubricate Drive Chains 4.3 Monthly PM and Friction Roll Hinge (200 Hours) Required Tools WARNING slotted screwdriver, SAE 90 grade oil, Do not repair or correct any shop cloth of these conditions without...
Page 68: Check Upper And Lower Spreader Belt Condition And Tension
Preventive Maintenance King Edge Vac Move to the top of the machine and locate Check Upper and Lower Spreader the pneumatically-driven hinged idler roll Belt Condition and Tension which presses against the red drive roll to help pull ﬂatwork into the center of the Perform only when the unit is OFF machine (Figure 4-20).
Page 69: Inspect Drive Belt Condition
King Edge Vac Preventive Maintenance Inspect Drive Belt Condition Clean Vacuum System In addition to the daily cleaning of the unit’s Perform only when the unit is OFF lint collection bags and exhaust blower ports, a with power disconnected. monthly cleaning of the entire vacuum system is required to keep the system at peak efﬁciency.
Page 70: Semi-Annual Pm (1000 Hours)
Preventive Maintenance King Edge Vac Thoroughly vacuum out all lint and other 4.4 Semi-Annual PM foreign matter from the bags. (1000 Hours) Thoroughly vacuum all lint and foreign matter from the blower exhaust ports. WARNING Thoroughly vacuum all lint and foreign...
Page 71 King Edge Vac Preventive Maintenance Figure 4-25: Press the metal tab and twist the casing to the left to remove it from the base. 4-17 INDEX...
Page 72: Check And Grease Bearings
Preventive Maintenance King Edge Vac Check and Grease Bearings Regularly grease bearings to help ensure smooth operation and dependability. It is important that only Shell Darina EP2 Grease or ® its equivalent be used. Use of unsuitable grease can cause bearing lockup or failure.
Page 73 King Edge Vac Preventive Maintenance Perform only when the unit is OFF CAUTION with power disconnected. Over-lubrication will destroy the bearing seals and cause Required Tools premature failure. wrench, grease gun, Shell Darina ® EP2 Grease or equivalent, clean lint-...
Page 74: Replace Rodless Air Cylinder Bearings
Preventive Maintenance King Edge Vac Replace Rodless Air Cylinder Bearings Required Tools part #0208-491, metric Allen wrench, small slotted screwdriver, Loctite ® thread lock Perform only when the unit is OFF with power disconnected. NOTE: This procedure requires Repair Kit 11” Rodless Air Cylinder (part #0208-491).
Page 75 King Edge Vac Preventive Maintenance From one end of the carrier bracket, re- move the two screws which secure the bearings (Figure 4-31, A). From the other end of the carrier bracket, remove the top end cap mounting screw (Figure 4-31, B).
Page 76: Annual Pm (2000 Hours)
Preventive Maintenance King Edge Vac With the new bearings in place, adjust the 4.5 Annual PM tension of the carrier bracket using the two (2000 Hours) hex nuts shown in Figure 4-34. Adjust the carrier so that it moves smoothly and is snug, but not tight.
Page 77: Check All Electrical Connections
King Edge Vac Preventive Maintenance Check All Electrical Connections Check Insulation Resistance to Earth Ground Over time, the continued heating and cooling process can cause electrical connects to become Required Tools loose. voltmeter Required Tools thin, slotted screwdriver Perform only when the unit is OFF with power disconnected.
Page 79: Chapter 5 Operating Principles
Operating Principles Chapter 5 OPERATING PRINCIPLES In order to maintain and troubleshoot the King Edge Vac spreader/feeder 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 feed and spread ﬂatwork:...
Page 80: Safety
CHICAGO ® Power System dealer, or by the Chicago Dryer Company service department. Components in the power system are located in the several places. The fused disconnect switch is incorporated into the electrical connection box door.
Page 81 King Edge Vac Operating Principles Disconnect Switch and Fuses The unit comes equipped with a disconnect switch (DDS). This switch (Figure 5-1, A) is in the electrical connection box on the right rear endframe. 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 82 Operating Principles King Edge Vac Main Electrical Panel Components Most power system components are located in the right front endframe (Figure 5-3). The table on the next page provides an explanation of each item indicated in the picture. INV1 INV2...
Page 83 King Edge Vac Operating Principles MAIN ELECTRICAL PANEL COMPONENTS (Right Endframe) Schematic Description CON1 Contactor - Inlet Conveyor (INV1) CON1A Timer- Blower Clean Off Air Blast Delay On Start Up CON2 Contactor - Exit Conveyor (INV2) CON1 Contactor - Upper Spreader (INV3)
Page 84 Operating Principles King Edge Vac Prefeeder Electrical Panel Components Some power system components are located in the left front endframe (Figure 5-4). The table on the next page provides an explanation of each item indicated in the picture. INV6 INV7 CON4 Figure 5-4: Components in the prefeeder electrical panel.
Page 85 King Edge Vac Operating Principles PREFEEDER ELECTRICAL PANEL COMPONENTS (Left Endframe) Schematic Description Circuit Breaker - T8 24VAC Output Circuit Circuit Breaker - T9 Florescent Light CON4 Contactor - Stations 1/2 (INV 6/7) Control Relay - Station Enable INV6 Inverter - Station 1 Motor...
Page 86 Operating Principles King Edge Vac Electrical Connection Box Panel Components Some power system components are located in the electrical connection box (Figure 5-5) at the right rear of the machine. The table below provides an explanation of each item indicated in the picture.
Page 87: Control System
King Edge Vac Operating Principles Control System Output signals from the right endframe MPC1 control board go through an output card before Various components work together to control they get to the output devices. These devices are the work of the machine. This control system also powered via the MPC1 board.
Page 88 Operating Principles King Edge Vac Main Electrical Panel The main electrical panel (Figure 5-7) is located in the right endframe. The table on the next page provides an explanation of each item indicated in the picture. PSC1 MPC1 Figure 5-7: Control components in the main electrical panel. Note that OC1 is positioned under OC6 and OC5 is positioned under SC1.
Page 89 King Edge Vac Operating Principles MPC1 Figure 5-8: MPC1 board in the left endframe. MAIN ELECTRICAL PANEL COMPONENTS Schematic Description Input Card - Start/Stop, Corner, Roller, Transfer, Spreader Encoder signals Input Card - Spread Home, Tail, Taut, Wall, Stain/Tear, Ironer, External Fault signals...
Page 90 Operating Principles King Edge Vac Photosensors Proximity Sensors The photosensors use a high-powered LED The proximity sensors use a magnetic ﬁeld pulse output to detect items. When an item is to detect the position of machine components. present, this beam is reﬂected back into a sensitive When a mechanism is in the proper position, this detector built into the photosensor.
Page 91 King Edge Vac Operating Principles = Connected to the NOTE: PX39 & PX40 encoders are mounted Prefeeder Control Circuit on the prefeeder transfer cylinder in the Left End Frame PX12 PX40 PE11 PE14L PE14R PX39 Top View Figure 5-10: Top view of sensor locations.
Page 92 Operating Principles King Edge Vac PHOTOSENSORS Control Board Sensor Name Function Type & Setting Red LED (Sensor NOT triggered) Detects when ﬂatwork enters the spread section of the unit. Alerts corner sensors that sheet is coming. For items shorter than 60”, it signals...
Page 93 King Edge Vac Operating Principles PROXIMITY SENSORS Control Board Sensor Name Function Type Red LED (Sensor NOT triggered) Detects when the transfer cylinder is all he way forward, allowing the Transfer Forward 12 mm ﬂatwork to be transferred from the clutch rolls to the transfer clamps.
Page 94: Compressed Air System
Operating Principles King Edge Vac 5.2 Compressed Air System It is important that the supply of compressed air be clean and dry and at 80 psi (550 kPa). All air is ﬁltered before it is used. The major components of the pneumatic system are: •...
Page 95: Air Cylinders
King Edge Vac Operating Principles Air Cylinders The machine has a number of air cylinders (Figure 5-13), which are use compressed air to create a mechanical movement. Flow Controls Flow controls (Figure 5-14) work similar to regulators or the check valves used on many air cylinders.
Page 96: Mechanical System
Operating Principles King Edge Vac Prefeed Drive System 5.3 Mechanical System Use the illustration (Figure 5-17) below to Components that make up the mechanical identify the mechanical components of the system include the following: prefeed drive system. • Prefeed Drive System The prefeed motor (Figure 5-17, A) powers •...
Page 97: Inlet Drive System
King Edge Vac Operating Principles Inlet Drive System This pulley drives a belt (C) which powers both the lower (D) and upper (F) inlet ribbon Use the illustration (Figure 5-18) and picture drive pulleys. An idler pulley (E) is included in...
Page 98: Spread Drive System
Operating Principles King Edge Vac Spread Drive System Lower Spread Subsystem There are two lower spread subsystems, each Use the illustrations (Figure 5-20, 5-21) below an exact mirror of the other. In each endframe, to identify the mechanical components of the...
Page 99: Discharge Drive System
King Edge Vac Operating Principles Discharge Drive System ByPass Drive System Use the illustration (Figure 5-22) below to Use the illustrations (Figures 5-22, 5-23) identify the mechanical components of the below to identify the mechanical components of discharge drive system.
Page 100: Sequence Of Operation
Operating Principles King Edge Vac Because all of the large pulleys are the same 5.4 Sequence of Operation size, the laydown assist and front bypass ribbon drive rolls turn at the same speed. The unit has 6 phases of operation. In addition, it will react to various error conditions.
Page 101: Stand-By Phase
King Edge Vac Operating Principles Stand-by Phase • One set of CR1 contactors allows power to ﬂow to energize CON1 and CON2 During this phase, the incoming power provided all of the motor thermostats is connected to the unit, but the unit is not contacts are closed.
Page 102: Prefeed/Input Phase
Operating Principles King Edge Vac Prefeed/Input Phase Transfer Phrase This phase begins when an operator places a This phase begins when the transfer clamp sheet on a station table. assembly moves forward to take the corners of the ﬂatwork piece from the clutch/brake rollers.
Page 103: Spread Phase
King Edge Vac Operating Principles Spread Phase Large Piece Discharge Phase This phase begins when the spread clamps take This phase begins after the piece has the ﬂatwork piece from the transfer clamps. been spread. Several things occur id quick succession •...
Page 104: Small Piece (Bypass Conveyor) Discharge Phase
Operating Principles King Edge Vac Small Piece (ByPass Conveyor) Error Conditions Discharge Phase Various operating conditions can result in an error condition. This phase begins after the BYPASS ON/OFF button has been pressed and the front bypass • As noted, if, during the spread phase, conveyor has raised into place.
Page 105: Chapter 6 Troubleshooting
If an issue occurs that is not addressed in this chapter, please contact your local authorized CHICAGO dealer or the Chicago Dryer Company factory Service Department. For a list of ® common issues that can occur in each system, refer to the Troubleshooting Symptoms page.
Page 106: Troubleshooting Symptoms
Troubleshooting King Edge Vac Troubleshooting Symptoms 6.1 CHI Diagnostic Message Index ..............6-6 6.2 LED Diagnostics .................... 6-8 6.3 Electrical Unit Does Not Start, No Message Displayed ..............6-10 Unit Does Not Start, Standard Display, No Error Message ..........6-11 Unit Does Not Start, Message reads:...
Page 107 King Edge Vac Troubleshooting 6.5 Prefeed/Inlet Section Station Carriage Does Not Clamp and Transport Flatwork ..........6-15 Station Carriage Continually Goes Up and Down ............6-15 Flatwork Stops at the Inlet Transfer Pickup Clamps ............6-15 Flatwork Stops at the Inlet Transfer Dropoff Point ............6-16 Flatwork Jams at Inlet Transfer Point ................
Page 108 Troubleshooting King Edge Vac 6.7 Spread Section Flatwork Not Properly Spread, Message Reads: UPPER SPREADER STALLED ................. 6-20 Upper Spreader Clamps Bang or Drag at the Center of the Unit ........6-20 Upper Spreader is not Reaching the Center Home Position ........... 6-21 Upper Spreader Speed Inconsistent ................
Page 109 King Edge Vac Troubleshooting 6.9 Sensor Function Sensor Function Issue, Message Reads: SENSOR FAILED/MISALIGNED/ INLET CONVEYOR SENSOR FAILED/MISALIGNED/REJECT AT INLET CONVEYOR SENSOR FAILED/MISALIGNED/IMPROPER MATERIAL ENTRY SENSOR FAILED/MISALIGNED/ LEFT CORNER SENSOR FAILED/MISALIGNED/ MATERIAL TAIL SENSOR FAILED/MISALIGNED/ MATERIAL TAUT SENSOR FAILED/MISALIGNED/ RIGHT CORNER SENSOR FAILED/MISALIGNED/ TRANSFER POSITION SENSOR FAILED/MISALIGNED/ UPPER SPREADER HOME ........
Page 110: Chi Diagnostic Message Index
Troubleshooting King Edge Vac 6.1 CHI Diagnostic Message Index Start Fault/CHI Panel Messages CIRCUIT BREAKER TRIPPED !SERVICE/CLEAR FAULT! ..................6-11 INVERTER OR MOTOR OVERLOAD !SERVICE/CLEAR FAULT! ..................6-11 CENTER STOP/INTERLOCK !SERVICE/CLEAR FAULT! ..................6-11 LEFT SIDE STOP/INTERLOCK !SERVICE/CLEAR FAULT! ..................6-11 RIGHT SIDE STOP/INTERLOCK !SERVICE/CLEAR FAULT! ..................6-11...
Page 111 King Edge Vac Troubleshooting Jam Messages CORNER CLUTCH JAMMED SHUTDOWN BEFORE REMOVING ................. 6-17 TRANSFER CYLINDER JAMMED SHUTDOWN BEFORE REMOVING ................. 6-18 UPPER SPREADER STALLED SHUTDOWN BEFORE REMOVING ................. 6-20 TAIL SENSOR COVERED SHUTDOWN BEFORE REMOVING ................. 6-26 JAM/SENSOR AT LEFT WALL SHUTDOWN BEFORE REMOVING .................
Page 112: Led Diagnostics
Troubleshooting King Edge Vac For the component/function that doesn’t 6.2 LED Diagnostics work, check the appropriate LEDs (Figure 6-1) against the chart below: Most of the control circuits on the unit operate in a similar way. If there is a malfunction, use •...
Page 113 King Edge Vac Troubleshooting Set 1 12 11 10 Run LED (24VDC) (24VDC) (24VDC) 9 10 9 10 12 11 10 12 11 10 +24V LED 1612-601 1612-601 1612-601 +5V LED 1612-530 PSC1 DETECT CN11 Set 2 +24VDC Set 3...
Page 114: Electrical
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.3 Electrical...
Page 115: Center Stop Interlock/!Service Or Clear Fault
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 116: Florescent Lamp Does Not Light
SERVICE OR CLEAR FAULT Open circuit between an inverter and its motor. An inverter-powered motor is bad. There is an overbraking problem. Contact the Chicago Dryer factory Service Department. 1. Bulb is burn out. • Check/replace as necessary. 2. Fixture/ballast is bad.
Page 117: Unit Starts, Blank Message Screen
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 118: Mechanical
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.4 Mechanical...
Page 119: Prefeed/Inlet Section
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.5 Prefeed/Inlet Section...
Page 120: Flatwork Stops At The Inlet Transfer Dropoff Point
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 121: Machine Stops, Message Reads
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 122: Transfer Section
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.6 Transfer Section...
Page 123: Corner Grabbed Then Dropped By The Transfer Clamp
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 124: Spread Section
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.7 Spread Section...
Page 125: Upper Spreader Is Not Reaching The Center Home Position
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 126: Flatwork Pulls Out Of Clamps When Spreading
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 127: Lower Spreader Belts Stop, Message Reads
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 128: Discharge Section
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.8 Discharge Section...
Page 129: Leading Edge Of Flatwork Folded Over
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 130: Excessive Gap Between Flatwork Pieces
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 131: Sensor Function
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.9 Sensor Function...
Page 132: Chi Panel
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.10 CHI Panel...
Page 133: Compressed Air System
King Edge Vac Troubleshooting WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. 6.11 Compressed Air System...
Page 134: Compressed Air Supply System Error
Troubleshooting King Edge Vac WARNING WARNING Only trained personnel with experience Read the REPAIR chapter and make Troubleshooting in electrical or mechanical repair should sure that the power is disconnected troubleshoot and repair the unit. before doing any repairs. ISSUE...
Page 135: Chapter 7 Repair
King Edge Vac Repair Chapter 7 REPAIR Although designed for long service, some individual consumable parts of the unit eventually wear during normal use and must be cleaned, adjusted or replaced. This chapter includes the following sections: Safety Considerations Spread Section...
Page 136: Safety Considerations
Repair King Edge Vac • Always keep hands and clothing away 7.1 Safety Considerations from the moving parts of the folder when it must be running to make repairs Before attempting any repair work, review or adjustments. these safety steps and precautions to protect yourself and the machine.
Page 137: Parts Availability
These procedures include: • Prefeeder Carriage Eccentric Grooved In addition, parts orders may be placed directly Bearing Adjustment with Chicago Dryer Company’s Parts Department while questions may be directed to the Service • Prefeeder Carriage Linear Bearing Department: (773) 235-4430.
Page 138: Prefeeder Carriage Eccentric Grooved Bearing Adjustment
Repair King Edge Vac Prefeeder Carriage Eccentric Grooved Bearing Adjustment If a prefeeder carriage becomes loose on its carriage rail, tension on the eccentric grooved bearings (Figure 7-1, A) must be adjusted. Note that all four grooved bearings on the assembly are actually identical.
Page 139: Prefeeder Carriage Grooved Bearing Replacement
King Edge Vac Repair Locate the two adjustment bolts on the Prefeeder Carriage Grooved Bearing rear of the bearing. Replacement Loosen the jam nut (Figure 7-3, A). These bearings often wear down in pairs, either both regular or both eccentric. Even if only one...
Page 140 Repair King Edge Vac Figure 7-5: The carriage motors are in slotted holes to make tension adjustment easy. INDEX...
Page 141: Prefeeder Carriage Belt Replacement
King Edge Vac Repair Prefeeder Carriage Belt Remove the belt from the machine and discard. Replacement Pull the drive belt over the rim of the pul- Replace a carriage carrier belt when it can no ley (Figure 7-7, A) and roll it into posi- longer be properly tensioned or if it becomes tion.
Page 142: Pneumatic Clutch/Brake Roller Alignment
Repair King Edge Vac Pneumatic Clutch/Brake Roller Alignment The function of the padded clutch rollers is to grasp the corners of the ﬂatwork for pick up by the transfer clamp. The padded clutch rollers located at the top of the inlet conveyor must be aligned parallel to each other for consistent clutching.
Page 143 King Edge Vac Repair The adjustment bolt changes the angle of the roller. Use the Allen key to loosen or tighten the adjustment bolt as needed to get the rollers parallel. Secure the retaining nut. Secure the three surrounding bracket bolts.
Page 144: Inlet Conveyor Drive Belt Tension Adjustment
Repair King Edge Vac Inlet Conveyor Drive Belt Tension Enabling/Disabling Automatic Adjustment Misfeed Reject Adjust tension of a inlet conveyor drive belt The unit is shipped from the factory with (Figure 7-11, A) when it begins to sag noticeably automatic reject enabled. This means that misfed or to skip on the pulley.
Page 145: Transfer Section
King Edge Vac Repair Transfer Clamp Check and 7.4 Transfer Section Adjustment The transfer clamp moves flatwork from The transfer clamps must grip the ﬂatwork the inlet section to the spread section. While ﬁrmly and evenly to ensure proper transfer from the transfer section is mechanically simple, the inlet section to the spread section.
Page 146 Repair King Edge Vac On the bottom of this unit is the main As appropriate: solenoid valve. Locate the override screw • If there is a gap in the clamp, or if it is on this valve (Figure 7-15). not ﬁrmly closed, it needs adjustment.
Page 147 King Edge Vac Repair Figure 7-17: Adjusting the transfer clamp. 7-13 INDEX...
Page 148: Transfer Clamp Assembly Replacement
Repair King Edge Vac Transfer Clamp Assembly Replacement Removing the Assembly Required Tools 7/16” wrench, 1/8”, 3/16” Allen keys, Phillips screwdriver, Loctite ® thread lock, scissors/knife, plastic wire ties Perform only when the unit is OFF with power disconnected. Turn power OFF at the main disconnect switch.
Page 149 King Edge Vac Repair Installation At the work bench, attach the rollers and the ﬂexible nose piece to the new trans- fer clamp assembly with the hardware removed earlier. Make sure the spacer under the roller compressed air devices is properly replaced.
Page 150 Repair King Edge Vac Figure 7-21: Transfer clamp rollers should contact the large bottom rollers evenly. 7-16 INDEX...
Page 151: Rodless Air Cylinder Carrier Bracket Tension Adjustment
King Edge Vac Repair Rodless Air Cylinder Carrier Bracket 7.5 Spread Section Tension Adjustment Sheets and other larger pieces of ﬂatwork are The rodless air cylinder located at the transfer prepared for feeding in the large piece spread point needs to be adjusted when the carrier...
Page 152: Spreader Clamp Mechanical Adjustment
Repair King Edge Vac Spreader Clamp Mechanical Upper Spreader Belt Tension Adjustment Adjustment Dropped ﬂatwork during the spread operation Adjust tension of the upper spreader belt when may indicate the spreader clamps are not properly it begins to sag noticeably or to skip on the timed gripping the ﬂatwork.
Page 153: Upper Spreader Belt Replacement
King Edge Vac Repair Upper Spreader Belt Replacement Loosen the locknuts (Figure 7-24, B) and turn each bolt the same number of turns Replace the upper spreader belt when it can counterclockwise to relax tension on the no longer be properly tensioned or if it becomes belt.
Page 154: Upper Spreader Clamp Grooved Bearing Replacement
Repair King Edge Vac Route the belts around the timed drive Upper Spreader Clamp Grooved pulley in the upper right endframe and Bearing Replacement around the timed idler pulley in the upper These bearings usually wear down in pairs, left endframe.
Page 155 King Edge Vac Repair Remove the screws which secure the worn bearings and remove them from the block. Be sure to keep track of the spacer. Use a clean cloth to wipe down the bearing block and the spacers. Carefully reposition the spacers (Figure 7-29).
Page 156: Lower Spreader Drive Belt Tension Adjustment
Repair King Edge Vac Lower Spreader Drive Belt Tension Adjustment Over time, the lower spreader drive belts will stretch due to normal wear. Adjust tension on a belt when it appears loose or begins to skip on the timed pulleys. Both conditions cause excessive wear on the belt and shorten its life.
Page 157: Lower Spreader Drive Belt Replacement
King Edge Vac Repair Lower Spreader Drive Belt Lower Spreader Belt Tension Check/ Replacement Replacement When a lower spreader drive belt shows signs The lower spreader belts on the unit will of excessive wear or evidence of cracking, it must stretch and wear over time.
Page 158: Lower Spreader Belt Gap Adjustment
Repair King Edge Vac Pull the belts around until the lacing clips Lower Spreader Belt Gap are accessible. Adjustment Remove the connecting pin and attach the When the ﬂatwork is pulled to one side as new belt with the pin.
Page 159 King Edge Vac Repair Use a small screwdriver to push in the Adjust the inside (closest to the center) lockout screw and turn it 1/4 turn clock- tension roller. wise to lock it in the “in” position. This Loosen the locknut and turn the bolt allows compressed air to flow to the to adjust gap to about 3/8”...
Page 160: Discharge/Bypass Section
Repair King Edge Vac Discharge/ByPass Conveyors 7.6 Discharge/ByPass Ribbon Tension Adjustment Section Tension on the discharge ribbons and both Sheets and other larger pieces of ﬂatwork front and rear bypass ribbons should be adjusted exit the unit and are fed to the ironer through the when ribbons sag or tend to track to one side.
Page 161: Discharge/Bypass Conveyors Ribbon Replacement
King Edge Vac Repair Locate the adjustment bolts (Figure 7-38) Discharge/ByPass Conveyors at the ends of the roll. While not shown, Ribbon Replacement those for the front bypass ribbons are the When ribbon tension can no longer be adjusted, same.
Page 162 Repair King Edge Vac Replacing Worn Ribbons Pull the worn ribbons around their tracks until all the lacing clips are accessible and Required Tools aligned. 3/8”, 9/16”, 3/4” wrenches, pliers Remove the connecting pin from an old ribbon and attach a new ribbon to one end.
Page 163 King Edge Vac Repair Replacing Broken or Missing Ribbons Release tension on the appropriate rib- bon set following the Discharge/ByPass Ribbons that break should be replaced Conveyors Ribbon Tension Adjustment immediately. To avoid excessive stress on only procedure earlier in this section.
Page 164: Discharge Conveyor Guide Ribbon Tension Adjustment/Replacement
Repair King Edge Vac Discharge Conveyor Guide Ribbon Tension Adjustment/Replacement Tension on the discharge conveyor guide ribbons cannot be adjusted mechanically because each ribbon in the set has an elasticized insert (Figure 7-41) which makes it self-adjusting. If these ribbons lose their proper tension and/ or begin to slip, the inserts should be replaced.
Page 165: Discharge Conveyor Drive Belt Tension Adjustment
King Edge Vac Repair Discharge Conveyor Drive Belt ByPass Conveyors Drive Belt Tension Adjustment Tension Adjustment Over a period of time, the discharge conveyor Over a period of time, the bypass conveyors drive belt will stretch from normal wear. When drive belt will stretch from normal wear.
Page 166: Discharge/Bypass Conveyor Drive Roll Tracking Tape Replacement
Repair King Edge Vac Discharge/ByPass Conveyor Drive Roll Tracking Tape Replacement Tracking tape is used to hold discharge and bypass ribbons in proper position during operation to keep ribbons from moving laterally or overlapping each other. Tracking tape is positioned underneath the...
Page 167 King Edge Vac Repair Remove the old tape from the drive roll. Rear ByPass Ribbons Mark the center position of each tape with This procedure involves lowering the rear a permanent marker so new tapes can be bypass conveyor while keeping the discharge properly positioned.
Page 168 Repair King Edge Vac While workers hold the discharge con- To apply the tape: veyor in position, carefully lift the bypass Cut a 9-7/16” (238 mm) for each conveyor. Remove the bypass conveyor’s placement. threaded rod from its tube (Figure 7-46).
Page 169 King Edge Vac Repair Front ByPass Ribbons To apply the tape: Cut a 9-7/16” (238 mm) for each Perform only when the unit is OFF placement. with power disconnected. Remove the backing from the tape Make sure there is enough 1" (25 mm) tape available to replace the old material.
Page 170 Repair King Edge Vac Figure 7-48: A pressure adjustment bolt is located at each end of the doffer roll. 7-36 INDEX...
Page 171: Discharge Conveyor Doffer Roll Cover Replacement
King Edge Vac Repair Discharge Conveyor Doffer Roll Pull or cut off the old canvas cover and the foam tubing. Cover Replacement Remove old adhesive from the each end Required Tools of the doffer roll with a scraper, coarse 7/16” wrench, utility knife, scraper/ sandpaper, or a steel brush.
Page 172 Repair King Edge Vac Apply contact adhesive to cover about 2” Doffer Roll Adhesive (50 mm) of each end of the roll (Figure 7-51). Push the foam tubing back into place and wipe off any excess adhesive that squeezes out at the ends.
Page 173: Sensors
King Edge Vac Repair In addition, periodic adjustment or replacement 7.7 Sensors of some sensors may be required. These procedures include: The spreader/feeder uses two types of sensors: photosensors, which rely on visual signals, and • Corner Photosensor Alignment proximity sensors, which rely on magnetic signals.
Page 174: Corner Photosensors Alignment
Repair King Edge Vac Corner Photosensors Alignment The corner photosensors watch as a ﬂatwork piece is brought into the machine and turn off when the trailing edge of the ﬂatwork clears them. These are retroreﬂective sensors, which means their proper operation depends on them being properly aligned with their reﬂectors.
Page 175: Roll Photosensors Alignment
King Edge Vac Repair Roll Photosensors Alignment Turn power ON at the main disconnect switch. The roll photosensors watch as the corners of the ﬂatwork move between the clutch/brake Press the green START button. rollers and turn off when only a small portion of Press any of the red Safety STOP but- material remains pinched between them.
Page 176: Taut Photosensors Alignment
Repair King Edge Vac Taut Photosensors Alignment On occasion, the tail of the sheet going onto the conveyor may ﬂy up and be seen by the taut sensors, triggering an early air blast. This can be corrected by changing the angle of the taut sensors to “see”...
Page 177: General Photosensor Sensitivity Adjustment
King Edge Vac Repair General Photosensor Sensitivity Required Tools Adjustment thin slotted screwdriver. The correct sensitivity for a sensor depends on its location. Some sensors have slightly Perform only when the unit is OFF reduced sensitivity to eliminate false triggering with power connected.
Page 178: Roll Photosensors Sensitivity Adjustment
Repair King Edge Vac At the same time, have the other worker Roll Photosensors Sensitivity check the input card red LED to make Adjustment sure it turns on or off as appropriate. For The roll sensors consist of two groups of four more information, refer to the OPERAT- sensors each (Figure 7-54).
Page 179: Photosensor Replacement
King Edge Vac Repair Photosensor Replacement Check that the new photosensor is posi- tioned properly by following the appropri- If a photosensor fails or is erratic, it should ate sensor alignment procedure earlier in be replaced immediately. All photosensors are this section.
Page 180: Proximity Sensor Positioning Adjustment
Repair King Edge Vac Proximity Sensor Positioning CAUTION Adjustment Adjust the position of Proximity sensors are mounted close to the the proximity sensor very surface of the objects to be sensed. These sensors carefully. If it is struck, the activate when their magnetic ﬁeld is disturbed as sensor must be replaced.
Page 181: Proximity Sensor Replacement
King Edge Vac Repair Proximity Sensor Replacement 7.8 Compressed Air If a proximity sensor fails or is erratic, it should System be replaced immediately. All proximity sensors The compressed air system provides the air are connected using a quick-release connector.
Page 182: Air Cylinder Air Flow Adjustment
Repair King Edge Vac Air Cylinder Air Flow Adjustment Air cylinders should open and close smoothly and without banging; paired air cylinders should open and close together. Adjusting the exhaust air ﬂow valves when necessary helps keep the unit operating smoothly, quietly and efﬁciently.
Page 183 King Edge Vac Repair Transfer Rodless (Figure 7-63, 1) • Adjust the air ﬂow to smoothly but quickly move the transfer clamps forward and backward. Transfer Clamp (Figure 7-63, 2) • Adjust both the left and right transfer clamp air cylinders to open and close the transfer clamps at the same time and at the same speed.
Page 184 Repair King Edge Vac Make sure all STATION buttons on the NOTE: The adjustment is a little CHI Panel are off and the panel displays counter-intuitive. In each case, the reads: air ﬂow into B is pushing the rod out, but controlling the exhaust...
Page 185: Inlet Clamps Air Pressure Adjustment
King Edge Vac Repair Inlet Clamps Air Pressure Use a small screwdriver to push in the lockout screw and turn it 1/4 turn clock- Adjustment wise to lock it in the “in” position. This If inlet clamp pressure is set too high, it can allows compressed air to ﬂow to the inlet...
Page 186: Roller Counterpoint Air Pressure Adjustment
Repair King Edge Vac Roller Counterpoint Air Pressure Adjustment Small compressed air vents (Figure 7-68) help push ﬂatwork into the rollers in a way that helps it not wrap around the rollers. However, if this air pressure is too high, it can interfere with ﬂatwork being spread behind the rollers.
Page 187: Inlet Transfer Rodless Air Cylinder Service
King Edge Vac Repair Inlet Transfer Rodless Air Cylinder Tighten the Drive T Service Required Tools Many of the following procedures will be small slotted screwdriver, stubby performed as a direct result of the weekly Phillips screwdriver, wrench, metric preventive maintenance checks on this device:...
Page 188 Repair King Edge Vac Use a small slotted screwdriver to pry off Tighten the Drive Blocks the black plastic dust caps which cover the drive T mounting bolts (Figure 7-72). CAUTION These can be discarded. This is a critical adjustment.
Page 189 King Edge Vac Repair Tighten the Carriage Block Required Tools small slotted screwdriver, stubby Phillips screwdriver, wrench, metric Allen wrench, carriage block jam nut tool or metric socket and vice grips, marker Perform only when the unit is OFF with power disconnected.
Page 190 Repair King Edge Vac Use the carriage block jam nut tool or a metric socket held by vice grips to loosen a carriage block jam nut (Figure 77, A). Insert a metric Allen wrench through the socket (Figure 77, B) and tighten the eccentric cam adjustment bolt.
Page 191 King Edge Vac Repair Locate the air cushion adjustment screw Tighten the Inner Band at the end of the cylinder near the air inlet Vibration in the outer band of the rodless air valve (Figure 78). cylinder indicates the inner band in loose and must be tightened.
Page 192 Repair King Edge Vac Remove the black plastic cap which covers the inner and outer band retaining screws (Figure 80). Remove the outer band retaining screw (Figure 81). Be careful not to remove the inner band screw which is right next to the end cap.
Page 193 King Edge Vac Repair CAUTION Be careful not to completely remove the inner band retaining screw. Loosen the inner band retaining screw (Figure 83, A). Be careful not to remove it completely. Have one worker hold back the outer band...
Page 194: Left Spreader Clamp Air Pressure Adjustment
Repair King Edge Vac Left Spreader Clamp Air Pressure Adjustment If flatwork is being damaged because the spreader clamps are gripping too tightly, or if the clamps are dropping ﬂatwork prematurely, the problem can be addressed by adjusting the left spreader clamp air cylinder air pressure.
Page 195 King Edge Vac Repair Locate the air adjustment knob on the Air Bar Alignment top of the regulator (Figure 7-86, B). There are two air bars used to lay down the Pull up on the knob to release the locking leading edge of the ﬂatwork.
Page 196 Repair King Edge Vac Finger Assist Air Pressure Adjustment Two “fingers” are used to assist with the quality of the ﬂatwork laydown by brieﬂy holding the edges in position just prior to the air blast (Figure 7-88). These ﬁngers are designed to pinch the ﬂatwork against the top edge of the air foil.
Page 197 King Edge Vac Repair Figure 7-92: Be sure to mark the position of the air foil before moving it. 7-63 INDEX...
Page 198 Repair King Edge Vac Loosen the air foil pivot bolt (Figure 7-92, Air Laydown Assist Air Pressure B). Be careful just to loosen the bolt, not Adjustment remove it completely. The discharge conveyor air assist is designed Loosen the air foil positioning bolt and to improve the laydown of the ﬂatwork as it leaves...
Page 199 King Edge Vac Repair Adjust the setting of the pressure regulator (Figure 7-93). Turn clockwise to increase pressure, turn counterclockwise to de- crease pressure. After the new air pressure setting has been made, lock it in by pressing down the adjustment cap.
Page 200 Repair King Edge Vac Locate the blower gate counterpoint air pressure adjustment knobs (Figure 7-95) at the rear of the machine, under the dis- charge bypass conveyor. Position one worker near the blower mo- tors. Turn power ON at the main disconnect switch.
Page 201 King Edge VAC 3024-029 King Edge VAC Spreader/Feeder CHI Panel Operation KING EDGE TYPE=00 04 PROGRAMS C-TOC INDEX...
Page 202 3024-029 King Edge VAC CONTENT I. OPERATION ..................C-3 CHI Panel Controls and Indicators ............C-3 Model Type/Number of Programs ............C-4 Program Selection ...................C-4 Speed Control ..................C-5 Counters ....................C-6 Jam Detection ..................C-6 Safety Stop Buttons ................C-6 Self-Diagnostics ..................C-6 II. PROGRAMMING ................C-7 Start Programming ..................C-7...
Page 203: Operation
SPEED buttons (D) Controls the speed of the unit in manual mode. Pressing  decreases the speed and  increases the speed. The speed is shown in the panel display. Figure C-1: The King Edge VAC CHI Panel. C-TOC INDEX...
Page 204: Model Type/Number Of Programs
Any ﬂatwork fed into the machine in this point Standard Measure will simply be pulled through the inlet belts and dropped on the ﬂoor. Not used for King Edge VAC Metric Measure Not used for King Edge VAC The machine will not operate properly if the type is set to either 01 or 03.
Page 205: Speed Control
King Edge VAC 3024-029 Speed Control AUTO Mode (PWM=0) The unit can operate in either manual or automatic speed mode. KING SHEET COTTON *AUTO XXX FPM CNT XXXXX In manual mode, the machine runs at the speed shown on the CHI Panel display. In auto mode, the machine’s speed is automatically controlled...
Page 206: Counters
3024-029 King Edge VAC Counters Jam Detection The standard message screen on the CHI If a piece of flatwork becomes jammed control panel shows the total running count of all in the machine, a flashing message on the pieces processed for the selected program since CHI display indicates where the jam is.
Page 207: Programming
King Edge VAC 3024-029 II. PROGRAMMING The spreader/feeder is programmed at the factory Start Programming for common piece sizes with typical values for item To program any of the CHI Panel’s function, names, conveyor speed, bypass and CHI select. follow these steps: Since each laundry is different, the unit can be reprogrammed as desired.
Page 208: Make Programming Changes
3024-029 King Edge VAC Make Programming Changes End Programming To change the FPM setting, press the + When ﬁnished changing program settings, or – buttons to increase or decrease the follow these steps to save or discard changes. speed. Saving Changes Press the CURSOR button to move to the ﬂatwork Item description.
Page 209: Adjustment
King Edge VAC 3024-029 III. ADJUSTMENT Start Adjustment Sometimes it may be necessary to adjust various settings in order to ﬁne tune the performance of To adjust any of the CHI panel’s functions, the unit. In addition, adjustments can be made...
Page 210: End Adjustment
3024-029 King Edge VAC End Adjustment NOTE: F o r t h e P r o g r a m When ﬁnished making adjustments, follow Adjustments (CHI) to be effective, these steps to save or discard changes. a program must be selected via a STATION button before entering adjustment mode.
Page 211: Inlet Adjustments (Inl
King Edge VAC 3024-029 Inlet Adjustments (INL) Transfer Adjustments (TRN) The corner stop delay and corner grab delay The transfer roll hold time and transfer spread can be individually adjusted. When INL is chosen delay can be individually adjusted. When TRN is...
Page 212: Spreader Adjustments (Spr
3024-029 King Edge VAC Spreader Adjustments (SPR) Discharge Adjustments (Feed) The spread delay and spread slow buffer can The tension time can be individually adjusted. be individually adjusted. When SPR is chosen When FEED is chosen from the SELECT from the SELECT ADJUSTMENT menu, the...
Page 213: Ironer Speed Interlock Adjustments (Irn
King Edge VAC 3024-029 Ironer Speed Interlock Adjustments IRON is actually two settings. The ﬁrst number set (3 digits after the word IRON), controls (IRN) the minimum speed at which the feeder can All of these settings deal with how the operate.
Page 214: Program Adjustments (Chi
3024-029 King Edge VAC Program Adjustments (CHI) When CHI is chosen from the SELECT ADJUSTMENT menu, the following displays: NOTE: Only CHI adjustments are STATION program speciﬁc. FAST=10” LSP290 TORQ.08S All others are global. AIR.16S GAP-07” PACE=420 It is important to use care with the FAST These adjustments apply speciﬁcally to the...
Page 215: Testing
King Edge VAC 3024-029 IV. TESTING The testing function should only be used to see With the machine off, check the continuity and hear the operation of the unit to verify proper of the fuse for this output and replace it if functioning or as an aid during troubleshooting.
Page 216: Start Testing
3024-029 King Edge VAC Start Testing Press and hold the TEST button; then, press the ENTER button. Release both To test any of the CHI Panel’s functions, buttons. The SELECT TEST menu dis- follow these ﬁrst steps: plays as follows: Locate the appropriate schematic(s).
Page 217: End Testing
King Edge VAC 3024-029 Look at the control boards to conﬁrm the End Testing correct LEDs light. If a component fails To leave test mode, follow these steps: to operate or an LED fails to trigger prop- erly, refer to the TROUBLESHOOTING When ﬁnished running a test, press the...
Page 218: Inlet Section Test (Inl
3024-029 King Edge VAC Inlet Section Test (INL) Spreader Section Test (SPR) The panel display shows: The panel display shows: CONVEYOR DOWN 8 CLEAN3 UPPER SPREAD IN17/OUT18 LOWER IN11/OUT12 GAP19 LEFT ROLL9 RIGHT ROLL10 The control system automatically begins to the The control system automatically begins two pneumatic clutch/brakes.
Page 219 King Edge VAC 3038-015e NOTE: When ordering parts, please provide the serial number and a complete description of the machine, including any non- standard features. Electrical part numbers can be found in the SCHEMATICS section (when available). King Edge VAC...
Page 220: Front View
3038-015e King Edge VAC Front View 35 34 = Optional PL-2 PL-TOC INDEX...
Page 221 King Edge VAC 3038-015e Front View continued... Part Number Description 2001-526 L.H. ENDFRAME ASSY (UPPER) KING EDGE 2001-525 R.H. ENDFRAME ASSY (UPPER) KING EDGE 1416-600-01 LENS RED 1416-605-01 LENS GREEN 1416-606-01 BASE UNIT 1416-601-01 POST 4” 3403-118 GUARD CHANNEL R.H. SIDE SECTION...
Page 222: Rear View
3038-015e King Edge VAC Rear View 52 53 Part Number Description 3403-006 REAR GUARD W/ PLEXIGLASS 129”x15”x18 GA 2001-526 L.H. ENDFRAME ASSY (UPPER) KING EDGE 2010-336 R.H. SUPPORT BRKT FOR RIBBONS FOR VACUUM 2010-337 L.H. SUPPORT BRKT FOR RIBBONS FOR VACUUM 0209-040 AIR FOIL ASSEMBLY 125”...
Page 223 King Edge VAC 3038-015e Rear View continued... Part Number Description 9000-200 EXIT SMOOTHING BRUSH/AIR BAR KIT W/MICRO 0605-386 AIR BAR ASSY SUPPORT BRACKET 2010-348 L.H. LOWER DISCHARGE ARM^ 0219-012 EXIT CONVEYOR BRUSH ASSEMBLY 1001-158 1”x63” CANVAS & 1”x3” ELASTIC SET 1001-157 PERFORATED RIBBON 3”...
Page 224: Rolls And Ribbons
3038-015e King Edge VAC Rolls and Ribbons PL-6 PL-TOC INDEX...
Page 225 King Edge VAC 3038-015e Rolls and Ribbons continued... Part Number Description 3209-476 DRIVE ROLL 3”x122-1/2”x7 GA W/CANVAS 3209-279 DRIVE ROLL 3”x 122-1/2”x 7 GA W/29 RINGS 3211-031 DOFFER ROLL 3”x120” W/RUBBER & CANVAS 3203-232 RAW IDLER ROLL 3” x 120” x 11 GA 1001-158 1”x63”...
Page 226: Air Bar Assembly
3038-015e King Edge VAC Air Bar Assembly Exit Conveyor Guide Part Number Description 0605-386 AIR BAR ASSY SUPPORT BRACKET 0205-220 STRAIGHT CONNECTOR 1/2” NPT x 1/2” OD 0601-300 U BOLT 1/4” FOR 1” PIPE 5206-160 TEE 3/8 x 3/8 x 1/2 BRASS...
Page 227: Exit Conveyor Guide
King Edge VAC 3038-015e Exit Conveyor Guide = 136” Machine Part Number Description 3407-348 EXIT CONVEYOR GUIDE ASSEMBLY 3407-349 EXIT CONVEYOR GUIDE ASSEMBLY S20-373 BRKT 2-1/2 x 3 x 1/4 x 1” L W/2 HOLES 0614-050 COLLAR 3/8” ID LOCKING...
Page 228: Left Side Bearings
3038-015e King Edge VAC Left Side Bearings Part Number Description 0402-763 BEARING HANGER 1” BORE PERM LUBE 0402-060 BEARING 2 BOLT FLANGE 5/8” BORE 0402-766 BEARING HANGER 1-1/4” BORE 0402-774 BEARING 1” BORE STAT MOUNT 0402-759 TENSION HANGER BEARING 1” BORE...
Page 229: Right Side Bearings
King Edge VAC 3038-015e Right Side Bearings Part Number Description 0402-766 BEARING HANGER 1-1/4” BORE 0402-763 BEARING HANGER 1” BORE PERM LUBE 0402-060 BEARING 2 BOLT FLANGE 5/8” BORE 0402-759 TENSION HANGER BEARING 1” BORE 0402-774 BEARING 1” BORE STAT MOUNT...
Page 230: Drive Detail (Left
3038-015e King Edge VAC Drive Detail (Left) PL-12 PL-TOC INDEX...
Page 231 King Edge VAC 3038-015e Drive Detail (Left) continued... Part Number Description 1223-900 BELT POLY CHAIN GT 1215-025 BUSHING JA-5/8 BORE 0608-039 SENSOR BRACKET 4” x 5” x 12 GA 1608-000 MACHINE SPEED SENSOR 8 MM ASSY 0608-161 RIGHT HAND BELT BEARING BRKT 1201-195 SPROCKET #40 12T 5/8”BORE KWAY 2 STSCR...
Page 232: Drive Detail (Right
3038-015e King Edge VAC Drive Detail (Right) PL-14 PL-TOC INDEX...
Page 233 King Edge VAC 3038-015e Drive Detail (Right) continued... Part Number Description 2801-390 MOTOR 1/2 HP 3/60/230/460 1725RPM FR 56C 1223-900 BELT POLY CHAIN GT 1215-020 BUSHING 1108-5/8 BORE 1221-250 PULLEY POWER GRIP 25T 1205-902 V BELT SHEAVE 10” OD 1” BORE W/ExTRA 1201-230 SPROCKET #40 16T 1”...
Page 234: Inlet Station Assy. Detail (L
3038-015e King Edge VAC Inlet Station Assy. Detail (L) PL-16 PL-TOC INDEX...
Page 235 King Edge VAC 3038-015e Inlet Station Assy. Detail (Left) continued... Part Number Description 1205-935 V BELT SHEAVE 3-1/4” OD 5/8” BORE 0608-405 STATION SENSOR BRACKET TOP L.H. 1608-002 MACHINE SPEED SENSOR-SHORT 12MM 0204-455 RAIL LINEAR ASSY 50” LONG 0605-271 INLET STATION TROLLEY MOUNT...
Page 236: Inlet Station Assy. Detail (R
3038-015e King Edge VAC Inlet Station Assy. Detail (R) 41 40 PL-18 PL-TOC INDEX...
Page 237 King Edge VAC 3038-015e Inlet Station Assy. Detail (Right) continued... Part Number Description 1205-935 V BELT SHEAVE 3-1/4” OD 5/8” BORE 0605-267 V BELT SHEAVE BRKT 2” x 8-1/4” x 1/4 GA 1223-900 BELT POLY CHAIN GT 0204-466 R.H. KING EDGE LINEAR BEARING ASSEMBLY...
Page 238: Inlet Drive Mechanism
3038-015e King Edge VAC Inlet Drive Mechanism PL-20 PL-TOC INDEX...
Page 239 King Edge VAC 3038-015e Inlet Drive Mechanism continued... Part Number Description 1205-807 V BELT SHEAVE 3-3/4” OD 1” BORE 0402-763 BEARING HANGER 1” BORE PERM LUBE 1208-136 BRAKE CLUTCH ROLL W/ 5/8 SHAFT 1208-133 BRAKE CLUTCH IDLER ROLL W/1-1/4” BORE...
Page 240: Inlet Drive Mechanism (Rear
3038-015e King Edge VAC Inlet Drive Mechanism (Rear) * = 130” Machine Only PL-22 PL-TOC INDEX...
Page 241 King Edge VAC 3038-015e Inlet Drive Mechanism (Rear) continued... Part Number Description 1607-220 SHARP CUTOFF SENSOR 8” W/CONNECTOR 0605-256 TAUT SENSOR MOUNT 6” x 1-7/16” x 12 GA 0202-450 VALVE IN LINE SPRING RETURN 1/4” OD 0202-490 SOLENOID 24 VAC...
Page 242: Transfer Clamp Assembly
3038-015e King Edge VAC Transfer Clamp Assembly PL-24 PL-TOC INDEX...
Page 243 King Edge VAC 3038-015e Transfer Clamp Assembly continued... Part Number Description 1608-002 MACHINE SPEED SENSOR-SHORT 12MM 0608-375 INLET/REJECT SENSOR MOUNT 2010-038 NYLON ROLLER 3-1/4” x 3/4” DIA 1210-053 SHAFT 1/4” x 4” 0607-242 L H TRANSFER CLAMP ROLLER W/COLLAR BRKT...
Page 244: Upper Clamp Assembly
3038-015e King Edge VAC Upper Clamp Assembly PL-26 PL-TOC INDEX...
Page 245 King Edge VAC 3038-015e Upper Clamp Assembly continued... Part Number Description 1803-018 2” ROUND BUMPER, W/1 LG & 3 SMALL HOLES 0603-051 UPPER TRANSFER CYL BRKT 10”x2”x2”x3/16 G 0206-834 E-CHAIN, 57 LINKS W/CONN LINK 0608-600 CYLINDER SUPPORT BRKT 7-3/4”x1-5/8”x12 G 0205-100 STRAIGHT CONNECTOR 1/8”...
Page 246: Spreader Clamp Assy. (Left
3038-015e King Edge VAC Spreader Clamp Assy. (Left) 13 14 12 15 16 * = 130” Machine Only ** = 136” Machine Only Part Number Description 1223-900 BELT POLY CHAIN GT 0206-830 E CHAIN 0204-402 LINEAR BEARING 0602-464 UPPER SPREADER BELT BRKT ASSY...
Page 247: Spreader Clamp Assy. (Right
King Edge VAC 3038-015e Spreader Clamp Assy. (Right) 1 15 14 17 16 12 * = 130” Machine Only ** = 136” Machine Only Part Number Description 1223-900 BELT POLY CHAIN GT 0206-830 E CHAIN 0204-402 LINEAR BEARING 0602-464 UPPER SPREADER BELT BRKT ASSY...
Page 248: Lower Spreader Detail
3038-015e King Edge VAC Lower Spreader Detail * ** * = 130” Machine Only ** = 136” Machine Only PL-30 PL-TOC INDEX...
Page 249 King Edge VAC 3038-015e Lower Spreader Detail continued... Part Number Description 1205-025 PULLEY CROWN FACE 3” x 3” 1” BORE 0614-150 COLLAR 5/8” ID LOCKING 0608-163 BELT SPREADER TOP BRKT 3” x2” x2” x7 GA 0608-164 BELT SPREADER BOTTOM BRKT 3”x2”x2”x7 GA 0608-059 BELT SPREAD OUTSIDE 47”...
Page 250 3038-015e King Edge VAC This page intentionally left blank. PL-32 PL-TOC INDEX...
Page 251: Spreader Belt Tensionerassembly
King Edge VAC 3038-015e Spreader Belt Tensioner Assembly Top View of King Edge Part Number Description 0607-135 BELT SPREADER ASSY 1210-066 SHAFT 5/8” OD x 3-7/8” L 1205-027 IDLER ROLL W/ 5/8” BEARINGS 2010-016 LOWER REAR EXTENSION ARM INSIDE 1205-028 ROLL 2-1/4”...
Page 252: Left Pneumatic Panel
3038-015e King Edge VAC Left Pneumatic Panel PL-34 PL-TOC INDEX...
Page 253 King Edge VAC 3038-015e Left Pneumatic Panel continued... Part Number Description 1409-002 MAIN PNEU PANEL 11” x 14” x 12 GA 0202-470 VALVE DUAL AIR SUPPLY 1/8” 0205-150 STRAIGHT CONNECTOR 1/4” NPT x 3/8” OD 0203-300 MUFFLER EXHAUST 1/4” NPT 0202-460 VALVE STACK SPRING RETURN 1/4”...
Page 254: Right Pneumatic Panel
3038-015e King Edge VAC Right Pneumatic Panel Part Number Description 1409-002 MAIN PNEU PANEL 11” x 14” x 12 GA 0202-470 VALVE DUAL AIR SUPPLY 1/8” 0205-150 STRAIGHT CONNECTOR 1/4” NPT x 3/8” OD 0203-300 MUFFLER EXHAUST 1/4” NPT 0202-460 VALVE STACK SPRING RETURN 1/4”...
Page 255: Main Air Filter Assembly
King Edge VAC 3038-015e Main Air Filter Assembly Part Number Description 5001-149 NIPPLE 1/2” x CLOSE 0203-195 REGULATOR 1/2” NPT 0205-365 ELBOW SWIVEL 1/2” NPT x 1/2” OD 0608-100 AIR FILTER BRKT 3-1/2” x 11-1/2” x 7 GA 0203-170 FILTER DRAIN 1/2” NPT 0203-175 GAUGE 1/8”...
Page 256: Regulator & Valves Location
3038-015e King Edge VAC Regulator & Valves Location Part Number Description 0202-450 VALVE IN LINE SPRING RETURN 1/4” OD 0202-490 SOLENOID 24 VAC 0202-500 PLUG IN FOR AIR VALVE 0205-255 ELBOW SWIVEL 1/8” NPT x 1/4” OD 0203-290 EXHAUST 1/8” NPT QUICK 5001-002 NIPPLE 1/8”...
Page 257: Air Reservoir Assembly (L
King Edge VAC 3038-015e Air Reservoir Assembly (L) Part Number Description 0205-150 STRAIGHT CONNECTOR 1/4” NPT x 3/8” OD 5203-020 HEX BUSHING 1/2 x 3/8 BRASS 0202-960 VALVE AIR 1/2” 24 VAC 5001-149 NIPPLE 1/2” x CLOSE 5208-100 CROSS 1/2” BRASS 0205-220 STRAIGHT CONNECTOR 1/2”...
Page 258: Photosensor Locations
3038-015e King Edge VAC Photosensor Locations PX12 PX40 PE14L PE14R PE11 PX39 Top View PE = PHOTO SENSOR PX = PROXIMITY SENSOR (LIGHT OPERATE) PX37 PX33 PE4A,B,C,D PE5A,B,C,D PE22 PE23 PE2A,B,C PE3A,B,C PE31 PE35 PX32 PX36 PE15 PE16 PE27 PE13...
Page 259 King Edge VAC 3038-015e Photosensor Locations continued... Schematic Location/Function Type/Setting Part Number Reference Spreader Inlet Diffuse dark operate 1607-215 w/connector PE2A, B, C Left Corner Retroreﬂective dark operate 1607-210 w/connector PE3A, B, C Right Corner Retroreﬂective dark operate 1607-210 w/connector...
Page 260: Pacing Light (Option
3038-015e King Edge VAC Pacing Light (Option) Part Number Description 1416-600-01 LENS RED 1416-605-01 LENS GREEN 1416-606-01 BASE UNIT 1416-601-01 POST 4” B05-485 1/4-20 x 3/4” PH TR HD M/S 0608-641 PACING LAMP MOUNTING BRKT PL-42 PL-TOC INDEX...
Page 261 King Edge Vac 3210-437b NOTE: When ordering parts, please provide the serial number and a complete description of the King Edge Vac, including any non- standard features . King Edge Vac Schematics and Parts Content Motor Circuits 460V Motor Circuit ........................SC-2 208-230V Motor Circuit ......................
Page 262: Motor Circuit
460V Motor Circuit SC-2 SC-TOC INDEX...
Page 263 King Edge Vac 3210-437b 460V Motor Circuit (6220633) Reference Part No. Description 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE 1410-391-01 CIRCUIT BREAKER 10 A 3 POLE CON7 1404-450 CONTACTOR 9 AMP 24 VAC 50/60 HZ...
Page 264: 208-230V Motor Circuit
208-230V Motor Circuit SC-4 SC-TOC INDEX...
Page 265 King Edge Vac 3210-437b 208-230V Motor Circuit (6220636) Reference Part No. Description 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE 1410-391-01 CIRCUIT BREAKER 10 A 3 POLE CON7 1404-450 CONTACTOR 9 AMP 24 VAC 50/60 HZ...
Page 266: Control Power/Communications
Control Power/Communications SC-6 SC-TOC INDEX...
Page 267 King Edge Vac 3210-437b Control Power/Communications (6270119) Reference Part No. Description 1612-750 INPUT BOARD 9 24VAC MPC1 1612-503 MACHINE CONTROLLER BOARD MPC2 1612-658 CHI PANEL CONTROLLER PSC1 1612-530 POWER SUPPLY 5VDC/24 VDC SC-7 SC-TOC INDEX...
Page 268: Controller Inputs
Controller Inputs SC-8 SC-TOC INDEX...
Page 269 King Edge Vac 3210-437b Controller Inputs (6270187) Reference Part No. Description AIRPRS 0203-275 AIR PRESSURE SWITCH 1/4” NPT 1612-601 INPUT BOARD 10-OC 24 VDC 1612-601 INPUT BOARD 10-OC 24 VDC 1612-601 INPUT BOARD 10-OC 24 VDC MPC1 1612-503 MACHINE CONTROLLER BOARD...
Page 270: Control Outputs
Control Outputs SC-10 SC-TOC INDEX...
Page 271 King Edge Vac 3210-437b Control Outputs (6270213) Reference Part No. Description 1401-502 RELAY 24 VAC 2 POLE CR10 1401-275 RELAY 1 POLE 24VAC/DC CR1B 1401-503 SOCKET FOR 2 POLE RELAY 1401-502 RELAY 24 VAC 2 POLE CR4B 1401-503 SOCKET FOR 2 POLE RELAY...
Page 272 3210-437b King Edge Vac 6270213: Control Outputs continued... Reference Part No. Description SV22R 0202-960 VALVE AIR 1/2” 24 VAC SV22RC 0202-165 PLUG FOR AIR VALVE COIL SV33 0202-460 VALVE STACK SPRING RETURN 1/4” OD SV33C 0202-490 SOLENOID 24 VAC SV35 0202-450 VALVE IN LINE SPRING RETURN 1/4”...
Page 273 King Edge Vac 3210-437b This page intentionally left blank. SC-13 SC-TOC INDEX...
Page 274: Prefeeder Control Circuit
Prefeeder Control Circuit SC-14 SC-TOC INDEX...
Page 275 King Edge Vac 3210-437b Prefeeder Control Circuit (6270329) Reference Part No. Description CB11 1410-391-01 CIRCUIT BREAKER 10 A 3 POLE 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE 1410-205-01 CIRCUIT BREAKER 0.5 A 2 POLE CON3 1404-450 CONTACTOR 9 AMP 24 VAC 50/60 HZ...
Page 276 3210-437b King Edge Vac This page intentionally left blank. SC-16 SC-TOC INDEX...
Page 277: Vac Control Circuit
24 VAC Control Circuit SC-17 SC-TOC INDEX...
Page 278: Interlock Circuit (System E-Stop
Interlock Circuit (system E-stop) SC-18 SC-TOC INDEX...
Page 279: Pneumatic Diagram
Pneumatic Diagram SC-19 SC-TOC INDEX...
Page 280: Prefeeder Electrical Panel
Prefeeder Electrical Panel SC-20 SC-TOC INDEX...
Page 281 King Edge Vac 3210-437b Prefeeder Electrical Panel (6280252) Reference Part No. Description 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE 1410-205-01 CIRCUIT BREAKER 0.5 A 2 POLE 1612-512 MACHINE CONTROLLER BOARD CON4 1404-450 CONTACTOR 9 AMP 24 VAC 50/60 HZ 1401-509...
Page 282: Disconnect Panel
Disconnect Panel SC-22 SC-TOC INDEX...
Page 283 King Edge Vac 3210-437b Disconnect Panel (6280175) Reference Part No. Description 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE CB10 1410-391-01 CIRCUIT BREAKER 10 A 3 POLE 1410-210-01 CIRCUIT BREAKER 1 A 2 POLE DISC1 1402-650 SWITCH DISCONNECT ASSY TYPE J...
Page 284: Main Eletrical Panel
Main Eletrical Panel SC-24 SC-TOC INDEX...
Page 289 02/20/07 King Edge TECHNICAL SPECIFICATIONS -VAC 6500-326 App:GW Spreader Feeder Production Variable Speed Drive Output Feet per Minute (m/min) Minimum Maximum (46) Motors Total (5.7) Left Station Drive , HP (kW) 1/ 2 (0.37) Right Station Drive , HP (kW) 1/ 2 (0.37) Lower Spreader left Drive , HP (kW)
Page 291 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 293 King Edge Vac Index INDEX Symbols Air Cylinder (cont) Rodless (cont) 24 VAC Outputs Testing, CHI Panel C-15 Service 7-53 Increase the Air Cushion 7-56 Tighten the Carriage Block 7-55 Tighten the Drive Blocks 7-54 Adjustment, CHI Panel C-9 Tighten the Drive T 7-53...
Page 294 Index King Edge Vac Belts (cont) CHI Panel Tension Adjustment About 5-9 Prefeeder Carriage 7-6 Adjustment C-9 Upper Spreader 7-18 Discharge Adjustments C-12 Tension Check/Replacement End Adjustment C-10 Lower Spreader 7-23 Inlet Adjustments C-11 Blower Gate Air Cylinder Air Flow Adjustment...
Page 295 King Edge Vac Index Compressed Air Supply Control System, Electrical 5-9 Checkout 2-15 CHI Panel 5-9 Connection 2-8 Communications and the Boards 5-9 Compressed Air System 7-47 Main Electrical Panel 5-10 About 5-16 MPC1 Boards 5-10 Air Bars 5-17 Photosensors 5-12...
Page 296 Index King Edge Vac Discharge/ByPass Section (cont) Error Conditions, Sequence of Operation 5-26 Discharge Phase Error Messages, CHI Panel 6-6 Large Piece, Sequence of Operation 5-25 Exhaust Blower Ports, Clean 4-3 Small Piece (ByPass), Sequence of Operation 5-26 Testing, CHI Panel C-18...
Page 297 King Edge Vac Index Inlet Section (cont) Lower Spreader Inlet Transfer Rodless Air Cylinder Belt Service 7-53 Air Cylinder Air Flow Adjustment 7-49 Increase the Air Cushion 7-56 Condition and Tension Check 4-14 Tighten the Carriage Block 7-55 Gap Adjustment 7-24...
Page 298 Index King Edge Vac Pre-Operational Checkout (cont) Compressed Air Supply Checkout 2-15 Operating Controls 3-4 Safety Device and Control Function Checkout CHI Panel 3-6 2-18 Operating Techniques 3-13 CHI Panel Function 2-19 Maximum Efﬁciency 3-13 Safety Device 2-18 Maximum Feeding Speed 3-13...
Page 299 King Edge Vac Index Program Adjustments, CHI Panel C-14 Safety Considerations, Repair 7-2 Program Selection, CHI Panel 3-9, C-4 Safety Device and Control Function Checkout 2-18 Proximity Sensor CHI Panel Function 2-19 About 5-12 Safety Device 2-18 Position Adjustment 7-46...
Page 300 Index King Edge Vac Setscrews, Check 4-15 Set Pacing (Option), Flatwork Handling 3-9 Task Table, PM 4-1 Shut-Down 3-13 Taut Photosensors Alignment 7-42 Site and Utility Requirements 2-2 Tension Adjustment Small Piece (ByPass) Discharge Phase, Sequence of ByPass Conveyor Drive Belt 7-31...
Page 301 King Edge Vac Index Troubleshooting CHI Diagnostic Message Index 6-6 Warranty 1-2 CHI Panel 6-28 Watch and Listen for Anything Abnormal 4-2 Compressed Air System 6-29 Waxing, Flatwork Handling 3-10 Discharge Section 6-24 Weekly PM (50 Hours) 4-4 Electrical 6-10...

Chicago Dryer King Edge VAc Instruction Manual

Introduction

Chapter 1 Introduction

Chapter 2 Installation

Chapter 3 Operating Guidelines

Chapter 4 Preventive Maintenance

Chapter 5 Operating Principles

Chapter 6 Troubleshooting

Troubleshooting Symptoms

Chapter 7 Repair

Chi Panel Operation

Picture Parts List

Schematics and Parts

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Chicago Dryer King Edge VAc