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Chicago Dryer AIR CHICAGO EXPRESS Instruction Manual

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AIR CHICAGO
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EXPRESS
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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: Table Of Contents

    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: Chapter 7 Repair

    Air Chicago Express Repair Chapter 7 REPAIR Although designed for long service life, some individual consumable components of the Air Chicago ® Express eventually wear during normal use and must be adjusted or replaced. Adjustment and replacement subjects covered are:...

  • Page 12: Safety Considerations

    Repair Air Chicago Express • Never bypass any of the unit’s safety 7.1 Safety Considerations features. Only operate the unit with endframe doors and all guards in Before attempting any repair work, review place and all safety features operating these safety steps and precautions to protect correctly.

  • Page 13: Parts Availability

    Orders may also be placed directly with the Chicago Dryer Company Parts Department. Questions may be directed to your local authorized CHICAGO dealer or the service department at ®...

  • Page 14: Ribbons And Rolls

    Second Crossfold Ribbon Tension Adjustment • Stacker Ribbon Tension Adjustment • Exit Conveyor Ribbon Tension Adjustment • Ribbon Replacement Transfer Ribbons First Crossfold Ribbons Primary Fold Ribbons Exit Conveyor Ribbons Stacker Ribbons Second Crossfold Ribbons Figure 7-1: Air Chicago Express ribbons sets. INDEX...

  • Page 15: Primary Fold Ribbon Tension Adjustment

    Air Chicago Express Repair Primary Fold Ribbon Tension Turn power ON at the main disconnect switch. Adjustment Run the unit briefly and make sure the Required Tools ribbons track straight. Wrenches: If tension on the ribbons is uneven, the 3/8”...

  • Page 16: First Crossfold Ribbon Tension Adjustment

    Repair Air Chicago Express First Crossfold Ribbon Tension Run the unit briefly and make sure the ribbons track straight. Adjustment If tension on the ribbons is uneven, the Required Tools ribbons will track toward the end of the Wrenches: drive roll where tension is highest.

  • Page 17: Transfer Ribbon Tension Adjustment

    Air Chicago Express Repair Transfer Ribbon Tension Adjustment Run the unit briefly and make sure the ribbons track straight. Required Tools If tension on the ribbons is uneven, the Wrenches: ribbons will track toward the end of the 3/8” drive roll where tension is highest.

  • Page 18: Second Crossfold Ribbon Tension Adjustment

    Repair Air Chicago Express Second Crossfold Ribbon Tension Run the unit briefly and make sure the ribbons track straight. Adjustment If tension on the ribbons is uneven, the Required Tools ribbons will track toward the end of the Wrenches: drive roll where tension is highest.

  • Page 19: Stacker Ribbon Tension Adjustment

    Air Chicago Express Repair Stacker Ribbon Tension Adjustment Tension on the stacker ribbons is maintained by a spring-tensioned idler roll (Figure 7-6). If proper tension on the ribbons is not being maintained, the spring has stretched and must be replaced.

  • Page 20: Ribbon Replacement

    Repair Air Chicago Express Rear Conveyor Section Ribbon Replacement Over a period of time, ribbons stretch. When Required Tools the tension on a set of ribbons can no longer Phillips screwdriver: #3 be adjusted, the entire set of ribbons must be Wrench: 7/16”...

  • Page 21: Parts List

    Air Chicago Express Repair Required Tools WARNING Phillips screwdriver: #3 Never turn on power while Pliers pulling the ribbons through. Wrenches: This is dangerous and 3/8” unnecessary. 7/16” 9/16” Pull the old ribbon through until the new Perform only when the unit is OFF ribbon is in its place.

  • Page 22: Tracking Tape Overview

    Repair Air Chicago Express Repeat Steps 3 and 4 to replace additional Tracking Tape Overview ribbons. Stagger the positions of the lacing Tracking tape helps hold ribbons from moving clips to give the flatwork a smooth flow. from side to side or overlapping each other on their rolls during operation.

  • Page 23: Exit Conveyor Ribbon Idler Roll Tracking Tape Replacement

    Air Chicago Express Repair Exit Conveyor Ribbon Idler Roll The exit conveyor idler roll axles are spring loaded. Use a screwdriver or other Tracking Tape Replacement blunt edge tool to press in on the hex- Tracking tape helps hold ribbons from moving...

  • Page 24: Riveted Tracking Tape Replacement

    Repair Air Chicago Express Riveted Tracking Tape Replacement Required Tools Drill Tracking tape helps hold ribbons from moving Drill bit: 1/16” from side to side or overlapping each other on Nail their rolls during operation. Tracking tape is Permanent marker...
  • Page 25 Air Chicago Express Repair Place a tarp, plastic drop cloth, heavy paper, or another temporary protective covering over any machine parts. Release tension on the appropriate set of ribbons; refer to the Ribbons section and the appropriate ribbon tension adjustment procedure.

  • Page 26: Chains And Belts

    Repair Air Chicago Express Repeat Steps 13 to 16 for each tracking 7.4 Chains and Belts tape location. Several drive chains and belts are used to Remove the temporary protective covering transmit mechanical power from the motors to and clean up the work area.

  • Page 27: Main Drive Chain Tension Adjustment

    Air Chicago Express Repair Main Drive Chain Tension CAUTION Adjustment Tighten the chain so the machine runs smoothly. Too Required Tools much tension will cause a Wrenches: 15/16” (2) jerking motion and can damage bearings. Perform only when the unit is OFF with power disconnected.

  • Page 28: Second Crossfold Ribbon Drive Chain Tension Adjustment

    Repair Air Chicago Express Second Crossfold Ribbon Drive CAUTION Chain Tension Adjustment Tighten the chain so the machine runs smoothly. Too Required Tools much tension will cause a Wrenches: 15/16” (2) jerking motion and can damage bearings. Perform only when the unit is OFF with power disconnected.

  • Page 29: Stacker Ribbon Drive Belt Tension Adjustment

    Air Chicago Express Repair Stacker Ribbon Drive Belt Tension Tighten both bolts to secure the adjust- ment. Adjustment Over time, the power twist belt will stretch WARNING due to normal wear and tear. Tension on the This safety interlock switch...

  • Page 30: Sensors

    Repair Air Chicago Express Photosensor Replacement 7.5 Sensors If a photosensor fails or is erratic, it should The Air Chicago uses two types of sensors: be replaced immediately. All photosensors use a Photosensors, which rely on visual signals, screw connector.

  • Page 31: Primary Fold Ski Position Detect Proximity Sensor Adjustment

    Air Chicago Express Repair Primary Fold Ski Position Detect Start the unit. Proximity Sensor Adjustment Use the CHI•Touch screen to move the skis as you watch the LED on the back of The primary fold ski position detect proximity the proximity sensors. Each should light...

  • Page 32: Primary Fold Ski Position Detect Proximity Sensor Replacement

    Repair Air Chicago Express Do not position the sensor closer than .04” Primary Fold Ski Position Detect (1 mm) to the metal plate. The sensor must Proximity Sensor Replacement be replaced if hit by the metal plate. If any proximity sensor fails or is erratic, it Turn power ON at the main disconnect should be replaced immediately.

  • Page 33: Compressed Air System

    Air Chicago Express Repair Screw the sensor into its connector re- 7.6 Compressed Air ceptacle. System Make sure the new proximity sensor is The folder uses air bars to create folds and positioned correctly. Within this section, air cylinders to create mechanical movement. It...

  • Page 34: Primary Fold Air Bar Alignment

    Repair Air Chicago Express Primary Fold Air Bar Alignment Required Tools Allen wrench: 1/8” Over time, the setscrews holding the primary fold air bars in position may loosen slightly, causing the bar to slip out of position. This will Perform only when the unit is OFF cause problems with creating proper primary with power disconnected.

  • Page 35: Crossfold Air Bar Alignment

    Air Chicago Express Repair Crossfold Air Bar Alignment Required Tools Allen wrench: 5/32” Crossfolds are accomplished by the action of the air bars pushing the towel into the opening between two rolls: Perform only when the unit is OFF with power disconnected.

  • Page 36: Primary Fold Ski Air Cylinder Air Flow Adjustment

    Repair Air Chicago Express Tighten the setscrews. Primary Fold Ski Air Cylinder Air Flow Adjustment If necessary, lower the rear protective panel. The movement of the primary fold skis is controlled by an air cylinder. The skis should Turn power ON at the main disconnect move quickly and smoothly from sensor to switch and start the folder.

  • Page 37: Stacker Door Air Cylinder Air Flow Adjustment

    Air Chicago Express Repair As appropriate: Stacker Door Air Cylinder Air Flow Adjustment • If the inward movement requires ad- justment, adjust the exhaust flow screw The movement of the stacker door is controlled on the retraction side (Figure 7-22, A) by an air cylinder.

  • Page 38: Air Valve Repair

    Repair Air Chicago Express As appropriate: Air Valve Repair • If the doors hit too hard when they Perform only when the power is disconnected open or if they open too slow, adjust and the air system is depressurized. the exhaust flow screw on the retrac-...
  • Page 41 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 43 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 45 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 46 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 47 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 48 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 49 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 50 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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