Chicago Ironer Model Powerhouse CT.pdf

POWERHOUSE™ CT

3200, 4200, 5200 Gas Heated Thermal Fluid Deep Chest Ironers Models I-IV

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Powerhouse CT Preventive Maintenance

4-1

PM Task Tables

Daily, Weekly Tasks

Chapter 4

PREVENTIVE MAINTENANCE

Various components of the Powerhouse™ CT require scheduled attention to ensure long life and trouble-free operation. The Preventive Maintenance (PM) Schedule on this page and the next outlines all of the PM tasks required at regular intervals. All tasks are the responsibility of qualified maintenance personnel unless otherwise indicated. Only trained and qualified personnel with experience in electrical, gas, thermal fluid, and/or mechanical repair should perform maintenance on the unit.

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. Note that the tables on this page and the next indicate the number of operating hours before each set of PM tasks should be performed.

Preventive maintenance should only be done when the unit is completely cool and 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.

Preventive Maintenance Schedule beginning

FREQUENCY OF TASKS BASED ON HOURS OF OPERATION

Preventive Maintenance Tasks Operator Maintenance Ironer (Folder) Condition

4.1 Daily (8 Hours)

Watch and Listen for Anything Abnormal X Running/Hot

General Cleanliness X Off/Disconnect Power/Cool

Clean Power Box Air Filter X Off/Disconnect Power/Cool

Clean Easi-Feed (Option) Components X Off/Disconnect Power/Cool

Check Left Endframe Side Gauges X X Running/Hot

Check Safety Equipment X X Running/Hot

Check Guide Tapes (Twice Daily) X Running/Hot

Clean Ironing Chests X Running/Hot

Wax Ironing Chests X Running/Hot

4.2 Weekly (50 Hours)

Clean Roll Padding and Roll Shafts X Off/Disconnect Power/Cool

Inspect Air Filter/Auto Drain X Off/Disconnect Power/Cool

Check Compressed Air System X Off/Power Connected/Cool

Clean Inside Endframes and Electrical Boxes and Clean Inverters

X Off/Disconnect Power/Cool

Check/Clean Circulation Pump Drip Pan X Off/Disconnect Power/Cool

Check Feed Ribbon Condition and Tension X Running/Hot

Additional PM Procedures

See Updates

Preventive Maintenance Powerhouse CT

4-2

Monthly, Semi-Annual Tasks

FREQUENCY OF TASKS BASED ON HOURS OF OPERATION

Preventive Maintenance Tasks Operator Maintenance Ironer (Folder) Condition

4.3 Monthly (200 Hours)

Check Setscrews X Off/Disconnect Power/Cool

Check and Clean All Drive Motor Cooling Fans X Off/Disconnect Power/Cool

Grease Feed Ribbon Drive Roll and Pivot Bearings X Off/Disconnect Power/Cool

Check Exhaust Blower System X Off/Disconnect Power/Cool

Check Feed Ribbon Guide Finger Position X Off/Disconnect Power/Cool

Change Guide Tape Position X Off/Disconnect Power/Cool

Check Chests and Gap Pieces X Off/Disconnect Power/Cool

Clean Burner Blower Wheel and Housing X Off/Disconnect Power/Cool

Clean Mixing Case/Electrode X Off/Disconnect Power/Cool

Check Pneumatic Lubricator Oil Level X Off/Disconnect Power/Cool

Test Expansion Tank Safety Relief Valve X Off/Power Connected/Cool

Check High Temperature Limit Controls X Off/Power Connected/Cool

Check Ironing Roll Diameter X Running/Hot

Check Roll to Chest Pressure X Running/Hot

Check Roll Padding Air Permeability X Running/Hot

4.4 Semi-Annual (1000 Hours)

Clean Air Filter/Auto Drain X Off/Disconnect Power/Cool

Clean the Canopies X Off/Disconnect Power/Cool

Test Low Pressure Gas Switch X Off/Disconnect Power/Cool

Check Gas Regulator Vent X Off/Disconnect Power/Cool

Inspect Exhaust System Ductwork X Off/Disconnect Power/Cool

Check Thermal Fluid System X Off/Disconnect Power/Cool

4-3

Annual, 2-Year, 3-Year, 5-Year Tasks

FREQUENCY OF TASKS BASED ON HOURS OF OPERATION

Preventive Maintenance Tasks Operator Maintenance Ironer (Folder) Condition

4.5 Annual (2,000 Hours)

Clean Exhaust Blower Wheel and Housing X Off/Disconnect Power/Cool

Check Temperature Sensors X Off/Disconnect Power/Cool

Check Electrical Connections X Off/Disconnect Power/Cool

Check Insulation Resistance to Earth Ground X Off/Disconnect Power/Cool

Check Gas Valves X Off/Disconnect Power/Cool

Check Gas Pressure at Ironer Inlet X Off/Disconnect Power/Cool

Inspect Heat Exchanger (External) X Off/Disconnect Power/Cool

Check and Clean Thermal Fluid Strainer X Off/Disconnect Power/Cool

Check Thermal Fluid Quality X Off/Disconnect Power/Cool

Ironer Operation Report X Off/Disconnect Power/Cool

4.6 Two Years (4,000 Hours)

Grease Circulation Pump Motor Bearings X Off/Disconnect Power/Cool

Grease Drive Motor Bearings X Off/Disconnect Power/Warm

Grease Inlet Motor Bearings X Off/Disconnect Power/Warm

4.7 Three Years (6,000 Hours)

Inspect Heat Exchanger (Internal) X Off/Disconnect Power/Cool

Change Drive Motor Gearbox Oil X Off/Disconnect Power/Warm

Change Inlet Motor Gearbox Oil X Off/Disconnect Power/Warm

4.8 Five Years (10,000 Hours)

Replace Ironing Roll Main Bearings X Off/Disconnect Power/Cool

Replace Feed Ribbon Drive Roll Bearings X Off/Disconnect Power/Cool

4-4

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 this unit.

Make sure the unit is completely cooled down and 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 and HOT.

Use Extreme Caution.

Operators and maintenance personnel should learn to understand the usual sights and sounds around a unit. For example, when there is 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.

4-5

General Cleanliness

It is important that lint, dirt, dust, and foreign do not enter the unit during operation. General cleanliness prevents damage to components, jamming, and soiling flatwork.

Required Tools Soft, lint-free cloth Vacuum cleaner or compressed air

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

CAUTION

Never use compressed air on or around electronic components. Doing so may damage them.

2. Use a vacuum cleaner or compressed air to clean the following:

• Feed table and feed ribbons

• General components as required

Clean Power Box Air Filter

To ensure the electric power box cooling fans operate effectively, the air filter must be cleaned daily.

Required Tools Compressed air

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove the fan air filter cover panel from the right rear endframe (Figure 4-1, A).

CAUTION

Always remove the electric power box air filter for cleaning. Do not clean it in place as this can force debris into the power box.

3. Pull the air filter out using the plastic pull tab (Figure 4-1, B).

4. Blow out the filter with compressed air, against the direction of the air flow.

5. Replace the filter and the cover panel.

Figure 4-1: The electric power box air filter must be cleaned daily.

A

B

Additional Daily PM Procedure

4-6

Clean Easi-Feed (Option) Components

If the unit is equipped with the Easi-Feed option, its suction chambers, vent ducts and lint collection bags must be cleaned after every eight-hour shift to maintain efficient operation.

Required Tools Vacuum cleaner

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove the wing-nuts from the access panels at the front of the Easi-Feed and open them (Figure 4-2, A).

3. Thoroughly vacuum out all lint and other foreign matter from the suction chambers (Figure 4-2, B).

4. Make sure the screen at the rear of the suc-tion chamber is completely clean.

5. Close the access panels and secure them with the wing-nuts removed in Step 2.

6. Remove the lint collection bags (Figure 4-3, A) from both the left and right end-frame vent ducts (Figure 4-3, B).

7. Thoroughly vacuum out all lint and other foreign matter from the bags and from the vent ducts.

8. Replace the lint collection bags.

Figure 4-3: The Easi-Feed lint collection bags and vent ducts require daily cleaning.

A

B

Figure 4-2: It is important to clean the Easi-Feed suction chambers after each 8 hours of operation.

A A

B

4-7

Check Left Endframe Side Gauges

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

On the outside of the left rear endframe are three gauges (Figure 4-4) which help monitor the thermal fluid system.

These are the:

• Pressure Differential Control display (A)

• Suction Pressure gauge (B)

• Discharge Pressure gauge (C)

With the unit running at normal operating temperatures, check each display/gauge to verify that its readings are within the normal range.

If any indicator does not show normal readings, determine the cause and correct it.

Check Safety Equipment

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

Never operate the unit without all safety guards in place and all safety devices working properly.

For more information, refer to Start-Up on page 3-10.

Check Guide Tapes (Twice Daily)

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

Guide tapes are required to give flatwork a smooth flow through the ironer.

Check the guides tapes twice a day for excessive stretching or wear. Replace as necessary. Replace any broken guide tapes immediately.

For more information, refer to Guide Tape Replacement on page 7-22.

Figure 4-4: These gauges allow the thermal fluid system to be monitored.

CBA

4-8

Clean Ironing Chests

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

Daily cleaning of the ironing chests prevents build-ups on the chest surface. This keeps the chests in good condition and helps maintain a fine flatwork finish.

Immediately after cleaning the chests must be waxed.

NOTE: Depending on whether or how much starch is used, it may be necessary to clean the chests more frequently.

For cleaning instructions, refer to Cleaning the Ironing Chests on page 3-14.

Wax Ironing Chests

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

Daily waxing of the ironer is necessary to produce a finer flatwork finish and to prevent flatwork from sticking to the ironer chest.

For waxing instructions, refer to Waxing the Ironing Chests on page 3-15.

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.

CAUTION

In addition to the PM tasks in this section, be sure to perform the higher frequency maintenance tasks described in the previous section.

4-9

Figure 4-5: Regular cleaning of the roll padding and roll shafts helps ensure longer component life.

B A

Clean Roll Padding and Roll Shafts

Required Tools Soft, lint-free cloth Vacuum cleaner or compressed air

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove canopies from each chest.

3. Inspect roll padding (Figure 4-5, A).

Remove any guide tape fragments which have become wrapped around the roll.

Remove large pieces of lint or other debris visible on the padding.

4. Inspect roll shafts (Figure 4-5, B). Wipe off any accumulation of wax, lint, or other debris.

5. Replace the canopies.

Inspect Air Filter/Auto Drain

Perform only when the unit is OFF with power disconnected and COOL.

The combination air filter with automatic drain unit (Figure 4-6, A), located inside the left rear endframe, 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 on cleaning the air filter/auto drain, refer to Clean Air Filter/Auto Drain on page 4-32.

Figure 4-6: Check the air filter/auto drain for dirt and condensate accumulation.

A B

4-10

Check Compressed Air System

Periodic checks of the compressed air system helps ensure the unit operates at peak efficiency.

Required Tools Screwdriver

Perform only when the unit is OFF with power CONNECTED and COOL.

Use Extreme Caution.

1. Turn power OFF at the main disconnect switch.

2. Turn ON the compressed air supply to the unit.

3. Remove all endframe panels.

4. Check and make sure that all rolls are locked in the up position.

5. Check the incoming compressed air pres-sure gauge at the back of the left endframe (Figure 4-6, B). It should register 90 psi (630 kPa).

6. If it does not, pull out the adjustment knob and adjust to the correct setting; then, push in the adjustment knob to lock it in.

7. Inspect each compressed air connection to make sure it is secure and there are no leaks.

8. Fix all leaks before proceeding.

9. Replace and secure all endframe panels except for the right front endframe panel.

10. Turn power ON at the main disconnect switch.

11. In the control panel, press the green CON- TROL POWER button.

WARNING

This safety interlock switch is only to be defeated temporarily while performing this procedure.

Never operate the unit unless all safety systems are working correctly.

Serious Injury Could Result.

12. The CHI•Touch screen will not display air pressure error messages while a safety interlock is open. As a temporary measure during this work, defeat the panel interlock switch on the right front endframe by in-serting one of the switch keys that shipped with the unit.

13. Locate the compressed air pressure switch in the front of the right endframe (Figure 4-7).

14. Remove the cover to the switch and dis-connect one of the control power wires.

Figure 4-7: The compressed air pressure switch is located inside the right front endframe.

4-11

15. Check the CHI•Touch screen to see if an Air Pressure Low error message displays.

• If the message displays, the switch is working properly. Reconnect the con-trol wire and replace the switch cover.

• If the message does not display, the switch is defective and must be re-placed.

16. Remove the key used to defeat the inter-lock.

17. Replace and secure the right front end-frame panel.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

18. Press the red CONTROL POWER button.

19. Turn power OFF at the main disconnect switch.

Clean Inside Endframes and Electrical Boxes and Clean Inverters

Required Tools Screwdriver Vacuum cleaner

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove all endframe panels and open the doors to both of the electrical boxes.

3. Thoroughly vacuum the inside of each endframe. While doing so:

a) On the drive side: Clean each drive motor’s inlet area, cooling fins and gearbox.

b) On the exhaust side: Clean each ex-haust motor’s inlet area and cooling fins.

c) At the left front endframe, remove the access hatch panel and clean both the inlet area and cooling fins of the inlet motor. Replace the access hatch panel.

4. Thoroughly vacuum the inside of both electrical boxes.

4-12

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.

5. While cleaning the power box, be sure to check and clean each inverter’s cooling fins and motor. Failure to clean the inverter may void the warranty.

6. Clean the inside of all endframe panels and both electrical box doors.

7. Replace and secure the left endframe panels, and close and secure the electrical box doors.

8. Leave the right endframe panels off for the next procedure.

Check/Clean Circulation Pump Drip Pan

A small amount of thermal fluid leakage from the pump seals is normal. Excessive leakage could indicate a problem with the pump.

Required Tools Clean cloths/absorbent material

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Check the drip pan under the thermal fluid circulation pump (Figure 4-8). If the amount of leakage appears to be excessive, refer to LZA- (Minimum Fluid Level) LED is ON on page 6-30.

NOTE: Verify local codes for the proper disposal of the thermal fluid. Always follow local codes.

3. If necessary, clean and replace. Follow local codes in disposing of thermal fluid.

4. Replace and secure the right endframe panels.

Figure 4-8: Contents of the circulation pump drip pan can give clues to the health of the pump.

4-13

Check Feed Ribbon Condition and Tension

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

WARNING

Never touch any part of the unit while it is moving.

Serious Injury Could Result.

Check feed ribbons for proper placement, tracking, tension (no visible sagging), and general condition (smoothness, fraying, tears).

Immediately replace any broken, worn or missing ribbons.

To adjust ribbons or replace worn ones, refer to Feed Ribbon Tension Adjustment on page 7-4 and/or Feed Ribbon Replacement on page 7-5.

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.

CAUTION

In addition to the PM tasks in this section, be sure to perform the higher frequency in the previous sections.

4-14

Check Setscrews

Required Tools Allen wrench

Perform only when the unit is OFF with power disconnected and COOL.

Setscrews hold bearings and other rotating parts in place. Check and make sure that all setscrews are tight.

Check and Clean All Drive Motor Cooling Fans

Required Tools Screwdriver Vacuum cleaner

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove all endframe panels.

3. Remove the left front access hatch panel.

4. Check the fan at the back of each motor (Figure 4-9).

5. Use a vacuum to clean out lint and dirt from the intake side of each motor, be sure to include:

• All drive motors in the right endframe.

• All exhaust blower motors in the left endframe.

• The inlet motor at the front of the left endframe.

• The circulation pump motor at the rear of the left endframe.

6. Clean motor cooling fins as necessary.

7. Make sure each motor cooling fan is free to turn without binding.

8. Replace the left front access hatch panel.

9. Replace and secure all endframe panels.

Figure 4-9: Make sure all motor cooling fans are free to turn without binding.

Additional Monthly PM Procedure

4-15

Grease Feed Ribbon Drive Roll and Pivot 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 an EP, bentonite clay, NLGI 2, 1000 cSt viscosity grease 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 specified, 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:

1. 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.

2. Follow directions on the grease gun pack-aging for other filling methods (dispenser, suction).

Be sure to grease:

• The feed ribbon drive roll bearing in the right front endframe (Figure 4-10).

• Pivot bearings (Figure 4-11) located on roll side of the right endframe and on both sides of the left endframe for each roll.

Required Tools Clean cloth Grease gun Grease: EP, bentonite clay, NLGI 2, 1000 cSt viscosity Screwdriver

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove the left and right front access hatch panels.

3. Remove left endframe panel(s) from each section.

Figure 4-10: The feed ribbon drive roll bearing in the right front endframe. There is also a bearing in the left front endframe.

Figure 4-11: Pivot bearings are located on the inner wall of the of right endframe (above) and on both sides of the left endframe.

4-16

4. For the bearings on the inner wall of the left endframe, determine the preferred access point (Figure 4-12).

5. Wipe the old grease from the bearings.

6. Insert the grease gun nozzle firmly onto the grease fitting.

CAUTION

Over-lubrication will destroy the bearing seals and cause premature failure.

7. 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.

8. Immediately wipe off the grease from the bearing. Failure to do so can cause lint ac-cumulation and premature bearing failure.

9. Replace and secure the left rear endframe panel.

10. Replace the front access hatch panels.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

Figure 4-12: Determine the preferred access point for the pivot bearings on the inner wall of the left endframe.

4-17

Check Exhaust Blower System

It is important to the proper operation of the unit that the exhaust blower system is checked and cleaned on a regular basis.

Required Tools Screwdriver Vacuum cleaner

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove the left endframe panel(s) from each chest section.

3. Remove the flexible hose connected to each exhaust blower motor (Figure 4-13).

4. Inspect the blower housing (Figure 4-14).

Vacuum lint and dust from the housing and from the blower.

5. Make sure that the flexible ducting is free from lint, wax, and other debris. Vacuum as necessary.

6. Replace the flexible exhaust hoses discon-nected in Step 3.

NOTE: If simple vacuuming does not adequately clean the blowers, perform Clean Exhaust Blower Wheel and Housing on page 4-38.

7. Replace and secure the left endframe panels.

Figure 4-13: Remove the flexible hose connected to each exhaust blower motor housing.

Figure 4-14: Inspect and clean the blower housing regularly to help ensure trouble-free operation.

4-18

Check Feed Ribbon Guide Finger Position

The feed ribbon guide fingers must rest directly against the leading edge of the first ironing chest to ensure proper flatwork feeding.

In addition, if any of the feed ribbon guide finger are bent or broken, ribbons may not track straight or may be damaged. This could also affect proper flatwork feeding.

Required Tools Flashlight Screwdriver

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove the right endframe panel from the front section.

3. Unscrew the wing nuts holding the chest access panel in position and remove it.

Figure 4-15: Make sure feed ribbon guide fingers rest directly against edge of the chest.

4. Inspect the fingers by looking inside the chest (Figure 4-15).

• If all of the fingers are not directly against the leading edge of the chest, the feed table/ribbon guide finger as-sembly requires adjustment. Refer to Feed Table/Ribbon Guide Finger Assembly Alignment on page 7-10.

• If any fingers are bent, use a pair of pliers to straighten and pull them back into position.

• If any fingers are missing, order a re-placement kit. For more information, refer to Feed Ribbon Guide Finger Replacement on page 7-11.

5. Replace and secure the chest access panel.

6. Replace and secure the front right end-frame panel.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

4-19

Change Guide Tape Position

Required Tools Wrenches: 3/4” (2)

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. If necessary for ease of access, move the folder out of the way.

3. Locate the guide tape position adjustment bolt at the right rear of the unit (Figure 4-16).

4. Loosen the locknuts and then change the position of the guide tapes by moving the entire guide tape tensioning assembly 1” (25 mm) in either direction.

5. Tighten the locknuts.

6. If necessary, reposition the folder at the rear of the unit.

Check Chests and Gap Pieces

Required Tools Flashlight Pliers

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch. Lockout and tagout both power and gas following the government-com-pliant work rules of your site.

2. Remove the right endframe panel from each section.

3. In each chest: Unscrew the wing nuts holding the chest access panel in position and remove it.

4. Remove the canopy for each chest.

WARNING

Follow your site’s government-compliant Confined Spaces procedure when entering the chest.

5. Visually inspect each chest and each gap piece for scratches and residue. If neces-sary, use a flashlight to help see.

6. If scratches or other physical damage is discovered, the chest must be recondi-tioned. Refer to Ironing Chest Recondi-tioning on page 7-53.

7. Clean any residue. Refer to Cleaning the Ironing Chests on page 3-14.

8. Replace and secure the chest access pan-els.

9. Replace and secure the right endframe panels.

Figure 4-16: Guide tape assembly adjustment bolt.

4-20

10. Replace each canopy. Make sure each canopy safety disconnect switch lever is depressed.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

Clean Burner Blower Wheel and Housing

To help ensure optimal operation, the burner combustion blower should be disassembled and thoroughly cleaned every month or after each 200 hours of operation.

Required Tools Allen wrenches:

5 mm 6 mm Masking tape Pen/pencil/marker Screwdriver Vacuum cleaner or compressed air Wrenches:

8 mm 3/4” 15/16”

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove the nut from the head bolt (Figure 4-17, A) and carefully open the burner unit on its hinge (B).

3. Remove the wiring box cover for the burner motor (Figure 4-18, A).

4. Carefully note and mark where each power and grounding wire is connected. Then, disconnect the power and ground wires for the motor.

5. Loosen the nut holding the fitting in place and remove the shielded cable from the motor wiring box.

6. While supporting the motor, remove the 4 bolts which secure it to the blower housing (Figure 4-18, B).

B

C

A

Figure 4-17: Open the burner on its hinge (B) after removing the head bolt (A).

A

B

Figure 4-18: Completely remove the burner motor from the machine.

4-21

CAUTION

Use great care in removing the blower motor and wheel from the housing. If the wheel is bent or distorted in any way, it must be replaced.

7. Carefully remove the blower motor and its attached blower wheel from the burner housing and place on a workbench.

8. Thoroughly clean all components, includ-ing the motor, wheel and burner system housing.

9. Carefully, bring the blower motor/wheel back to the burner housing and reattach.

Make sure the bolts are secure.

10. Reconnect the shielded power cable to the motor’s wiring box and reconnect the power and ground wires based on the way they were marked in Step 4.

11. Replace the motor’s wiring box cover.

Make sure the cover’s rubber gasket is properly seated.

12. Leave the burner unit open for the next procedure.

Clean Mixing Case/Electrode

To help ensure optimal operation, the mixing case and its associated components should be removed, disassembled and thoroughly cleaned every month or after each 200 hours of operation.

Required Tools Allen wrenches:

4 mm 6 mm Pliers Shims: 1.5 or 2 mm Vacuum cleaner or compressed air Wrench: 3/4”

Perform only when the unit is OFF with power disconnected and COOL.

NOTE: This procedure assumes the burner unit is already open from the previous procedure.

1. Disconnect the black electrode wire (Fig-ure 4-19, A) from the terminal inside the mixing case.

2. Loosen the setscrew which holds the mixing case in position (Figure 4-17, C, Figure 4-19, B).

B A

Figure 4-19: Work carefully when removing the mixing case from the unit.

4-22

Figure 4-21: The lubricator is located inside the right front endframe.

A

B C

D

3. Carefully remove the mixing case assem-bly (Figure 4-20) from the unit.

4. Thoroughly clean the mixing case and electrode. Handle carefully to avoid damaging the electrode ceramic. If the ceramic is cracked or otherwise damaged, the electrode must be replaced.

5. Check the electrode gap. It should be 1.5 to 2 mm:

• Adjust as necessary.

• If the electrode needs replacement, refer to Mixing Case/Electrode Re-placement on page 7-80.

6. Carefully replace the mixing case assem-bly in the burner unit.

7. Make sure it is firmly seated and then tighten the setscrew loosened in Step 2.

8. Reconnect the black electrode wire.

9. Close the burner unit.

10. Replace and secure the head bolt nut re-moved in Step 2 of Clean Burner Blower Wheel and Housing on page 4-20.

Check Pneumatic Lubricator Oil Level

Required Tools Clean cloth Festo special oil Mild soap solution Screwdriver: small

Perform only when the unit is OFF with power disconnected and COOL.

An automatic device is used to keep the machine’s air cylinders lubricated and operating smoothly.

Every month or 200 hours of operation, check the oil level and condition in the pneumatic lubricator, which is located inside the right front endframe (Figure 4-21).

Check Oil Level/Use Rate

1. Turn power OFF at the main disconnect switch.

2. Remove the right front endframe panel.

3. Check the oil level and condition.

• If the oil level is below the lower win-dow (Figure 4-21, A), it must be topped off. See Adding Oil on page 4-23.

• If the oil is cloudy, the bowl must be cleaned. See Cleaning on page 4-23.

Figure 4-20: Handle the mixing case carefully during cleaning to avoid damage to the electrode.

4-23

Figure 4-22: Check the endframe wall to determine whether the pneumatic lubricator requires adjustment.

4. Check the endframe wall opposite the lift air cylinder exhaust valves (Figure 4-22).

There should be a small, fine oil film from the lubricator.

5. As appropriate:

• If the wall is clean, oil flow must be increased. See Adjusting the Droplet Rate.

• If the film appears excessive or is drip-ping, oil flow must be decreased. See Adjusting the Droplet Rate.

6. Wipe the air cylinder exhaust area clean.

7. If no maintenance is needed, replace and secure the right front endframe panel.

Adding Oil

1. Vent air from the bowl by opening the vent screw next to the droplet sight glass (Figure 4-21, B) until the air noise stops.

2. Twist counterclockwise to unscrew the bowl.

3. Add Festo special oil to within 1 inch of the top of the bowl.

4. Replace the bowl.

5. Tighten the vent screw.

6. Replace and secure the right front end-frame panel.

Cleaning

If any dirt or debris can be seen in the bowl, or if the oil is cloudy, the bowl must be cleaned and fresh oil added.

1. Vent air from the bowl by opening the vent screw next to the droplet sight glass (Figure 4-21, B) until the air noise stops.

2. Unscrew the bowl by twisting counter-clockwise.

3. Drain bowl; then clean using only soapy water.

4. Rinse thoroughly and dry.

5. Add fresh Festo special oil to within 1 inch of top.

6. Replace the bowl.

7. Tighten the vent screw.

8. Replace and secure the right front end-frame panel.

Adjusting the Droplet Rate

1. Adjust oil flow by turning the adjusting screw (Figure 4-21, C):

• Clockwise to decrease flow.

• Counterclockwise to increase flow.

2. Make adjustments in 1/8 to 1/4-turn incre-ments; avoid excessive changes.

3. The interval between drops may be ob-served in the oil droplet sight glass (D).

4. Replace and secure the right front end-frame panel.

4-24

Test Expansion Tank Safety Relief Valve

Perform only when the unit is OFF with power CONNECTED and COOL.

Use Extreme Caution.

1. Turn power ON at the main disconnect switch.

2. Turn ON the compressed air supply to the unit.

3. Press the green CONTROL POWER button.

4. Press the CIRCULATION PUMP ON/ OFF button.

5. Wait about 10 seconds for the motor to come up to full speed. It’s green LED will light and the temperature control display will light.

WARNING

Do not touch a hot pipe with bare hands.

6. Press the lever handle on the pressure relieve valve (Figure 4-23). Listen for the sound of fluid flowing. If the pipe is cool, touch the pipe to feel the movement.

Figure 4-23: Make sure the safety relief valve only allows fluid to flow when it is open.

NOTE: Do not hold onto the valve handle while closing. Simply let go; the spring will do the rest.

Also, it may take two or three openings and closings before the valve will seat properly and completely close.

7. Release the handle. The flow should stop.

If it does not after 3 tries, the valve is de-fective and must be replaced.

8. Leave power and compressed air ON for the next procedure.

4-25

Check High Temperature Limit Controls

Periodic checks of the high temperature limit controls helps ensure the unit operates safely.

Perform only when the unit is OFF with power CONNECTED and HOT.

Use Extreme Caution.

1. The machine should be in the following state from the previous procedure:

• Power ON at the main disconnect switch.

• Compressed air supply to the unit ON.

• Control power ON.

• Circulation pump ON.

2. Heat the unit. Refer to Start-Up on page 3-10. It will not be necessary to lower the rolls or start the machine.

3. Open the Powerhouse control box door at the rear of the left endframe.

4. Locate the four high temperature limit controls (Figure 4-24).

5. Unplug the connector to the left most control. The appropriate red LED in the left endframe control panel should light and the burner system should shut down.

6. Replace the plug.

7. Press the small black reset button on the control just beneath the plug.

8. Reset and restart the burner system.

9. Repeat Steps 3 to 6 for each of the three remaining controls.

10. Close and secure the Powerhouse control box door.

11. Leave the heat system on for the next procedure.

Figure 4-24: Temperature limit controls in the Powerhouse control box.

4-26

Check Ironing Roll Diameter

To ensure high quality flatwork finishing, it is necessary to physically check the actual pulling pressure of the roll on the bed of the chest.

Acceptable diameters are shown in the table below:

Model Max Diameter (New Padding)

Min Diameter (Replace Padding)

3200 31.693-31.850” (805-809 mm)

31.614” (803 mm)

4200 41.456-41.614” (1053-1057 mm)

41.377” (1051 mm)

5200 51.417-51.574” (1306-1310 mm)

51.338” (1304 mm)

When the roll diameter is at or below the minimum, the padding must be replaced.

Required Tools Tape measure: 30 foot (10 m) flat steel Wood: 1” x 4” X 1’ (2 per canopy)

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

1. With the unit hot from the previous proce-dure, touch the ROLLS ▼ button on the CHI•Touch screen.

2. When the rolls are fully lowered, press the green START button.

3. When the machine is running, touch the SPEED ▼ button until the unit is running at minimum speed (30 fpm).

WARNING

Specific procedures that require the unit to be running should be done with extreme caution and attention to detail.

4. Let the unit run for about twenty minutes.

5. Press the square red STOP button.

6. Remove all canopies.

WARNING

These safety interlock switches are only to be defeated temporarily while performing this procedure.

Never operate the unit unless all safety systems are working correctly.

Serious Injury Could Result.

Have a second person ready at a red safety STOP button during this procedure.

7. The ironer will not operate while a safety interlock is open. As a temporary measure during this work, defeat the canopy inter-lock switches by laying a short length of 1” x 4” across each switch opening.

NOTE: The following steps must be repeated for each roll.

8. Press the green START button and run the ironer at the slowest speed until the pad-ding overlap is on top. Press the square red STOP button.

CAUTION

Use only a flat steel tape measure. Do not use a steel tape measure with a bowed or curved surface and do not use a plastic or textile tape measure. The chest surface could be damaged.

4-27

9. Tuck the leading edge of the 30 foot (10

m) tape measure under the overlap.

10. Press the green START button and run the unit at its slowest speed to pull the tape measure around the circumference of the ironing roll.

WARNING

The tape measure will become HOT and may burn your hands.

Protect your hands.

11. Note the measurement of the circumfer-ence.

12. Divide this measurement by 3.1416 to get the diameter and compare with the tolerances noted at the beginning of this procedure.

NOTE: If the diameter does not meet the specification, the padding needs to be replaced.

13. Touch the ROLLS ▲ button to raise the rolls. Pull the measuring tape from the roll.

14. Touch the ROLLS ▼ button and repeat Steps 8 to 13 for each roll.

15. Remove the lengths of 1” x 4” used to de-feat the canopy safety interlock switches.

16. Replace the canopies.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

17. Leave the unit running for the next pro-cedure.

Check Roll to Chest Pressure

To ensure high quality flatwork finishing, it is necessary to physically check the actual pulling pressure of the roll on the bed of the chest.

NOTE: The LEFT and RIGHT ROLL PRESSURE gauges at the front of the left endframe show the downward pressure being exerted on each end of the ironing rolls by the large air cylinders in each endframe. These settings are adjusted inside the left endframe to ensure that roll pressure against the chest is even across the width of the unit.

The actual pulling pressure of the roll on the bed of the chest must be measured using the following procedure.

Required Tools Guide tape Scale: hand-held, 0-20 lb range

Perform only when the unit is RUNNING and HOT.

Use Extreme Caution.

1. Tie a 24 inch length of 1/2 inch guide tape (60 cm length of 12 mm guide tape) to the weight scale.

2. Press the green START button.

WARNING

Specific procedures that require the unit to be running should be done with extreme caution and attention to detail.

4-28

3. Set the ironer speed to 100 feet (30 m) per minute.

4. Make sure that the ironer temperature is between 330 and 360 degrees Fahrenheit (165 - 180 C).

5. Let the tape run into the first chest close to one end of the roll, and note the pulling force on the scale.

6. Make the same measurement at the other end of the roll.

7. The pulling force should be 5 to 10 pounds (2.5 - 5 kg) on each end, and the difference between the readings at the ends should not be more than ±1 pound (±0.5 kg).

8. If the readings are not within range, the roll pressure needs to be adjusted.

9. Press the square red STOP button.

10. Remove the left endframe panel at the first roll.

11. Locate the two air pressure regulators (Figure 4-25), one for the right side (green tubing) of the rolls, and one for the left side (red tubing). These control the downward pressure exerted by the large air cylinders in each endframe. These two pressure regulators adjust the pressure for all of the rolls.

12. Select the regulator for the low pressure side. Pull out the adjustment knob on the air pressure regulator and increase the air pressure by 5 psi (35 kPa).

13. Push in the adjustment knob to lock in the new setting.

14. Replace and secure the front left endframe panel.

15. Start the unit.

16. Repeat Steps 5 to 7 to determine whether the measurement is now in range. If not repeat Steps 9 to 14.

17. Continue this process until the roll pull-ing force is within range, and each end is within tolerance.

NOTE: Do not exceed 50 psi (350 kPa) with the air pressure regulators.

18. If this adjustment does not prevent the padding from moving, and the padding has been correctly installed, the chest-to-roll adjustment is necessary. Refer to Chest-to-Roll Adjustment on page 7-56.

CAUTION

Call the factory for assistance. Do not attempt this adjustment without consulting the factory FIRST.

19. Leave the unit running for the next pro-cedure.

Figure 4-25: Air pressure regulators in the left endframe used for roll pressure adjustment.

4-29

Check Roll Padding Air Permeability

The amount of air moving through the ironing roll affects the quality of flatwork finish. Too much air and energy is being wasted; too little air and not enough moisture will be removed from the flatwork.

Perform this procedure only after the machine has been operating and processing flatwork for at least 1 hour.

Required Tools Crescent wrench Gloves/protective clothing Screwdriver: small Vacuum gauge (part # 4009-000)

Perform only when the unit is OFF with power CONNECTED and HOT.

Use Extreme Caution.

WARNING

Specific procedures that require the unit to be running or hot should be done with extreme caution and attention to detail.

1. Stop the unit by pushing the square red STOP button.

2. Open the power box door.

3. Remove the left endframe panel at the first roll.

WARNING

These safety interlock switches are only to be defeated temporarily while performing this procedure.

Never operate the unit unless all safety systems are working correctly.

Serious Injury Could Result.

4. The unit will not operate while a safety interlock is open. As a temporary measure during this work:

• Defeat the panel interlock switch on the left front endframe by inserting one of the switch keys that shipped with the unit.

• Defeat the panel interlock switch on the power box by inserting one of the switch keys that shipped with the unit.

• Use a crescent wrench to manually turn the main disconnect switch to ON.

5. Access the padded roll through the open-ing as shown in Figure 4-26.

Figure 4-26: Use caution when measuring vacuum pressure on a hot ironing roll.

4-30

WARNING

The ironing roll and surrounding area will be hot.

Wear protective clothing and gloves to avoid burns.

6. Place the cup of the vacuum gauge directly on the roll padding and note the reading:

• If the needle is in the low area of the gauge, too little air is moving through the roll:

• The padding could be clogged with wax or there might be a blockage in the exhaust system.

• Troubleshoot to determine the problem.

• Repair and then retest.

• If the needle is in the green area of the gauge, air permeability is within ac-ceptable limits. Go to Step 10.

• If the needle is in the high area of the gauge, too much air is moving through the roll. Go to the next step.

7. Locate INV10 for the first roll’s exhaust blower (Figure 4-27):

• Remove the faceplate.

• Remove the jumper wire between STF and SD.

• Press the PU/EXIT button to choose PU operation mode.

• Press the MODE button to choose parameter setting mode.

• Turn the inverter wheel until P. 1 shows in the inverter’s display panel.

• Press the SET button to display the currently set value.

• Turn the inverter wheel as necessary to adjust the frequency setting. Change as necessary to bring the needle of the vacuum gauge into the green area.

• Press the SET button to change the parameter to the displayed setting.

• Press the MODE button twice to exit parameter setting mode and PU operation mode and return to normal operation.

• Replace the jumper between STF and

SD.

• Replace the faceplate.

8. Remove the key used to defeat the end-frame interlock.

Figure 4-27: Exhaust blower motor inverter in the power box.

4-31

9. Replace and secure the left front endframe panel.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

10. Repeat this process for each of the remain-ing rolls.

11. Turn the main disconnect switch to OFF.

12. Close and secure the power box door.

13. If appropriate, shut down the unit. For more information, refer to Shut-Down on page 3-19.

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.

CAUTION

In addition to the PM tasks in this section, be sure to perform the higher frequency

4-32

Clean Air Filter/Auto Drain

The air filter with auto drain (Figure 4-28) 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/filter replacement is necessary.

WARNING

Before disassembling the air filter/auto drain, turn off the air supply and depressurize the system and filter.

Required Tools Clean, soft cloth Mild detergent solution

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn OFF the compressed air supply and depressurize the unit.

2. Turn power OFF at the main disconnect switch.

3. Press the black plastic tab on the side of the bowl case down (Figure 4-28, 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).

4. Pull down on the bowl case to remove

it. The filter base does not need to be re-moved from the machine.

5. Take the bowl (Figure 4-29, A) and rinse with ONLY water and household soap;

then, dry with a soft, clean cloth.

6. Unscrew the filter assembly and separate the components (Figure 4-29, C, D, E).

Figure 4-28: Press the plastic tab and twist the casing to line up the marks to remove the filter bowl from the machine.

A

B

Figure 4-29: Replace the filter element and clean the other components using only soap and water.

A

E

D

C

B

7. Discard the filter element (D).

8. Clean the other components (B, C, E) with ONLY water and household soap; then, dry with a clean soft cloth.

9. Re-assemble the clean components, insert-ing a new filter element, and install the filter assembly back on the base.

10. Re-attach the clean bowl, lining up the marks as in Step 3.

11. Press up on the bowl and twist left or right until the plastic tab snaps into position.

4-33

Clean the Canopies

Required Tools Detergent solution: mild Hose Towels

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Remove each canopy and place in a suit-able work area.

3. Using a mild detergent solution, thor-oughly clean the canopies of any accu-mulations.

4. After cleaning, make sure canopies are completely dry.

5. Replace the canopies.

Test Low Pressure Gas Switch

As part of the gas burner safety system, it is important to periodically make sure the gas low pressure reset switch is working properly.

Perform only when the unit is OFF with power disconnected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Turn OFF the ball valve at the head of the gas train (Figure 4-30, A).

3. Follow normal start up procedures. For more information, refer to Start-Up on page 3-10.

4. As soon as the BURNER ON/OFF button is pressed, the GAS PRESSURE SWITCH red PSA- LED should light and indicate a gas pressure switch fault.

5. At the burner system at the rear of the unit, open the ball at the head of the gas train.

6. Press the red RESET button on top of the low pressure gas switch (Figure 4-30, B).

The button can be pressed through the cover.

7. Press the system RESET button in the left endframe control panel.

8. The GAS PRESSURE SWITCH red PSA- LED should go out and the system should begin its normal ignition sequence. If it does not, trace the problem and resolve

it. For more information, refer to Gas Burner System on page 6-23.

B

A

Figure 4-30: Gas low pressure gas control reset lever.

4-34

Check Gas Regulator Vent

The gas regulator must “breathe” in order to operate properly and safely. If the vent restrictor or vent pipe/tube becomes plugged, burner ignition failure and/or improper unit operation can occur.

WARNING

Only qualified personnel should troubleshoot and repair the gas regulator vent.

Perform only when the unit is OFF with power disconnected and COOL.

Vent Restrictor

Remove and inspect the vent restrictor for obstructions. If the check valve ball cannot be heard rattling inside, replace the vent restrictor.

Vent Pipe or Tubes

Inspect the vent pipes/tubes for obstructions.

Replace any that may be plugged, pinched, crimped, or otherwise damaged.

For more information, refer to Venting the Regulator on page 2-51.

Inspect Exhaust System Ductwork

The integrity of both exhaust systems is important for both operator safety and operational efficiency.

Required Tools Flashlight

Perform only when the unit is OFF with power disconnected and COOL.

1. Look at exterior of both the gas flue vent and the roll exhaust vent ductwork sys-tems.

• Look for visible signs of damage, cracking.

• On gas flue, use leak detection equip-ment.

2. Pull ductwork apart at a convenient open-ing.

• Inspect the exhaust duct for excess lint/debris.

• Examine the gas flue duct insulation for signs of wear or damage.

4-35

Check Thermal Fluid System

Over time, the expansion and contraction of joints caused by the heating and cooling of the system can cause leaks. Normal system operation also causes some loss of fluid.

Periodic checks help ensure the system is operating efficiently and help avoid unnecessary interruptions due to thermal fluid system problems.

This check includes:

• Check Fluid Level

• Check Overflow Container

• Inspect for Leaks

• Inspect Insulation

Check Fluid Level

Required Tools Ruler Wrench: 3/4”

Perform only when the unit is OFF with power connected and COOL.

1. Turn power OFF at the main disconnect switch.

2. Make sure the compressed air to the unit is OFF.

3. Loosen the dip chain fitting at the top of the expansion tank (Figure 4-31) and remove.

4. Measure the dry portion of the chain. It should be about 14 1/4” (360 mm) long:

• If it is noticeably above this, there is too much fluid in the system.

• If it is noticeably below this, there is too little…