Chicago King Edge Spreader Feeder.pdf

King EdgEtm Ct Large Piece Spreader/Feeder in St

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©Chicago Dryer Company Instruction Manual #3018-049b

CHICAGO DRYER COMPANY

2200 N. Pulaski Road, Chicago, Illinois, USA 60639-3737

Telephone: (773) 235-4430 Fax: (773-235-4439) www.chidry.com

TOC INDEX

King Edge CT Table of Contents i

TABLE OF CONTENTS

MANUAL

Updates

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

PICTURE PARTS LIST

SCHEMATIC PARTS LIST

APPENDIX

Floor Plans

Technical Specifi cations

Torque Specifi cations

INDEX

Table of Contents King Edge CT ii

ChAPtER 1 intROdUCtiOn

1.1 Warranty .................................................................................................. 1-2

1.2 Scope of Manual ..................................................................................... 1-2

1.3 Safety ...................................................................................................... 1-3 Safe Work Habits .................................................................................... 1-3 Safety Features ....................................................................................... 1-4

1.4 Equipment Description ............................................................................ 1-6 Machine Widths ....................................................................................... 1-6 Optional Equipment ................................................................................. 1-6 iii

ChAPtER 2 inStALLAtiOn

2.1 Site and Utility Requirements .................................................................. 2-2

2.2 Installation Procedures ............................................................................ 2-3 Inspection ................................................................................................ 2-3 Uncrating, Placement and Alignment ...................................................... 2-4 Floor Trough Installation .......................................................................... 2-6 Compressed Air Supply Connection........................................................ 2-7 Electrical Connections ............................................................................. 2-8

2.3 Pre-Operational Checkout ..................................................................... 2-14 Final Protective Wrapper Removal ........................................................ 2-14 Security of Hardware ............................................................................. 2-15 Clean the Corner Photosensors ............................................................ 2-16 Compressed Air Supply Checkout......................................................... 2-16 Safety Device Checkout ........................................................................ 2-18 Spread/Feed Function Checkout........................................................... 2-20 Checkout Completion ............................................................................ 2-21 Cleaning the Unit ................................................................................... 2-21 iv

ChAPtER 3 OPERAting gUidELinES

3.1 Safety Features ....................................................................................... 3-2 Main Disconnect Switch .......................................................................... 3-2 Safety STOP Buttons .............................................................................. 3-2 Safety Guards ......................................................................................... 3-2 Safety Interlock Switches ........................................................................ 3-3 Safety Labels........................................................................................... 3-3

3.2 Operating Controls .................................................................................. 3-4 CHI•Touch Main Screen Controls and Indicators .................................... 3-6

3.3 Daily Operating Procedures .................................................................... 3-7 Start-Up ................................................................................................... 3-7 Interconnected Stop Circuit (Option) Operation Notes ............................ 3-8 Flatwork Handling.................................................................................... 3-9 Handling Jams and Misfeeds Safely ..................................................... 3-12 Shut-Down............................................................................................. 3-13

3.4 Operating Techniques ........................................................................... 3-13 Maximum Efficiency .............................................................................. 3-13 Maximum Feeding Speed ..................................................................... 3-14 v

ChAPtER 4 PREvEntivE mAintEnAnCE

PM Task Tables .................................................................................................. 4-1 Daily, Weekly Tasks ................................................................................. 4-1 Monthly, Semi-Annual, Annual Tasks ...................................................... 4-2

4.1 Daily PM (8 Hours) .................................................................................. 4-3 Watch and Listen for Anything Abnormal ................................................ 4-3 General Cleanliness ................................................................................ 4-3 Check Safety Equipment ......................................................................... 4-4

4.2 Weekly PM (50 Hours) ............................................................................ 4-4 Check and Clean Photosensors and Reflectors...................................... 4-5 Check and Clean Inverters ...................................................................... 4-5 Check For String Accumulation ............................................................... 4-6 Check Pneumatic Clutch/Brake Roller Alignment ................................... 4-6 Check Prefeeder Carriage Linear Bearing Assemblies, and Lubricate Prefeeder Carriage Rails and Grooved Bearings .................................... 4-7 Check Spreader Clamp Linear Bearing Assemblies, and Lubricate Upper Spreader Rails and Grooved Bearings ......................................... 4-8 Inspect Air Filter/Auto Drain..................................................................... 4-9 Check Air Pressure Settings.................................................................. 4-10 Check Ribbon Condition and Tension ....................................................4-11

4.3 Monthly PM (200 Hours) ........................................................................4-11 Clean and Lubricate Drive Chains and Friction Roll Hinge ................... 4-12 Check Upper and Lower Spreader Belt Condition and Tension ............ 4-13 Inspect Drive Belt Condition .................................................................. 4-14 Check Setscrews................................................................................... 4-14

4.4 Semi-Annual PM (1000 Hours) ............................................................. 4-15 Clean Air Filter/Auto Drain ..................................................................... 4-15 Check and Grease Bearings ................................................................. 4-16

4.5 Annual PM (2000 Hours) ....................................................................... 4-18 Check All Electrical Connections ........................................................... 4-19 Check Insulation Resistance to Earth Ground ...................................... 4-19 vi

ChAPtER 5 OPERAting PRinCiPLES

Safety ................................................................................................................ 5-2

5.1 Electrical System ..................................................................................... 5-2 Power System ......................................................................................... 5-2 Control System ........................................................................................ 5-7

5.2 Compressed Air System ........................................................................ 5-14 Air Filter/Regulators............................................................................... 5-14 Air Pressure Switch ............................................................................... 5-14 Air Reservoir .......................................................................................... 5-14 Air Valves .............................................................................................. 5-14 Air Cylinders .......................................................................................... 5-15 Flow Controls ........................................................................................ 5-15 Air Bars .................................................................................................. 5-15 Pneumatic Clutch/Brake ........................................................................ 5-15

5.3 Mechanical System ............................................................................... 5-18 Prefeed Drive System ........................................................................... 5-18 Inlet Drive System ................................................................................. 5-19 Spread Drive System ............................................................................ 5-20 Discharge Drive System ........................................................................ 5-21 ByPass Drive System ............................................................................ 5-21

5.4 Sequence of Operation ......................................................................... 5-22 Stand-by Phase ..................................................................................... 5-22 Start-up Phase ...................................................................................... 5-23 Prefeed/Input Phase.............................................................................. 5-24 Transfer Phrase ..................................................................................... 5-24 Spread Phase........................................................................................ 5-25 Large Piece Discharge Phase ............................................................... 5-25 Small Piece (ByPass Conveyor) Discharge Phase ............................... 5-26 Error Conditions .................................................................................... 5-26 vii

ChAPtER 6 tROUbLEShOOting

Troubleshooting Symptoms ............................................................................... 6-2

6.1 LED Diagnostics ...................................................................................... 6-6

6.2 Electrical .................................................................................................. 6-8

6.3 Mechanical .............................................................................................6-11

6.4 Prefeed/Inlet Section ............................................................................. 6-13

6.5 Transfer Section .................................................................................... 6-16

6.6 Spread Section ...................................................................................... 6-18

6.7 Discharge/ByPass Section .................................................................... 6-22

6.8 Sensor Function .................................................................................... 6-24

6.9 Compressed Air System ........................................................................ 6-25 viii

ChAPtER 7 REPAiR

7.1 Safety Considerations ............................................................................. 7-2

7.2 Parts Availability ...................................................................................... 7-3

7.3 Prefeed/Inlet Section ............................................................................... 7-3 Prefeeder Carriage Grooved Bearing Replacement ............................... 7-4 Prefeeder Carriage Drive Belt Tension Adjustment ................................. 7-5 Prefeeder Carriage Drive Belt Replacement ........................................... 7-6 Pneumatic Clutch/Brake Roller Alignment............................................... 7-7 Pneumatic Clutch/Brake Roller Drive Belt Tension Adjustment ............... 7-8 Inlet Conveyor Drive Belt Tension Adjustment ........................................ 7-9

7.4 Transfer Section ...................................................................................... 7-9 Transfer Clamp Check and Adjustment ................................................. 7-10 Transfer Clamp Assembly Replacement ............................................... 7-12

7.5 Spread Section ...................................................................................... 7-13 Spreader Clamp Mechanical Adjustment .............................................. 7-14 Upper Spreader Belt Tension Adjustment ............................................. 7-14 Upper Spreader Belt Replacement ....................................................... 7-15 Upper Spreader Clamp Grooved Bearing Replacement ....................... 7-16 Lower Spreader Drive Belt Tension Adjustment .................................... 7-18 Lower Spreader Drive Belt Replacement .............................................. 7-18 Lower Spreader Belt Tension Check/ Replacement .............................. 7-19 Lower Spreader Belt Gap Adjustment ................................................... 7-20

7.6 Discharge/ByPass Section .................................................................... 7-22 Discharge/ByPass Conveyors Ribbon Tension Adjustment .................. 7-23 Discharge/ByPass Conveyors Ribbon Replacement ............................ 7-24 Discharge Conveyor Guide Ribbon Tension Adjustment/Replacement 7-27 Discharge Conveyor or ByPass Conveyors Drive Belt Tension Adjustment ............................................................................................ 7-28 ByPass Conveyors Drive Chain Tension Adjustment ............................ 7-29 Discharge/ByPass Conveyor Drive Rolls Tracking Tape Replacement . 7-30 Discharge Conveyor Doffer Roll Pressure Adjustment .......................... 7-33 Discharge Conveyor Doffer Roll Cover Replacement ........................... 7-34 ByPass Conveyor Doffer Roll Cover Replacement ............................... 7-36

Repair topics continued on the next page...

ix

7.7 Sensors ................................................................................................. 7-38 General Photosensor Sensitivity Adjustment ........................................ 7-38 Inlet Material Photosensor Sensitivity Adjustment................................. 7-39 Roll Photosensor Sensitivity Adjustment ............................................... 7-40 Tail Photosensor Sensitivity Adjustment ................................................ 7-41 Corner Photosensors Alignment............................................................ 7-42 Taut Photosensor Alignment.................................................................. 7-43 Photosensor Replacement .................................................................... 7-44 Proximity Sensor Positioning Adjustment .............................................. 7-45 Proximity Sensor Replacement ............................................................. 7-46

7.8 Compressed Air System ........................................................................ 7-47 Air Cylinder Air Flow Adjustment ........................................................... 7-48 Roller Counterpoint Air Pressure Adjustment ........................................ 7-51 Spreader Clamp Back Air Pressure Adjustment .................................... 7-52 Air Bar Alignment................................................................................... 7-53 Air Foil Position Adjustment................................................................... 7-54 Air Laydown Assist (Option) Air Pressure Adjustment ........................... 7-55 Air Valve Repair ..................................................................................... 7-56

King Edge CT / King Edge Vac CT 3023-591b

Chicago Dryer Company 1

F. Y. I. Service Bulletin

ELECTRICAL SYSTEM

TROUBLESHOOTING UPDATE

In an ongoing effort to provide you with the most complete and up-to-date information, we are including this additional information on your machine, which may differ from the manual. Please read this bulletin carefully. It contains current and updated information specific to your unit.

Any questions you may have regarding the information in this bulletin should be directed to your local authorized CHICAGO® distributor or the Chicago Dryer Company Service Department at:

Chicago Dryer Company (773) 235-4430 2300 North Pulaski Road Fax (773) 235-4439 Chicago, Illinois USA 60639-3737 Email service@chidry.com

Purpose The purpose of this bulletin is to provide updated information on troubleshooting the electrical system of King Edge CT and King Edge Vac CT machines.

Safety It is always recommended that all maintenance procedures be handled by at least two qualified persons. Using the “buddy system” facilitates a quicker procedure and decreases the risk of an accident.

WARNING

Follow lockout/ tag out procedures approved for your site. Follow local regulations. Failure to do so could result in serious injury.

Make sure that power is

OFF at the main disconnect switch before beginning any repair procedure.

2 Chicago Dryer Company

3023-591b King Edge CT / King Edge Vac CT

WARNING

Only trained personnel with experience in gas, electrical or mechanical repair should troubleshoot and repair the unit.

Troubleshooting

WARNING

Read the REPAIR chapter and make sure that the power is disconnected before doing any repairs.

6.2 Electrical

ISSUE POSSIBLE CAUSE SOLUTION

Unit Does Not Power Up

1. Main disconnect switch

OFF.

• Turn main disconnect switch ON.

2. One or more legs of the main power source is dead.

• Test and repair as necessary.

3. Fuse(s) in the main discon-nect switch have blown.

• Determine and correct cause before replacing fuse.

4. Incoming power supply is incorrect.

• Check for fluctuating or incorrect incom-ing voltage. Machine power require-ments are shown on the nameplate.

5. Circuit breaker CB4 is tripped, disabling the micro-processor.

• Reset.

• If circuit breaker continues to trip, check for short in the circuit wiring and replace any defective components.

6. PWS3 is bad. • Test and replace as necessary.

7. Microprocessor unit is bad. • Test and replace as necessary.

Unit Starts, Blank CHI•Touch Screen

1. CB2 is tripped. • Reset.

• If circuit breaker continues to trip, check for short in the circuit wiring and replace any defective components.

2. PWS2 is bad. • Test and replace as necessary.

3. Touch screen is bad. • Test and replace as necessary.

Unit Does Not Start

Message reads:

Interlock breaker tripped

1. CB 9 is tripped, disabling 24VDC start circuit.

• Reset.

• If circuit breaker continues to trip, check for short in the circuit wiring and replace any defective components.

Chicago Dryer Company 3

WARNING

Only trained personnel with experience in electrical or mechanical repair should troubleshoot and repair the unit.

Troubleshooting

WARNING

Read the REPAIR chapter and make sure that the power is disconnected before doing any repairs.

ISSUE POSSIBLE CAUSE SOLUTION

Unit Does Not Start

Message reads:

Start to reset Estop (Air)

1. Channel in CR2 is open. • Press a red safety STOP button; then, twist to release and reset. This simulta-neously breaks both CR2 channels and then resets them. Restart machine.

• If that does not work, turn power OFF at the main disconnect switch. Leave the machine off for a few moments; then, initiate normal start up sequence.

• If that does not work:

- Access the main electrical panel.

- Use a crescent wrench to turn power on at the main disconnect switch. Wait until the machine completes it-s start-up sequence.

- Look at CR2. It has three LEDs. The upper LED shows the component is powered. The lower two LEDs indicate whether the A and B channel circuits are complete. Most likely one of the two channel LEDs will be out. If both LEDs are lit, refer to Possible Cause #2 below.

- Refer to SCHEMATICS, 24V Interlock Circuit schematic and use a volt meter to find the open in the channel circuit.

- For Channel A (upper LED), use TB15A as reference and test each point in circuit. If the circuit is closed, you should see 0v; if the circuit is open, you should see 11.4v.

- For Channel B (lower LED), use TB10B as reference. Voltages are 0v for closed circuits; 7.6 for open.

- Once the open in the circuit it located, determine the cause and repair.

2. Problem with PWS4 or problem in one of its cir-cuits.

• Test PWS4 for 24VDC at output. Most likely it will be absent.

- Disconnect + wire(s) connected to power supply output.

- Retest for 24VDC at power supply output.

- If it is present, power supply is good and there is a short one of the PWS4 cir-cuits. Determine the cause and repair.

- If it is absent, power supply is bad.

Replace.

4 Chicago Dryer Company

3023-591b King Edge CT / King Edge Vac CT

WARNING

Only trained personnel with experience in gas, electrical or mechanical repair should troubleshoot and repair the unit.

Troubleshooting

WARNING

Read the REPAIR chapter and make sure that the power is disconnected before doing any repairs.

ISSUE POSSIBLE CAUSE SOLUTION

Unit Does Not Start

Message reads:

E-stop right side E-stop center E-stop left side

WARNING

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

1. Indicated red safety STOP button is pushed in or defective.

• Reset appropriate STOP button.

• If problem persists, test and replace but-ton as necessary.

Unit Does Not Start

Message reads:

Front cover open

1. The front access guard is open.

• Lower guard into position.

• If problem persists, test and replace interlock switch as necessary.

Unit Does Not Start

Message reads:

Door panel right Door panel left

1. Indicated door is open or missing.

• Close/replace endframe door.

• If problem persists, test and replace interlock switch as necessary.

Unit Does Not Start

Message reads:

Air pressure lo

1. Incoming air pressure is below 60 psi (415 kPa).

• Make sure air supply to feeder is ON and supply hose is not obstructed or loose.

• Make sure air supply to unit is at least 80 psi (550 kPa).

• Make sure air filter is clean. Refer to the PREVENTIVE MAINTENANCE chapter, Semi-Annual PM section, Clean Air Filter/Auto Drain procedure.

Unit Does Not Start

Message reads:

MP tripped

1. One of the motor protectors is tripped.

• Reset.

• If motor protector continues to trip, check for short in the circuit wiring and replace any defective components.

Unit Does Not Start

Message reads:

Interlock open

1. Internal communications error.

• Power down machine and restart.

• If the error repeats:

- Check the CAT5 cable connection between the communications head and the PC LAN2 port. Make sure it is secure.

- If it is, there is a problem with the PC or the communications head. Contact the Factory Service Department.

Chicago Dryer Company 5

WARNING

Only trained personnel with experience in electrical or mechanical repair should troubleshoot and repair the unit.

Troubleshooting

WARNING

Read the REPAIR chapter and make sure that the power is disconnected before doing any repairs.

ISSUE POSSIBLE CAUSE SOLUTION

Unit Does Not Start

Message reads:

Inverter fault

1. Inverters lost power due to a machine fault.

• Reset the inverter:

- Turn the power OFF at the main dis-connect switch.

- Wait one minute.

- Turn power ON at the main disconnect switch.

• If the fault repeats:

- Input voltage is too high or low. The voltage should be between 185v and 245v.

- There is a motor over current. Check for excessive physical load on the motor.

- Open circuit between an inverter and its motor.

- An inverter-powered motor is bad.

- There is an overbraking problem.

Contact the Chicago Dryer factory Service Department.

Unit Starts, Then Shuts Down

2. Control latching circuit (hold) is defective.

• Perform the following check:

- Press a red safety STOP button or open an interlock switch.

- Press START and check for message indicating open safety switch location.

- See if message stays displayed or disappears after a few seconds.

• If message disappears after a few seconds:

- Check wiring connections between PB6 (start) and their associated con-tacts, CR0, WAGO I/O control module, P01, and CR1.

- Check WAGO I/O control module and P01. Replace if necessary or consult factory.

- Check CR0/CR1. Replace if necessary.

• If message stays displayed:

- Close all safety switches.

- Press the START button and make sure the momentary indicator does not light at all, even for 1-2 seconds. If indicator lamp lights for 1-2 seconds while the machine is running, see next cause.

3. WAGO block is faulty. • Check/replace as necessary.

King Edge CT Introduction

1-1

Chapter 1 intROdUCtiOn This chapter includes the following sections:

1.1 Warranty 1.3 Safety

1.2 Scope of manual 1.4 Equipment description

The King EdgeTM CT automatic cornerless spreader/feeder allows operators to feed sheets or other large pieces of flatwork into a flatwork ironer or automatic folder from two stations. A built-in bypass conveyor allows feeding of small pieces through the King Edge without altering the position of the feeder or its discharge conveyor.

Like the rest of the CHICAGO® product line, the King Edge (Figure 1-1) is designed, manufactured, and assembled in Chicago, Illinois. Before the CHICAGO® nameplate is affixed to any machine, a final inspection is performed, including thorough testing under load conditions.

Any questions concerning the installation, operation, or repair of the unit should be directed to a local authorized CHICAGO® dealer or the Chicago Dryer Company factory Service Department at:

Chicago Dryer Company (773) 235-4430 2200 North Pulaski Road Fax (773) 235-4439 Chicago, Illinois USA 60639-3737 Email service@chidry.com

Figure 1-1: The King Edge provides high quality spreading and feeding.

Introduction King Edge CT

1-2

1.1 Warranty

A full page warranty statement is located at the front of this instruction manual. Please take the time to review this warranty and understand its provisions.

1.2 Scope of manual

This instruction manual will help you keep your CHICAGO® product operating safely, efficiently, and with minimum expense. Individual chapters in this manual provide the necessary information required for safe installation, operation, maintenance, troubleshooting, and repair.

Updates Occasionally, new information about the unit becomes available after publication of this manual. If you receive a CHICAGO® FYI Service Bulletin pertaining to your unit, insert the bulletin in the front of the manual.

Chapter 1 - introduction Provides an overview of the unit and its key features, of this manual, and of important safety features.

Chapter 2 - installation Describes recommended procedures for determining a suitable location for the unit and connecting the utilities. This chapter also includes checkout procedures to ensure all systems are working properly. Local requirements often vary, so follow local codes at all times.

Chapter 3 - Operating guidelines Gives recommendations for operating the unit at maximum efficiency. This chapter includes instructions for operators and suggestions for work organization.

Chapter 4 - Preventive maintenance Contains procedures for Daily, Weekly, Monthly , Semi-Annual , and Annual maintenance. Follow these procedures to keep the unit operating safely and at maximum efficiency.

A Preventive Maintenance Schedule is located at the front of this chapter.

Chapter 5 - Operating Principles Describes the operation of the unit in detail. A good understanding of this chapter will help avoid operation errors and assist with troubleshooting and maintenance.

Chapter 6 - troubleshooting Contains issues, possible causes, and solutions in all areas of operation.

Chapter 7 - Repair Contains procedures for making adjustments, repairs and parts replacement for the unit. Please follow all safety recommendations carefully.

CHI•Touch Operation Bulletin Describes in detail the operation of the

CHI•Touch control system. Programming, adjustment and test modes are detailed.

Parts List Contains detailed drawings and part specifications to assist in ordering replacement parts. It is divided into views in which the parts are grouped by function.

Schematics Contains electrical drawings showing power and motor circuits, control and interlock circuits, and any other relevant drawings, including part specifications.

Appendix Contains Technical Specifications, a Floor

Plan, and other relevant information for the unit.

1-3

1.3 Safety

Safe operation and maintenance of the unit must be the first priority of all supervisors, operators and maintenance personnel. Safety begins with safe work habits. In addition, the unit is equipped with built-in features to promote safety.

Safe Work habits during daily Operation

• Take the flatwork only after it has cleared the unit. Do not pull on the flatwork while it is still in the machine.

• Post the “Operator Safety” reminders in a place where everyone will see it.

Read these reminders and follow the recommendations.

• Read and follow all safety labels.

• Keep hands and clothing away from the moving parts of the spreader/feeder while it is operating.

• Always turn off the unit before clearing a jam.

• Operate the unit only with all guards and endframe doors in place and all safety features operating correctly. Never operate the unit with any safety features bypassed.

maintenance and Repair

WARning Always use extreme caution when performing any repair procedure that requires the unit to be operating.

Keep hands and loose clothing from coming into contact with any of the moving parts.

Serious injury Could Result.

When the unit is running, one person should be ready at a red safety StOP button at all times to stop the unit if necessary.

Before attempting any repair work, review these safety steps and precautions to protect yourself and the unit.

• Safety should be the primary concern of anyone performing corrective maintenance.

• Except where specifically directed, make sure that the main disconnect switch to incoming power is OFF.

• It is recommended that all maintenance procedures be handled by at least two qualified persons. Using the “buddy system” facilitates a quicker procedure and decreases the risk of an accident.

• Your site should have procedures that comply with government regulations and standards for equipment lockout/tagout during maintenance and repair. Ask your supervisor for specific information. It is the users’ responsibility to make sure they comply with all safety procedures.

1-4

WARning Know the proper procedure for locking out and tagging equipment during repair procedures.

Follow the rules of your work site. Failure to do so could result in serious injury.

make sure the power is disconnected before servicing the unit.

do not repair or correct any condition without reading and understanding the REPAiR chapter.

Only qualified personnel should troubleshoot and repair this unit.

Safety Features

There are several general categories of safety features:

• Main Disconnect Switch

• Safety STOP Buttons

• Safety Guards

• Safety Interlock Switches

• Safety Labels

• Safety Messages in the Manual main disconnect Switch

The main disconnect switch is located on the right endframe door. When turned to OFF, the main disconnect switch locks out the incoming electrical power to the unit.

Unless otherwise indicated, turn the main disconnect switch to OFF before performing any maintenance or repair work.

For more information on operating the main disconnect switch, refer to the INSTALLATION chapter, Installation Procedures section, Electrical Connections procedure.

Safety StOP buttons

There are six red safety STOP buttons arrayed around the unit, one at each corner and one at each operator station.

Pressing any of these buttons immediately stops all moving parts, releases internal air pressure, and locks out operation of the machine.

A fault message displays in the CHI•Touch screen. Twist to release/reset a pressed STOP button.

The preferred method of stopping the operation of the unit is by pressing the red portion of the Start/Stop button located at either operator station.

1-5

Safety guards

A windowed front access guard allows operators to see the internal parts of the spreader/ feeder when it is in operation while providing protection from moving parts.

Both endframes and other appropriate areas of the unit are covered with protective panels to prevent fingers or hands from coming into contact with moving parts. The guards and panels also serve to keep foreign objects from entering the unit and damaging components.

When an endframe door is opened or the front guard is raised, all rotating parts stop moving.

Safety interlock Switches

Safety interlock switches are located behind each endframe door and the front guard.

Whenever any of these components is opened or removed, its associated interlock switch is opened and all rotating parts stop moving.

The safety interlock switches are not intended to lockout the unit. Site management is responsible for developing and implementing lockout/ tagout procedures that comply with government standards for use when servicing the unit.

Safety Labels

WARNING (orange) and CAUTION (yellow) labels (Figure 1-2) are placed at locations around the unit to keep operators and maintenance personnel alert in particular areas.

WARNING labels alert personnel that personal injury may result from not following recommended procedures.

CAUTION labels alert personnel the unit may be damaged if conditions, practices, or procedures are not observed.

When training operators, take the time to locate, review, and understand all areas where labels are posted.

NOTE: Do not remove safety labels at any time. If a label needs to be replaced, contact Chicago Dryer Company for free replacements.

Figure 1-2: Safety labels remind operators and maintenance personnel that care must be taken when working near these areas.

1-6

Safety messages in this manual

WARNING and CAUTION messages also appear in this manual to highlight essential safety information.

WARNING messages alert personnel that personal injury may result from not following recommended procedures.

WARning never bypass any of the safety devices. this could result in serious injury.

BLACK BOX WARNING messages alert personnel of the operating condition a unit must be in before performing any procedure.

Personal injury may result from not following recommended procedures.

Perform only when the unit is OFF with power disconnected.

CAUTION messages alert personnel that the unit may be damaged if conditions, practices, or procedures are not observed.

CAUtiOn never use compressed air on or around electronic components.

1.4 Equipment description

A general overview of the King Edge spreader/ feeder includes:

• Machine Widths

• Optional Equipment machine Widths

The King Edge comes in a standard 120” (3050 mm) width and is available in an extra wide model, 136” (3455 mm). Consult the factory for other requirements or special requests.

Optional Equipment

The following optional equipment is available on all models:

Interconnected Stop Circuit: Pressing a red safety STOP button on the feeder, ironer or folder stops the entire finishing line.

Variable Speed Interconnect: The speeds of each machine in a finishing line are automatically coordinated for maximum efficiency.

Single Point Electrical Connection: Allows the unit to receive its electrical supply from the ironer.

Chicago Automatic Reject Processor:

Allows operator to press a stain or tear reject button after a piece is fed into the unit for automatic handling by the Chicago® folder at the end of the finishing line.

Pacing Lights: Allows operating standards to be set and provides a visual signal to indicate whether operators are reaching target production rates.

CHI•Linc: Production data collection and reporting system for archiving and analysis of production and efficiency information.

King Edge CT Installation

2-1

Chapter 2 inStALLAtiOn This chapter contains installation instructions for the King EdgeTM CT spreader/feeder and includes the following sections:

2.1 Site and Utility Requirements

2.2 installation Procedures

2.3 Pre-Operational Checkout

The spreader/feeder is tested under load conditions at the factory and inspected to ensure proper operation. It is shipped in working condition and is completely assembled, requiring only setup of the exit conveyors. Sufficient strapping, blocking, and bracing were provided to give reasonable assurance that no shipping damage would occur.

NOTE: If the spreader/feeder is received in damaged condition, notify the carrier at once.

Chicago Dryer Company’s responsibility for shipping damage, other than the standard warranty, ceases upon delivery to the carrier. For more information on the warranty, see the full page warranty statement at the front of this manual.

Installation King Edge CT

2-2

2.1 Site and Utility

Requirements

Figure 2-1 shows the clearances required for the spreader/feeder. The dimensions noted are the minimums recommended for efficient production and service, as well as maintenance access.

It is strongly recommended that enough clear space be provided around the spreader/feeder to allow for efficient access.

NOTE: The correct location of the spreader/feeder is of extreme importance.

The site must have a level, sturdy floor capable of supporting the spreader/feeder’s weight without significant flexing. For weight specifications and other technical information refer to the APPENDIX, Technical Specifications.

No special foundation, floor grouting, or installation of anchors is required. Generally, the locking wheels will hold the spreader/feeder in position and still allow for repositioning when necessary.

Floor grouting or installation of anchors may be required to comply with local codes or conditions, or aboard a ship.

36” (915 mm)

36” (915 mm)

72” (1830 mm)

Figure 2-1: Recommended clearances for installation of the King Edge.

2-3

Compressed air that is clean and dry must be provided for the unit. This is very important because the air will blow directly on the flatwork.

The compressed air supply must meet the pressure and air flow requirements noted in the APPENDIX, Technical Specifications. Also, refer to Compressed Air Supply Connection on page 2-7.

The electrical requirements of the unit are shown on the nameplate (Figure 2-2), located on the back of the right endframe. Wiring must be locally supplied.

A fused main disconnect switch is incorporated into the upper right endframe door. However, local codes may require a separate disconnect switch and must be locally supplied. Refer to Electrical Connections on page 2-8.

2.2 installation Procedures

Installation of the spreader/feeder includes:

• Inspection

• Uncrating, Placement and Alignment

• Floor Trough Installation

• Compressed Air Supply Connection

• Electrical Connections inspection

Carefully inspect all shipments before they are accepted from the carrier. Upon delivery, make sure all items listed on the bill have been received.

Any shortage, breakage, or damage noticed at the time of delivery should be indicated on the carrier’s freight bill and signed by the driver or carrier’s representative.

Damage noticed after delivery should be reported to the carrier at once. Request their inspection of the shipment and fill out a concealed damage inspection report.

NOTE: N o t i f y t h e c a r r i e r immediately if any damage has been done to the unit during shipment.Figure 2-2: The nameplate gives important information about the unit.

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Uncrating, Placement and Alignment

Required tools Crowbar Forklift Screwdriver Sledgehammer Wire cutters/knife Wrenches:

1/2” (2) 9/16” (2) 3/4” 15/16” (2) 1-1/16 (2)

1. Before unpacking the unit, make sure that the proposed site is acceptable and any necessary foundations have been prepared.

2. Remove the crating, strapping, and other packaging materials from the unit. Leave the protective plastic covers on the con-trols. These protective coverings should be left in place until the unit is ready for use.

3. Open both endframe doors and remove any materials that shipped with the unit.

Close and secure the doors.

CAUtiOn the unit should only be moved by qualified riggers using proper equipment.

4. With the unit still on its skid, move it into approximate position. Remove the bolts which secure the unit to the skid.

CAUtiOn do not drop or twist the unit.

5. As appropriate:

• If the unit is equipped with eye bolts, lift the unit straight up using the two eye bolts on top of each endframe and carefully remove the skid from under it.

OR

• Lift one endframe and carefully re-move the skid from under it and then repeat for the other endframe.

6. While either the entire unit or one side of the unit is suspended, attach the lock-ing floor castors (Figure 2-3) which were removed for shipping.

7. Carefully lift the discharge conveyor and hold it in a raised position.

8. Carefully lift the bypass conveyor and position the threaded rod in its tube (Figure 2-4, A). There is one on each side.

9. Use the stop nut (Figure 2-4, B) to ap-proximately set the height of the bypass conveyor.

Figure 2-3: Locking floor casters stored in an endframe for shipping.

Figure 2-4: ByPass conveyor support and positioning bolt location.

A C b

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10. Lower the discharge conveyor onto the bypass conveyor.

11. Attach the discharge conveyor tensioning idler to its bracket (Figure 2-5) on both sides of the machine. Make sure the spacer goes between the bracket and the bearing and the washer/nut go to the inside.

12. Cut and remove the tape securing the dis-charge conveyor air cylinders. Make sure all tape is removed.

13. Swivel each cylinder (Figure 2-6, A) into position (B) and attach it to the bypass conveyor with the hardware provided:

• The spacer washers and one nut go to the outside while the lock washer and other nut go to the inside.

• Make sure it is fastened securely but still able to move.

14. Connect the compressed air hose (Figure 2-6, C) by pressing it into its fitting (D).

15. Move the unit into final position in front of the ironer.

16. Figure 2-7 shows the desired relative positioning of the bypass conveyor and the discharge conveyor idler rolls to the ironer inlet.

17. Use the stop nut (Figure 2-4, B) to adjust the height of the bypass conveyor. Tighten down the locknut (C) to secure the posi-tion.

NOTE: Secure the unit to its foundation if required by local code. Always follow local codes.

18. Set the locking casters.

Figure 2-5: Attach the discharge conveyor tensioning idler to its bracket.

Figure 2-6: Attachments to be made at each end of the discharge conveyor.

A b

C d

Ironer inlet

Bypassconveyor

Discharge conveyor

Figure 2-7: Position the bypass exit conveyor so that it is just slightly higher than the ironer inlet.

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19. Attach the provided locking floor pads to the front crossbar (Figure 2-8, A). There is one for the left and one for the right side of the machine.

20. Adjust each pad so that it will rest firmly against the floor when fully extended (Figure 2-8, B). Secure the adjustment by tightening the locking nut (C).

21. Push the locking lever (Figure 2-8, D) fully down to extend the pads and firmly secure the unit in position.

Floor trough installation

Now it is time to install the floor trough which will catch wet linen which is dropped during processing.

1. Install the four trough brackets which shipped with the machine, two in front and two in the back, on the crossbars. If necessary, pull the front bypass conveyor forward a little to seat the rear brackets.

2. Position them about 12-18” (305-460 mm) away from each endframe and facing each other (Figure 2-9).

3. Slide the galvanized steel trough into position so that it is firmly resting on the support brackets (Figure 2-10). Make sure the angled corners face the machine front.

Figure 2-9: Position the floor troughs facing each other about 12-18” from the endframe.

Figure 2-10: The angled corners must face front to accommodate the locking floor pads.

Figure 2-8: The locking floor pads help secure the unit in position.

Ab d

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Compressed Air Supply Connection

The unit requires a compressed air supply to drive certain parts of the machine and direct the laydown of the flatwork onto the discharge conveyor.

The air must be clean and dry to assure proper operation and long service life of the pneumatic components. Also, the air will come into direct contact with the flatwork.

The compressed air supply must meet the pressure and airflow requirements noted in the APPENDIX, Technical Specifications.

Required tools Teflon tape/pipe thread compound Wrench: 7/8”

NOTE: Do not use copper tubing or solid pipe for the compressed air connections. Use a sturdy flexible air hose to accommodate machine movement.

1. Run a sturdy, flexible air hose from the external compressed air source to the 1/2” inlet fitting (Figure 2-11) at the back of the left endframe.

2. Use Teflon tape or pipe thread compound to assure a leak-proof connection. If de-sired, a quick release coupling may be used.

CAUtiOn do NOT turn on the compressed air supply at this time.

Figure 2-11: Compressed air supply connection.

2-8

Electrical Connections

The nameplate (Figure 2-2), located on the back of the right endframe, shows the electrical requirements of the unit.

All labor and materials required to bring the electrical service to the unit are a local responsibility.

All electrical wiring must comply with local codes and a qualified electrician must size and connect the wiring.

CAUtiOn the incoming electric power service must match the specific electrical requirements shown on the nameplate.

See the unit’s nameplate to determine the power supply requirements. If high or low voltage is suspected, check the electrical service to determine the actual voltage conditions. Improper or fluctuating voltage may damage motors and other electrical system components, and void the factory warranty.

NOTE: A fused disconnect switch is incorporated into the right endframe door. Check local regulations to determine whether a separate external fused disconnect switch is also required.

Follow local codes at all times.

NOTE: The unit is available with an Interconnected Stop Circuit.

If this circuit is not included, be sure to follow the Feeder/Ironer Interlock (Option) Wiring on page 2-12.

The unit offers two different types of electrical connection:

• Single Point and Other Cable Connections (Options)

• Standard Wiring

2-9

Required tools Scissors/knife

Single Point Electrical Connection (Option)

1. Locate the power cable at the right rear of the unit at the top of the electrical connec-tion box (Figure 2-12).

2. Uncoil the cable and connect to the recep-tacle on the right front of the ironer (Figure 2-13, A). Twist the lock ring to make sure the connection is secure.

Communications Cable Connection (Option)

1. If the unit was shipped with the optional communications cable, locate it at the right rear of the machine (Figure 2-14, A). Uncoil the cable and connect to the communications port on the right front of the ironer (Figure 2-13, B).

interconnected Stop Circuit Cable Connections (Option)

1. If the unit was shipped with the optional Interconnected Stop Circuit, it also will be located at the right rear of the unit.

NOTE: Save this plug. It will be needed if the feeder unit is ever run as a single machine.

2. Remove the feedback plug from the stop circuit connector (Figure 2-14, B).

3. Uncoil the stop circuit cable (Figure 2-14, C) and attach it to the stop circuit connec-tor. Pull the latch to secure the connection.

4. Remove the feedback plug from the ironer behind the spreader/feeder (Figure 2-13, C) and connect the stop circuit cable to its plug.

Pull the latch the secure the connection.

A bC

Figure 2-13: All cable connections are at the right front of the ironer.

Figure 2-12: Single point connections simply installation.

A b

Figure 2-14: The communication cable is at the right rear of the spreader/feeder.

2-10

Standard Electrical Wiring

WARning Only a qualified electrician should make the electrical connections to the unit.

improper installation could result in serious injury.

Required tools Screwdriver Wire cutter/stripper Wire nuts

1. The main disconnect switch is located on the right endframe door (Figure 2-15, A).

Turn it to the OFF position.

2. Open the upper (Figure 2-15, B) and lower right endframe door latches.

3. Rotate and hold the yellow lever while holding the main disconnect switch in the OFF position (Figure 2-16), then open the right endframe door.

4. Remove the electrical connection termi-nal box cover at the rear of the endframe (Figure 2-17, A). Figure 2-16: Rotate the yellow lever and hold against the red main disconnect switch to open or close the right endframe door.

Figure 2-15: Open the right endframe door for various wiring tasks.

A b

Figure 2-17: The electrical supply is connected inside the terminal box.

b

2-11

5. Bring the supply lines to the connection point at the rear of the right endframe (Fig-ure 2-18). Use three wires for the power supply and a green fourth wire for ground.

6. Extend the lines through conduit or green-field.

7. Wires can be seen extending from the connection point. Pull these wires back through the hole and out of the way.

8. Pull the external wiring through the hole and secure the conduit or greenfield to the endframe.

9. Connect the three power supply wires to the power wires in the box (Figure 2-17, B) and the green fourth wire to the green grounding wire (C). Use wire nuts to se-cure the connections.

10.…