Chicago Folder-Stacker Model Skyline S-16CT Line.pdf
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- Solicitation number
- 36C25624Q0735
About this file
This document is an instruction manual for the preventive maintenance and repair of a Skyline CT Flatwork Folder series models S1 to S20. The manual details the various preventive maintenance tasks required at daily, weekly, monthly, semi-annual, and annual intervals to ensure long life and trouble-free operation of the folder. Key tasks include inspecting and cleaning components, checking air pressure settings, lubricating bearings, and performing electrical system checks. The manual also provides troubleshooting guidance and repair procedures for the folder's mechanical, electrical, and compressed air systems. While this is not a federal contract opportunity document, the information provided could be relevant for a solicitation seeking preventive maintenance and repair services for similar laundry equipment.
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SKYLINETM CT
Flatwork Folder Series Models: S1 to S20
IN
ST
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C
TI
O N
M A
N U
A L
Skyline CT S1-S20 Preventive Maintenance
4-1
Chapter 4
PREVENTIVE MAINTENANCE
Various components of the SkylineTM folder require scheduled attention to ensure 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.
Since operators run the machines, they should be trained on site to visually inspect common areas daily and notify maintenance personnel when problems are found, such as worn or broken ribbons. All PM intervals are based on 8-hour/day operation. Increase the PM frequency for two- or three-shift operations.
Preventive maintenance should only be done when the power is turned OFF at the main disconnect switch. Specific preventive maintenance that requires the unit to be running should be done with extreme caution and attention to detail.
PM Task Table
FREQUENCY OF TASKS BASED ON 40 HOURS PER WEEK OPERATION
Preventive Maintenance Operator Maintenance Unit Condition
4.1 DAILY (8 Hours)
Watch and Listen for Anything Abnormal X Running
General Cleanliness X Off/Disconnect Power
Check and Clean Photosensors X Off/Disconnect Power
Check Safety Equipment X X Running
4.2 WEEKLY (50 Hours)
Check and Clean Inverters X Off/Disconnect Power
Inspect Air Filter/Auto Drain X Off/Disconnect Power
Check Air Pressure Settings X Off/Power Connected
Check Ribbon Condition and Tension X Running
4.3 MONTHLY (50 Hours)
Check Setscrews X Off/Disconnect Power
Inspect Drive Belts X Off/Disconnect Power
Grease Bearings X Off/Disconnect Power
Check and Clean Crossfold Drive Motors X Off/Disconnect Power
Check First Crossfold Blade (Option) and Second Crossfold Air Cylinders X Running
4.4 SEMI-ANNUAL (1000 Hours)
Clean Air Filter/Auto Drain X Off/Disconnect Power
Clean and Lubricate Drive Chains X Off/Disconnect Power
4.5 ANNUAL (2000 Hours)
Check All Electrical Connections X Off/Disconnect Power
Check Insulation Resistance to Earth Ground X Off/Disconnect Power
Preventive Maintenance Skyline CT S1-S20
4-2
4.1 Daily PM (8 Hours)
WARNING
Do not repair or correct any of these conditions without reading and understanding the REPAIR chapter.
Only qualified personnel should troubleshoot and repair the unit.
Make sure the power is turned OFF at the main disconnect switch.
Follow lockout/tagout procedures approved for your site. Follow local regulations. Failure to do so could result in serious injury.
Watch and Listen for Anything Abnormal
Perform only when the unit is
RUNNING.
Use extreme caution.
Operators and maintenance personnel should learn to understand the usual sights and sounds around a unit. For example, when there is a noise at a roll, the bearings may be worn or other mechanical problems may exist. Stop the unit immediately and follow-up with the necessary maintenance or repair.
General Cleanliness
Required Tools Soft, lint-free cloth Vacuum cleaner or compressed air
Perform only when the unit is OFF with power disconnected.
CAUTION
NEVER use compressed air on or around electronic components. Damage can result.
It is important to prevent buildup of lint, dirt, dust, and foreign material in the unit. General cleanliness prevents damage to components, jamming, and soiling flatwork.
Keep the area as well as the folder as clean as possible. Check and clean these items daily.
Receiving shelves
Ribbons
General components
4-3
Check and Clean Photosensors
Most control problems can be avoided by keeping the photosensors (Figure 4-1) clean.
For information on photosensor location, refer to the OPERATING PRINCIPLES chapter, Electrical System section, Control System subsection.
Required Tools Soft, lint-free cloth Vacuum cleaner or compressed air
Perform only when the unit is OFF with power disconnected.
Use compressed air to blow off loose debris on each photosensor.
Wipe each photosensor with a soft, lint-free cloth.
1.
2.
Check Safety Equipment
Perform only when the unit is
RUNNING.
Use extreme caution.
The machine should never be operated without all safety guards in place and all safety devices working properly.
Check that all four red safety STOP buttons, the main safety guard, and the red wire safety guard all bring the operation of the machine to a complete halt and depressurize the compressed air system.
For more informat ion, refer to the OPERATING GUIDELINES chapter, Daily Operating Procedures section, Start-Up procedure.
NOTE: Repair any faulty safety devices before continuing to operate the unit.
Figure 4-1: Photosensors must be kept clean to help ensure reliable functioning.
4-4
4.2 Weekly PM (50 Hours)
WARNING
Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.
Check and Clean Inverters
Check and clean the inverters and their cooling fins (Figure 4-2) weekly with a vacuum cleaner.
Failure to do so may void your warranty.
Required Tools Vacuum cleaner
Perform only when the unit is OFF with power disconnected.
Turn power OFF at the main disconnect switch.
Open the upper left endframe door.
CAUTION
Failure to clean the inverter and its cooling fins could void the warranty.
Never use compressed air on or around electronic components. Doing so may damage them.
Check and clean all inverters and their cooling fins with a vacuum cleaner.
Close and secure the upper left endframe door.
1.
2.
3.
4.
Figure 4-2: Check and clean the inverters weekly.
4-5
Inspect Air Filter/Auto Drain
Perform only when the unit is OFF with power disconnected.
The combination air filter with automatic drain unit (Figure 4-3) should be inspected on a weekly basis.
A visible coating of dirt or condensate on the filter element surface or excessive pressure drop is an indication that cleaning is necessary.
For instructions within this chapter on cleaning the air filter/auto drain, refer to the Semi-Annual PM section, Clean Air Filter/Auto Drain procedure.
Figure 4-3: Check the air filter/auto drain for dirt and condensate accumulation.
Check Air Pressure Settings
Maintaining proper incoming and internal air pressures helps keep the machine operating at peak efficiency.
The machine has a total of 5 standard air gauges/pressure regulators. Each must be checked. Two more may be included depending upon optional equipment.
Perform only when the unit is OFF with power connected.
Use extreme caution.
WARNING
Use protective eyewear and make sure that the compressed air supply connection is secure.
Turn ON the compressed air supply to the unit.
Turn power ON at the main disconnect switch. Wait about 45 seconds for the machine to go through the boot up process.
When it is finished, “Start to reset Estop (Air)” displays in the CHI•Touch screen.
Press and release the START button. The CHI•Touch screen displays “Air pressure low”.
Wait several sections for the compressed air system to pressurize. When the ma-chine is ready, “Paused” displays in the CHI•Touch screen. It is not necessary to start the machine.
1.
2.
3.
4-6
Locate the pressure gauges on the right endframe (Figure 4-4, A, B, C), inside the right endframe (D) and above the second/third crossfold air tank (E). The air pressure gauges should be set as listed below:
A Primary Fold Air Blast-LO 30 psi (205 kPa)
B Primary Fold Air Blast-HI 60 psi (415 kPa)
C Incoming Air Pressure 80 psi (550 kPa)
D First Primary Fold Counterpoint 5
E Second/Third Crossfolds 70 psi (480 kPa)
NOTE: These settings are pre-set at the factory. Air pressures can be changed to meet the needs of different weights of flatwork.
5.
Air pressure gauges at the right front of the unit.
Second/Third crossfold pressure gauge.
A
B
C
E
First primary fold counterpoint air pressure control.
Figure 4-4: Standard air gauges.
D
4-7
First Crossfold Blade (Option)
If the unit has the first crossfold blade option, there will be an additional gauge near the blade above the delivery table (Figure 4-5). It should be set to 60 psi (415 kPa).
Aircumulator (Option)
If the unit has the aircumulator option, there will also be two gauges in the right endframe (Figure 4-6) that should be set to the following pressures:
A Clamp air cylinders 80 psi (550 kPa)
B Drape air blast 30 psi (205 kPa)
Triple Crown (Option)
The Triple Crown option offers a third primary fold. The air pressure gauges should be set as listed below. See Figure 4-4.
A Primary Fold Air Blast-LO 40 psi (275 kPa)
B Primary Fold Air Blast-HI 70 psi (480 kPa)
Check Ribbon Condition and Tension
Perform only when the unit is
RUNNING.
Use extreme caution.
WARNING
Never touch any part of the unit while it is moving.
Serious injury could result.
Check all ribbons for proper placement, tracking, tension (no visible sagging), and general condition (smoothness, fraying, tears).
To adjust ribbons or replace worn ones, refer to the REPAIR chapter, Ribbons section, and the appropriate Ribbon Tension Adjustment or Ribbon Replacement procedure.
NOTE: Ribbons that break should be replaced immediately.
Figure 4-6: Aircumulator air pressure gauges in right endframe.
A B
Figure 4-5: Optional first crossfold blade air pressure gauge above delivery table.
4-8
4.3 Monthly PM
(200 Hours)
WARNING
Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.
Figure 4-7: Make sure the setscrews are sufficiently tightened.
Check Setscrews
Setscrews (Figure 4-7) hold sprockets, bearings, and other rotating parts securely in place. Check and make sure that all setscrews are tight.
Required Tools Allen wrench set
Perform only when the unit is OFF with power disconnected.
4-9
Figure 4-8: Make sure drive belts are properly tensioned and in good physical condition.
C
A
B
Inspect Drive Belts
Carefully inspect the condition of the drive belts. There are two:
Main drive belt (Figure 4-8, A)
Delivery drive belt (Figure 4-8, B)
Perform only when the unit is OFF with power disconnected.
Turn power OFF at the main disconnect switch.
NOTE: The delivery drive belt is located on the opposite side of the machine from crossfold discharge.
Remove the right upper endframe panel and, as appropriate, either the left or right lower endframe panel.
Check each belt’s tension and condition:
If the tension on a belt cannot be ad-justed replace it.
If any belt shows excessive wear or is damaged, replace it.
For more information on adjusting belt tension and/or replacing belts, refer to the REPAIR chapter, Chains and Belts section, and the appropriate belt tension adjustment or replacement procedure.
Replace and secure the endframe panels.
1.
2.
3.
5.
4-10
Grease Bearings
Regularly grease bearings to help ensure smooth operation and dependability. A special high temperature lubricant is required to properly grease all bearings. It is important that only Shell Darina® SD 2 grease or its equivalent be used.
Use of unsuitable grease can cause bearing lockup or failure. Problems can also result if the new grease is incompatible with the grease that is already in the bearings.
Failure to use the correct lubricant will void the factory warranty.
CAUTION
Before using a grease other than Shell Darina® SD 2, check with the factory service department to verify that the grease meets specifications and is compatible with the grease already in the bearings.
If any other grease is being considered:
Check with the Chicago Dryer Company service department to verify that the grease meets specifications and is compatible with the grease already in the bearings.
Follow directions on the grease gun pack-aging for other filling methods (dispenser, suction).
Be sure to grease the:
Main drive pulley bearing inside (Figure 4-9, A).
Main drive pulley bearing outside (Figure 4-9, B).
Delivery drive bearings (Figure 4-9, C).
Roll bearings: primary drive (Figure 4-9, D) intermediate drive (E), primary idler (F), and intermediate idler (G).
Crossfold bearings (Figure 4-10).
1.
2.
Figure 4-10: Some crossfold bearings are behind safety covers; others are not.
Figure 4-9: Primary fold bearings.
B
A
C
D
E
F
G
4-11
NOTE: Check all roll bearings which have grease fittings and lubricate them as necessary following this procedure.
Required Tools Clean, lint-free cloth Grease gun Shell Darina® SD 2 Grease or equivalent Wrench: 1/2”
Perform only when the unit is OFF with power disconnected.
Turn power OFF at the main disconnect switch.
Remove any protective covers, panels or endframe doors as necessary (For ex-ample, the crossfold drive safety covers, Figure 4-11).
Wipe the old grease from the bearings.
Insert the grease gun nozzle firmly onto the grease fitting.
1.
2.
3.
4.
CAUTION
Over-lubrication will destroy the bearing seals and cause premature failure.
Add lubricant slowly until a slight bead of lubricant forms at the seal. As soon as the bead forms, stop adding grease to prevent damage from over-lubrication.
CAUTION
Failure to wipe off excess lubricant will cause lint to adhere to the bearings and may cause premature failure.
Immediately wipe off the grease from the bearing. Failure to do so can cause lint accumulation and premature bearing failure.
Replace or close and secure any protective covers, panels, or endframe doors.
WARNING
Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.
5.
6.
7.
Figure 4-11: Crossfold drive safety covers.
4-12
Check and Clean Crossfold Drive Motors
The crossfold drive motors require monthly cleaning to ensure proper operation.
Required Tools Vacuum cleaner
Perform only when the unit is OFF with power disconnected.
Turn power OFF at the main disconnect switch.
Use a vacuum to clean out lint and dirt from the intake side (Figure 4-12) of both crossfold motors.
Make sure the motor cooling fans are free to turn without binding.
1.
2.
3.
Figure 4-12: Removing lint and dirt from the intake side of the motor ensures proper operation.
4-13
Figure 4-14: The second crossfold air cylinders control movement of the flip blade and finger bar.
A B
Check First Crossfold Blade (Option) and Second Crossfold Air Cylinders
Perform only when the unit is
RUNNING.
Use extreme caution.
If the unit is equipped with the optional first crossfold blade, an air cylinder (Figure 4-13) controls the down and up movement of the blade.
The blade must move down and up quickly, but must not hit hard at either end of its travel.
Two air cylinders are involved in the second crossfold: The one on the outside of the endframe (Figure 4-14, A) controls the flip blade; the one located inside of the frame (B) controls the finger bar.
Each blade must move up and down quickly, but must not hit hard at either end of its travel.
For more information on adjusting the air flow valves for these cylinders, refer to the REPAIR chapter, Compressed Air System section, First Crossfold Blade (Option) Air Cylinder Adjustment or Second Crossfold Air Cylinders Adjustment procedure.
4.4 Semi-Annual PM
(1000 Hours)
WARNING
Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.
Figure 4-13: First crossfold air cylinder flow controls.
B
4-14
Clean Air Filter/Auto Drain
The air filter with auto drain requires periodic cleaning to maintain maximum filtering efficiency and to avoid excessive pressure drop.
The cleaner the compressed air supply, the less maintenance will be required. A visible coating of dirt or condensate on the filter element surface or excessive pressure drop is an indication that cleaning is necessary.
WARNING
Before disassembling the air filter/auto drain, turn off the air supply and depressurize the system and filter.
Required Tools Alcohol Compressed air Mild detergent solution
Perform only when the unit is OFF with power disconnected.
Turn off the compressed air supply and depressurize the unit.
Turn power OFF at the main disconnect switch.
Press the black plastic tab on the side of the bowl case down (Figure 4-15, A) and rotate it left or right until the two marks on the bowl case light up with the single mark on the filter base (B).
Pull down on the bowl case to remove
it. The filter base does not need to be re-moved from the machine.
Take the polyurethane bowl (Figure 4- 16, A) and rinse with ONLY water and household soap.
Twist counterclockwise the black plastic base (Figure 4-16, B) which holds the filter element (C) in place.
1.
2.
3.
4.
5.
6.
Remove the filter element, wash it in alco-hol, and blow it out from the inside.
Clean the other components (Figure 4-16, B, D) with alcohol.
Re-assemble the clean components. Twist the filter base clockwise to lock it in posi-tion.
Re-attach the clean polyurethane bowl, lining up the marks as in Step 3.
Press up on the bowl and twist left or right until the plastic tap snaps into position.
7.
8.
9.
10.
11.
Figure 4-15: Press the plastic tab and twist the casing to line up the marks to remove the filter bowl from the machine.
B
A
Figure 4-16: All the components in the air filter assembly can be washed with alcohol, EXCEPT the bowl.
A
B
C
D
4-15
Clean and Lubricate Drive Chains
The four drive chains listed below require monthly maintenance:
Main drive chain (Figure 4-8, C)
First crossfold pinch roll drive chains-2 (Figure 4-17, A, B)
Crossfold conveyor/exit drive chain (Figure 4-18)
Carefully inspect the condition of the drive chains. Check the tension on the chains. Replace any chain that shows signs of excessive wear and can no longer be adjusted.
For information on adjusting tension, refer to the REPAIR chapter, Chains and Belts section and the appropriate chain tension adjustment procedure.
Required Tools Clean cloth SAE 90 grade oil Wrench: 1/2”
Perform only when the unit is OFF with power disconnected.
Turn the power OFF at the main discon-nect switch.
Remove the upper right endframe panel.
Clean off old lubricant from the drive chain.
Lightly lubricate the chain with a good quality SAE 90 grade oil.
Replace and secure the upper right endframe panel.
Under the delivery table, remove the two protective covers for the crossfold drive chains (Figure 4-11).
Clean off old lubricant from the drive chains.
Lightly lubricate the chains with a good quality SAE 90 grade oil.
Replace and secure each cover.
WARNING
Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Figure 4-18: Crossfold conveyor/exit drive chain at the discharge side of the machine.
Figure 4-17: Each first crossfold pinch roll has its own drive chain.
B
4-16
4.5 Annual PM
(2000 Hours)
WARNING
Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.
Check All Electrical Connections
Over time, the continued heating and cooling process can cause electrical connects to become loose.
Required Tools Screwdriver: small, thin
Perform only when the unit is OFF with power disconnected.
WARNING
Only a qualified electrician should make or correct any electrical connections in or to the unit.
Turn power OFF at the main disconnect switch.
Open the upper left endframe door.
Test each wire’s connection by gently pulling on it.
Tighten any loose connections.
Close and secure the upper left endframe door.
1.
2.
3.
5.
4-17
Check Insulation Resistance to Earth Ground
Required Tools Voltmeter
Perform only when the unit is OFF with power disconnected.
WARNING
Only a qualified electrician should make or correct any electrical connections in or to the unit.
Turn power OFF at the main disconnect switch.
Connect a voltmeter between the unit’s frame and a separate, known earth ground.
If there is a reading on the voltmeter, check and repair the folder’s ground con-nection.
1.
2.
3.
| Table of Contents |
| Manual |
| Updates |
| Electrical System Troubleshooting Update |
| Air Filter/Auto Drain PM Update |
| Pinch Roll Friction Material Replacement Update |
| Static Bar Upgrade |
| Ch. 1: Introduction |
| 1.1 Warranty |
| 1.2 Scope of the Manual |
| 1.3 Safety |
| Safe Work Habits |
| Safety Features |
| 1.4 Equipment Description |
| Models and Model Numbers |
| Orientation |
| Folds |
| Machine Widths |
| Optional Stacker/Conveyor(s) |
| Additional Optional Equipment |
| Ch. 2: Installation |
| 2.1 Site and Utility Requirements |
| 2.2 Installation Procedures |
| Inspection |
| Uncrating and Positioning |
| Mechanical Setup |
| Compressed Air Supply Connection |
| Electrical Connection |
| Status Light (Option) Installation |
| Chicago Automatic Reject Processor (Remote Stain/Tear Reject Buttons) (Option) Installation |
| Receiving Shelves Set-Up |
| Stacker/Sorting Stackers Installation (S13-S20 models) |
| Final Protective Wrapper Removal |
| 2.3 Pre-Operational Checkouts |
| Security of Hardware |
| Compressed Air Supply Checkout |
| Crossfold Ribbon Rotation Checkout |
| Safety Device, Jog Reverse and Static Bar Checkout |
| Input Ribbon Tension Adjustment |
| Primary Fold Operation Checkout |
| Crossfold Operation Checkout |
| Optional Features Checkout |
| Checkout Completion |
| Cleaning the Unit |
| Ch. 3: Operating Guidelines |
| 3.1 Safety Features |
| Main Disconnect Switch |
| Safety STOP Buttons |
| Safety Guards |
| Safety Interlock Switches |
| Safety Labels |
| 3.2 Operating Controls |
| 3.3 Daily Operating Procedures |
| Start-Up |
| Clearing a Jam Safely |
| Interconnected Stop Circuit (Option) Operation Notes |
| Fold Operation |
| Chicago Automatic Reject Processor (Remote Stain/Tear Reject Option) |
| Shut-Down |
| 3.4 Operating Techniques |
| Processing Standards |
| Maximum Productivity |
| General Operating Techniques |
| Ch. 4: Preventive Maintenance |
| PM Task Table |
| 4.1 Daily PM (8 Hours) |
| Watch and Listen for Anything Abnormal |
| General Cleanliness |
| Check and Clean Photosensors |
| Check Safety Equipment |
| 4.2 Weekly PM (50 Hours) |
| Check and Clean Inverters |
| Inspect Air Filter/Auto Drain |
| Check Air Pressure Settings |
| Check Ribbon Condition and Tension |
| 4.3 Monthly PM (200 Hours) |
| Check Setscrews |
| Inspect Drive Belts |
| Grease Bearings |
| Check and Clean Crossfold Drive Motors |
| Check First Crossfold Blade (Option) and Second Crossfold Air Cylinders |
| 4.4 Semi-Annual PM (1000 Hours) |
| Clean Air Filter/Auto Drain |
| Clean and Lubricate Drive Chains |
| 4.5 Annual PM (2000 Hours) |
| Check All Electrical Connections |
| Check Insulation Resistance to Earth Ground |
| Ch. 5: Operating Principles |
| Safety |
| 5.1 Electrical System |
| Power System |
| Control System |
| Static Bar |
| 5.2 Compressed Air System |
| Air Filter/Regulators |
| Air Pressure Switch |
| Air Reservoirs |
| Air Valves |
| Air Bars |
| Air Cylinders |
| 5.3 Mechanical System |
| Primary Fold Drive System |
| Crossfold Drive System |
| Ribbon Sets |
| 5.4 Sequence of Operation |
| Stand-By Phase |
| Start-Up Phase |
| Single Lane Model Primary Fold Operation (S-1, S-5, S-9, S-13, S-17) |
| Triple Crown Primary Fold Operation (All models) |
| Aircumulator Operation (All Models) |
| Two Lane Model Primary Fold Operation (S-2, S-6, S-10, S-14, S-18) |
| Three Lane Model Primary Fold Operation (S-3, S-7, S-11, S-15, S-19) |
| Four Lane Model Primary Fold Operation (S-4, S-8, S-12, S-16, S-20) |
| Crossfold Operation (Models S-5 to S-20) |
| Stacker (Option) Operation |
| Ch. 6: Troubleshooting |
| Troubleshooting Symptoms |
| 6.1 LED Diagnostics |
| 6.2 Electrical |
| Unit Does Not Power Up |
| Unit Does Not Start, Message: |
| Start to reset Estop (Air) |
| Start hold 5sec |
| Interlock open |
| Pinch guard open |
| E-stop |
| Air pressure lo |
| Inverter fault |
| Unit Starts, Then Shuts Down |
| Unit Starts, Blank CHI•Touch Screen |
| Static Bar Does Not Work |
| 6.3 Mechanical |
| Noisy Operation |
| Ribbon Set Not Working, No Message |
| Rotating Elements Stop |
| Ribbons Do Not Track Straight |
| Drive System Mechanical Error |
| Drive System Electrical Error |
| 6.4 Primary Folding |
| Primary Folding Does Not Work |
| No Message Displayed |
| Sensor Failure Message |
| Jam Error Message |
| Primary Folding is Erratic |
| Primary Folding is Erratic at Slow Speeds |
| Primary Folding is Erratic-Late First Fold |
| Lane is Dumping Flatwork Between the Ironer and the Folder |
| Flatwork is Caught by Rolls Before Primary Air Blast |
| Flatwork Exiting to Rear of Unit Catches in Crossfold Inlet Area |
| 6.5 First Crossfold |
| First Crossfold Bypassed |
| No Message Displayed |
| Sensor Failure Message |
| Delivery Ribbons Stop About 1/2 Second with No Air Blast, No Message |
| Delivery Ribbons Stop About 2 Seconds with no Air Blast, No Message |
| Delivery Ribbons Stop, Air Blast, But No Fold, No Message |
| Jam Error Message |
| Flatwork Wraps Around Pinch Roll |
| 6.6 Second Crossfold |
| Second Crossfold Conveyor Ribbons Do Not Work |
| No Second Crossfold |
| No Message Displayed |
| Sensor Failure Message |
| Inaccurate Second Crossfold |
| Inaccurate Second Crossfold, Uneven from Side to Side |
| Jam Error Message |
| 6.7 Third Crossfold |
| Third Crossfold Ribbons Do Not Work |
| No third Crossfold |
| No Message Displayed |
| Sensor Failure Message |
| Inaccurate Fold |
| Jam Error Message |
| 6.8 Crossfold Exit |
| Exit Conveyor Ribbons Do Not Work, Sensor Error Message |
| Flatwork Does Not Come Out of the Crossfold Exit Area |
| Jam Message |
| 6.9 Sensor Function |
| Sensor Function Issue |
| Photosensor is Dirty |
| Photosensor is “Seeing a Ribbon” |
| Photosensor Not Working |
| Machine Speed Sensor Not Working |
| 6.10 Compressed Air System |
| Unit Does Not Start or Jog, Message: Air pressure lo |
| No Air Supply to Unit |
| Poor Air Pressure in Unit |
| No or Poor Air Supply to Air Devices |
| Compressed Air Supply System Error |
| 6.11 Aircumulator (Option) |
| Aircumulator not working |
| Clamps not holding flatwork |
| Flatwork falling on floor |
| Ch. 7: Repair |
| 7.1 Safety Considerations |
| 7.2 Parts Availability |
| 7.3 Ribbons |
| Input Ribbon Tension Adjustment |
| Intermediate Ribbon Tension Adjustment |
| Intermediate Ribbon Tension Adjustment: Triple Crown Option |
| Second Primary Fold Ribbon Tension Adjustment: Triple Crown Option |
| Lower Delivery Ribbon Tension Adjustment |
| Second Crossfold Conveyor Ribbon Tension Adjustment |
| Third Crossfold Ribbon Tension Adjustment |
| Crossfold Exit Ribbon Tension Adjustment |
| Ribbon Replacement |
| 7.4 Rolls |
| Second Primary Fold Pinch Point Gap Adjustment |
| First Crossfold Pinch Rolls Gap Adjustment |
| Tracking Tape Overview |
| Input Ribbon Idler Roll Tracking Tape Replacement |
| Intermediate Ribbon Idler Roll Tracking Tape Replacement |
| Riveted Tracking Tape Replacement |
| First Crossfold Pinch Rolls Friction Material Replacement |
| 7.5 Chains and Belts |
| Main Drive Chain Tension Adjustment |
| First Crossfold Pinch Rolls Drive Chains Tension Adjustment |
| Crossfold Exit Drive Chain Tension Adjustment |
| Main Drive Belt Tension Adjustment |
| Main Drive Belt Replacement |
| Lower Delivery Drive Belt Tension Adjustment |
| 7.6 Sensors |
| Lateral Photosensor Alignment |
| First Primary Fold Photosensor Sensitivity Adjustment |
| Photosensor Replacement |
| Machine Speed Sensor Adjustment |
| Machine Speed Sensor Replacement |
| 7.7 Compressed Air System |
| Air Bar Alignment |
| First Crossfold Air Bar Height Adjustment |
| First Crossfold Blade (Option) Air Cylinder Air Flow Adjustment |
| Second Crossfold Air Cylinders Mechanical Adjustment |
| Second Crossfold Air Cylinders Air Flow Adjustment |
| Air Valve Repair |
| 7.8 Aircumulator (Option) |
| Aircumulator Assembly Air Cylinder Air Flow Adjustment |
| Aircumulator Clamp Air Cylinder Air Flow Adjustment |
| Aircumulator Air Bar Alignment |
| Aircumulator Clamp Bar Adjustment |
| CHI•Touch Opertion |
| I. Operation |
| Main Screen Controls and Indicators |
| Using the CHI•Touch Screen |
| Setting the Access Level |
| Setting the Data Display Time Frame |
| Automatic Operation |
| Manual Operation |
| Aircumulator (Option) Operation |
| Triple Crown (Option) Operation |
| Dual Sorting Stackers (Option) Operation |
| Viewing Program Production Data |
| Setting the Program/Operator/Account |
| Machine Status Information |
| Safety Stop Buttons |
| Self-Diagnostics |
| Jam Detection |
| II. Programming |
| Setting Program Parameters |
| Program Parameters |
| III. Adjustment |
| Adjusting Program Parameters |
| Primary Fold Adjustments |
| Aircumulator (Option) Adjustments |
| IV. Testing |
| Testing General Machine Operation |
| Testing Specific Sections |
| Testing Individual Components |
| Parts List |
| General |
| Front View |
| Rear View |
| Primary Fold Components |
| Left Side Bearings |
| Right Side Bearings |
| Drive Side Detail (Right) |
| Drive Side Detail (Right) – Triple Crown Option |
| Rolls and Ribbons |
| Rolls and Ribbons – Triple Crown Option |
| Misc. Parts and Pieces (Left) |
| Misc. Parts and Pieces (Right) |
| Crossfold Components |
| Crossfold Drive Detail |
| Crossfold Rolls and Ribbons |
| Crossfold Bearing Detail (L) |
| Crossfold Bearing Detail (R) |
| Crossfold Table Sensor Location (Right Discharge) |
| Crossfold Section – Sensors and Air Bars |
| Pneumatic Components |
| First Crossfold Air Bar Detail |
| First Primary Air Bar Assy. (1 & 2 Lane) |
| First Primary Air Bar Assy. (3 & 4 Lane) |
| Second Primary Air Bar Assy. (1 & 2 Lane) |
| Second Primary Air Bar Assy. (3 & 4 Lane) |
| Air Filter/Air Tank Assembly (Left Discharge) |
| Air Filter/Air Tank Assembly (Right Discharge) |
Optional Aircumulator Assy.
| Schematics |
| Motor Circuits |
| 400-460V Motor Circuit |
| 208-230V Motor Circuit |
| 24V Interlock Circuit |
| Fold Circuits |
| Primary Inputs |
| Primary Outputs |
| Control Circuits |
| Control |
| Crossfold I/O - AS-i Network |
| Inverter Control |
| Pneumatic Diagram |
| Main Electrical Panel |
| Stacker |
| 1.0 Installation |
| 1.1 Safety |
| 1.2 Site and Utility Requirements |
| 1.3 Inspection |
| 1.4 Installation Procedures |
| Uncrating and Positioning |
| Compressed Air Supply Connection |
| Electrical Connection |
| Receiving Shelf Set-Up |
| Final Protective Wrapper Removal |
| 1.5 Pre-Operational Checkout |
| Security of Hardware |
| Compressed Air Supply Checkout |
| Electrical Connection Checkout |
| Safety Device and Stacker Function Checkout |
| Checkout Completion |
| Cleaning the Unit |
| 2.0 Operating Guidelines |
| 2.1 Safety Features |
| Safety STOP Buttons |
| Safety Guards |
| Safety Interlock Switches |
| Safety Labels |
| 2.2 Operating Controls |
| Safety STOP button |
| CLEAR CONVEYOR button |
| 2.3 Daily Operating Procedures |
| Start-Up |
| Proper Stacks |
| Clearing a Jam Safely |
| 3.0 Preventive Maintenance |
| PM Task Table |
| 3.1 Daily PM (8 Hours) |
| Watch and Listen for Anything Abnormal |
| General Cleanliness |
| Check and Clean Photosensors |
| Check Safety Equipment |
| 3.2 Weekly PM (50 Hours) |
| Check and Clean Inverters |
| Check Ribbon Condition |
| 3.3 Monthly PM (200 Hours) |
| Check Setscrews |
| Grease Air Cylinder Pivot Bolts |
| Grease Stacker Door Bearings |
| Inspect Drive Belts |
| 3.4 Annual PM (2000 Hours) |
| Check All Electrical Connections |
| Check Insulation Resistance to Earth Ground |
| 4.0 Operating Principles |
| 4.1 Safety |
| 4.2 Electrical System |
| Power System |
| Control System |
| 4.3 Compressed Air System |
| Air Regulator/Gauge |
| Air Valve |
| Flow Controls |
| Air Cylinders |
| 4.4 Mechanical System |
| Stacker Drive System |
| Conveyor Drive System |
| Ribbon Sets |
| 5.0 Troubleshooting |
| Stacker Ribbons Move Too Slowly or Do Not Move |
| Flatwork Bypasses Stacker to Table, Ribbons Do Not Stop |
| Flatwork Does Not Feed into Stacker |
| Flatwork Does Not Stack Evenly |
| Trap Door Error: Ribbons Stop But Doors Do Not Operate |
| Conveyor: Ribbon Sets Do Not Advance |
| 6.0 Repair |
| 6.1 Safety Considerations |
| 6.2 Parts Availability |
| 6.3 Stacker Ribbon Tension Adjustment |
| 6.4 Conveyor Ribbon Tension Adjustment |
| Lower Conveyor Ribbons |
| Upper Conveyor Ribbons |
| 6.5 Ribbon Replacement |
| Preparation |
| Replacing Worn Ribbons |
| Replacing Broken or Missing Ribbons |
| 6.6 Tracking Tape Replacement |
| 6.7 Stacker Ribbon Drive Belt Tension Adjustment |
| Main Drive Belt |
| Auxiliary Drive Belt |
| 6.8 Photosensor Adjustments/Replacement |
| Inlet Photosensor Alignment |
| Door Photosensor Alignment |
| Photosensor Sensitivity Adjustment |
| Photosensor Replacement |
6.9 Stacker Door Air Cylinder Air Flow Adjustment
| Stacker Parts |
| Standard Stacker |
| Front View |
| Top View |
| Left Endframe View |
| Right Endframe View |
| Rolls and Ribbons |
| Extra Wide Stacker |
| Front View - XW Model |
| Top View - XW Model |
| Left Endframe View - XW Model |
| Right Endframe View - XW Model |
| Rolls and Ribbons - XW Model |
| Common Components |
| Left Side Bearings |
| Right Side Bearings |
| Pneumatic Assembly |
| Stacker: Conveyor Assembly |
| Stacker Schematics |
| Stacker 208/240V |
| Sorting Stacker 208/240V |
| Stacker Conversion Adapter |
| Appendix |
| Floor Plans |
| Technical Specifications |
| Torque Specifications |
Index
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btnUpdates:
File details come from the government source that posted it. Updated .