Chicago Dryer Edge MAXX Instruction Manual Download

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SC-12

Display/Control

240 - TOP FLOOR CONVEYOR

239 - BOTTOM FLOOR CONVEYOR

SERVO I/O CONTROL

INVERTER/MOTOR CONTROL OUTPUTS

138 - FAULT IN
139 - STAIN OUT
140 - TEAR OUT

IRONER/FOLDER INTERFACE
137 - ENCODER IN

152 - SPREAD LIMIT

SERVO CONTROL

(1)

program select

318 - PS1

317 - PS0

320 - START (pulse)

324 - TORQ LIMIT (select)

323 - OVERRIDE (select)

322 - SYNC/TORQ (pulse)

321 - RUN (taut sensor)

319 - PS2

301 - LEFT INLET FORWARD
302 - RIGHT INLET FORWARD

303 - LEFT INLET MIDSPEED
304 - LEFT INLET LOSPEED

305 - EXIT FORWARD
306 - LO SPREAD IN (RETURN)
307 - RIGHT INLET MIDSPEED
308 - RIGHT INLET LOSPEED

309 - LEFT TRANSFER IN (SPREAD)
310 - LEFT TRANSFER OUT (INLET)

311 - LEFT TRANSFER LOSPEED
312 - EXIT FAST

313 - RIGHT TRANSFER IN (SPREAD)
314 - RIGHT TRANSFER OUT (INLET)
315 - RIGHT TRANSFER LOSPEED
316 - LO SPREAD OUT (SPREAD)

234 - RIGHT LAYDOWN AIR BLAST

236 - RIGHT SENSORS CLEAN

235 - LEFT SENSOR CLEAN

237 - SPREAD BACK PRESSURE
238 - EXIT TAIL BLOW
239 - BOTTOM FLOOR CONVEYOR
240 - TOP FLOOR CONVEYOR

233 - LEFT LAYDOWN AIR BLAST

226 - SPEED CONTROL

225 - RUN LATCH

228 - RIGHT TRANSFER FORWARD

232 - RIGHT FLOOR CONVEYOR

231 - LEFT FLOOR CONVEYOR

230 - RIGHT TRANSFER REVERSE

229 - LEFT TRANSFER REVERSE

227 - LEFT TRANSFER FORWARD

218 -

217 - RIGHT INLET DOWN

221 - RIGHT TRANSFER LEFT CLAMP
222 - RIGHT TRANSFER RIGHT CLAMP
223 - RIGHT LO SPREAD PRESSURE
224 - RIGHT SPREADER CLAMP

219 - RIGHT INLET LEFT CLUTCH
220 - RIGHT INLET RIGHT CLUTCH

210 -

212 - LEFT INLET RIGHT CLUTCH

209 - LEFT INLET DOWN

213 - LEFT TRANSFER LEFT CLAMP
214 - LEFT TRANSFER RIGHT CLAMP
215 - LEFT LO SPREAD PRESSURE
216 - LEFT SPREADER CLAMP

211 - LEFT INLET LEFT CLUTCH

PNEUMATIC CONTROL OUTPUTS

201 - CONTROL POWER LATCH
202 - ALARM

203 - TEACH ENABLE
204 - READY

205 - LEFT PACE GREEN
206 - RIGHT PACE GREEN
207 - LEFT PACE RED
208 - RIGHT PACE RED

CABLE1

16' cable

4-GREEN

2-RED

1-ORG

CENTER

SERVO DIAGNOSTIC POINTS (ON=OK)

136 - SERVO SYNC OUTPUT

135 - SERVO MOVE DONE

134 - SERVO ZEROED

133 - SERVO OK

LEFT SIDE

124 - CENTER TAUT

123 - GAP(EXIT) SENSOR

150 - SPREAD TAUT

111 - SPREAD CENTER

131 - TRANSFER IN(@SPREADER) SENSOR
132 - TRANSFER OUT(@INLET) SENSOR

130 - reserved

129 - TRANSFER FORWARD SENSOR

128 - TRANSFER IN(@SPREADER) SENSOR

127 - TRANSFER OUT(@INLET) SENSOR

126 - reserved

125 - TRANSFER FORWARD SENSOR

122 - LOWER WALL SENSOR

121 - UPPER WALL SENSOR

120 - TAIL SENSOR

119 - SPREAD(CORNER) SENSOR

118 - reserved

117 - INLET(LIFT) SENSOR

116 - reserved

115 - reserved

114 - RIGHT CORNER SENSOR

113 - LEFT CORNER SENSOR

110 - LOWER WALL SENSOR

109 - UPPER WALL SENSOR

108 - TAIL SENSOR

107 - SPREAD(CORNER) SENSOR

106 - AIR PRESSURE SWITCH

105 - INLET(LIFT) SENSOR

104 - reserved

103 - reserved

102 - RIGHT CORNER SENSOR

INPUTS/SENSORS

101 - LEFT CORNER SENSOR

I21 - RUN/START

I20 - STOP/PAUSE

I19 - RIGHT PANEL

I18 - LEFT PANEL

I17 - E-STOP RELAY

I16 - MOTOR PROTECTOR AUXILIARIES

I15 - INVERTER FAULT RELAYS

I14 - RIGHT SIDE E-STOPS

I13 - CENTER E-STOPS

I12 - LEFT SIDE E-STOPS

I11 - TOUCH/AREA SENSOR

I10 - CIRCUIT BREAKER

INTERLOCK DIAGNOSTIC POINTS (ON=OK)

serial port

24VDC

P01

CR0B

[START]

COMM

PWR

2
1

3 KEY

OPTIONAL SWITCH

1612-690

MPC1

OPERATOR INTERFACE

DISP1
KYBD1

(OPEN TO REMOVE)

556

OUT

0-10V

322

ANALOG

516 516

317 318

321

-24VOUT

314

313

-24VOUT

516

306

309 310

302

305

-24VOUT

530

+24VOUT

234

233

225 226

+24VOUT

-24VOUT

516

301

-24VOUT

516

MOTION CONTROL

COM

324

-24VOUT

+24V

-24V -24V

+24V

323

320

319

316

315

-24VOUT

-24V

+24V

OC10

OC11

OC9

AOC1

EC1

-24V

+24V

312

308

311

307

304

-24VOUT

+24VOUT

238

237

230

229

+24VOUT

240

239

+24VOUT

232

231

+24VOUT

-24VOUT

+24V

-24V

303

OC4

OC5

OC6

OC7

OC8

+24V

-24V

-24VOUT

228

227

235 236

CR5

RUN

LATCH

218

[RUN]

P02 530

210

217

POWER

RIGHT

+24VOUT

209

602

+24VOUT

CLAMP CONTROL

530

SV3

222

224

CR6

SC3

221

214

-24V

213

223

216

GND

+24VOUT

215

SV2

OC2

SC2

+24VOUT

OC3

+24V

220

212

219

211

GND

-24V

+24V

P03

602

RIGHT

POWER

+24VDCO

530

201

138

+24VOUT

202

408 408

-24VIN

133 134

137

-24VIN

130

129

-24VIN

408

122

125

-24VIN

117

121

118

-24VIN

408

-24VIN

114

113

109

106

-24VIN

110

SENSORS

408

-24VIN

408

126

205 206

207

140

+24VOUT

208

-24V -24V

139

135 136

-24VIN

132

131

-24VIN

-24V

OC1

IC9

IC8

IC10

-24V

127

124

123

119 120

-24VIN

-24V

116

115

-24VIN

111

108

-24VIN

112

-24V

IC6

IC8

IC7

IC9

IC7

-24VIN

-24V

128

+24V

+24V +24V

204

203

402 408

105

101 102

I19

I18

+24VIN

-24VIN

402

I14

I11

+24VIN

I10

24V

+24VIN

INTERLOCK

402

I15

+24VDCI

+24VIN

P01

-24V -24V

107

103 104

I21

I20

+24VIN

-24VIN

-24V

I16

I13

+24VIN

I12

+24VIN

I17

-24V

IC1

IC2

IC3

IC4

[CONTROL]

0VDC

GND

+24VIN

CC1

+24V

CR1B

+24V +24V

+24V

-24VIN

-24V

+24V

-24VIN

408

IC5

CONTROL

LATCH

POWER

CR1

CON4A

[E-STOP]

NC Code:
Date:

Scale:

CAD By:

Approved By:

Drawn By:

CHICAGO DRYER COMPANY

n/a

Txxx

MTB

xxx

MTB

DISPLAY/CONTROL

EDGE-MAXX

11-05-03

6270211

B (11-05-03) add output tables, swap 131/132, serial=green

A (4-22-03) original release

revisions

TERMINATOR

600

TOC

INDEX

SC-TOC

Summary of Contents for Edge MAXX

Page 1: ...EDGE MAXX Dual Input Large Piece Spreader Feeder INSTRUCTION MANUAL...

Page 2: ...Chicago Dryer Company Instruction Manual 3018 0032E CHICAGO DRYER COMPANY 2200 N Pulaski Chicago Illinois USA 60639 3737 Telephone 773 235 4430 Fax 773 235 4439 www chidry com...

Page 3: ...stallation Chapter 3 Operating Guidelines Chapter 4 Preventive Maintenance Chapter 5 Operating Principles Chapter 6 Troubleshooting Chapter 7 Repair CHI PANEL BULLETIN PICTURE PARTS LIST SCHEMATIC PAR...

Page 4: ...s Edge MAXX 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 Equipme...

Page 5: ...al Positioning Easi Glide Preparation Option 2 7 Reject Conveyor Positioning 2 8 Electrical Connection 2 9 2 3 Pre Operational Checkout 2 14 Final Protective Wrapper Removal 2 14 Security of Hardware...

Page 6: ...s 3 3 3 2 Operating Controls 3 4 Front Controls 3 4 Right Rear Controls 3 6 CHI Panel Controls and Indicators 3 7 3 3 Daily Operating Procedures 3 8 Start Up 3 8 Interconnected Stop Circuit option Ope...

Page 7: ...s Air Cylinders 4 7 Inspect Air Filter Auto Drain 4 9 Check Air Pressure Settings 4 9 Check Belt and Ribbon Condition and Tension 4 11 4 3 Monthly PM 200 hours 4 11 Check Setscrews 4 12 Check Spreader...

Page 8: ...lve Solenoids 5 15 Air Cylinders 5 15 Flow Controls 5 15 Air Bars 5 15 Pneumatic Clutch Brake 5 15 5 3 Mechanical System 5 16 Inlet Drive System 5 16 Transfer Drive System 5 17 Spread Drive Systems 5...

Page 9: ...nostic Message Index 6 6 6 2 LED Diagnostics 6 8 6 3 Electrical 6 9 6 4 Mechanical 6 13 6 5 Inlet Section 6 14 6 6 Transfer Section 6 16 6 7 Spread Section 6 19 6 8 Discharge Section 6 23 6 9 Reject S...

Page 10: ...Clamp Check and Adjustment 7 10 Transfer Clamp Assembly Replacement 7 12 Transfer Clamp Eccentric Grooved Bearing Tension Adjustment 7 13 Transfer Clamp Grooved Bearing Replacement 7 14 Transfer Belt...

Page 11: ...t Tension Adjustment 7 36 Side Conveyor Belt Replacement Tension Spring Check Replacement7 37 Reject Conveyor Drive Belt Tension Adjustment 7 39 Reject Conveyor Ribbon Tension Adjustment Replacement 7...

Page 12: ......

Page 13: ...wo operator stations for higher production rates Like the rest of the CHICAGO product line the Edge Maxx is designed manufactured and assembled in Chicago Illinois Before the CHICAGO nameplate is af x...

Page 14: ...or operating the unit at maximum ef ciency This chapter also includes instructions for the operators and suggestions for work organization Chapter 4 Preventive Maintenance Contains procedures for Dail...

Page 15: ...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...

Page 16: ...he right rear endframe 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 perfor...

Page 17: ...ely stops all rotating and moving parts releases compressed air pressure and shuts down the machine To reset a pressed STOP button twist it Thepreferredmethodofstoppingtheoperation of the unit is by p...

Page 18: ...dths The Edge Maxx comes in a standard 120 3050 mm width Consult the factory for other requirements or special requests Optional Equipment The following optional equipment is available on all models E...

Page 19: ...operation It was shipped in working condition and is completely assembled Suf cient strapping blocking and bracing were provided to give reasonable assurance that no shipping damage would occur NOTE N...

Page 20: ...level sturdy oor capable ofsupportingthespreader feeder sweightwithout significant flexing For weight specifications and other technical information refer to the APPENDIX Technical Speci cations No s...

Page 21: ...pection of the shipment and ll out a concealed damage inspection report NOTE Notify the carrier immediately if any damage has been done to the unit during shipment Compressed air that is clean and dry...

Page 22: ...nit is equipped with eye bolts lift the unit straight up using the two eye bolts on top of each endframe and care fully remove the skid from under it OR Lift one endframe and carefully re move the ski...

Page 23: ...c connectors A B which will t together in only one way and the photosensor has a screw connector C Use plastic wire ties to secure Install the upper conveyor belt making sure it goes around the drive...

Page 24: ...r has been removed The DISCHARGE CONVEYOR UP DOWN switch is in the UP position Figure 2 6 A The discharge conveyor safety bracket is engaged B 1 a b c NOTE Donotusecoppertubing or solid pipe for the c...

Page 25: ...inlet of the next machine as possible Carefully lift one endframe with a jack Remove and save the caster closest to the Easi Glide wheel Lower the endframe and move the jack to the other endframe Car...

Page 26: ...the pads and rmly secure the unit in position OR Secure the unit to its foundation if required by local code For use aboard a ship the unit may be welded at the footpads Always follow local codes Turn...

Page 27: ...ons Improper or uctuating voltage may damage motors and other electrical system components and void the factory warranty NOTE A fused disconnect switch is incorporated into the electrical connection b...

Page 28: ...Figure 2 15 B NOTE Save this plug It will be needed if the feeder unit is ever run as a single machine Remove the feedback plug from the stop circuit connector Figure 2 16 A Uncoil the stop circuit c...

Page 29: ...Agreen fourth wire for ground is required Extend the lines through conduit or green eld If it will be necessary to move the unit leave plenty of slack in the green eld for this purpose Pull the extern...

Page 30: ...eps to ensure that the spreader feeder will automatically shut down when the ironer does Required Tools screwdriver drill drill bits ttings In the ironer locate the run circuit Install a NC SPDT contr...

Page 31: ...endframe of the unit Open the left endframe door Route the wire as indicated in Figure 2 23 Use the provided cable anchors Connect the cable wires to the terminal block Figure 2 20 as follows White s...

Page 32: ...so may result in serious injury to operators or maintenance personnel Final Protective Wrapper Removal Remove any and all remaining protective wrapping or packaging Remove the protective plastic cover...

Page 33: ...time 1 2 Compressed Air Supply Checkout Check the primary air pressure regulators and make sure each has the correct initial setting Perform only when the unit is OFF with power disconnected WARNING...

Page 34: ...eci c machine performance problem 7 8 WARNING Stand clear whenever the discharge conveyor is moving Failure to do so could result in serious injury Standing clear of the discharge conveyor ip the disc...

Page 35: ...9 A at one of the stations All rotating and conveying elements of the feeder should operate The CHI panel Figure 2 29 B will display the start up diagnostic messages The main air valve will open and s...

Page 36: ...a square red station Stop button At one of the stations test the two mass sensors one at a time Press down on the lower inlet belt just above a mass sensor Figure 2 31 A The upper arm should raise all...

Page 37: ...otates toward the middle of the machine helping to convey the bottom of the piece As the piece reaches the center the transfer conveyor ribbons Figure 2 34 B carry the bottom of the piece toward the r...

Page 38: ...ure Process several pieces at each station Press a square red Stop button at either station Each photosensor on the unit is physically aligned and sensitivity adjusted for testing purposes before ship...

Page 39: ...ng it manually could damage the Easi Glide mechanism Lock Front Casters for Easi Glide Units Special locking front casters are used in conjunction with the Easi Glide option These casters can be locke...

Page 40: ...ng the Unit During shipment and installation of the spreader feeder some dirt or other contaminants may have accumulated that will mark processed atwork With the power disconnected wipe down the unit...

Page 41: ...dures 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 read understand and...

Page 42: ...od to pause operation of the machine is to press a red Stop button Figure 3 3 B at the front of the unit near the center To completely power down the unit press any red stop button then twist to unloc...

Page 43: ...rnment standards for use when servicing the unit Safety Labels WARNING orange and CAUTION yellow labels are placed at locations around the unit to keep operators and maintenance personnel alert in par...

Page 44: ...t of the unit include Figure 3 7 START STOP buttons A SAFETY STOP buttons B STAIN REJECT option button C TEAR REJECT option button D CHI Panel E INTERCONNECTED STOP CIRCUIT option indicator lights F P...

Page 45: ...lly automatic operation of the unit under a wide range of conditions For a complete description of the CHI Panel s functions refer to the CHI PANEL OPERATION bulletin If the machine is ChiLinc enabled...

Page 46: ...ses to allow for hand feeding small pieces NOTE Be sure to engage the RED exit conveyor safety latch when the conveyor is in the UP position and to release the latch before trying to move the conveyor...

Page 47: ...itions in the CHI panel Display in order to change settings The and buttons F and G are used to increase and decrease the various fold system settings The button is also used to reset the item counter...

Page 48: ...it when ribbons are missing or broken Serious damage and injury could result Start Up The following steps are suggested for start up of the spreader feeder each day Perform all daily preventive mainte...

Page 49: ...t the unit At one station test the two mass sen sors one at a time Press down on the lower inlet belt just above a mass sen sor Figure 3 10 A The upper arm should raise all moving parts should stop an...

Page 50: ...on Front Controls speci cs regarding interpreting the indicator lights Flatwork Handling The way that operators use the feeder is very important They can increase productivity extend the life of the u...

Page 51: ...NTER The SELECT ADJUSTMENT menus displays Press ENTER again to return to normal operation 1 2 3 4 5 Feeding Large Pieces NOTE The unit is designed to process large pieces of atwork ranging in size fro...

Page 52: ...s follow the site standards to avoid repetitive motion injury 5 a b c 6 Feeding Small Pieces Flip the DISCHARGE CONVEYOR UP DOWN switch to the UP position When the discharge conveyor reaches it full u...

Page 53: ...up to 5 fpm 1 5 mpm If the spreader feeder is too fast the atwork will bunch as it feeds into the ironer If the speed is set too slow the atwork will be excessively stretched When the unit is operatin...

Page 54: ...nnel if there is a consistent problem 1 2 3 4 5 Handling Misfeeds Safely In many cases the CHI control system will reject items which are not fed correctly the center misfeed and spread corner detecto...

Page 55: ...o the unit from the approximate center of the long edge of the atwork Make sure there are no folds in the atwork On units with the optional Stain Tear Reject system push the appropriate button after t...

Page 56: ...feeder is not being pushed to its maximum intake speed limit The more often the upper conveyor arm raises the closer to the maximum intake speed you are operating Gap Buster Feature The sensor at the...

Page 57: ...y Equipment X X Running 4 2 WEEKLY 50 hours Check and Clean Photosensors and Re ectors X Off Disconnect Power Check and Clean Inverters X Off Disconnect Power Check For String Accumulation X Off Disco...

Page 58: ...nd follow up with the necessary maintenance or repair General Cleanliness It is important to prevent the buildup of lint dirt dust and foreign material in the unit General cleanliness prevents damage...

Page 59: ...For more information refer to the OPERATING GUIDELINES chapter Daily Operating Procedures section Start Up procedure NOTE Repair any faulty safety devices before continuing to operate the unit 4 2 Wee...

Page 60: ...free cloth 1 2 Check and Clean Inverters Checkandcleantheinvertersandtheirscooling ns Figure 4 2 weekly with a vacuum cleaner Failure to do so may void your warranty Required Tools metric Allen wrench...

Page 61: ...evenly against each other Check Pneumatic Clutch Brake Roller Alignment Perform only when the unit is OFF with power disconnected Make sure the clutch brake rollers are seated evenly against each oth...

Page 62: ...ect switch Use a small amount of dry silicon lubricant on a clean dry lint free cloth and wipe the left and right transfer carriage rails Figure 4 4 A after each 50 hours of operation Repeat Step 2 fo...

Page 63: ...Check Transfer Clamp Assembly and Grooved Bearings Required Tools metric Allen wrench Perform only when the unit is OFF with power disconnected Turn power OFF at the main disconnect switch Move one o...

Page 64: ...e next step Refer to the Repair section Tighten the Drive Blocks procedure Grasp the carriage assembly Figure 4 8 C check to see whether there is any loose ness by trying to wiggle it laterally If any...

Page 65: ...eep the machine operating at peak ef ciency Perform only when the unit is OFF with power disconnected WARNING Wear protective eyewear when working with compressed air components Move the left side of...

Page 66: ...ar B and at center right in the machine The air pressure gauges factory default settings are listed A Left Spreader Clamps Back Pressure 50 psi 345 kPa B Inlet Conveyor Lift Pressure gauge only not ad...

Page 67: ...no visual sagging and general condition smoothness fraying and tears For belt and or ribbon adjustment and replacement instructions refer to the REPAIR chapter and the appropriate section and procedu...

Page 68: ...aring assembly check Check Spreader Clamp Linear Bearing Assemblies Perform only when the unit is OFF with power disconnected Check the grooved bearings in the assembly by taking the spreader clamp Fi...

Page 69: ...ing belt tension and or replacing belts refer to the REPAIR chapter Spread section and the appropriate procedure Close and secure the endframe doors 1 2 3 4 5 6 7 Check Transfer Belts Condition and Te...

Page 70: ...nspect the lower spreader drive belts one in each endframe Figure 4 15 B and the discharge conveyor drive belt Figure 4 16 C Carefully inspect the black inlet drive belt Figure 4 17 B the red transfer...

Page 71: ...ve chain for proper tension If the chain is worn and loose replace it Close and secure the right endframe door 1 2 3 4 5 6 4 4 Semi Annual PM 1000 hours WARNING Do not repair or correct any of these c...

Page 72: ...ch Press the tab on the side of the plastic case Figure 4 22 A and rotate it 1 4 turn to the left to remove it from the base Figure 4 22 B The base does not need to be removed from the machine Unscrew...

Page 73: ...y CAUTION Before using a grease other than Shell Darina EP2 check with the factory service department to verify that the grease meets speci cations and is compatible with the grease already in the bea...

Page 74: ...ring or its roll 1 2 turn and add the remaining 1 2 stroke slowly 1 2 3 4 5 6 CAUTION Over lubrication will destroy the bearing seals and cause premature failure If a slight bead of grease forms at th...

Page 75: ...Tools Phillips screwdriver grease gun Shell Darina EP2 Grease or equivalent clean lint free cloth Perform only when the unit is OFF with power disconnected Turn power OFF at the main disconnect switch...

Page 76: ...each wire s connection by gently pulling on it Tighten any loose connections Close both doors 1 2 3 4 5 Check Insulation Resistance to Earth Ground Required Tools voltmeter Perform only when the unit...

Page 77: ...requirements how power is distributed throughout the spreader feeder and the controls sensors and switches operating the unit Compressed Air System This section reviews compressed air requirements ho...

Page 78: ...by the Chicago Dryer Company service department 5 1 Electrical System The electrical components of the unit are divided into two areas Power System Control System The power system moves the rolls and...

Page 79: ...he rating of these fuses which is dependent on line voltage NOTE Thepowersuppliedtothe unit must match the requirements listed on the nameplate Step Down Transformers If the unit is installed in a pro...

Page 80: ...des an explanation of each item indicated in the picture The page after shows control relays not called out in this picture CON1 CR31 INV1 CON2 INV2 INV4 INV3 Figure 5 3 Components in the electrical p...

Page 81: ...l Relay Interconnect Stop Circuit Input Signal option CREO Control Relay Interconnect Stop Circuit Output Signal option DSC1 Main Disconnect Switch FILT1 Filter Incoming Power INV1 Inverter Left Inlet...

Page 82: ...er Fault Contacts CR4 Control Relay Motor Protectors CR5 Control Relay Run CR6 Control Relay Run Latch CR41 CR42 Control Relays Left Inlet Touch Sensors CR43 CR44 Control Relays Right Inlet Touch Sens...

Page 83: ...rol panel Two LED s on the communications head of the control panel show when it is receiving information from the CHI Panel RX and sending data to it TX Communications and the Control Panel All the i...

Page 84: ...omponents are located in the I O control panel Figure 5 5 in the right endframe The table on the next page provides an explanation of each item indicated in the picture PO3 P02 TERM Figure 5 6 Control...

Page 85: ...CONTROL COMPONENTS Module Description ANLG Analog Output Motion Control CLMP Clamp Control COMM Communications Head CHI Panel Interface INT Interlocks MOTION Motion Control PO1 PO2 PO3 DC Power Suppl...

Page 86: ...ach photosensor Proximity Sensors The proximity sensors use a magnetic eld to detect the position of machine components When a mechanism is in the proper position this is detected by the disturbance o...

Page 87: ...Edge Maxx Operating Principles 5 11 Top View PE45R PE24 PE24 PX52 PX11 SPREADER RAIL TRANSFER RAIL PX32 PX28 PX31 PX27 PE45E PE23 Figure 5 8 Photosensor and proximity sensor locations TOC INDEX...

Page 88: ...sfer clamp to the spreader clamps Drops the piece to the oor reject conveyor Dark Operate Background Suppression ON PE50A PE50B Taut Sensors Detects when the atwork is close to being completely spread...

Page 89: ...er cylinder is in the home position at the station inlet 12 mm PX32 Right PX25 Left Transfer Forward located at the end of each transfer cylinder Detects when the transfer cylinder is all he way forwa...

Page 90: ...l the air pressure used to perform various functions The table below lists the recommended setting for each regulator These can be adjusted to meet speci c processing needs A Main High Pressure 80 psi...

Page 91: ...ssed air to create a mechanical movement Flow Controls Flow controls Figure 5 12 work similar to regulators or the check valves used on many air cylinders They control the pressure and rate of air ow...

Page 92: ...D and upper Figure 5 15 16 E inlet belt drive pulleys An idler pulley F is included in the drive chain so that pulleys D and E turn in opposite directions A shaft Figure 5 16 G extends through pulley...

Page 93: ...fer components An identical set of equipment handles the left side transfer action In the right endframe the right transfer motor Figure 5 17 A powers the right transfer system A shaft from this motor...

Page 94: ...r jaws one attached to front side and one attached to the back side of the belt move in opposite directions Theactionofthespreaderjawsispneumatically controlled Lower Spread Subsystem This discussion...

Page 95: ...ft of the laydown assist roll and powers it On the other end of the assist roll in the right endframe is a gear Figure 5 22 E This gear drives a chain F which in turn powers another slightly smaller g...

Page 96: ...ey G This pulley powers the side conveyor belt H which helps move the bottom of the atwork toward the transfer conveyor Transfer Conveyor Drive Subsystem Use the illustration Figure 5 24 below to iden...

Page 97: ...Use the illustration Figure 5 24 below to identify the mechanical components of the reject conveyor drive system At the rear of the machine a motor Figure 5 25 A powers the reject drive system A shaf...

Page 98: ...tart up Phase This phase begins when an operator pushes the green Start button at either station 24Vdc from PWS1 ows to energize the CR0 coil closing the CR0 A B and C contacts The closing of the CR0B...

Page 99: ...sfer clamp assembly moves forward to take the corners of the atwork piece from the clutch brake rollers The I O control panel checks for a signal from PX27 to determine whether the transfer clamp is i...

Page 100: ...int both sensors must see the piece at the same time otherwise an error condition is assumed and the piece is dropped In addition the I O control panel board must receive a signal from SVO indicating...

Page 101: ...achine Error Conditions Various operating conditions can result in an error condition As noted if during the spread phase the taut sensors PE50A B do not simultaneously detect the piece the resulting...

Page 102: ......

Page 103: ...ider each system when troubleshooting the unit Each section in this chapter lists issues possible causes and solutions If an issue occurs that is not addressed in this chapter please contact your loca...

Page 104: ...hen Shuts Down 6 11 Unit Starts Blank Message Screen 6 12 Unit Is Running Normally Then Goes into Standby State or Unit Starts and Goes Immediately Into Standby State Message reads IRONER FOLDER NOT R...

Page 105: ...e Noise or Cylinder Outer Band is Vibrating 6 18 6 7 Spread Section Flatwork Not Properly Spread Message Reads UPPER SPREADER STALLED 6 19 Upper Spreader Clamps Bang or Drag at the Center of the Unit...

Page 106: ...INLET CONVEYOR SENSOR FAILED MISALIGNED LEFT CORNER SENSOR FAILED MISALIGNED MATERIAL TAIL SENSOR FAILED MISALIGNED MATERIAL TAUT SENSOR FAILED MISALIGNED RIGHT CORNER SENSOR FAILED MISALIGNED TRANSF...

Page 107: ...e MAXX Troubleshooting 6 5 6 12 Compressed Air System No Air Supply to Unit 6 28 Poor Air Pressure in Unit 6 28 No or Poor Air Supply to Air Devices 6 28 Compressed Air Supply System Error 6 29 TOC IN...

Page 108: ...TERLOCK SERVICE CLEAR FAULT 6 10 LEFT DOOR STOP INTERLOCK SERVICE CLEAR FAULT 6 10 RIGHT DOOR STOP INTERLOCK SERVICE CLEAR FAULT 6 10 COMMUNICATION ERROR FAULTY CODE RETURNED 6 27 COMMUNICATION ERROR...

Page 109: ...TDOWN BEFORE REMOVING 6 21 JAM SENSOR AT RIGHT WALL SHUTDOWN BEFORE REMOVING 6 21 JAM SENSOR AT INLET CONV SHUTDOWN BEFORE REMOVING 6 21 Sensor Messages SENSOR FAILED MISALIGNED INLET CONVEYOR 6 26 SE...

Page 110: ...311 308 312 24V 24V EC1 AOC1 OC9 OC 11 OC10 24V 24V 24VOUT 24VOUT 24VOUT 315 316 319 320 323 24V 24V 24V 24V 24VOUT 324 COM MOTION CONTROL 516 24VOUT 301 516 24VOUT 24VOUT 226 225 233 234 24VOUT 530 5...

Page 111: ...C transformer T3 or 24VDC PWS1 or PWS2 is bad Test and replace as necessary 6 Circuit breaker CB3 CB4 or CB5 is tripped dis abling 24VAC circuit or one of the 24VDC circuits Reset If circuit breaker c...

Page 112: ...CLEAR FAULT RIGHT SIDE STOP INTERLOCK SERVICE OR CLEAR FAULT LEFT DOOR STOP INTERLOCK SERVICE OR CLEAR FAULT RIGHT DOOR STOP INTERLOCK SERVICE OR CLEAR FAULT 1 A safety switch is open in the starting...

Page 113: ...age 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 i...

Page 114: ...running see next cause 2 CHI Panel faulty Check P01 wiring to CHI Panel Check CHI Panel output If necessary replace CHI Panel Unit Starts Blank Message Screen 1 No voltage at the CHI panel Check and...

Page 115: ...r to the REPAIR chap ter and the appropriate section and procedure 3 Inverter or motor protector fault Refer to Electrical section problems Circuit Breaker Motor nverter Fault Rotating Elements Stop 1...

Page 116: ...lace fuse Flatwork Jams at Inlet Con veyor or Inlet Conveyor Stalls 1 Poor atwork condition Make sure that the atwork is free of knots fold and tears 2 Insuf cient air pressure at the main valve bank...

Page 117: ...ection 3 Pneumatic clutch brake malfunction Check Repair replace as necessary 4 Air valve malfunction Check Repair replace as necessary 5 Air pressure is poor Make sure the incoming air pressure is se...

Page 118: ...ntenance procedure 2 Air valve malfunction Check For more information within this chapter refer to Compressed Air System section Repair replace as necessary 3 Fuse on output board may be bad Check Rep...

Page 119: ...cessary Corner Grabbed then Dropped by the Transfer Clamp 1 The transfer clamps are not closing properly Adjust Refer to the REPAIR chapter Transfer Section section Transfer Clamp Check and Adjustment...

Page 120: ...ot Working 1 Problem with reject con veyor Check For more information within this chapter refer to Reject Section section 2 Transfer conveyor drive belt is loose or slipping Check Adjust belt tension...

Page 121: ...INTENANCE chapter Weekly PM section Lubricate Upper Spreader Rail procedure 3 Servomotor or associated component malfunction Check Consult factory if necessary 4 Taut sensors PE50 A B malfunction Chec...

Page 122: ...gh Adjust TORQ setting Refer to the CHI PANEL OPERATION bulletin Adjust ment section Program Adjustments CHI procedure 3 The inverter may need to be adjusted Adjust the inverter Contact the factory Se...

Page 123: ...excessive torque Adjust Contact the factory Service Department for assistance Upper Spreader Clamps Re turn to the Center too Fast 1 The SPREAD slow buffer needs to be adjusted Increase the SPREAD SL...

Page 124: ...ive Pull to One Side 1 Black lower spreader belt gap needs adjustment Adjust Refer to the REPAIR chap ter Spread Section section Lower Spreader Belt Gap Adjustment procedure 2 The lower spreader belt...

Page 125: ...cedure Flatwork Pieces Overlap 1 GAP settings need adjust ment Adjust Refer to the CHI PANEL OP ERATION bulletin Adjustment sec tion CHI Adjustments procedure 2 Tail sensors may be dirty misaligned or...

Page 126: ...Between Flatwork Pieces 1 GAP settings need adjust ment Adjust Refer to the CHI PANEL OPERATION bulletin Adjustment section Program Adjustments CHI procedure 2 Tail sensors may be dirty misaligned or...

Page 127: ...ip check for short or other problem in motor circuit 4 CR39 has failed Check Replace as necessary 5 MTR10 drive belt is loose or slipping Check Adjust belt tension as neces sary Refer to the REPAIR ch...

Page 128: ...ocedure 3 There is an open circuit between the sensor and the input card Check connections between the sen sor and input card Main control circuit board is defective Replace Sensor is defective Replac...

Page 129: ...ontrol module is bad Replace CHI Panel is Not Functioning Message reads COMMUNICATION ERROR NO RESPONSE FROM CON TROL 1 Serial communications cable from the CHI Panel to Wago I O control mod ule is lo...

Page 130: ...PLES chapter Compressed Air System section Air Filter Regulators subsec tion 2 Air lter regulator auto drain is dirty Service Refer to the PREVENTIVE MAINTENANCE chapter Semi Annu al PM section Clean...

Page 131: ...the Wago I O control modules for each air valve An LED lights for each valve Refer to the SCHEMAT ICS When the LED does not come on when the valve is supposed to open the I O module is defective and...

Page 132: ......

Page 133: ...k when the tension can no longer be adjusted or when atwork does not properly enter or exit the unit Replace tracking tape when it is worn smooth or when ribbons slip in place Replace the doffer roll...

Page 134: ...led by at least two quali ed persons Using the buddy system decreases the risk of an accident Always keep hands and clothing away from the moving parts of the folder when it must be running to make re...

Page 135: ...y approved and tested replacement parts when repairing a CHICAGO unit They are designed for each model and serial number machine Overnight shipment of most parts is available 7 3 Inlet Section Sheets...

Page 136: ...yor should make a slight indent in the lower conveyor belt when properly adjusted Figure 7 1 However proper pressure can only be determined by the effective grasp and transport of the atwork during op...

Page 137: ...ected Turn power off at the main disconnect switch Locate the adjustment nuts at the center of the arm under the belt Figure 7 3 Tighten the nuts to increase the tension on the spring until the belt c...

Page 138: ...t conveyor motor cover in place and move the cover Figure 7 5 A so that the inlet belt B can be seen Loosen the nuts which secure the inlet con veyor motor in position Figure 7 5 C Pull the motor towa...

Page 139: ...ain solenoid air valve on the inside wall of the left endframe Figure 7 6 and locate the valve s override screw Use a small screwdriver to push in the lockout screw and turn it 1 4 turn clock wise to...

Page 140: ...tic Clutch Brake Roller Drive Belt Tension Adjustment Over time a station s power twist drive belt will stretch due to normal wear and tear Tension on the belt must be adjusted if it is noticeably sla...

Page 141: ...ver operate the unit unless all safety covers are in place and all safety equipment is working correctly Start the unit and check the operation of the clutch rollers 4 a b 5 6 7 8 7 4 Transfer Section...

Page 142: ...as sembly C 5th from left is for the left clamp of the right station transfer clamp as sembly D 6th from left is for the right clamp of the right station transfer clamp as sembly 1 2 3 4 5 Locate the...

Page 143: ...fully open the jaw without dis turbing the position of the grip Tighten the screws which secure the grip in position Push the clamp jaw closed to re check the alignment Repeat the Checking the Clamps...

Page 144: ...clamp body Figure 7 12 B Save Place the cylinder aside with its air hoses still attached Repeat Step 3 a to c with the second air cylinder Remove the four screws from the bottom of the transfer clamp...

Page 145: ...ge rail tension on the eccentric grooved bearings Figure 7 15 must be adjusted Note that all four grooved bearings on the assembly are actually identical The eccentric bearings are identi ed as such b...

Page 146: ...endframe 3 4 5 6 7 8 9 10 Transfer Clamp Grooved Bearing Replacement These bearings often wear down in pairs either both regular or both eccentric Even if only one grooved bearing shows signs of exces...

Page 147: ...cloth bag in the right endframe 4 5 6 7 8 9 10 A Figure 7 18 Make Sure the at washers are correctly positioned when installing new grooved bearings B C Transfer Belt Tension Adjustment Adjust tension...

Page 148: ...re 7 20 Two bracket assemblies hold the sections of the upper spreader belt in position B A B Loosen the bracket bolts which secure the belt and remove the bracket assembly Remove the belt from the ma...

Page 149: ...ader Belt Gap Adjustment Spreader Clamp Mechanical Adjustment Dropped atwork during the spread operation may indicate the spreader clamps are not properly gripping the atwork The clamps can be adjuste...

Page 150: ...tory 1 2 3 4 5 6 7 8 Upper Spreader Belt Replacement Replace the upper spreader belt when it can no longer be properly tensioned or if it becomes excessively worn cracked or frayed Required Tools 1 2...

Page 151: ...necessary refer to Figure 7 24 The belt ends should extend 1 to 3 25 to 75 mm beyond the edges of the bracket Make sure the plastic wire ties are pulled very snug These keep the ends of the belt from...

Page 152: ...ock Remove the end screw from the appropri ate spreader rail at the center of the unit Figure 7 26 Raise the rail slightly and slide the bear ing block off the rail Place it on a work table Remove the...

Page 153: ...s Both conditions cause excessive wear on the belt and shorten its life Required Tools 9 16 wrench Perform only when the unit is OFF with power disconnected Turn power OFF at the main disconnect switc...

Page 154: ...n the unit which will stretch and wear over time Belt stretching is automatically compensated for by spring loaded tension arms Replace the belts if the spreader belt teeth have been damaged when the...

Page 155: ...re is at least a 1 4 gap be tween the tensioning nuts and the xed re taining plate Figure 7 29 to allow proper belt movement during operation 1 2 3 4 5 6 7 8 9 Lower Spreader Belt Gap Adjustment When...

Page 156: ...in the lockout screw and turn it 1 4 turn clockwise to lock it in the in position This allows compressed air to ow to the spreader valve Move into the front middle of the machine Use care Locate the...

Page 157: ...to verify proper adjustment Make further adjustments as necessary 13 13 14 15 16 17 18 Figure 7 34 Spreader belt gap adjustment locknut A and bolt B B A 7 6 Discharge Section Sheets and other larger...

Page 158: ...conveyor Figure 7 35 B Loosen the locknuts Figure 7 35 C and adjust each screw the same number of turns clockwise until the ribbons are snug against the roll Test the tension by pulling up lightly on...

Page 159: ...rge conveyor Figure 7 36 1 2 3 4 5 6 7 8 9 Repeat Steps 7 to 9 to replace additional worn ribbons Stagger the positions of the lacing clips to give the atwork a smooth ow Adjust ribbon tension followi...

Page 160: ...because each ribbon in the set has an elasticized insert Figure 7 37 which makes it self adjusting If these ribbons lose their proper tension and or begin to slip the inserts should be replaced When t...

Page 161: ...connecting pins from all the ribbons and move them away from the drive roll It is not necessary to remove them from the machine Remove the old tape from the drive roll Mark the center position of eac...

Page 162: ...d ows easily into the ironer If the doffer roll is not applying suf cient pressure against the discharge ribbons it will stop rolling or only roll sporadically If the doffer roll is applying too much...

Page 163: ...the ends of each doffer roll with a scraper coarse sandpaper or a steel brush Wipe off any remaining residue with a clean cloth Using a fresh cloth or brush apply paint thinner on the entire surface o...

Page 164: ...winding process NOTE The drive roll cover material should be spiral wound at about a 45 angle Spiral wind the cover around the length of the roll Figure 7 43 A Trim each end of the cover so that it i...

Page 165: ...ct Conveyor Drive Belt Tension Adjustment Reject Conveyor Ribbon Tension Adjustment Reject Conveyor Ribbon Tension Adjustment Replacement Reject Conveyor Drive and Idler Roll Tracking Tape Replacement...

Page 166: ...ce the cover removed in Step 3 WARNING Never operate the unit unless all safety covers are in place and all safety equipment is working correctly Start the unit and check the operation of the transfer...

Page 167: ...s Required Tools pliers permanent marker scraper sandpaper steel brush soft cloth Perform only when the unit is OFF with power disconnected Make sure there is enough 1 25 mm tape available to replace...

Page 168: ...s 7 a b c d 8 9 Side Conveyor Drive Belt Tension Adjustment Over time a side conveyor s power twist drive belt will stretch due to normal wear and tear Tension on the belt must be adjusted if it is no...

Page 169: ...e operation of the side conveyor 4 a b 5 6 7 8 Side Conveyor Belt Replacement Tension Spring Check Replacement Each side conveyor belt will stretch and wear over time Belt stretching is automatically...

Page 170: ...pull the tensioning spring out from the arm tube Figure 7 51 Measure the length of the uncompressed spring If it is not 5 1 2 the spring has lost elasticity and must be replaced If the spring is good...

Page 171: ...itch Locate the safety cover for the reject con veyor drive belt Figure 7 52 Remove the bolts which secure the cover and set it aside Remove the reject conveyor drive belt by slowly hand turning the m...

Page 172: ...d be replaced When the cotton ribbons show excessive wear they should also be replaced Required Tools pliers Perform only when the unit is OFF with power disconnected Verify the replacement ribbons ar...

Page 173: ...ound their tracks until all the lacing clips are accessible and aligned 1 2 3 Remove the connecting pins from all the ribbons and move them away from the drive and idler rolls It is not necessary to r...

Page 174: ...lint or dust Use either a clean soft cloth to clean each lens In addition periodic adjustment or replacement ofsomesensorsmayberequired Theseprocedures include General Photosensor Alignment Exit Gap P...

Page 175: ...c it should be replaced immediately All photosensors are connected using a quick release connector Replacing a photosensor is 2 step process First physically install the new sensor and then make sure...

Page 176: ...Press the CURSOR button until the ash ing cursor is under SENSE and then press ENTER The panel display shows SENSOR ACTIVATION TEST 1 2 3 4 5 6 As appropriate If the display does not change for severa...

Page 177: ...en return to the SENSORACTIVATION TEST message On the CHI Panel press the TEST button to re display the test selection menu Press the TEST button a second time to leave test mode completely and return...

Page 178: ...n disconnect switch Take a small rectangular piece of white cardboard and place it in between the spreader belts Figure 7 58 A and di rectly in the sight of sight from the sensor to be adjusted Figure...

Page 179: ...g the Photosensors Setting 7 8 9 10 Proximity Sensor Positioning Adjustment Proximity sensors are mounted close to the surface of the objects to be sensed These sensors activate when their magnetic el...

Page 180: ...r Figure 7 61 A Cut plastic wire ties or remove any screws which are helping to secure the pigtail It must be free to move Loosen the lock nut which secures the sen sor in position Figure 7 60 B 7 61...

Page 181: ...63 A CAUTION Adjust the position of the proximity sensor very carefully If it is struck the sensor must be replaced Loosen the outer locknut Figure 7 63 B and move the sensor closer to the target surf...

Page 182: ...uide Rail Proximity Sensors to complete the procedure 1 2 3 4 5 6 7 Replacing a Pigtail Connector Proximity Sensor Required Tools 1 2 11 16 wrenches 1 mm shim knife scissors plastic wire ties Perform...

Page 183: ...en and close smoothly and without banging paired air cylinders should open and close together Adjusting the exhaust air ow valves when necessary helps keep the unit operating smoothly quietly and ef c...

Page 184: ...ow adjusted A B A B Figure 7 66 Flow control valves for the lower spreader belt push air cylinder are located under the discharge conveyor A B B A NOTE The adjustment is a little counter intuitive In...

Page 185: ...adjustment is working correctly 5 6 7 8 9 Discharge Conveyor Air Cylinder Air Flow Adjustment Make sure the discharge conveyor is operating correctly in that it both raises and lowers smoothly and ev...

Page 186: ...ystem 1 2 3 4 Locate the override screw on the spreader clamps back pressure solenoid air valve Figure 7 69 A With a small screwdriver push the screw in and turn it 1 4 turn clockwise to lock it down...

Page 187: ...it is OFF with power disconnected If necessary Turn power OFF at the main discon nect switch Turn OFF the compressed air supply to the unit Make sure the compressed air system is depressurized Pull th...

Page 188: ...s NOTE This procedure is best performed with two workers Required Tools metric Allen wrenches Perform only when the unit is OFF with power disconnected If necessary Turn power OFF at the main discon n...

Page 189: ...ccentric cam can be tightened A B Figure 7 74 It is important that the drive blocks are securely against the drive T B A Tighten the Carriage Block Required Tools metric Allen wrench small slotted scr...

Page 190: ...the index clamp center plate removed in Step 2 5 6 7 8 9 10 11 Increase the Air Cushion Required Tools small slotted screwdriver Perform only when the unit is OFF with power disconnected If the rear a...

Page 191: ...e compressed air supply to the unit Make sure the compressed air system is depressurized Pull the station s transfer clamp assembly toward the center of the machine Manually move the rodless air cylin...

Page 192: ...and retaining screw Figure 7 81 A Be careful not to remove it completely Have one worker hold back the outer band Figure 7 81 B while the other uses the end of a cleanAllen wrench or similar tool to p...

Page 193: ...onnect switch The adjustment point is located slightly above and in front of the discharge drive roll at the center of the unit Access the ad justment point from the front of the unit Before making an...

Page 194: ...OFF at the main disconnect switch Locate the air foil positioning bolt Figure 7 83 at the rear of the unit There is one on each side 1 2 Open the left and right endframe doors Locate the air foil pivo...

Page 195: ...just touches the discharge ribbons Loosen the various mounting bolts and set screws as necessary to make these adjust ments Figure 7 86 A B Once adjustments are made make sure all adjustments bolts an...

Page 196: ......

Page 197: ...Edge Maxx 3024 024e C 1 Edge Maxx Dual Spreader Feeder CHI Panel Operation CHICAGO EDGE TYPE 0 04 PROGRAMS TOC INDEX C TOC...

Page 198: ...tics C 6 II PROGRAMMING C 7 Start Programming C 7 Make Programming Changes C 8 End Programming C 8 III ADJUSTMENT C 9 Start Adjustment C 9 End Adjustment C 10 Ironer Speed Interlock Adjustments IRONER...

Page 199: ...t continues to run but will not accept atwork CHI SELECT button C Turns the Gap Buster exit conveyor feature on and off SPEED buttons D Controls the speed of the unit in manual mode Pressing decreases...

Page 200: ...ings although it would be rare for any operation to require that many The machine ships from the factory set for 4 programs To change the number of available programs in increments of 4 Within the rst...

Page 201: ...les pre programmed settings to automatically follow the speed encoder signal from the ironer to operate MANUAL Mode PWM 1 02 KING SHEET COTTON SPEED XXX FPM CNT XXXXX When running in manual mode press...

Page 202: ...tend the display time To reset all counts to zero press and hold the button for 3 seconds 1 2 3 4 Jam Detection If a piece of flatwork becomes jammed in the machine a flashing message on the CHI displ...

Page 203: ...ol panel WARNING Never touch any part of the machine while it is running Serious injury could result Only trained repair personnel should work on the unit Always think carefully around moving machiner...

Page 204: ...hed changing program settings follow these steps to save or discard changes Saving Changes Press the ENTER button to save As appropriate Press the CD button to leave program ming mode OR Press another...

Page 205: ...a STATION button before entering adjustment mode With the desired adjustment menu dis played press the CURSOR button until the ashing cursor is under the setting to be adjusted 1 2 3 4 Sometimesitmay...

Page 206: ...to save or discard changes Saving Changes Press the ENTER button to save The SE LECT ADJUSTMENT menu displays Press the ADJUST button to leave adjust ment mode Canceling Changes Press the ADJUST butt...

Page 207: ...nd it Setting 1 allows the unit to operate in manual controlling its own speed Setting 2 is no longer used Refer to the table below for more information about each available function to use as a guide...

Page 208: ...elect High Range Select Standard Setting IPACE Sets the feed rate in pieces per minute of the optional pacing lamp The same setting applies to both stations 6 12 MIN 1 Green light indicates constant t...

Page 209: ...24VDC start control and safety circuits must be powered and working If there is a complete failure of the 24VAC circuit and CB3 and T3 are good then verify that the coils of CR0 start circuit CR1 DC...

Page 210: ...the unit Test mode can only be entered if the spread feed system is off Make sure no STATION button is lit and the CHI Panel display reads FEEDER OFF 1 2 3 4 5 6 7 Press and hold the TEST button then...

Page 211: ...o the TROUBLESHOOTING chapter for possible causes NOTE The numbers appearing in the messages correspond to hardware output LED s Use the schematic diagrams as a reference 10 11 12 End Testing To leave...

Page 212: ...sfer section This test has a complex display The top line of the panel is constant and shows LTRAN F 125 0 127 I 128 This top line deals with input from the transfer rodless air cylinder proximity sen...

Page 213: ...erent displays Each one showing for several seconds FOR 228 GRAB 221 222 BAK This line deals with the pneumatic forward movement of the transfer rodless air cylinder and closing of the right inlet sta...

Page 214: ...andard Testing The panel display shows SENSOR ACTIVATION TEST The control system automatically begins to test each individual input device As long as the display does not change no sensor problems wer...

Page 215: ...Section Components Inlet Conveyor Detail PL 11 Inlet Drive Mechanism PL 12 Inlet Drive Train PL 15 Transfer Section Components Transfer Clamp Assembly PL 16 Transfer Rail Support Assy PL 19 Spread Se...

Page 216: ...SENSOR BRKT 2 1 2 x30 3 4 x12 GA 4 3210 007 1 AIR CYLINDER GUARD LEFT HAND 5 0607 340 1 L H LINEAR RAIL SUPPORT BRKT ASSY 6 0608 710 4 SENSOR CLEANING NOZZLE MOUNT 7 0608 748 3 AIR BAR SENSOR BRACKET...

Page 217: ...R W 2 BRAKE KIT ASSY 29 2001 675 1 R H FRONT PANEL ENDFRAME 30 0603 074 1 L H REJECT CONVEYOR SUPPORT BRACKET 31 2814 026 1 BOTTOM CONVEYOR PULLEY COVER ASSY 32 2007 155 1 BOTTOM FRONT CONNECTING CHAN...

Page 218: ...1 FRONT GUARD CHANNEL ASSEMBLY 6 N10 085 2 SHEET PLEXIGLASS 1 4 x7 1 2 x 33 2404 7 0208 428 2 AIR CYLINDER 3 4 BORE 2 STROKE W CUSH 8 0405 050 2 BEARING ROD END 1 4 FEMALE 9 3403 201 1 R H INSIDE CLUT...

Page 219: ...5 2 AIR CYLINDER 2 1 2 BORE 20 STROKE DC 26 3407 203 1 REJECT CONVEYOR ASSEMBLY 27 2010 223 1 DISCHARGE CONVEYOR ARM 19 313 x3 x1 4 GA 28 0605 366 2 FEED GUIDE ASSY ENDPLATE 29 0608 751 1 CONVEYOR AIR...

Page 220: ...E ROLL GROOVED W 1 BORE 3 x3 7 1205 230 1 IDLER ROLL GROOVED W BRACKET 8 1003 953 2 TEV TEX RIBBON 3 x 86 W PIN W V GUIDE 9 4215 003 4 LOCKING WASHER 1 3 4 ODx5 8 ID x14GA 10 1607 610 2 PHOTOSENSOR BA...

Page 221: ...521 1 RAW DRIVE ROLL 3 x 136 x 11 GA 22 3211 031 1 DOFFER ROLL 3 x120 W RUBBER CANVAS 23 3211 051 1 DOFFER ROLL 3 x136 W RUBBER CANVAS 24 0607 265 1 R H DOFFER ROLL BRKT W 5 8 ID COLLAR 25 1001 188 7...

Page 222: ...x PL 8 Right Side Bearings ID Part Number Qty Description 1 0402 763 5 BEARING HANGER 1 BORE PERM LUBE 2 0402 774 4 BEARING 1 BORE STAT MOUNT 3 0402 766 1 BEARING HANGER 1 1 4 BORE 1 1 3 1 1 1 2 2 2 2...

Page 223: ...40 16T 1 BORE KWAY 2 STSCRW 9 1215 020 1 BUSHING 1108 5 8 BORE 10 1221 250 1 PULLEY POWER GRIP 25T 11 0608 069 1 LOWER BELT BRACKET 8 1 2 x 10 1 2 12 1215 250 2 BUSHING SDS 1 BORE 13 1221 350 2 PULLE...

Page 224: ...FULL KWAY 9 1213 047 1 LEFT LOWER SPREADER MOTOR MOUNT 10 1221 151 1 PULLEY 14T 1 W REBORED 5 8 BORE W KWAY 11 1223 300 1 BELT TIMING 1 WIDE 12 1221 350 1 PULLEY 36 TEETH 1 WIDE 13 1215 250 1 BUSHING...

Page 225: ...5 050 1 BEARING ROD END 1 4 FEMALE 9 0203 200 2 ELBOW FLOW CONTROL 1 8 NPT 10 0208 428 1 AIR CYLINDER 3 4 BORE 2 STROKE W CUSH 11 0205 075 1 STRAIGHT CONNECTOR 1 8 NPT x 1 4 OD 12 0608 024 2 INPUT CON...

Page 226: ...ST BELT 4 L 38 LINKS LONG 3 4003 100 2 GREASE FITTING 1 4 28 STRAIGHT 4 1607 713 4 RECEIVER 5 1208 136 2 BRAKE CLUTCH ROLL W 5 8 SHAFT 6 0607 101 2 UPPER CLUTCH MOUNT ASSY EDGE 1 2 4 5 1 2 3 4 9 5 6 7...

Page 227: ...1 4 OD 15 1210 007 1 SHAFT 1 1 4 OD x 27 L W FULL KWAY 16 B10 410 2 COUPLING NUT RED 3 8 x 1 4 17 1208 133 2 BRAKE CLUTCH IDLER ROLL W 1 1 4 BORE 18 1607 710 4 EMITTER 19 0608 710 2 SENSOR CLEANING NO...

Page 228: ...3038 010k Edge Maxx PL 14 This page intentionally left blank TOC INDEX PL TOC...

Page 229: ...0 1 V BELT DOUBLE SIDE 51 AA 51 4 1205 842 1 V BELT SHEAVE 4 1 2 OD 1 BORE 5 1205 945 1 V BELT SHEAVE 4 OD 5 8 BORE 6 0614 150 1 COLLAR 5 8 ID LOCKING 7 B06 325 1 5 8 11 x 3 1 2 HX HD M S 8 B10 726 1...

Page 230: ...3038 010k Edge Maxx PL 16 Transfer Clamp Assembly 1 2 3 4 9 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 17 12 12 12 13 14 13 9 10 11 12 13 12 TOC INDEX PL TOC...

Page 231: ...9 B05 597 2 1 4 20 x 1 SHOULDER BOLT HX HD 10 0405 050 2 BEARING ROD END 1 4 FEMALE 11 0208 425 2 AIR CYLINDER 7 8 BORE 1 STROKE 12 0203 200 6 ELBOW FLOW CONTROL 1 8 NPT 13 0205 775 4 BARB FITTING 1...

Page 232: ...3038 010k Edge Maxx PL 18 This page intentionally left blank TOC INDEX PL TOC...

Page 233: ...AIL SUPPORT BRKT ASSY 4 2003 078 1 UPPER SPREADER CENTER BOX ASSY 5 0607 339 1 R H LINEAR RAIL SUPPORT BRKT ASSY 6 1803 009 3 RUBBER BUMPER 5 x 2 x 1 THICK 7 0204 465 1 RAIL LINEAR 100 LONG 8 0402 060...

Page 234: ...1 RAIL LINEAR 71 3 0607 345 1 CENTER BUMPER BRACKET WELDED ASSY 4 0608 728 1 LINEAR BEARING CENTER BRACKET 5 0205 075 1 STRAIGHT CONNECTOR 1 8 NPT x 1 4 OD 6 0208 435 1 AIR CYLINDER 1 1 4 BORE 2 STRO...

Page 235: ...ET ASSEMBLY 17 0204 260 1 SPREADER CLAMP RHT 18 0608 732 1 LINEAR RAIL MOUNTING BRACKET 19 0204 265 1 SPREADER CLAMP LFT 20 0607 424 1 LH UPPER SPREADER BELT BRACKET ASSEMBLY 21 0204 471 1 L H LINEAR...

Page 236: ...5 0607 135 1 BELT SPREADER ASSY 6 3604 200 2 SPRING COMPRESSION 1 1 8 OD 5 1 2 LONG 7 0607 132 1 OUTSIDE BELT SPREADER ASSY 8 1003 230 1 RUFF TOP RIBBON 3 x 126 W PIN 9 1003 198 1 RUFF TOP RIBBON 3 x...

Page 237: ...BBON 3 x 123 W PIN 17 0608 059 1 BELT SPREAD OUTSIDE 47 x 8 x 10 GA 18 0608 810 1 BELT SPREADER GUIDE BRACKET 19 2010 017 1 LOWER FRONT EXTENSION ARM INSIDE 20 B15 460 1 BUSHING 1 x 5 8 14 GA NARROW 2...

Page 238: ...511 1 BELT SPREADER BRKT 12 x 2 x 3 8 GA 6 B06 370 1 5 8 11 x 6 HX HD FULL THRD 7 0205 075 1 STRAIGHT CONNECTOR 1 8 NPT x 1 4 OD 8 0208 725 1 CYLINDER 1 1 16 BORE 5 8 STROKE NONRO 9 B10 200 2 10 32 HE...

Page 239: ...HD M S 6 B10 200 2 10 32 HEX NUT 7 0208 725 1 CYLINDER 1 1 16 BORE 5 8 STROKE NONRO 8 0205 075 1 STRAIGHT CONNECTOR 1 8 NPT x 1 4 OD 9 B06 370 1 5 8 11 x 6 HX HD FULL THRD 10 0605 511 1 BELT SPREADER...

Page 240: ...4 PH TR HD M S 6 B10 250 6 1 4 20 HEX NUT 7 1202 661 1 GEAR 36T 12 PITCH 1 BORE W KW 8 0608 812 2 CONVEYOR SHAFT MOUNTING BRACKET 9 0402 763 2 BEARING HANGER 1 BORE PERM LUBE 10 1210 184 1 SHAFT 1 OD...

Page 241: ...ANGER 1 BORE PERM LUBE 2 1003 182 4 RUBBERIZED RIBBON 2 x 25 3 4 W PIN 3 1003 183 4 ELASTIC RIBBON 2 x 6 1 4 W PIN 4 1210 172 1 SHAFT 1 DIA x 30 1 2 LONG W 9 RINGS 5 3407 212 1 TRANSFER CONVEYOR TABLE...

Page 242: ...63 4 BEARING HANGER 1 BORE PERM LUBE 3 1205 772 1 V BELT SHEAVE 2 1 2 OD 1 BORE 4 3209 424 2 RAW DRIVE ROLL 2 1 4 x 92 x 11 GA 5 1003 176 30 ELASTIC RIBBON 2 x 12 W PIN 6 3407 209 1 REJECT CONVEYOR TA...

Page 243: ...FER CONVEYOR TABLE ASSY 6 2814 023 1 L H SIDE MOTOR COVER 7 2007 161 1 BOTTOM REAR CONNECTING CHANNEL ASSY 8 3407 203 1 REJECT CONVEYOR ASSEMBLY 9 2814 025 1 BOTTOM CONVEYOR MOTOR COVER ASSY 10 2809 3...

Page 244: ...x35 3 4 x16 GA 2 S13 175 1 TUBING 1 1 4 SQ 11 GA 145 1 2 L 3 0608 691 1 IDLER ROLL BRACKET 3 x 6 1 4 x 10 GA 4 1205 231 1 IDLER ROLL 3 x 3 GROOVED W BEARING 5 4215 003 2 LOCKING WASHER 1 3 4 ODx5 8 I...

Page 245: ...2809 325 2 MOTOR 1 6 HP 90 RPM 5 1210 183 2 SHAFT 1 OD x 13 3 4 L W FULL KWAY 6 1205 229 2 DRIVE ROLL GROOVED W 1 BORE 3 x3 7 0402 763 4 BEARING HANGER 1 BORE PERM LUBE 8 1003 181 2 POLYFLAKE RIBBON...

Page 246: ...r Locations PE45R PE24 PE24 PX52 PX11 SPREADER RAIL TRANSFER RAIL PX32 PX28 PX31 PX27 PE45E PE23 PE13 PE1 PX29 PX25 PE17 PE5 PE50B PE19 PE50A PE7 PE20 PE8 PE22 PE21 PE10 PE9 PE2 PE14 R E R E R E R E T...

Page 247: ...ROUND 1607 610 PE20 Tail Sensor Right PHOTOSENSOR REFLECT 1607 630 PE21 Upper Wall Right PHOTOSENSOR DIFFUSE 1607 620 PE22 Lower Wall Right PHOTOSENSOR DIFFUSE 1607 620 PE23 Exit Gap PHOTOSENSOR BACKG...

Page 248: ...SV19 SV36 SV16 SV15 SV38 SV33 SV2 SV23 17 9 30 28 29 27 22 21 SPR 14 13 SPR SV SV11 SV34 SV24 SV12 SV35 SV11 SV37 SV35 SV24 SV16 SV SV23 SV15 SV12 SV36 SV19 SV20 SV34 SV33 SV2 9 17 30 28 29 27 22 21...

Page 249: ...Brake Valves VALVE IN LINE SPRING RETURN 1 4 OD 0202 450 0202 365 0202 500 SV21 Left Transfer Clamp VALVE MODULAR BANK 0202 355 0202 360 N A SV22 Right Transfer Clamp VALVE MODULAR BANK 0202 355 0202...

Page 250: ......

Page 251: ...d features Edge Maxx Schematics and Parts Motor Circuits 460V Motor Circuit SC 2 230V Motor Circuit SC 6 Control Circuits 24VAC Interlock Circuit SC 10 Display Control SC 12 Controller I O Sensors Val...

Page 252: ...SC 2 460V Motor Circuit TOC INDEX SC TOC...

Page 253: ...401 275 RELAY 1 POLE 24VAC DC CR54 1401 275 RELAY 1 POLE 24VAC DC CR55 1401 275 RELAY 1 POLE 24VAC DC CR56 1401 275 RELAY 1 POLE 24VAC DC CR57 1401 275 RELAY 1 POLE 24VAC DC DISC1 1402 650 SWITCH DISC...

Page 254: ...MTR5 2801 390 MOTOR 1 2 HP 3 60 230 460 1725RPM FR 56C MTR6 2801 390 MOTOR 1 2 HP 3 60 230 460 1725RPM FR 56C MTR7 2801 390 MOTOR 1 2 HP 3 60 230 460 1725RPM FR 56C MTR8 2809 325 MOTOR 1 6 HP 90 RPM...

Page 255: ...Edge Maxx 3210 393d SC 5 This page intentionally left blank TOC INDEX SC TOC...

Page 256: ...30 W T CON3 4 2 6 3 1 5 MP6 L31 L32 L33 MTR7 1 2HP 2 4 MP7 1 3 6 5 GND PWS1 24VDCI 00 0VDC 24VDC 2 5A U V GND R SVO S W T 2 4 MP8 1 3 6 5 CR31 GND MTR8 1 6HP 12 8 9 5 L40 L41 2 6 4 L43 1 6HP GND MTR9...

Page 257: ...401 275 RELAY 1 POLE 24VAC DC CR54 1401 275 RELAY 1 POLE 24VAC DC CR55 1401 275 RELAY 1 POLE 24VAC DC CR56 1401 275 RELAY 1 POLE 24VAC DC CR57 1401 275 RELAY 1 POLE 24VAC DC DISC1 1402 650 SWITCH DISC...

Page 258: ...801 390 MOTOR 1 2 HP 3 60 230 460 1725RPM FR 56C MTR5 2801 390 MOTOR 1 2 HP 3 60 230 460 1725RPM FR 56C MTR6 2801 390 MOTOR 1 2 HP 3 60 230 460 1725RPM FR 56C MTR7 2801 390 MOTOR 1 2 HP 3 60 230 460 1...

Page 259: ...Edge Maxx 3210 393d SC 9 This page purposely left blank TOC INDEX SC TOC...

Page 260: ...11 14 11 14 11 14 14 11 11 14 COM CR3 CR4 CR45 CR44 CR43 CR42 CR41 RIGHT SIDE E STOPS PB6 REAR FRONT PB5 PB3 LEFT RIGHT PB4 CENTER E STOPS PE45 PR45 CR45 CR43 PT43 PT44 CR44 CR42 PT42 PT41 CR41 A2 I1...

Page 261: ...OTOR PROTECTOR MP8A 1414 685 AUX CONTACT FOR MOTOR PROTECTOR PB1 1414 130 OPERATOR MUSHROOM HEAD TURN TO RELEASE PB1B 1414 135 MOUNTING BASE PB1C 1414 285 CONTACT BLOCK 1 N C SEALED PB2 1414 130 OPERA...

Page 262: ...14 RIGHT CORNER SENSOR 113 LEFT CORNER SENSOR 110 LOWER WALL SENSOR 109 UPPER WALL SENSOR 108 TAIL SENSOR 107 SPREAD CORNER SENSOR 106 AIR PRESSURE SWITCH 105 INLET LIFT SENSOR 104 reserved 103 reserv...

Page 263: ...INPUT 4x24VDC LO IC5 1406 748 INPUT 4x24VDC LO IC6 1406 748 INPUT 4x24VDC LO IC7 1406 748 INPUT 4x24VDC LO IC8 1406 748 INPUT 4x24VDC LO IC9 1406 748 INPUT 4x24VDC LO KYBD1 1611 020 PANEL MPC1 1612 6...

Page 264: ...R BLAST SV34 PX11 PE21 PE45R PE22 SPREAD TAIL P02 PE13E LEFT PE13R SV19 8 6 4 7 5 3 PE20 PE19 UPPER WALL LOWER WALL PE14E PE14R SV20 RIGHT CORNER ROLLER SENSING CONTROL CLUTCH BRAKE VALVES 2 1 CLUTCH...

Page 265: ...CABLE PE13R 1607 713 RECEIVER PE13R C 1607 714 RECEIVER CABLE 12 PE14E 1607 710 EMITTER PE14E C 1607 711 EMITTER CABLE PE14R 1607 713 RECEIVER PE14R C 1607 714 RECEIVER CABLE 12 PE17 1607 610 PHOTOSEN...

Page 266: ...R PE7 1607 610 PHOTOSENSOR BACKGROUND PE7 C 1607 680 CABLE 5 METER PE8 1607 630 PHOTOSENSOR REFLECT PE8 C 1607 670 CABLE 3 METER PE9 1607 620 PHOTOSENSOR DIFFUSE PE9 C 1607 670 CABLE 3 METER PS6 0203...

Page 267: ...AN4 AN3 LG COM TORQUE OVERRIDE B 2 B 1 B 1 B 12 B 2 B 11 S S taut sensors dark operate PE50B PE50A 54 53 E STOP CON4 move complete OUTPUT INPUT 133 134 135 136 TORQ LIMIT SYNC OUT PED ZEROPT ALARM 324...

Page 268: ...ER TRANSFER RIGHT FC14E FC14R FC13R FC13E RIGHT SPREAD CLAMP RIGHT LOWER CYL24 SV24 SV23 FC23E FC23R OPEN OPEN 4 2 5 1 3 1 5 3 4 2 FC15R FC15E OPEN SENSOR BLOWOFF UP DOWN 4 2 1 3 5 SV9 INLET CONVEYOR...

Page 269: ...3 4 BORE 2 STROKE CYL8 0208 430 AIR CYLINDER 3 4 BORE 2 STROKE CYL9 0208 428 AIR CYLINDER 3 4 BORE 2 STROKE W CUSH FC13E 0203 200 ELBOW FLOW CONTROL 1 8 NPT FC13R 0203 200 ELBOW FLOW CONTROL 1 8 NPT F...

Page 270: ...202 450 VALVE IN LINE SPRING RETURN 1 4 OD SV11C 0202 500 PLUG IN FOR AIR VALVE SV11S 0202 365 SOLENOID 24VDC FREE SV12 0202 450 VALVE IN LINE SPRING RETURN 1 4 OD SV12C 0202 500 PLUG IN FOR AIR VALVE...

Page 271: ...355 VALVE MODULAR BANK SV30S 0202 360 SOLENOID 24VDC BANK SV33 0202 080 VALVE SOL 24VDC SCH 25 SV34 0202 080 VALVE SOL 24VDC SCH 25 SV35 0202 450 VALVE IN LINE SPRING RETURN 1 4 OD SV35C 0202 500 PLUG...

Page 272: ...30 24VOUT 530 24VOUT 24VOUT 24VOUT 516 24VOUT 24VOUT AN1 AN1 AN1 AN1 1 2 C 14 NO 11 12 NC A1 A2 CR46 L40 L41 L30 L29 L28 L25 L26 L27 L21 L20 L15 L14 L19 L13 POWER GND P03 24V 24V 516 516 24VOUT 24VOUT...

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Page 277: ...kW 0 25 0 186 Exit conveyor HP kW 0 33 0 25 Upper spreader HP kW 1 0 0 745 Left floor HP kW 0 16 0 125 Right floor HP kW 0 16 0 125 Center floor HP kW 0 16 0 125 Bottom floor HP kW 0 16 0 125 Electri...

Page 278: ......

Page 279: ...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...

Page 280: ......

Page 281: ...4 20 Pneumatic Clutch Brake Roller Alignment 4 5 Safety Equipment 4 3 Setscrews 4 12 Topic continued on next page Symbols 24 VAC Outputs Testing CHI Panel C 13 A Additional Electrical Panel Control R...

Page 282: ...r Auto Drain 4 16 Corner Photosensors Installation 2 15 Clean and Lubricate Drive Chain 4 15 Clutch Brake Pneumatic About 5 15 Roller Alignment 7 7 Alignment Check 4 5 Drive Belt Tension Adjustment 7...

Page 283: ...Clutch Brake Roller 7 8 Reject Conveyor 7 39 Side Conveyor 7 36 Transfer Conveyor 7 33 Tension Spring Check Replacement Side Conveyor 7 37 Drive Chain Lubricate 4 15 E Easi Glide Option Installation...

Page 284: ...ing 6 14 Input Conveyor Installation 2 4 Inspect Air Filter Auto Drain 4 9 Drive Belts 4 14 Rodless Air Cylinders 4 7 Inspection Installation 2 3 Installation Procedures 2 3 Compressed Air Supply Conn...

Page 285: ...6 Operating Techniques 3 15 Gap Buster Feature 3 16 Maximum Ef ciency 3 15 Maximum Feeding Speed 3 16 Operation CHI Panel C 3 Controls and Indicators C 3 Counters C 6 Jam Detection C 6 Model Type Num...

Page 286: ...3 Safety Considerations 7 2 Ribbons Condition and Tension Check 4 11 Replacement Discharge Conveyor Broken or Missing Ribbons 7 27 Worn Ribbons 7 27 Discharge Conveyor Guide 7 28 Reject Conveyor 7 40...

Page 287: ...eed Control CHI Panel 3 13 C 5 Automatic 3 13 C 5 Manual 3 13 C 5 Spread Section 7 17 Lower Spreader Belt Gap Adjustment 7 23 Tension Check Replacement 7 22 Drive Belt Replacement 7 22 Tension Adjustm...

Page 288: ...acement 7 35 Drive Belt Tension Adjustment 7 33 Ribbon Tension Adjustment Replacement 7 34 Conveyor Drive Subsystem 5 20 Conveyor Gears Greasing 4 19 Convyeor Ribbons Condition and Tension Check 4 11...

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