LaserLine Flatwork Ironer Series, Instruction Manual

Page 1: ...GL16 Gas Heated Flatwork Ironer INSTRUCTION MANUAL...

Page 2: ...Chicago Dryer Company Technical Manual 3011 079a Chicago Dryer Company 2200 N Pulaski Chicago Illinois 60639 Telephone 773 235 4430 Fax 773 235 4439...

Page 3: ...The Heat Shield Inside The Ironing Cylinder 2 4 UV Flame Scanner Installation 2 4 Flame Safeguard Check 2 5 Exhaust Blower Installation 2 6 Electrical Connection 2 7 Gas Connection 2 11 Receiving She...

Page 4: ...3 4 Operating Techniques 3 10 Conditioning Flatwork Before Ironing 3 10 Unit Settings 3 12 Processing Standards 3 12 CHAPTER 4 PREVENTIVE MAINTENANCE 4 1 Daily PM 4 2 General Cleanliness 4 2 Clean Co...

Page 5: ...Clean Gas Regulator Vent 4 15 Check Gas Pressure 4 15 Change Oil in Gear Reduction Units 4 15 Check Clean Spark Plug and Pilot Assembly 4 16 Check Mechanical Electrical Connections 4 17 CHAPTER 5 OPER...

Page 6: ...2 Parts Availability 7 2 7 3 Feed Section 7 3 Feed Ribbon TensionAdjustment 7 3 Feed Ribbon Replacement 7 4 Feed Ribbon Drive Roll Friction Material Replacement 7 6 Doffer Roll Cover Replacement 7 7 G...

Page 7: ...ing Replacement 7 31 7 10 Burner System 7 33 Pilot Air and Gas Adjustment 7 33 Gas Air Mixer Adjustment 7 35 Gas Air Mixer Cleaning 7 36 Heat Shield Detachment From Burner Assembly 7 36 Replacing Heat...

Page 8: ...Skyline S1 S20 Installation...

Page 9: ...439 Chicago Illinois 60639 Purpose The purpose of this bulletin is to make sure that you do not accidentally interchange temperature controllers or high limit circuit cards which are used with differe...

Page 10: ...48 Return 6 x 250 1002 576 Model 11 Return 6 x 72 1002 507 Model 13 Return 6 x 80 1002 508 Model 14 and Tandem Return 6 x 84 1002 511 Model 16 Return 6 x 102 1002 502 Model 18 and Tandem Return 6 x 10...

Page 11: ...bbons These ribbons provide superior quality linen nish Safety Perform only when the unit is OFF with power connected and COOL It is recommended that all maintenance procedures be handled by at least...

Page 12: ......

Page 13: ...ar receiving shelf Like the rest of the CHICAGO product line the GL16 is designed manufactured and assembled in Chicago Illinois Before the CHICAGO nameplate is affixed to any unit a final inspection...

Page 14: ...Chapter 4 Preventive Maintenance The PREVENTIVE MAINTENANCE chapter gives procedures for Daily Weekly Monthly and Semi Annual Maintenance Follow these procedures to keep the unit operating safely and...

Page 15: ...rming any repair procedure that requires the unit to be temporarily moving Keep hands and loose clothing from coming into contact with any of the moving belts or other moving parts Serious Injury Coul...

Page 16: ...orner of the unit Pressing any of the four STOP buttons immediately stops all rotating parts Safety Guards A red safety finger guard covers the moving parts at the front of the unit It runs the entire...

Page 17: ...FF with power disconnected and COOL Safety Messages in this Manual WARNING and CAUTION messages appear in this manual to highlight essential safety information WARNING messages alert personnel that pe...

Page 18: ...Skyline S1 S20 Installation...

Page 19: ...tify 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 fu...

Page 20: ...ithin this chapter proceed to the Installation Procedures section Electrical Connection procedure Each unit has specific gas requirements verify the local gas supply matches the gas requirements speci...

Page 21: ...materials except the guide tapes Figure 2 2 the protective plastic cover and the brown paper on the ironing cylinder Protective coverings should be left in place so the unit will remain clean until it...

Page 22: ...burner and the burner flame at the right end of the burner The UV flame scanners send signals to the flame safeguard To install the UV flame scanners 1 Turn the power OFF at the main discon nect swit...

Page 23: ...Only DIP switches 4 and 8 should be set to ON 4 Make sure the flame signal voltmeter re lay is secure inside the base for the flame safeguard Figure 2 9 5 Carefully plug the flame safeguard into the c...

Page 24: ...n of maintenance time All labor and materials required for venting the unit are a local responsibility Comply with local codes and regulations for proper installation Ductwork The 10 254 mm diameter d...

Page 25: ...electrical requirements of the unit Figure 2 11 All labor and materials required to bring the electrical service to the unit are a local responsibility All electrical wiring must complywithlocalcodes...

Page 26: ...the rear of the left end frame 2 Unlock the door latch Figure 2 12 B on the main electrical box 3 With the main disconnect switch in the OFF position rotate the yellow lever clockwise hold yellow lev...

Page 27: ...greenfield or flexible conduit Run the greenfield through the clips on the top rear of the canopy and down the back of the left end frame to the top of the main elec trical box Figure 2 15 2 The elec...

Page 28: ...hed to the jumper wire at the upper left of the box terminal 90 to 91 6 Remove the jumper wire and connect the two red wires from the sail switch to these terminals 7 After all electrical connections...

Page 29: ...checking the pressure of the gas supply within this chapter proceed to the Pre Operational Checkout section Gas Connection Checkout procedure Gas Supply All labor and materials required for the gas co...

Page 30: ...scharge side of the regulator to the short nipple A 4 Connect a short nipple C to the inlet of the regulator B Connect the female half of union D to the short nipple C 5 Connect short nipples E and G...

Page 31: ...clog the discharge Carefully consider the route that the pipe will have to follow from the back of the left end frame to the final discharge point Make this run as short and straight as possible Be su...

Page 32: ...t the shelf into position for shipping and the inner two are used to bolt the shelf into its final position Final Protective Wrapper Removal Plastic Wrap Removal 1 Carefully remove any remaining plast...

Page 33: ...r sprocket The unit starts but will shut down after 5 sec onds if this sensor has moved from the correct position Check that the sensor is 0 06 1 5 mm from the teeth of the sprocket For information wi...

Page 34: ...proper rotation of the combustion blower motor 1 Turn the power OFF at the main discon nect switch WARNING The safety interlock switch is only to be defeated temporarily while performing this procedu...

Page 35: ...nections in or to the unit 8 If the rotation of the motor is NOT in the direction of the arrow turn the power OFF at the main disconnect switch 9 Open the main electrical box 10 To correct the rotatio...

Page 36: ...p of the blower motor as it slows down The rotation di rection should be clockwise Figure 2 26 WARNING Only a qualified electrician should make or correct any electrical connections in or to the unit...

Page 37: ...eps 1 and 2 to test remaining three red STOP buttons 4 Start the unit again 5 Push the red safety finger guard Figure 2 28 All moving parts of the unit stop and the green START button lamp goes out Sp...

Page 38: ...JOG REV for a few seconds and release it The rotating elements should move backward slowly When released the JOG switch springs back to the center position and the rotat ing elements stop Delivery Rib...

Page 39: ...ure below for the type of gas that is being used natural manufactured gas or liquefied petroleum gas For Natural or Manufactured Gas WARNING Turn the power OFF at the main disconnect switch before per...

Page 40: ...akage before proceeding WARNING Turn the power OFF at the main disconnect switch before performing this procedure 1 Make sure the external manual gas sup ply valve is turned OFF and the power is turne...

Page 41: ...pipe fitting NOTE The manometer will now be able to indicate the gas pressure immediately down stream of the installed regulator 6 After the manometer is connected turn power ON at the main disconnect...

Page 42: ...tion within this section go back to Gas Supply If needed adjust the downstream gas pressure from the installed regulator using the procedure in Step 14 If the gas pressure is within limits skip to Ste...

Page 43: ...50 to 280 mm for LP gas as indicated on the manometer If the gas pressure is not within limits go back to Step 14 to adjust the installed regulator 18 Within ten seconds after the burner gas valve ope...

Page 44: ...ould Result Checkout Completion Whenever any of these checkout steps are unsuccessful proceed to the TROUBLESHOOTING chapter If the problem cannot be determined solved contact your local CHICAGO distr...

Page 45: ...ily Operating Procedures 3 4 Operating Techniques NOTE It is extremely important that the daily operation of the unit be properly supervised at all times All operating and maintenance personnel must r...

Page 46: ...to the INSTALLATION chapter Installation Procedures section Electrical Connection procedure Safety Stop Buttons The preferred method of stopping the operation of the unit is by pressing any of the fo...

Page 47: ...fety Labels WARNING orange and CAUTION yellow labels are placed at locations around the unit to keep operators and maintenance personnel alert in particular areas Figure 3 5 WARNING labels alert perso...

Page 48: ...twork to the front or rear of the unit Finished flatwork can be delivered to the front receiving shelf for hand folding by setting the DELIVERY lever to FRONT If a separate automatic folding unit has...

Page 49: ...r is turned ON at the main disconnect switch the display will light and the ON indicator will be lit To set the desired temperature first turn the GAS switch ON Then use the increase or decrease butto...

Page 50: ...g HIGH LIMIT red indicator lamp F Lights if the temperature in the ironing cylinder exceeds the maximum set in the high temperature limit switch approximately 425 F 220 C As a safety precaution when t...

Page 51: ...he DELIVERY lever is set to the center OFF position on Type R units 4 Make sure the GAS switch is turned to OFF 5 Turn the power ON at the main disconnect switch Start the unit by pressing the green S...

Page 52: ...ntly damage the ironing cylinder and return ribbons and void the factory warranty Note Use only a standard sheet or table cloth dedicated solely to waxing the ironing cylinder 7 Feed the waxing cloth...

Page 53: ...wcases Work from side to side to prevent dirt and heat buildup at the ends of the ironing cylinder This also preserves padding life Rewax the ironing section before ironing thicker flatwork such as ta...

Page 54: ...rs are involved in producing the best flatwork finish possible with the unit Conditioning Flatwork Before Ironing Unit Settings Processing Standards The conditioning of flatwork before ironing and the...

Page 55: ...section must work harder in order to process the work by either slowing down the speed or increasing the temperature After extraction the optimum MR is 30 35 for polyester cotton fabrics and 45 50 for...

Page 56: ...roperly dried and ironed Thin single layer material can be processed at higher speeds Double thickness items such as pillowcases and thicker material like tabletop flatwork must be finished at lower s...

Page 57: ...F 149 163 C All cotton or polyester cotton blends 325 370 F 163 188 C CAUTION VISA material has a high polyester content and can melt when ironed at too high a temperature or too slow a speed This can...

Page 58: ...Skyline S1 S20 Installation...

Page 59: ...e v o C l l o R n o i s s e r p m o C k c e h C X l o o C r e w o P t c e n n o c s i D f f O s l e n a P e c i v r e S d n i h e B n a e l C X l o o C r e w o P t c e n n o c s i D f f O r e d n i l...

Page 60: ...ibbons on Type R units General components as required CAUTION Using compressed air on or around electronic component boards may damage them Clean Combustion Blower Air Filter CAUTION Operation of the...

Page 61: ...proceed to the REPAIR chapter Feed Section Guide Tape Replacement procedure Check Red STOP Buttons and Red Safety Finger Guard The unit should never be operated without all safety guards in place Chec...

Page 62: ...y PM WARNING Do not repair or correct any of these conditions without reading and understanding the REPAIR chapter of this manual Only QUALIFIED PERSONNEL should troubleshoot and repair this unit Make...

Page 63: ...d clean the inside and outside surfaces of the left and right end frame doors and the rear protective backplate 3 Clean any lint and wax vapor buildup in side the unit 4 Clean the top and bottom surfa...

Page 64: ...ing considered 1 Check with the Chicago Dryer Company factory Service Department to verify the grease meets specifications and is com patible with the grease already in the bear ings 2 Follow directio...

Page 65: ...rame doors To use the grease gun 1 Turn the power OFF at the main discon nect switch 2 Open both of the end frame doors 3 Wipe old lubricant off the bearings 4 Insert the grease gun nozzle firmly onto...

Page 66: ...of the ironing cylinder Figure 4 8 4 Remove any lint buildup by blowing off the heat shield 5 Close and secure the protective backplate CAUTION Keep foreign objects out of ironing cylinder Perform onl...

Page 67: ...er operation 1 Turn the power OFF at the main discon nect switch 2 Open the end frame doors 3 Use a vacuum to clean out lint and dirt from the intake side Figure 4 10 of the drivemotor combustionblowe...

Page 68: ...rticles hair etc in the blower fan wheel between the blades can cause overheating especially of the end frame controls and possible premature component failure 1 Turn the power OFF at the main discon...

Page 69: ...the handle to wards the outside of the filter housing 5 Open the left end frame door Remove the clamp securing the discharge hose to the combustion blower housing Figure 4 14 Move the hose out of the...

Page 70: ...are listed at the end of the INSTALLATION chapter Follow these directions WARNING Do not repair or correct any of these conditions without reading and understanding the REPAIR chapter Only QUALIFIED...

Page 71: ...r soft cleaning cloth vacuum cleaner compressed air Figure 4 17 Touchless temperature sensors A and UV flame scanners B located in the right end frame A B A B Figure 4 16 Touchless temperature sensors...

Page 72: ...nit is OFF with power disconnected and COOL Required Tools cleaning cloth SAE 90 grade oil Perform only when the unit is RUNNING and COOL Figure 4 18 The drive chain is located inside the right end fr...

Page 73: ...ay be plugged pinched crimped or otherwise damaged Perform only when the unit is OFF with power disconnected and COOL For more information within this manual on the gas regulator go back to the INSTAL...

Page 74: ...Required Tools wrench ruler tape measure compressed air anti seize compound Check Clean Spark Plug and Pilot Assembly 1 Turn the power OFF at the main discon nect switch and lock out the gas supply 2...

Page 75: ...ion of the spark plug Required Tools wrench slotted screwdriver cleaning cloth Check Mechanical Electrical Connections Heating cooling and normal vibrations may cause connections to loosen over time P...

Page 76: ...Skyline S1 S20 Installation...

Page 77: ...oduce the flatwork finish Exhaust System This section explains how the exhaust blower and sail switch work together in the exhaust canopy to provide ventilation for the unit Heating System This sectio...

Page 78: ...nts are located inside the main electrical box NOTE The power supplied to the unit must match the requirements listed on the nameplate Figure 5 1 Main Electrical Box Refer to the schematics for interc...

Page 79: ...b m o C S T I U C R I C C I R T C E L E G N I T C E T O R P S R E K A E R B T I U C R I C c i t a m e h c S n o i t p i r c s e D 1 B C e l o p 2 r o t o m e v i r d n i a M 2 B C e l o p 2 y r a m i...

Page 80: ...I d n a t e k c o r p s r e d n i l y c g n i n o r i e h t f o n o i t a r e p o n w o d t u h s l l i w d e t c e t e d t o n s i n o i t o m f i t i n u C I M C k c o l r e t n I n o i t o M r e d...

Page 81: ...The drive chain D is turned by the gear reducer sprocket C and powers the drive rolls There is a spring tensioned idler sprocket which tensions the drive chain in the right end frame The spring tensi...

Page 82: ...der F 3 Flatwork is then carried under the spring tensioned compression roll E which smooths and flattens the flatwork 4 To keep the flatwork tight against the iron ing cylinder F a set of return ribb...

Page 83: ...r System Flame Safeguard Temperature Control System Touchless Temperature Sensors and UV Flame Scanners These systems work together to monitor and control the operation of the heating system For detai...

Page 84: ...i e r e h t n e h w r e n r u b e h t r e t n e o t e u n i t n o c t o n s e o d s a G d e s o l c r o t a c i d n i n e p o e v l a v s a g n e p o s i e v l a v s a g e h t n e h W e m a l f o n d...

Page 85: ...s i h T r e n r u b n i a m d r a u g e f a s H e r u t a r e p m e T l o r t n o C r o s n e S 2 C T I r e d n u a e r a e c a f r u s e g r a l a s w e i v r o s n e s e r u t a r e p m e t s s e l...

Page 86: ...on duits from the other electrical wires The yellow common lead wires for each scanner are connected together and to ter minal S2 of the flame safeguard The relay CR5 in the flame safeguard mounting b...

Page 87: ...more information on possible causes and solutions associated with each LED proceed to the TROUBLESHOOTING chapter Heating System section m e t I n o i t p i r c s e D A n e e s e b n a c D E L d e r...

Page 88: ...et the desired temperature use the in crease or the decrease buttons E 4 HEAT indicator B is on during the heat ing cycle and stays lit until the ACTUAL temperature increases to meet the SET temperatu...

Page 89: ...The high limit touchless temperature sensor ITC1 is aimed closer to the end of the ironing cylinder in the right end frame where the greatest heat buildup may occur It provides constant millivolt sign...

Page 90: ...in drive motor MTR1 Mechanical Start Up Stage This stage contains the sequence that occurs when the unit begins operating without ignition of the burner 1 The green START button is pressed the 24 VAC...

Page 91: ...MPERATURE CON TROL senses a high temperature condition the red HIGH LIMIT indicator lamp on the front panel lights and the flame safeguard shuts down the heating system The unit must be given time to...

Page 92: ...ystem error produces an alarm out put causing the SYSTEM ERROR red LED on the flame safeguard to come on FLAME SAFEGUARD red indicator lamp on the front panel comes on Burner Flame Trial 10 seconds Af...

Page 93: ...204 C at the high limit touchless temperature sensor If this occurs High limit temperature control HTL1 trips HIGH LIMIT LT3 indicator lamp on the front panel comes on 2 After the burner operation st...

Page 94: ...Skyline S1 S20 Installation...

Page 95: ...that is not addressed in this chapter please contact your local authorized CHICAGO dealer or the ChicagoDryer Company factory Service Department For a list of common issues that can occur in each sys...

Page 96: ...Ribbons Stop 6 6 6 2 Speed Control No Speed Adjustment 6 7 6 3 Ironing Quality Flatwork Feeds Poorly into Ironing Section 6 8 Flatwork Jams or Sticks to Ironing Cylinder Poor Ironing Quality 6 8 Flatw...

Page 97: ...6 VDC 6 17 Pilot Flame Partial or Lazy 6 18 Burner Ignition Flame Does Not Travel Down the Entire Length of the Burner Within 10 Seconds After Ignition 6 21 Touchless Temperature Sensors Operating Inc...

Page 98: ...m o c e v i t c e f e d e c a l p e R e v i t c e f e d s i h c t i w s G O J 4 e c a l p e R h c t i w s G O J e h t t a C A V 4 2 r o f k c e h C h c t i w s e h t d n a t n e s e r p s i C A V 4 2...

Page 99: ...c a l p e R e v i t c e f e d s i n o t t u b T R A T S 6 n o t t u b T R A T S n e e r g e h t t a C A V 4 2 r o f k c e h C t n e s e r p s i C A V 4 2 f i h c t i w s e h t e c a l p e R h c t i w...

Page 100: ...t e k c o r p s l l o r e v i r d e h t t c e p s n I s t e k c o r p s n r o w y n a e c a l p e r d n a s t e k c o r p s e s o o l n e k o r b s i t f a h s l l o r e v i r D 3 n e k o r b y n a e...

Page 101: ...r o f g n i r i w e h t t c e p s n I s e r i w e v i t c e f e d y n a e c a l p e R b o n k D E E P S t a n o i t c e n n o c e s o o L 2 r e t r e v n i r o d n a b o n k D E E P S e h t t a s n o...

Page 102: ...u j d a d e e c o r p l a u n a m s i h t n i h t i w n o i t a m r o f n i e r o m r o F e h t o t R I A P E R r e t p a h c n r u t e R n o i t c e S n r u t e R t n e m t s u j d A n o i s n e T n...

Page 103: ...A R E P O r e t p a h c s e u q i n h c e T g n i t a r e p O n o i t c e s e h t n o r u c c o s t o p s d e r o l o c t s u r f I 3 x a w d e s n e d n o c a s i e r e h t k r o w t a l f e h t r o...

Page 104: ...t o w t f I t i n u e h t h g u o r h t e v o m o t e u n i t n o c y a m k r o w t a l f e b t s u m w o r a n i g n i s s i m s e p a t o w t n a h t e r o M s i h t n i h t i w s n o i t c u r t s...

Page 105: ...c e h t n a e l C k c a b o g l a u n a m s i h t n i h t i w s n o i t c u r t s n i g n i n a e l c e h t o t E C N A N E T N I A M E V I T N E V E R P r e t p a h c M P y l i a D n o i t c e s r e...

Page 106: ...r u d e c o r p y l t c e r r o c n i g n i t a r e p o s i h c t i w s l i a S 4 e h t r o f t i u c r i c e h t k c e h c g n i n n u r t i n u e h t h t i W l a n i m r e t n e e w t e b V 0 2 1 r...

Page 107: ...m r e t d n a l a r t u e n d n a 0 9 s l a n i m r e t s i V 5 1 1 f I x o b l a c i r t c e l e n i a m e h t e d i s n i l a r t u e n t n e m e c a l p e r s d e e n d r a u g e f a s e m a l f e...

Page 108: ...e c o r p V 6 s i l a n g i s e m a l F 2 e v o b a 1 e s u a C e l b i s s o P r o f n o i t u l o S e h t e e S t n e i c i f f u s n i s i e m a l f t o l i P 3 n o i t a m r o f n i e r o m r o F...

Page 109: ...p s n I e r u s s e r p w o l f r i a n o i t s u b m o C 2 g n i t t e s d a b a s a h h c t i w s r o s n e s o D y r a s s e c e n f i e c a l p e r d n a h c t i w s e h t t c e p s n I g n i t t...

Page 110: ...H d e r e h t f I 3 s i e r u t a r e p m e t r e d n i l y c g n i n o r i e h t n e e r g e h t e s a c e h t s i s i h t f I t o h o o t f f o e b o s l a l l i w t h g i l E V L A V S A G s i h t...

Page 111: ...n s t i n u d a b s i d r a u g e f a s e m a l F 2 e v o b a 1 e s u a C e l b i s s o P r o f n o i t u l o S e h t e e S e h t f o e d i s t u p n i e h t n o e g a t l o v o n s i e r e h t f I e...

Page 112: ...i h t n i h t i w R I A P E R r e t p a h c m e t s y S r e n r u B n o i t c e s p i T r e n r u B e c n a n e t n i a M e r u d e c o r p s i r e n r u b e h t o t w o l f s a G 4 t n e i c i f f u...

Page 113: ...r i A e r u d e c o r p d e g g o l c e r a s p i t r e n r u b e h T l a u n a m s i h t n i h t i w s n o i t c u r t s n i g n i n a e l c r o F e h t o t d e e c o r p R I A P E R r e t p a h c r...

Page 114: ...s e c e n f i e c a l p e r d n a e r i w e h t t c e p s n I e h t o t k c a b o g l a u n a m s i h t n i h t i w s n o i t c u r t s n i E C N A N E T N I A M E V I T N E V E R P r e t p a h c M P...

Page 115: ...r e p m e T s r e n n a c S e r u d e c o r p s s e l h c u o t e h t m o r f s e r i W 2 e h t o t r o s n e s e r u t a r e p m e t e r a L O R T N O C E R U T A R E P M E T g n i d n u o r g r o r...

Page 116: ...d e c o r p r e n r u B n e h T y l l a m r o N s t r a t S n w o D s t u h S s i r e n r u b e h t o t w o l f s a G 1 t n e i c i f f u s n i e u s s I e h t o t k c a b o G w o l F s a G r a l u g...

Page 117: ...o T n a e l C e m a l F V U d n a s r o s n e S e r u t a r e p m e T s r e n n a c S e r u d e c o r p d n e t h g i r e h t n i r e n n a c s e m a l f V U e h t n g i l a e R l a u n a m s i h t n...

Page 118: ...c t i w s s a g e h t n r u T t i n u e h t g n i t a r e p o e r o f e b m e l b o r p e h t t c e r r o c d n a d e t a e h r e v o s a w L O R T N O C E R U T A R E P M E T 1 e r u t a r e p m e t...

Page 119: ...t c e n n o c E R U T A R E P M E T e h t d n a r o s n e s e r u t a r e p m e t L O R T N O C d n a s r o s n e s e r u t a r e p m e t s s e l h c u o t e h t k c e h C n o i t a m r o f n i e r o...

Page 120: ...c r e n r u B m e t s y S n o i t c e s e r u t a r e p m e T s s e l h c u o T t n e m e c a l p e R r o s n e S e r u d e c o r p s e m a l F f o s d n E m o r F g n i m o C r e d n i l y C g n i n...

Page 121: ...the flatwork is unsatisfactory after other causes have been ruled out Clean the ironing cylinder when deposits or debris affect the finish of processed flatwork Follow the Preventive Maintenance Sched...

Page 122: ...er lockout tagout procedures for equipment during repair work Follow the rules of your work site Failure to do so could result in serious injury WARNING Do not repair or correct any condition without...

Page 123: ...ty interlock switches are open As a temporary mea sure during this work defeat the safety interlock switch in each end frame 3 Locate the adjusting screws Figure 7 2 A inside both end frames which sec...

Page 124: ...at break should be replaced immediately The entire set of ribbons should be replaced to avoid excessive stress on only one new slightly shorter ribbon At a minimum it is recommended that ribbons be re...

Page 125: ...justing screws Figure 7 2 A which secure each feed ribbon drive roll bearing in position Loosen the locknuts B while holding the screws in position and back off each screw the same number of turns cou...

Page 126: ...ll the lacing clips are accessible and aligned at the front of the unit Remove all the connecting pins from the feed rib bons Position the feed ribbons away from the drive roll 6 Place a tarp plastic...

Page 127: ...drive roll by hand while a second person holds the roll of material and guides the material onto the drive roll pressing it firmly into place NOTE The drive roll friction material should be spiral wo...

Page 128: ...temporary protective cover ing from the feed ribbons and clean up the area 15 Align and overlap the ends of the first guide tape Be sure the trailing edge of the guide tape is on top and the leading...

Page 129: ...finger guard c Under the compression roll d Behind the guide tape bar e Over the compression roll f Forward through the red safety finger guard Figure 7 8 4 Align and overlap the ends of the first re...

Page 130: ...roning cylinder at either end and 3 8 9 mm from the ironing cylinder in the middle Figure 7 10 1 Turn the power OFF at the main discon nect switch 2 Remove the connecting pin from each feed ribbon and...

Page 131: ...cing is more than 3 8 9 mm tighten the nuts equally on each side of the threaded adjusting rod Figure 7 11 until the middle of the feed table is 3 8 from the ironing cyl inder If the spacing is less t...

Page 132: ...at the main discon nect switch 2 Open both end frame doors The unit will not operate while the safety interlock switches are open As a temporary mea sure during this procedure defeat the safety inter...

Page 133: ...n ribbons can no longer be adjusted the entire set of ribbons must be replaced Replacing Individual Return Ribbons Ribbons that break should be replaced immediately The entire set of ribbons should be...

Page 134: ...ly Bring it up to meet the other end Connect the ends of the ribbon with a new pin 10 Repeat Steps 5 to 9 to replace additional ribbons Stagger the positions of the lacing clips to give the flatwork a...

Page 135: ...p in place when the tension is adjusted properly the friction material must be replaced 1 Verify the correct replacement parts and supplies are available including the size of the friction material an...

Page 136: ...hand while a second person holds the roll of material and guides the material onto the drive roll pressing it firmly into place NOTE The drive roll friction material should be spiral wound at about a...

Page 137: ...the safety interlock switches are open As a temporary mea sure during this procedure defeat the door switch in each end frame WARNING The safety interlock switches are only to be defeated temporarily...

Page 138: ...longer be adjusted the entire set of ribbons must be replaced Ribbons that break should be replaced immediately The entire set of ribbons should be replaced in order to avoid excessive stress on only...

Page 139: ...are the cor rect size and there is sufficient quantity to complete the procedure See the PARTS LIST 2 Turn the power OFF at the main discon nect switch Remove the protective backplate from the rear of...

Page 140: ...under the center of each delivery ribbon and wound around the delivery ribbon drive roll 1 Verify there is enough 1 25 mm tape available to replace the old material One roll of tracking tape is requi...

Page 141: ...e tape with the vertical cen ter mark and wrap the tape so that it goes around at least twice against the rota tional direction of the roll Figure 7 20 12 Use a nail to pierce the tracking tape and ex...

Page 142: ...he end frame doors are closed 3 Turn the power ON at the main discon nect switch 4 Press the green START button Turn the SPEED knob to the slowest speed 5 Feed the piece of paper into the ironing sect...

Page 143: ...o increase the tension and away to de crease Tighten the locknut once the ad justment has been made 6 Place the spring loaded handles in their bracket slots inside the end frame to add tension to the...

Page 144: ...hat these materials are available 5 Use a staple puller to remove the staples holding the ends of the guide tapes to gether Move the guide tapes out of the way 6 Remove the red safety finger guard at...

Page 145: ...ean cloth 10 In a strip along the full length of the com pression roll apply the cement on 1 4 to 1 3 of the surface of the roll Figure 7 23 and smooth with a putty knife 11 Position the replacement c...

Page 146: ...Check the gap between the front and trail ing edges of the pad Figure 7 26 There should be a gap of 3 16 to 1 4 5 mm to 6 mm If the gap is wider than this or un even unwind the pad and repeat Steps 1...

Page 147: ...rson must remain with the unit at all times until the safety finger guard has been replaced 32 While the unit is running the new pads and covers will settle in and the pressure may decrease Periodical...

Page 148: ...for mation within this manual go back to the OPERATING GUIDELINES chapter Daily Operating Procedures section Waxing procedure 7 7 Drive Chain The drive chain in the right end frame powers the various...

Page 149: ...peed 4 Look at the machine speed sensor Fig ure 7 29 The LED on the back of the sensor should blink each time a tooth of the ironing cylinder sprocket passes 5 Press a red STOP button Turn the power O...

Page 150: ...the return ribbons and guide assembly CAUTION Avoid gouging or leaving any flat spots on the cylinder The unit will work properly only if the fine polished surface of the cylinder is preserved 7 9 Iro...

Page 151: ...tton at all times to stop the unit if necessary 11 Turn power OFF at the main disconnect switch 12 Repeat Steps 8 to 11 to clean the entire surface of the ironing cylinder 13 Remove the temporary prot...

Page 152: ...it may have to be cut off instead CAUTION Be careful not to damage the surface of the trunnion when you remove the old ring 6 Clean any rust or scale from the surface of the trunnion and lightly oil t...

Page 153: ...ure Sensor Replacement UV Flame Scanner Replacement UV Flame Scanner Alignment Adjustment Pilot Air and Gas Adjustment Thegaspilottypicallydoesnotneedadjustment However with an air adjustment fitting...

Page 154: ...knut Figure 7 31 B on the pilotcombustionairfitting toadjusttheflame 2 Turn air adjustment screw Figure 7 31 C so pilot flame is not lazy and only at end of flame pipe NOTE The pilot flame should be v...

Page 155: ...mixer adjust ment cap nut Figure 7 33 3 Loosen the locknut Figure 7 34 A WARNING Adjust the screw in increments of 1 8 turn of a rotation To close the valve and lower the flame turn the adjustment scr...

Page 156: ...FF at the main disconnect switch 2 Unscrew the air injector with the air el bow and piping still connected 3 Clean the inside and outside surfaces of the air injector 4 If necessary remove and clean t...

Page 157: ...om the burner For more information within this section go back to Heat Shield Detachment From Burner Assembly procedure 3 Remove Burner Assembly For more in formation within this section proceed to Bu...

Page 158: ...FF 2 Press a red STOP button Turn the power OFF at the main disconnect switch 3 Turn off the gas supply to the unit 4 Disconnect the heat shield from burner For more information within this section go...

Page 159: ...from the burner by turning counter clockwise Figure 38 E 13 Remove the combustion blower air hose Figure 7 39 A from the burner assem bly 14 Disconnect the cable and wire inside the combustion air pre...

Page 160: ...s sembly to its support 22 Remove the burner assembly slowly while pushing the 1 x 4 25 mm x 1220 mm pipe from the right side 23 Stop moving the assembly before the tail pipe clears the support hole a...

Page 161: ...he burner assembly reverse the steps in the Burner Removal procedure and refer to the following additional guidelines When the assembly has been pushed back into the ironing cylinder use the 1 x 4 25...

Page 162: ...de of the TEMPERATURE CONTROL 8 Tighten the corner screws of the white gray plastic retainer 9 Connect the socket to the TEMPERA TURE CONTROL 10 Close and secure the right end frame door Touchless Tem...

Page 163: ...use permanent damage 4 Connect the wires for the new UV flame scanner in the junction box and tighten the wire nuts 2 Loosen the clamp Figure 7 44 A and carefully remove the touchless tempera ture sen...

Page 164: ...l the scanner sees the flame FLAME SIGNAL reading of 9 V to 10 V is good FLAME SIGNAL reading of 6 V to 8 V is questionable FLAME SIGNAL reading below 6 V is not a reliable signal If the FLAME SIGNAL...

Page 165: ...y pressure slightly to realign the hold ing tube 8 Remove the 1 2 pipe from the holding tube 9 Install the plastic adaptor on the holding tube 10 Repeat Steps 3 and 4 to check the new alignment of the...

Page 166: ...Skyline S1 S20 Installation...

Page 167: ...on Front View Page 2 5 4801 120 CANOPY ONLY MODEL 16 20 120 GAS 5 4801 100 CANOPY COMPLETE MODEL 16 20 120 GAS 6 4801 122 CANOPY ONLY MODEL 16 20 110 GAS 6 4801 099 CANOPY COMPLETE MODEL 16 20 110 GAS...

Page 168: ......

Page 169: ...ture Parts List INDEX Front View 2 Rear View 4 Left Side Bearings 6 Right Side Bearings 7 Drive Side View 8 Gas System Detail 10 Rolls and Ribbons 12 Left Indication Panel 16 Right Indication Panel 17...

Page 170: ...EL ALUM SET 1 6372 5 4801 120 1 CANOPY ONLY MODEL 16 120 GAS 6 4801 122 1 CANOPY ONLY MODEL 16 110 GAS 7 3210 016 1 FINGER GUARD 136 x 11 25 x 14 GA 8 3210 120 1 FINGER GUARD 126 x 11 1 4 x 14 GA 9 48...

Page 171: ...HP 3 50 220 440 1440 RPM FR 143T 18 2001 551 1 ENDFRAME DOOR COMPLETE MODEL 16 19 4019 633 1 BUMPER DOOR 28 1 4 W 2 END CAPS 20 0603 050 1 RECEIVING SHELF ARM R H 21 3407 132 1 TOP RECEIVING TABLE 137...

Page 172: ...CEIVING SHELF ARM L H 6 1411 550 2 BUTTON STOP TURN RELEASE 1 N C 7 4801 120 1 CANOPY ONLY MODEL 16 120 GAS 8 4801 122 1 CANOPY ONLY MODEL 16 110 GAS 9 3403 147 1 REAR INSULATING COVER ASSY GL16 120 1...

Page 173: ...37 x 30 x 14 GA 23 3407 133 1 TOP RECEIVING TABLE 127 x 30 x 14 GA 24 3004 6372 1 WARNING LABEL ALUM SET 1 6372 25 1413 477 1 SWITCH 26 4805 100 1 COLLAR 9 START 4 LONG 27 4819 220 1 ELBOW 9 DIA 90 DE...

Page 174: ...GF NEXT PIVOT or 0402 793 BEARING 1 BORE PIVOT MNT GF OPPOSITE 3 0403 763 2 BEARING CAM FOLLOWER 1 3 4 BORE ASSY 4 0406 059 1 HARDENED RING 10 3 4 OD 5 N A 6 0402 768 1 BEARING 1 1 4 BORE STAT MOUNT 7...

Page 175: ...1 BORE PIVOT MNT GF NEXT PIVOT or 0402 793 BEARING 1 BORE PIVOT MNT GF OPPOSITE 4 0402 774 1 BEARING 1 BORE STAT MOUNT 5 0402 768 1 BEARING 1 1 4 BORE STAT MOUNT 6 0402 780 1 BEARING BALL 2 1 4 BORE 7...

Page 176: ...8 PL 3031 009c GL16 Drive Side View Type R Only...

Page 177: ...BRACKET 2 x 1 1 2 x 12 GA 11 1201 447 1 SPROCKET 50 19T 1 1 4 BORE KWAY 2 STSC 12 3601 855 1 TENSION ROD 3 8 x 2 3 4 13 3603 837 1 SPRING 1 x 5 14 1211 031 1 IDLER ARM 1 x 6 x 1 4 GA 15 1210 125 1 SHA...

Page 178: ...6 Gas System Detail ID Part Number Qty Description 1 5001 248 2 NIPPLE 1 x 2 2 2206 429 2 MAGNETIC VALVE 1 NPT 120 VAC 3 5002 155 1 ELBOW RED 90 DEG 1 4 x 1 8 4 5001 002 1 NIPPLE 1 8 x CLOSE 5 5001 05...

Page 179: ...001 501 1 NIPPLE 3 x CLOSE 27 5001 351 1 NIPPLE 1 1 2 x CLOSE 28 5002 240 1 ELBOW RED 90 DEG 2 x 1 1 2 29 2204 225 1 BURNER GAS AIR MIXER 30 5001 154 1 NIPPLE UV SCANNER 1 2 x 3 1 2 31 2212 820 1 FLAM...

Page 180: ...12 PL 3031 009c GL16 Rolls and Ribbons Type R Machine Only NOTE Ribbon Quantities May Vary Per Model Lengths...

Page 181: ...ly 1011 904 3211 219 DOFFER ROLL 1 1 4 x91 x16 GA W FELT 85 Felt Only 1011 902 3211 220 DOFFER ROLL 1 1 4 x66 x16 GA W FELT 60 Felt Only 1011 900 4004 250 PINT PADDING CEMENT NOTE Cement included with...

Page 182: ...1 2 x126 x11 GA W FLEXTRA 120 Flextra 1013 702 3209 245 DRIVE ROLL 5 1 2 x116 x11 GA W FLEXTRA 110 Flextra 1013 650 3202 028 DRIVE ROLL 5 1 2 ODx106 L 11G W FLEXTRA 100 Flextra 1013 600 3202 029 DRIVE...

Page 183: ...15 GL16 PL 3031 009c This Page Blank on Purpose...

Page 184: ...YELLOW 24 V 2 1416 577 2 INDICATOR LIGHT GREEN 3 4202 310 1 TEMP CONTROL 1 16 DIN TYPE K 4 1411 560 01 1 SWITCH STOP 22 MM W 1 N C CONTACT BLOCK 5 1416 576 2 INDICATOR LIGHT RED 6 1402 008 1 SWITCH W...

Page 185: ...0 1 SPEED INDICATOR 2 1414 510 1 KNOB FOR SPEED CONTROL SWITCH 3 1402 550 1 SPEED CONTROL POT 5K 4 1411 560 01 1 SWITCH STOP 22 MM W 1 N C CONTACT BLOCK 5 3006 050 1 PANEL RHT MEDIUM 6 1402 000 1 SWIT...

Page 186: ...18 PL 3031 009c GL16 Disconnect Panel...

Page 187: ...404 450 CONTACTOR 9 AMP 24 VAC 50 60 HZ 6 4206 520 HI LIMIT TYPE K 7 1401 509 RELAY 24 VAC 1 POLE 8 1410 269 CIRCUIT BREAKER 10 AMP 2 POLE 9 1402 650 SWITCH DISCONNECT ASSY TYPE J 10 1401 508 RELAY 12...

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Page 189: ...GL16 Schematics and Parts 3210 361...

Page 190: ...2...

Page 191: ...FUSE 5 A TYPE J FU4 1407 633 FUSE 30 AMP TYPE JLL FU5 1407 633 FUSE 30 AMP TYPE JLL INV1 1615 155 01 INVERTER 1 HP AC 230 V MPD 1405 205 MOTOR PROTECTOR 0 63 1 AMP MPE 1405 230 MOTOR PROTECTOR 1 1 6...

Page 192: ...4...

Page 193: ...1407 710 FUSE 10 A TYPE J FU4 1407 633 FUSE 30 AMP TYPE JLL FU5 1407 633 FUSE 30 AMP TYPE JLL INV1 1615 155 01 INVERTER 1 HP AC 230 V MPD 1405 230 MOTOR PROTECTOR 1 1 6 AMP MPE 1405 405 MOTOR PROTECT...

Page 194: ...6...

Page 195: ...U4 1407 633 FUSE 30 AMP TYPE JLL FU5 1407 633 FUSE 30 AMP TYPE JLL INV1 1615 155 01 INVERTER 1 HP AC 230 V MPD 1405 430 MOTOR PROTECTOR 4 6 3 AMP MPE 1405 470 MOTOR PROTECTOR 9 14 AMP MPG 1405 430 MOT...

Page 196: ...8...

Page 197: ...1407 720 FUSE 20 A TYPE J FU4 1407 633 FUSE 30 AMP TYPE JLL FU5 1407 633 FUSE 30 AMP TYPE JLL INV1 1615 155 01 INVERTER 1 HP AC 230 V MPD 1405 405 MOTOR PROTECTOR 2 5 4 AMP MPE 1405 455 MOTOR PROTECT...

Page 198: ...10...

Page 199: ...MOTOR PROTECTOR MPEA 1414 680 AUX CONTACT FOR MOTOR PROTECTOR MPGA 1414 680 AUX CONTACT FOR MOTOR PROTECTOR PB1 1411 560 01 SWITCH STOP 22 MM W 1 N C CONTACT BLOCK PB2 1411 560 01 SWITCH STOP 22 MM W...

Page 200: ...12...

Page 201: ...206 520 HI LIMIT TYPE K ITC1 4203 000 TOUCHLESS THERMOCOUPLE SCANNER ASSY ITC1F 4208 255 JACK 3 WIRE GRADE TYPE K ITC1W 4204 490 WIRE THERMOCOUPLE TYPE K ITC2 4203 000 TOUCHLESS THERMOCOUPLE SCANNER A...

Page 202: ...14...

Page 203: ...GL16 15...

Page 204: ...Skyline S1 S20 Installation...

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Page 211: ...rature Range F C 200 400 95 200 Gas Supply Connection inch DN 1 DN 25 Motors Total 2 1 6 1 62 Drive HP kW 1 2 0 37 Exhaust Blower 1 HP kW 1 0 75 Combustion Blower 1 3 0 25 Delivery Drive 1 3 0 25 Elec...

Page 212: ...rature Range F C 200 400 95 200 Gas Supply Connection inch DN 1 DN 25 Motors Total 2 1 6 1 62 Drive HP kW 1 2 0 37 Exhaust Blower 1 HP kW 1 0 75 Combustion Blower 1 3 0 25 Delivery Drive 1 3 0 25 Elec...

Page 213: ...ature Range F C 200 400 95 200 Gas Supply Connection inch DN 1 DN 25 Motors Total 2 1 6 1 62 Drive HP kW 1 2 0 37 Exhaust Blower 1 HP kW 1 0 75 Combustion Blower 1 3 0 25 Delivery Drive 1 3 0 25 Elect...

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Page 215: ...ZE SAE 2 SAE 5 SAE 8 Cap Screws Brass Type 303 1 4 20 6 11 12 13 5 5 1 4 28 7 13 15 16 6 7 5 16 18 13 21 25 27 8 9 5 16 24 14 23 30 33 9 10 3 8 16 23 38 50 52 15 17 3 8 24 26 40 60 60 16 18 7 16 14 37...

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Page 237: ...extracted flatwork from the completely dry flatwork Divide the weight difference by the completely dry flatwork weight Finally multiply the resulting weight by 100 to determine the MR percentage The o...

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