DUO - STAR 20 (Steam Heater) Manual

Dear Customer,
Thank you for your purchase of CHICAGO equipment. This letter is to inform
you that a complete instruction manual was not available to ship with your
order.
To provide you with the most up-to-date information possible the following
section(s) are currently in the process of being revised or developed and may
be incomplete or missing:
 Manual Body (Chapters 1-7)  Stacker Section (Folders Only)

 CHI-Touch Bulletin  Bulletin body
✔ Parts List (for following reasons)
  Stacker Parts List
✔ Only partial available at time of shipping
  Only partial available at time of shipping
 Some parts may have changed  Some parts may have changed
(part updates not yet included) (part updates not yet included)
 Not available at time of shipping  Not available at time of shipping
 Schematics (for following reasons)  Stacker Schematics

 Wiring diagrams only  Wiring diagrams only
(no parts available at this time) (no parts available at this time)
 Some parts may have changed  Some parts may have changed
(part updates not yet included) (part updates not yet included)
 Not available at time of shipping  Not available at time of shipping
We have enclosed this letter to assure you, our valued customer, that any
missing information will be forwarded to you or your distributor at the earliest
available time, at no additional charge. Any available documentation on your
product has been included. We apologize for any inconvenience.
If you require assistance during installation and start-up or have any

questions about the operation or maintenance of your CHICAGO product,
please contact your local CHICAGO distributor or our factory service
department at www.chidry.com or (773) 235-4430. Have your Model and
Serial Number handy.
Sincerely,
CHICAGO DRYER COMPANY
3010343
Skyline S1-S20 Installation
INSTRUCTION MANUAL
DUO-STAR 20™
Steam Heated
Flatwork Ironer/Folder
©
Chicago Dryer Company
Instruction Manual #3015-017b
CHICAGO DRYER COMPANY

2200 N. Pulaski Road, Chicago, Illinois, USA 60639-3737
Telephone: (773) 235-4430 Fax: (773-235-4439) www.chidry.com
Duo-Star 20 Steam Table of Contents
TABLE OF CONTENTS
MANUAL
Chapter 1 - Introduction
Chapter 2 - Installation
Chapter 3 - Operating Guidelines
Chapter 4 - Preventive Maintenance
Chapter 5 - Operating Principles
Chapter 6 - Troubleshooting
Chapter 7 - Repair
CHI PANEL OPERATION
PICTURE PARTS LIST
SCHEMATICS LIST
APPENDIX
Floor Plans
Technical Specifications
Manufacturer’s Bulletins
Torque Specifications
Operating Standard
INDEX
TOC INDEX i
Table of Contents Duo-Star 20 Steam
CHAPTER 1 INTRODUCTION
1.1 Warranty................................................................................................... 1-2
1.2 Scope of the Manual................................................................................ 1-2
1.3 Safety....................................................................................................... 1-3

Safe Work Habits..................................................................................... 1-3
Safety Features........................................................................................ 1-4
ii TOC INDEX
CHAPTER 2 INSTALLATION
2.1 Site and Utility Requirements................................................................... 2-2
2.2 Installation Procedures............................................................................. 2-3

Inspection................................................................................................. 2-3
Uncrating and Positioning........................................................................ 2-4
Exhaust Blower Installation...................................................................... 2-5
Compressed Air Supply Connection........................................................ 2-8
Electrical Connection............................................................................... 2-8
Steam Connection.................................................................................. 2-12
Receiving Shelf Set-Up.......................................................................... 2-15
Final Protective Wrapper Removal......................................................... 2-15
2.3 Pre-Operational Checkout...................................................................... 2-16

Security of Hardware.............................................................................. 2-16
Compressed Air Supply Checkout......................................................... 2-18
Electrical Connection Checkout............................................................. 2-19
Safety Device and Control Function Checkout...................................... 2-20
Ironing Cylinder Paper Removal............................................................ 2-22
Heating Operation Checkout.................................................................. 2-22
Fold System Checkout........................................................................... 2-24
Checkout Completion............................................................................. 2-25
Cleaning the Unit.................................................................................... 2-25
TOC INDEX iii

CHAPTER 3 OPERATING GUIDELINES

3.1 Safety Features........................................................................................ 3-2
Main Disconnect Switch........................................................................... 3-2
Safety Stop Buttons................................................................................. 3-2
Safety Guards.......................................................................................... 3-3
Safety Interlock Switches......................................................................... 3-3
Safety Labels........................................................................................... 3-3
3.2 Operating Controls................................................................................... 3-4

Right Endframe Controls.......................................................................... 3-4
CHI Panel................................................................................................. 3-6
3.3 Standard Operating Procedures.............................................................. 3-7

Start-Up.................................................................................................... 3-7
Waxing..................................................................................................... 3-8
Flatwork Handling.................................................................................. 3-10
Clearing a Jam Safely.............................................................................3-11
Fold Operation....................................................................................... 3-12
Shut-Down............................................................................................. 3-14
3.4 Operating Techniques............................................................................ 3-14

Conditioning Flatwork Before Ironing..................................................... 3-15
Unit Settings........................................................................................... 3-16
Processing Standards............................................................................ 3-17
Maximum Productivity............................................................................ 3-18
iv TOC INDEX
CHAPTER 4 PREVENTIVE MAINTENANCE

PM Task Tables................................................................................................... 4-1
Daily, Weekly Tasks.................................................................................. 4-1
Monthly, Semi-Annual Tasks.................................................................... 4-2
4.1 Daily PM (8 Hours)................................................................................... 4-3

Watch and Listen for Anything Abnormal................................................. 4-3
General Cleanliness................................................................................. 4-3
Check and Clean Photosensors............................................................... 4-4
Check Guide Tapes.................................................................................. 4-4
Check Safety Equipment.......................................................................... 4-4
Wax Ironing Cylinder................................................................................ 4-4
4.2 Weekly PM (50 Hours)............................................................................. 4-5

Check Ironing Cylinder............................................................................. 4-5
Clean Behind Service Panels................................................................... 4-6
Inspect Air Filter/Auto Drain..................................................................... 4-6
Check Air Pressure Settings.................................................................... 4-7
Check and Clean Inverter........................................................................ 4-8
Grease “Weekly” Bearings....................................................................... 4-9
Oil Roll Bearing Pivots............................................................................4-11
Check and Clean Motors........................................................................ 4-12
Check and Clean Exhaust Blower Wheel.............................................. 4-12
Check Ribbon Condition and Tension.................................................... 4-13
4.3 Monthly PM (200 Hours)........................................................................ 4-14

Grease Bearings.................................................................................... 4-14
Check Setscrews................................................................................... 4-15
Oil Drive Chain and Tension Springs...................................................... 4-16
Check Compression Roll Pressure and Cover Condition...................... 4-17
4.4 Semi-Annual PM (1000 Hours).............................................................. 4-17

Clean Air Filter/Auto Drain...................................................................... 4-18
Grease Flatwork Transfer Guide............................................................ 4-19
Check Mechanical and Electrical Connections...................................... 4-19
TOC INDEX v
CHAPTER 5 OPERATING PRINCIPLES

Safety ................................................................................................................. 5-2
5.1 Electrical System...................................................................................... 5-2

Power System.......................................................................................... 5-2
Control System......................................................................................... 5-6
5.2 Compressed Air System......................................................................... 5-10

Air Filter/Regulators............................................................................... 5-10
Air Reservoirs......................................................................................... 5-10
Air Valves............................................................................................... 5-10
Air Cylinder..............................................................................................5-11
Air Bars....................................................................................................5-11
5.3 Mechanical System................................................................................ 5-12

Ironer Drive System................................................................................ 5-12
Transfer/Primary Fold/Delivery Drive System........................................ 5-13
Ribbon Sets............................................................................................ 5-14
5.4 Heating and Exhaust Systems............................................................... 5-15

Rotary Union.......................................................................................... 5-16
Siphon Tube........................................................................................... 5-17
5.5 Sequence of Operation.......................................................................... 5-18

Stand-By Stage...................................................................................... 5-18
JOG Operation Stage............................................................................. 5-18
Mechanical Start-Up Stage.................................................................... 5-19
Heating System Operation Stage........................................................... 5-20
Primary Fold Operation Stage................................................................ 5-21
vi TOC INDEX
CHAPTER 6 TROUBLESHOOTING
Troubleshooting Symptoms................................................................................ 6-2
6.1 LED Diagnostics....................................................................................... 6-6
6.2 Electrical................................................................................................... 6-8
6.3 Mechanical System.................................................................................6-11
6.4 Ironing Quality........................................................................................ 6-14
6.5 Heating System...................................................................................... 6-17
6.6 Exhaust System..................................................................................... 6-18
6.7 Primary Folding...................................................................................... 6-19
6.8 CHI Panel............................................................................................... 6-22
6.9 Sensor Function..................................................................................... 6-23
TOC INDEX vii

CHAPTER 7 REPAIR
7.1 Safety Considerations.............................................................................. 7-2
7.2 Parts Availability....................................................................................... 7-3
7.3 Feed Section............................................................................................ 7-4

Feed Ribbon Tension Adjustment............................................................. 7-4
Feed Ribbon Replacement...................................................................... 7-6
Feed Ribbon Drive Roll Friction Material Replacement........................... 7-8
Guide Tape Replacement........................................................................7-11
Doffer Roll Cover Replacement.............................................................. 7-14
Feed Table Alignment and Positioning................................................... 7-16
7.4 Compression Roll................................................................................... 7-19

Compression Roll Pressure Check........................................................ 7-20
Compression Roll Pressure Adjustment................................................. 7-21
Compression Roll Cover Replacement.................................................. 7-21
7.5 Ironing Section....................................................................................... 7-26

Main Drive Chain Tension Adjustment.................................................... 7-26
Ironing Cylinder Reconditioning............................................................. 7-27
7.6 Rotary Union Maintenance..................................................................... 7-30

Areas of Wear........................................................................................ 7-30
Disassembling the Rotary Union............................................................ 7-31
Inspecting the Rotary Union................................................................... 7-33
Repairing the Rotary Union.................................................................... 7-34
Replacing the Rotary Union................................................................... 7-34
7.7 Return Section....................................................................................... 7-36

Return Ribbon Tension Adjustment........................................................ 7-37
Return Ribbon Replacement.................................................................. 7-38
Return Ribbon Drive Roll Friction Material Replacement....................... 7-41
Repair topics continued on the next page...
viii TOC INDEX

7.8 Primary Fold/Delivery Sections.............................................................. 7-44

Flatwork Transfer Guide Mechanical Adjustment................................... 7-45
Transfer Ribbon Tension Adjustment..................................................... 7-45
Transfer Ribbon Replacement............................................................... 7-46
Intermediate Ribbon Replacement......................................................... 7-48
Delivery Ribbon Tension Adjustment...................................................... 7-50
Delivery Ribbon Replacement................................................................ 7-52
Transfer Ribbon/ Delivery Drive Chain Tension Adjustment................... 7-54
Transfer, Intermediate and Delivery Rolls Tracking Tape
Replacement.......................................................................................... 7-55
7.9 Sensors.................................................................................................. 7-57

Ironer Inlet and Second Primary Fold Photosensor Sensitivity
Adjustment............................................................................................. 7-57
First Primary Fold Photosensor Sensitivity Adjustment.......................... 7-58
First Primary Fold Photosensor Position Alignment............................... 7-59
Photosensor Replacement..................................................................... 7-60
Machine Speed Sensor Position Adjustment......................................... 7-61
Machine Speed Sensor Replacement.................................................... 7-62

Air Bar Alignment................................................................................... 7-63
Transfer Guide Air Cylinders Air Flow Adjustment.................................. 7-64
Air Valve Repair...................................................................................... 7-65
TOC INDEX ix
Duo-Star 20 Steam Introduction
Chapter 1
INTRODUCTION
This chapter contains the following sections:
1.1 Warranty
1.2 Scope of the Manual
1.3 Safety
The Duo-Star 20™ Steam-Heated Flatwork Ironer (Figure 1-1) is a one-piece unit that dries, irons,
and folds sheets, pillowcases, table linen, and other types of flatwork. The unit processes polyester/cotton
blends, VISA®, or all-cotton fabrics. The unit is available in standard 1-lane or an optional 4-lane model,
giving items one or two primary folds. All of the flatwork is returned to the front receiving shelf. This
unit is not designed to process anything other than flatwork.
Like the rest of the CHICAGO® product line, the Duo-Star 20 Steam is designed, manufactured, and
assembled in Chicago, Illinois. Before the CHICAGO® nameplate is affixed to any machine, a final
inspection is performed, including thorough testing under load conditions.
Any questions concerning the installation, operation, or repair of the Duo-Star 20 Steam ironer should
be directed to your local authorized CHICAGO® dealer or:
 Chicago Dryer Company  (773) 235-4430

2200 North Pulaski Road Fax (773) 235-4439
Chicago, Illinois 60639-3737 E-mail service@chidry.com
Figure 1-1: The Duo-Star 20 Steam provides high quality flatwork finishing.
TOC INDEX 1-1

Introduction Duo-Star 20 Steam
Follow these procedures to keep the unit

1.1 Warranty operating safely and at maximum efficiency. A
A full page warranty statement is included in Preventive Maintenance Schedule is located at
this Instruction Manual. Please take the time to the front of this chapter.
review this warranty and understand its provisions.
Chapter 5 - Operating Principles
1.2 Scope of the Manual Describes the operation of the unit in detail. A
good understanding of this chapter will help avoid
This instruction manual will help you keep
operation errors and assist with troubleshooting
your CHICAGO® Duo-Star 20 Steam ironer
and maintenance.
operating safely, efficiently, and with minimum
expense. Individual chapters in this manual
provide the necessary information required
Chapter 6 - Troubleshooting
for safe installation, operation, maintenance, Contains issues, possible causes, and solutions
troubleshooting, and repair. in all areas of operation.
Updates Chapter 7 - Repair

Occasionally, new information about the unit Contains procedures for making adjustments,
becomes available after the publication of this repairs and parts replacement for the unit. Please
manual. If you receive a CHICAGO® FYI Service follow all safety recommendations carefully.
Bulletin pertaining to your unit, insert the bulletin
in the front of the manual. CHI Panel Operation
Describes in detail the operation of the CHI Panel
Chapter 1 - Introduction
fold control system. Fold system programming,
Provides an overview of the unit and its key adjustment and test modes are detailed.
features, of this manual, and of important safety
features. Parts List
Contains detailed drawings and part
Chapter 2 - Installation
specifications to assist in ordering replacement
Describes recommended procedures for parts. It is divided into views in which the parts
determining a suitable location for the unit and are grouped by function.
connecting the utilities. This chapter also includes
checkout procedures to ensure all systems are Schematics
working properly. Local requirements often vary,
Contains electrical drawings showing power
so follow local codes at all times.
and motor circuits, control and interlock circuits,
and other relevant drawings, including part
Chapter 3 - Operating Guidelines
specifications.
Gives recommendations for operating the unit
at maximum efficiency. This chapter includes Appendix
instructions for operators and suggestions for
Contains Technical Specifications, a Floor
work organization.
Plan, manufacturer’s bulletins, and other relevant
information for the unit.
Chapter 4 - Preventive Maintenance
Contains procedures for Daily, Weekly, Index
Monthly, Semi-Annual, and Annual
Contains an alphabetical listing/cross-
maintenance.
reference of all topics and procedures within
this Instruction Manual.
1-2 TOC INDEX

Maintenance and Repair

1.3 Safety
Safe operation and maintenance of the unit WARNING
must be the first priority of all supervisors,
Always use extreme caution
operators, and maintenance personnel. Safety
when performing any
begins with safe work habits. In addition, the
unit is equipped with built-in safety features for repairs that require the unit
protection. to be operating.
Keep hands and loose

Safe Work Habits clothing from coming into
contact with any of the
During Daily Operation moving parts.
• Take the flatwork only after it has Serious Injury Could Result.
cleared the unit. Do not pull on the
finished flatwork while it is still in the When the unit is running,
machine. one person should be ready
at a red safety STOP button
• Post the “Operator Safety” reminders at all times to
in a place where everyone will see it.
stop the unit if necessary.
Read these reminders and follow the
recommendations.
Before attempting any repair work, review
• Read and follow all safety labels.
these safety steps and precautions to protect
• Keep hands and clothing away from the yourself and the machine.
moving parts of the ironer while it is
• Safety should be the primary concern
operating.
of anyone performing corrective
• Always turn off the unit before clearing maintenance.
a jam.
• Except where specifically directed, make
• Operate the unit only with all guards and sure that the main disconnect switch to
endframe doors in place and all safety incoming power is OFF and the machine
features operating correctly. Never completely COOL.
operate the unit with any safety features
• It is recommended that all maintenance
bypassed.
procedures be handled by at least two
• Never stand, sit, or kneel on a receiving qualified persons. Using the “buddy
shelf. system” facilitates a quicker procedure
and decreases the risk of an accident.
• Your site should have procedures that

comply with government regulations and
standards for equipment lockout/tagout
during maintenance and repair. Ask your
supervisor for specific information. It
is the users’ responsibility to make sure
they comply with all safety procedures.
TOC INDEX 1-3

Safety Features
WARNING
Know the proper There are six categories of safety features:
procedure for locking out • Main Disconnect Switch
and tagging equipment
during repair procedures. • Safety Stop Buttons
• Safety Guards
Follow the rules of your work
• Safety Interlock Switches
site. Failure to do so could
result in serious injury. • Safety Labels
• Safety Messages in this Manual
Make sure the power is
disconnected before
servicing the unit. Main Disconnect Switch
The main disconnect switch is located on the

Do not repair or correct any outside of right endframe door. When turned to
condition without reading OFF, the main disconnect switch shuts off the
and understanding the incoming electrical power to the unit.
REPAIR chapter.
Unless otherwise indicated, turn the main
disconnect switch to OFF before performing any
Only qualified personnel
maintenance or repair work.
should troubleshoot and
repair this unit.
Safety Stop Buttons
There are four red safety STOP buttons located

at each corner of the unit.
Pressing any of these buttons immediately

stops all moving parts, and locks out operation
of the machine. A fault message appears in the
CHI Panel. Twist to release/reset a pressed STOP
button.
The preferred method of stopping the operation

of the unit is by pressing the red STOP button.
1-4 TOC INDEX

Safety Guards Safety Labels
A red safety finger guard covers the moving WARNING (orange) and CAUTION (yellow)
parts at the front of the unit. It runs the entire labels (Figure 1-2) are placed at locations around
length of the unit’s working area and physically the unit to keep operators and maintenance
restricts hands from coming into contact with personnel alert in particular areas.
moving and heated parts. Pushing the safety
finger guard stops all moving parts, and locks WARNING labels alert personnel that
out operation of the machine. A fault message personal injury may result from not following
appears in the CHI Panel. recommended procedures.
Both endframes and the rear of the unit are CAUTION labels alert personnel the unit
covered with protective doors and panels to may be damaged if conditions, practices, or
prevent fingers or hands from coming into contact procedures are not observed.
with moving and heated parts. Opening a door or
When training operators, take the time to
removing a panel immediately stops all rotating
locate, review, and understand all areas where
parts.
labels are posted.
Safety Interlock Switches

NOTE: Do not remove safety
Safety interlock switches are located inside labels at any time. If a label
each endframe and behind the protective panels needs to be replaced, contact
at the rear of the unit. If any of these is opened Chicago Dryer Company for free
or removed, the interlock switch at that location replacements.
is disconnected, all rotating parts stop moving.
These switches are not intended to lockout

the unit. Site management is responsible for
developing and implementing procedures that
follow government standards for lockout/tagout
when servicing the unit.
Figure 1-2: Safety labels remind operators and

maintenance personnel that care must
be taken when working near these areas.
TOC INDEX 1-5

Safety Messages in this Manual
WARNING and CAUTION messages appear

in this manual to highlight essential safety
information.
WARNING messages alert personnel that

personal injury may result from not following
recommended procedures.
WARNING
Never operate the unit unless
all safety covers are in place
and all safety equipment is
working correctly.
BLACK BOX WARNING messages alert

personnel of the operating condition a unit
must be in before performing any procedure.
Personal injury may result from not following
recommended procedures.
Perform only when the unit is OFF

with power disconnected and COOL.
CAUTION messages alert personnel that the

unit may be damaged if conditions, practices,
or procedures are not observed.
CAUTION
Never use compressed air
on or around electronic
components. Doing so may
damage them.
1-6 TOC INDEX

Duo-Star 20 Steam Installation
Chapter 2
INSTALLATION
This chapter contains installation instructions for the Duo-Star 20™ Steam and includes the following
sections:
2.1 Site and Utility Requirements
2.2 Installation Procedures
2.3 Pre-Operational Checkout
The unit was tested under load conditions at the factory and inspected to ensure proper operation. It
was shipped in working condition and is completely assembled except for the receiving shelves and the
exhaust blower assembly. Sufficient strapping, blocking, and bracing were provided to give reasonable
assurance that no shipping damage would occur.
NOTE: If the unit is received in damaged condition, notify the carrier at once.
Chicago Dryer Company’s responsibility for shipping damage, other than the standard warranty,
ceases upon delivery to the carrier. For more information on the warranty, see the full page warranty
statement at the front of this manual.
TOC INDEX 2-1

Installation Duo-Star 20 Steam
Shimming of the endframes is generally

2.1 Site and Utility needed to level the unit. No special foundation,
Requirements floor grouting, or installation of anchors is
required. However, floor grouting or installation
Figure 2-1 shows the clearance requirements of anchors may be required to comply with local
for the unit. These are the minimum dimensions codes or aboard a ship.
recommended for efficient production, service,
and maintenance access. A short run of 10” (DN 250) diameter vent
ducting must be supplied locally for the exhaust
blower and canopy. Adequate ventilation
NOTE: The location of the unit
is required. For more information, refer to
is extremely important.
Ventilating the Work Area on page 2-7.
The site should have a relatively level,

sturdy floor capable of supporting the unit’s
weight without significant flexing. For weight
specifications, refer to APPENDIX: Technical
Specifications.
36” (915 mm)
36” (615 mm) 36” (615 mm)
Figure 2-1: Recommended clearances for installation.
2-2 TOC INDEX

The electrical requirements of the unit are

shown on the nameplate (Figure 2-2), located 2.2 Installation
on the back of the right endframe. Wiring and a Procedures
separate, fused disconnect switch of suitable size
must be locally supplied if local codes require Installation procedures of the unit include the
one. following.
Check local codes for clearance requirements • Inspection

to any electrical box. For more information, refer • Uncrating and Positioning
to APPENDIX: Technical Specifications.
• Exhaust Blower Installation
Each unit has specific steam requirements;
verify the local steam supply matches the steam • Compressed Air Supply Connection
requirements specified on the unit’s nameplate. • Electrical Connection
For more information, refer to APPENDIX:
Technical Specifications. • Steam Connection
Compressed air provided for the unit must be • Receiving Shelf Set-Up
clean and dry. This is very important because the • Final Protective Wrapper Removal
air will blow directly on the flatwork.
The compressed air must meet the pressure Inspection

and air flow requirements. For more information,
refer to APPENDIX: Technical Specifications. Carefully inspect all shipments before they are
accepted from the carrier. Upon delivery, make
sure all items listed on the bill have been received.
Any shortage, breakage, or damage noticed at

the time of delivery should be indicated on the
carrier’s freight bill and signed by the driver or
carrier’s representative.
Damage noticed after delivery should be

reported to the carrier at once. Request their
inspection of the shipment, and fill out a
concealed damage inspection report.
NOTE: N o t i f y t h e c a r r i e r
immediately if any damage has
been done to the unit during
shipment.
Figure 2-2: The nameplate contains important
information.
TOC INDEX 2-3

Uncrating and Positioning 3. Open both endframe doors and remove

any materials shipped with the unit. Close
Required Tools and secure the doors.
Crowbar
Forklift CAUTION
Screwdriver The unit should only be
Sledgehammer
Wire cutter/knife moved by qualified riggers
Wrenches: 9/16” or 3/4” using proper equipment.
1. Before unpacking the unit, make sure the

4. With the unit still on its skid, move it into
proposed site is acceptable and necessary
approximate position. Remove the bolts
foundations have been prepared. For more
which secure the unit to the skid.
information, refer to Site and Utility Re-
quirements on page 2-2.
CAUTION
2. Remove the crating, strapping, and other Do not drop or twist the unit.
packaging materials except the guide tapes
(Figure 2-3), the protective plastic cover
and the brown paper on the ironing cyl- 5. As appropriate, using care not to drop or
inder. These protective coverings should twist the unit:
be left in place so the unit remains clean
until it is ready to use. • If the unit is equipped with eye bolts,
lift the unit straight up using the two
eye bolts on top of each endframe and
carefully remove the skid from under it.
• OR
• Lift one endframe and carefully re-

move the skid from under it and then
repeat for the other endframe.
6. The endframes of the unit should rest

firmly on the floor. If necessary, add shims
to level the unit. Secure the unit to its
foundation, if required by local code or
conditions. For use aboard a ship, the unit
Figure 2-3: Do not remove the guide tapes when may be welded at the foot pads.
removing the shipping materials.
7. After the unit is placed and secured, re-
move the plastic covers from the unit. Do
not remove the guide tapes or the brown
paper on the ironing cylinder.
2-4 TOC INDEX

8. Remove the following items (Figure 2-4) Exhaust Blower Installation

from the box removed from the endframe:
The exhaust canopy includes a blower to expel
• One grease gun (A) excess heated air and moisture. This system
contributes to the safety and comfort of operating
• One 14 oz. (400 g) cartridge of high personnel, proper operation of the ironing section,
temperature grease (B) and reduction of maintenance time.
• One 1 lb. (450 g) can of powdered wax All labor and materials required for venting
(C)--not included with Chrome ironing the unit are a local responsibility. Comply with
cylinder option local codes and regulations for proper installation.
• One Instruction Manual (D)
Ductwork
• One steam trap (E)
The 10” (DN 250) diameter ductwork for the
• One roll of guide tape (F) exhaust blower and all associated hardware for
the exhaust system must be locally supplied.
• One roll of Nomex tie tape (G)
Follow local codes and good engineering
practice to design the exhaust system. Every
effort should be made to keep the ductwork as
short and straight as possible.
D Check the canopy nameplate for the maximum

C length of ductwork. For longer runs, a booster
B blower may be required. Do not use elbows
greater than a 45° angle in the exhaust ducting.
If the blower vent ducting is to be connected

E to a larger duct for outside venting, consult a
F
A G ventilation expert to ensure proper installation
and operation.
Figure 2-4: Several items are supplied with each

unit.
TOC INDEX 2-5

Locating the Exhaust Blower Installing the Exhaust Blower
NOTE: Proper installation is Required Tools

required for all warranties and Wrench: 9/16”
applicable certification labels to be
valid. Call the factory if you have 1. Remove the four bolts by the 10” (DN
any questions. 250) opening at the center of the canopy
(Figure 2-5, A).
2. Position the exhaust blower so that its

CAUTION input (Figure 2-6, B) directly aligns with
Do not reverse the the canopy exhaust opening (Figure 2-5,
blower housing. B). Secure the blower in place with the
bolts removed in Step 1.
The exhaust blower is designed for vertical

installation directly on top of the exhaust canopy
(Figure 2-5). Remote mounting is possible if there
are height limitations or to reduce noise.
B
It is particularly important that a straight
section of ductwork be attached directly to the
blower discharge (Figure 2-6, A).
When installed, a blower can be rotated up to A

45° to the left or right of vertical to help make C
this configuration.
Figure 2-5: Position each blower so that its input

NOTE: Exceeding a 45° rotation is directly in line with the canopy
from vertical for the blower may exhaust opening (B).
not maintain proper air movement.
Figure 2-6: The exhaust blower assemblies are

mounted on top of the exhaust canopy.
2-6 TOC INDEX

3. For remote installation: Ventilating the Work Area
a) The exhaust blower assembly must be

mounted VERTICALLY within 15 ft WARNING
(5 m) of the unit to maintain proper The room housing the unit
air movement. must be provided with
adequate make-up air to
b) Mount the exhaust blower assembly ensure operator safety as
using heavy anchors or mountings
well as the proper operation
screws.
of the ironing section and
c) Extend 10” (DN 250) round exhaust other fuel-burning equipment
ducting from the canopy discharge to in the area.
the exhaust blower inlet.
4. Extend the 10” (DN 250) round exhaust A permanent fresh air supply or natural air
ducting from the exhaust blower output ventilation is required for the unit. Check local
to the outside discharge point, making regulations to determine the exact makeup air
the length of the run as short and straight requirements. Follow local codes at all times.
as possible.
The discharge must be properly designed to

maintain the required air flow:
• To ensure the correct removal of by-

products, it is recommended that the
unit be connected to a separate exhaust
system.
• The discharge must be protected from

backdrafts and precipitation.
• No screen or filter should be connected

at the discharge unless it is connected to
a commercial lint collector.
TOC INDEX 2-7

Compressed Air Supply Connection Electrical Connection

The unit requires a compressed air supply to
raise and lower the compression rolls and to fold CAUTION
flatwork. The air must be clean and dry. This is The incoming electric
very important because air will blow directly on power service must match
the flatwork. the specific electrical
requirements shown
The compressed air supply must meet the
pressure and airflow requirements noted in
on the nameplate.
APPENDIX: Technical Specifications.
The nameplate (Figure 2-2), located on the
The incoming air connection is made at the rear
back of the right endframe, shows the electrical
of the right endframe (Figure 2-7 A); the drain
requirements of the unit. All labor and materials
connection directly to the filter/drain/regulator
required to bring the electrical service to the unit
unit inside the right endframe (B).
are a local responsibility.
The compressed air supply should be equipped
All electrical wiring must comply with local
with a separate shut-off valve and a dirt leg with
codes, and a qualified electrician should size the
a drain cock, supplied locally.
wiring.
Required Tools Refer to the nameplate to determine the power

Teflon tape/pipe thread compound supply requirements. If high or low voltage
Wrench: 7/8” is suspected, check the electrical service to
determine the actual voltage conditions.
1. Run copper tubing, or a sturdy flexible
Improper or fluctuating voltage will cause the
hose, if preferred, from the external source
safety systems to possibly damage motors and
to the 1/2” (DN 15) inlet fitting (Figure 2-7
other electrical system components, and void the
A). Use Teflon tape or pipe thread com-
factory warranty.
pound to assure leak proof connections.
2. Run tubing from the drain fitting (Figure NOTE: A fused, main disconnect
2-7 B) to an open drain, such as a floor switch has been incorporated into
drain. Use Teflon tape or pipe thread com- the right endframe door. Check
pound to assure leak proof connections. local regulations to determine
whether a separate external fused
disconnect switch is still required.
A Follow local codes at all times.
Figure 2-7: The compressed air supply connection

is at the rear of the right endframe.
2-8 TOC INDEX

Exhaust Blower Motor

C
Required Tools A
Allen wrench: 3/16”
Screwdriver
Wire cutter/stripper
Wire nuts
B
1. Open wiring box cover to the exhaust
blower (Figure 2-8, A).
2. Bring the wires from the exhaust blower

greenfield (Figure 2-5, C) into the wiring
box and attach the greenfield to the box. Figure 2-8: The exhaust blower motor must be
connected in the wiring box.
3. Follow the label on the wiring box cover
(Figure 2-8, B) on the motor case to wire
for high or low voltage as appropriate.
• Make sure to connect the grounding

wire to the lug (C). B
• Use wire nuts to secure the connec-

tions.
4. Replace the wiring box cover.
5. The main disconnect switch is located on A

the right endframe door. Turn it to the OFF
position (Figure 2-9, A).
Figure 2-9: The main disconnect switch is located
6. Turn the door latch (Figure 2-9, B) on the on the right endframe door.
right endframe door and open the door.
7. Remove the terminal box cover at the rear

of the right endframe (Figure 2-10).
Figure 2-10: Remove the terminal box cover to

wire the exhaust blower and incoming
power.
TOC INDEX 2-9

8. The greenfield for the exhaust blower mo-

tor is routed through clips on the top rear of
the canopy (Figure 2-11, A). If the exhaust
blower has been mounted remotely, the
electrical wires must be extended from the A
remote location to the unit through conduit
or Greenfield.
C
9. Bring the greenfield down the back of the
right endframe and secure to the connec- B
tion point (Figure 2-11, B).
10. The electrical connections for the exhaust

blower motor are made in the terminal box Figure 2-11: Bring the exhaust blower greenfield to
at the rear of the right endframe: the right rear endframe.
a) Connect the power wires for the ex-

haust blower motor to terminals L16,
L17, and L18 on the left side of the
strip (Figure 2-12, A).
b) Connect the green fourth wire to the

grounding terminal G on the left side B
A
of the strip.
Figure 2-12: Terminal box connections.
2-10 TOC INDEX

Main Power Connection 5. Remove the temporary wires and connect

the three power supply wires to terminals
L1, L2, and L3 and the green fourth wire
WARNING to the grounding terminal G on the right
Only a qualified electrician side of the strip (Figure 2-12, B).
should make the electrical
connections to the unit.
Improper installation could WARNING
result in serious injury. The machine must be
properly grounded to ensure
operator safety.
Required Tools
Screwdriver 6. Make sure the other end of the ground
Wire cutter/stripper wire is connected to a proper earth ground.
1. Bring the supply lines to the connection 7. After all electrical connections have been
point at the rear of the right endframe (Fig- made, replace the terminal box cover.
ure 2-11, C). Use three wires for the power
8. Close and secure the right endframe door.
supply and a green fourth wire for ground.
2. Extend the lines through conduit or green- CAUTION

field.
Do not attempt to start the
3. Temporary wires can be seen extending machine at this time. Leave
from the connection point. Pull these wires the disconnect switch OFF.
back through the hole and out of the way.
4. Pull the external wiring through the hole

and secure the conduit or greenfield to the
endframe.
TOC INDEX 2-11

Steam Connection The steam connection to the unit is made at the

back of the left endframe. A 1” (DN 25) steam
supply connection (Figure 2-13, A) and a 3/4”
CAUTION (DN 20) condensate return connection (B) are
The steam supply must provided. The steam trap is supplied with the
match the specific ironing unit. Other components must be locally supplied.
section steam requirements
as specified in APPENDIX:
Technical Specifications. NOTE: Pipe joint compound or
tape is required on all steam line
connections to ensure a leakproof
The nameplate (Figure 2-2), located on the installation. Comply with local
back of the left endframe shows the maximum codes.
steam pressure of the unit. See APPENDIX:
Technical Specifications for steam requirements.
Comply with local codes and regulations for
proper installation.
All labor and materials required for the steam

connection to the unit are a local responsibility.
Local codes and regulations must be followed for
proper installation.
Carefully consider the steam piping runs before

you begin. The heating system is controlled with
these valves. That means that the operator will
have to be able to reach these valves for every
A
start-up and shut-down. Make the valves as easy
to reach as possible.
B
Insulation on all steam piping is recommended.
This will promote safety for operators and
maintenance personnel, and will increase the
efficiency of the unit. Only insulating materials
approved for steam piping should be used.
Comply with local codes.
WARNING
Only qualified personnel Figure 2-13: The steam connections are made at the
should make the steam and back of the left endframe.
condensate connections to
the unit. Improper installation
could result in serious injury.
2-12 TOC INDEX

Condensate (Steam Return) Piping 2. Begin the condensate return assembly by

Installation connecting the short nipples (J and L) to
each side of the steam trap (K).
Required Tools
Pipe thread compound CAUTION
Pipe wrench The steam trap must
be installed so that the flow
All components used must be full size. All
of steam is in the same
components can be locally supplied or are
available as an option with the unit. direction as the arrow
on the unit.
• For safety and efficiency, all pipes
should be insulated and they must be the
correct size. 3. Carefully note the direction of the arrow
on the steam trap. Attach the strainer (F)
• The trap, which is included with the on the inlet side (the tail of the arrow).
ironer, must be level and must be The branch leg should be on the bottom
installed in the correct direction. of the strainer.
• The strainer and check valve, which 4. Connect a short nipple (E) and a male
may be obtained either locally or as an union (D) to the inlet side of the strainer
option, must be installed correctly. (F).
• The shut-off valve must be accessible 5. On the branch leg of the strainer (F), con-
for startup and shutdown. nect a 45° 3/4” street elbow (G).
• Sealant must be applied to all joints.
6. Connect a short 3/4” nipple (H) to the
1. Connect a short 3/4” nipple (Figure 2-14, street elbow.
B) and a female union (C) to the steam
return (condensate) coupling (A) in the 7. Connect a 3/4” blow down valve (I) on
back of the left endframe. the short nipple above. This completes the
piping on the inlet side of the steam trap.
R Q P O N M L K J F E D C B A
Unit
G Endframe
Figure 2-14: The steam condensate return piping.
TOC INDEX 2-13

8. Attach the check valve (M) on the outlet Steam Supply Piping Installation
side of the steam trap (the point of the
arrow). Be careful to install the check All components used must be full size.
valve correctly. Components can be locally supplied, or are
available as an option with the unit.
CAUTION 1. Connect a short nipple (Figure 2-15,

The check valve must B) and female union (C) to the steam
be installed so that the inlet coupling (A) in the back of the left
inlet and discharge are endframe.
correctly aligned. 2. Make up an assembly with the steam
shut-off valve (F). Connect a short nipple
(E) to this valve, and a male union (D) to
9. Connect a short nipple (N) and a female
the nipple.
union (O) to the discharge side of the
check valve. 3. The male union (D) on the steam shut-off
valve assembly just completed should now
CAUTION be connected to the female union (C) on
the steam supply piping.
The steam trap must be level.
It will not function properly if 4. Connect the boiler steam supply piping to
it is installed at an angle. the steam shut-off valve.
10. The male union (Figure 2-14, D) on the CAUTION

condensate return assembly just completed Do not open any steam
should now be connected to the female valves at this time.
union (C) on the unit steam return (con-
densate) line. Ensure that the steam trap is
LEVEL. The steam trap will not operate
correctly unless it is level.
11. Make up an assembly with the condensate

shut-off valve (R). Connect a short nipple Inlet F E D C B A
Unit
Endframe
(Q) to this valve, and a male union (P) to
the nipple.
12. The male union (P) on the condensate

shut-off valve assembly just completed Figure 2-15: Install the hardware for the steam
should now be connected to the female connection as shown.
union (O) on the steam trap assembly.
13. Connect the boiler condensate return pip-

ing to the condensate shut off valve.
CAUTION
Do not open any steam
valves at this time.
2-14 TOC INDEX

Receiving Shelf Set-Up Final Protective Wrapper Removal

The unit is shipped with the shelf in a down 1. Carefully remove any remaining plastic
position (Figure 2-16). protective coverings from the unit. Do
not remove the guide tapes (Figure 2-3).
1. The machine is shipped with the shelf
folded down for shipment. 2. Remove any wooden wedges used to
hold the ironing cylinder in place during
2. Lift the shelf into position and place its shipment, and save the wedges for main-
bracket arms in the two support bolts. tenance and repair work.
3. The brown paper covering the ironing

cylinder will be removed after machine
phasing is verified, and safety and control
functions have been checked.
Figure 2-16: The front receiving shelf is held in

place by two support bracket arms.
TOC INDEX 2-15

Security of Hardware
2.3 Pre-Operational
Checkout Required Tools
Allen wrench set
NOTE: For more information Shim: 1 or 1.5 mm
about the controls mentioned in Wrench set
the following procedures, refer
to Operating Controls on page 1. Open both endframe doors.
3-4.
2. In the right endframe, locate the machine
speed sensor (Figure 2-17). It is mounted
on a bracket very close to the teeth of the
Before the unit can be placed into full
ironing cylinder sprocket.
operation, perform the following procedures:
• Security of Hardware 3. The unit will shut down after five seconds
if this sensor has moved from the correct
• Compressed Air Supply Checkout position.
• Electrical Connection Checkout 4. Make sure the sensor is 0.04” to 0.06” (1 to
• Safety Device and Control Function 1.5 mm) from the teeth of the sprocket. For
Checkout information on adjusting the position of
the sensor, refer to Machine Speed Sensor
• Ironing Cylinder Paper Removal Position Adjustment on page 7-61.
• Heating Operation Checkout 5. Check all hardware connections and tight-
• Fold System Checkout en as necessary. Make sure all setscrews
are sufficiently tightened to hold their
• Checkout Completion respective components in position.
• Cleaning the Unit
WARNING
Do not put the unit into
service until all controls
are functioning properly.
Failure to do so may result in
serious injury to operators or
maintenance personnel.
Figure 2-17: The machine speed sensor must be

correctly positioned near the teeth of
the ironing cylinder sprocket.
2-16 TOC INDEX

NOTE: To a l l o w f o r h e a t
expansion, bearings in the left
endframe (Figure 2-18) do not
have setscrews. Do NOT put
setscrews into these bearings.
However, any shaft collars do
have setscrews that must be
secured.
6. Make sure all protective wrappers and

wooden wedges holding the ironing cylin-
der are removed; refer to Final Protective
Wrapper Removal on page 2-15.
7. Close and secure both endframe doors.
CAUTION
Do not attempt to START the
machine at this time. Figure 2-18: Do NOT put setscrews into left
endframe bearings.
TOC INDEX 2-17

Compressed Air Supply Checkout

The machine has three standard air gauges/
pressure regulators. Each must be checked to C
verify it has the correct initial pressure setting.
WARNING
Use protective eye wear.
Make sure the B
compressed air supply
connection is secure.
A
1. Turn ON the compressed air supply to the
unit. The compressed air system pressur-
izes as soon as the air is turned on.
2. Locate the pressure regulators/gauges

at the rear of the right endframe (Figure
2-19). The table below the picture shows
the correct air pressure settings.
Figure 2-19: Air pressure regulators at the rear of

the right endframe.
One Lane Models
Must be at least
A Incoming
80 psi (550 kPa)
B Primary Fold Air Blast 45 psi (310 kPa)
C Transfer Guide 42 psi (290 kPa)
2-18 TOC INDEX

Electrical Connection Checkout Exhaust Blower Motor Rotation

Checkout
After all utility connections are completed,
the unit can be energized and checked for proper Follow these steps to verify the correct rotation
electrical operation. of the exhaust blower motor.
All maintenance procedures should be handled 1. Turn power ON at the main disconnect
by at least two qualified persons. Using the switch.
“buddy system” facilitates a quicker procedure
and decreases the risk of an accident. 2. Start the unit by pressing the green START
button.
Required Tools 3. IMMEDIATELY press a red safety STOP

Screwdriver button.
4. Look at the vented cap of the exhaust

blower motor as it slows down. The rota-
tion direction should be clockwise (Figure
2-20).
5. As appropriate:
• If the motor is rotating in the correct

direction, go to the next procedure.
• If the rotation of the motor is not in the

correct direction, go to the next step.
Figure 2-20: The exhaust blower motor should be

turning in the direction of the arrow.
TOC INDEX 2-19

Safety Device and Control Function

WARNING Checkout
Only a qualified electrician
should make or correct any The machine can now be checked for proper
electrical connections in or safety device and control function operation.
to the unit. After that, the brown paper covering the ironing
cylinder can be removed.
6. Turn power OFF at the main disconnect

NOTE: W o r k w i t h a n o t h e r
switch.
person. The “buddy system” is
7. Open the right endframe door. the safest system.
8. Remove the terminal box cover at the rear

of the right endframe. All test procedures should be handled by at
least two qualified people. Using the “buddy
9. Disconnect and interchange any two of system” facilitates a quicker procedure and
the three exhaust blower electrical supply decreases the risk of an accident.
wires connected to left side of the terminal
block (Figure 2-21).
WARNING
Do not place the machine
NOTE: Make sure the electrical
into service until all controls
supply wires are securely
connected.
are functioning properly.
Failure to follow this rule
may cause serious injury
10. Replace the terminal box cover. to operators or
maintenance personnel.
12. Repeat Steps 1 to 4 to make sure the

exhaust blower motor is rotating in the
correct direction.
Figure 2-21: Terminal box connections.
2-20 TOC INDEX

Safety Device Check Control Function Check
1. Turn power ON at the main disconnect 1. Press the green START button.
switch.
2. Turn the SPEED knob (Figure 2-22, E)
2. Press the green START button (Figure clockwise to increase the speed.
2-22, A). All rotating and conveying ele-
ments of the machine should operate. 3. Make sure the ironing cylinder, feed rib-
bons, and return ribbons change speed as
3. There are four red safety STOP buttons the knob is turned. The CHI Panel will
on the unit, one on each endframe of the show the increase in speed.
machine (Figure 2-22, B).
4. Turn the SPEED knob counterclockwise
• With the unit running, test each button to decrease the speed.
in turn to make sure the unit comes to
a complete stop. 5. Make sure the ironing cylinder, feed rib-
bons, and return ribbons change speed as
• Make sure an error message displays the knob is turned. The CHI Panel will
in the CHI Panel (C) show the decrease in speed.
• Restart the unit after each red safety 6. Set the ironer to its slowest setting.
STOP button test.
7. Press the red STOP button.
4. Restart the unit.
5. Test the red safety finger guard at the front WARNING

of the ironer (Figure 2-22, D) by pushing Make sure the SPEED control
in on it. Make sure that all moving ele- knob is turned to the slowest
ments stop and than an error displays in speed before using the JOG
the CHI Panel. switch. Failure to do so may
result in unsafe conditions or
damage to the unit.
8. Turn the JOG switch (Figure 2-22, F) to

JOG FWD for a few seconds and release
it. JOG FWD causes the rotating elements
to move forward slowly. When released,
the JOG switch springs back to the center
C position and the rotating elements of the
E F unit stop.
D A 9. Turn the JOG switch to JOG REV for a
few seconds and release it. JOG REV caus-
es the rotating elements to move slowly in
reverse. When released, the JOG switch
springs back to the center position and the
B rotating elements of the unit stop.
10. Stop the unit and turn power OFF at the

Figure 2-22: All rotating parts should stop when
main disconnect switch.
you press the red safety finger guard.
TOC INDEX 2-21

Ironing Cylinder Paper Removal Heating Operation Checkout

Perform the following procedures to make sure
Perform only when the unit is
RUNNING and COOL. that the heating system is functioning correctly.
Use Extreme Caution.
WARNING
Check all internal and
CAUTION external steam connections
Do not use sharp objects for leaks before proceeding
to remove the brown paper to heat up the unit.
protecting the ironing
cylinder. Avoid scratching
the cylinder surface during
Inspect the Steam Piping System
paper removal.
1. Open the left endframe door.
1. Remove the brown paper from the ironing
cylinder. Tear away a strip across the full WARNING
length at the front of the cylinder, under This safety interlock switch
the feed table. is only to be defeated
2. Turn power ON at the main disconnect
temporarily while performing
switch. this procedure.
Never operate the unit
3. Turn the SPEED knob fully counterclock- unless all safety systems are
wise to set the machine to its slowest working correctly.
speed. Serious Injury Could Result.
4. Press the green START button.
2. The ironer will not operate while a safe-
WARNING ty microswitch is open. As a temporary
measure during this work, defeat the door
Never attempt to remove
interlock switch by inserting one of the
debris from the cylinder
switch keys that shipped with the unit.
while it is moving.
3. Start the unit.
5. Allow the paper to discharge onto the front 4. Turn the SPEED control knob to the
receiving shelf. Wait until it is clear of the slowest speed.
machine before removing.

7. Check to make sure that all paper has

been removed.
8. Repeat Steps 2 to 7 as necessary.
2-22 TOC INDEX

9. Tighten all connections that may have

CAUTION loosened during shipment or were not
Heat the ironing cylinder properly secured during installation.
gradually. Failure to do so
can permanently damage 10. Turn on the main disconnect switch
and start the unit. Reopen the STEAM
the rotary union joint and/or
SUPPLY SHUT-OFF valve one half turn.
siphon tube.
Repeat Steps 6 through 10 until all steam
connections are tight.
5. Slowly open the STEAM SUPPLY
11. Once all checkout procedures are com-
SHUT-OFF valve one half  turn to allow
plete, remove the interlock switch key.
steam to gradually enter the ironing cylin-
der. This valve is connected to the steam
inlet line on the back of the left endframe. WARNING
NOTE: The rotary union may all safety covers are in place
leak slightly as the unit is first and all safety equipment is
started up. Let the unit run for working correctly.
about one half hour to allow the
union to wear in while performing
12. Replace and secure the left endframe
the following check-out steps.
panel.
13. Immediately start the unit again and

6. When the steam pressure gauge indicates continue with the next procedure.
3 to 5 psi (20 to 35 kPa), fully open the
CONDENSATE SHUT-OFF valve. This
is connected to the steam return line on
the back of the left endframe.
WARNING
should adjust or service
steam components.
7. Carefully inspect all internal and external

steam connections.
WARNING
Shut off power at the main
disconnect switch.
8. If steam is leaking from any connection,

immediately close the STEAM SUPPLY
SHUT-OFF valve and shut off power at
the main disconnect switch.
TOC INDEX 2-23

Heat Ironing Cylinder Fold System Checkout

Follow these steps to heat up the ironing Flatwork is automatically measured for its total
cylinder. length and then processed with two primary folds.
1. With the machine running, make sure that

the COMPRESSION ROLL switch is in NOTE: The unit will not fold
the UP position. pieces shorter than 45” (1145
mm). Pieces over 45” are given
2. Make sure that the SPEED control knob two primary folds.
is turned to the slowest rate.
CAUTION
NOTE: Basic functions are
Heat the ironing cylinder
checked during the installation
gradually. Failure to do so procedure. Fine tune the folding
can permanently damage operation using the programming
the rotary union joint and/or and adjustment directions in CHI
siphon tube. PANEL OPERATION.
3. Make sure that the CONDENSATE

SHUT-OFF valve is fully open.
4. As the STEAM PRESSURE gauge

shows a steady pressure, open the STEAM
SUPPLY SHUT-OFF valve another 1/2
turn to gradually allow more steam to enter
the ironing cylinders.
5. Repeat Step 4 until the STEAM SUP-

PLY SHUT-OFF valve is fully opened. It
should take approximately 20 minutes to
completely open the valve.
6. Engage the compression rolls by setting

the COMPRESSION ROLL switch to
DOWN.
2-24 TOC INDEX

Single Lane Models Primary Folding Checkout Completion

1. Start the unit. If any checkout step is unsuccessful, refer
to TROUBLESHOOTING and REPAIR for
2. Press the MANUAL button on the CHI
additional information.
control panel (Figure 2-23). The PRIMA-
RY indicator light for 2 folds should be on. If the problem cannot be determined and/or
solved, contact your local CHICAGO® distributor
3. Use a piece of flatwork between 25” and
or Chicago Dryer Company’s factory service
120” (630 - 3000 mm) long. Feed the piece
department.
into the center of the ironer. See that:
• The flatwork comes onto the ribbons Cleaning the Unit

squarely.
During shipment and installation of the unit,
• First primary fold air blast folds the dirt or other contaminants may accumulate that
linen in half evenly. will soil or mark processed flatwork.
• Second primary fold air blast folds the Clean the unit by running old pieces of
linen in quarters evenly. flatwork using the entire width of the unit.
• Finished flatwork is delivered to the For information on processing flatwork, refer
front receiving shelf. to Flatwork Handling on page 3-10.
NOTE: U n i t s w i t h c h r o m e
ironing cylinders do not require
an initial waxing.
After completing all checkout procedures,

the ironing cylinder can be waxed. For more
information, refer to Waxing on page 3-8.
Figure 2-23: Folding operations are controlled from

the CHI Panel.
TOC INDEX 2-25

Duo-Star 20 Steam Operating Guidelines
Chapter 3
OPERATING GUIDELINES
In order to operate the Duo-Star 20™ Steam safely and with maximum efficiency, it is necessary to
become familiar with the following guidelines.
3.1 Safety Features
3.2 Operating Controls
3.3 Standard 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 read,
understand, and adhere to the Operator Safety Reminders for CHICAGO® Flatwork
Ironer and Folders bulletins (Figure 3-1). These bulletins must be posted at the
operating site.
Operator Safety Reminders for Chicago ® Flatwork Ironer Operator Safety Reminders for Chicago ® Folders
POST AND READ POST AND READ
Read and Learn The instruction manual MUST be carefully read by the person in charge of laundry
1. NEVER TRY TO REMOVE OR ADJUST JAMMED LINEN OR MATERIAL operations BEFORE installing or operating the Folder.
WHILE THE MACHINE IS RUNNING. Attempting to reposition or un-jam linen or service
the ironer while it is running can result in serious injury to the operator or damage to the ironer . Training Operators MUST be trained and instructed so that the Folder is operated properly and all
If something is jammed, SHUT THE IRONER OFF at the power source before trying to remove safety regulations are followed.
it. If your ironer has compression roll levers, learn how these levers work and always use them
to fully raise padded rolls before shutting o ff power, allowing ironer to cool, and attempting to Safe Operation The Folder MUST never be left unattended while it is running. Always shut down the
remove jammed linen or service the irone r. ALWAYS AVOID CONTACT WITH HEATED PARTS. machine when it is not in use.
Emergency All laundry personnel MUST be instructed on how to use stop buttons. Personnel should also
2. NEVER reach over, under, or behind safety finger guard or into any area near heated roll or Shut-Down be familiar with the location and method of stopping the Folder by using the disconnect switch.
moving parts without first shutting off ironer at power source. If you break this rule, you are taking
the chance of getting caught in the rolls or ribbons and possibly incurring serious injury from the Safety Labels Laundry personnel MUST be familiar with all safety labels and their meaning. Insure that
ironer’s heat or pressure. This rule should be followed whether you are working at the front, side, labels are read, understood, and followed at all times. Explain all safety precautions to
or rear of the ironer. employees who CAN NOT read English.
3. CHECK operation of safety fi nger guard at the beginning of every shift. Touching the safety Receiving Shelves Do not stand, sit or kneel on any receiving shelves or conveyors. They are not designed to
guard should activate a switch which will stop the irone r. If this safety feature is not working prop - and Conveyors hold the weight of a person.
erly, shut off the ironer at the power source and notify your manage r. Do not attempt to operate
the ironer until the safety fi nger guard is repaired and working properl y. Always make sure that Utility The Folder MUST be properly grounded and operated on the correct voltage as shown
ALL other safety guards and end panels are in place before operating the ironer . Connections on the Folder nameplate. Warranty will be voided and damage to motors may occur if the
Folder is operated at a different voltage than stated on the nameplate.
4. ALWAYS make sure that all ribbons and tapes are in place and working properly . They are Safety Features Safety guards and end panels MUST be installed at all times. If it is necessary to remove a guard
designed to hold linen so it is properly ironed and to prevent jamming. NEVER REPLACE OR or end panel for service work, use extreme care to avoid injury, and replace the guard or panel as
ADJUST TAPES, RIBBONS, OR PADDING WHILE IRONER IS RUNNING. Keeping your ironer
soon as possible. NEVER operate the folder unless all safety guards and end panels are in place.
well-waxed also helps to prevent jams
Safe Repair The “buddy system” SHOULD be used when doing any repair or maintenance work.
5. DO NOT iron anything except flatwork because damage to the ironer or injury can result. Your Follow local OSHA regulations for proper lock out - tag out requirements. One person
ironer is designed for processing flatwork only. should perform the work while the other monitors machine functions for safety.
6. DO NOT stand, sit, or kneel on any shelf at the front or rear of the ironer . These are not de- Servicing the When performing service or maintenance on the Folde r, always STOP THE FOLDER
signed to support a person ’s weight. Folder AND DISCONNECT POWER to the machine.
Clearing a Jam NEVER reach into any part of the Folder while it is running. If necessary, QUALIFIED
7. USE the “Buddy System” when servicing the ironer to make sure no one else accidentally turns
PERSONNEL should remove jammed flatwork with the FOLDER OFF AND POWER
the ironer on while you are working on it. When servicing, power to the ironer should be shut of f
at the wall switch, fuse box, or power source. DO NOT ATTEMPT TO CLEAN HEATED ROLL DISCONNECTED TO THE MACHINE. Use the Jog Reverse button BRIEFLY to
WHILE IRONER IS RUNNING OR HOT. Serious injury can result. Never try to service an ironer clear a jam if necessary.
while it is running.
Static Bar DO NOT touch the static bar. The static bar MUST be turned off while servicing
folders that are equipped with a static bar. When waxing an ironer, discharge the wax
8. PROTECT yourself and your fellow workers by making sure that everyone follows these simple cloth to the front of the ironer if possible, or insure that the static bar of the folder is
rules. Read and follow all safety labels. Learn which parts are hot and how your ironer works
turned OFF before sending a wax cloth through the system.
- including how to shut it o ff in an emergency. Do not get close to heated or moving parts or wear
loose clothing or jewelry when near the irone r. If you see someone breaking these rules, help Alteration The Folder MAY NOT be altered in any manner without written permission from Chicago
him/her prevent serious injury to themselves or others, by seeing that he or she follows the rules Dryer Company.
and shuts the ironer o ff first. You can help prevent accidents by explaining these rules to employ -
ees who do not read English. Cleanliness The Folder MUST be kept clean and free of lint and debris.
9. IF IN DOUBT, ask your supervisor or contact our Service Department for instructions. They Labels and DO NOT remove safety labels, nameplates, or any markings originally provided with the
will be glad to show you how to safely and ef ficiently operate or service the irone r. Only qualified Nameplates Folder. If any item is damaged, contact Chicago Dryer Company for free replacements.
personnel should service the irone r.
6371
Figure 3-1: The Operator Safety Reminders for CHICAGO® Flatwork Ironer and Folders bulletins must be
read by all personnel.
TOC INDEX 3-1

Operating Guidelines Duo-Star 20 Steam
Main Disconnect Switch

3.1 Safety Features
The main disconnect switch (Figure 3-2) is
The unit is manufactured with several built-in
located on the right endframe door. When turned
features to promote safety and proper operating
to OFF, the main disconnect switch shuts off the
procedures.
incoming electrical power to the unit.
WARNING Unless otherwise indicated, turn the main

Never bypass any of the disconnect switch to OFF before performing any
maintenance or repair work.
safety devices.
Serious Injury Could Result.
Safety Stop Buttons
There are five general categories of safety There are four red safety STOP buttons (Figure
features: 3-3, A) located at each corner of the unit.
• Main Disconnect Switch Pressing any of these buttons immediately

stops all moving parts, and locks out operation
• Safety Stop Buttons of the machine. A fault message appears in the
• Safety Guards CHI Panel. Twist to release/reset a pressed STOP
button.
• Safety Interlock Switches
The preferred method of stopping the operation
• Safety Labels of the unit is by pressing the red STOP button.
Figure 3-2: The main disconnect switch is located Figure 3-3: The red safety STOP buttons (A) and
on the right endframe door. red safety finger guard (B) provide
immediate shut-down capability.
3-2 TOC INDEX

Safety Guards Safety Labels

A red safety finger guard (Figure 3-3, B) Warning (orange) and Caution (yellow) labels
covers the moving parts at the front of the unit. are placed at locations around the unit to keep
It runs the entire length of the unit’s working area operators and maintenance personnel alert in
and physically restricts hands from coming into particular areas (Figure 3-5).
contact with moving and heated parts. Pushing
the safety finger guard stops all moving parts, WARNING labels alert personnel that
and locks out operation of the machine. A fault personal injury may result from not following
message appears in the CHI Panel. recommended procedures.
Both endframes and the rear of the unit are CAUTION labels alert personnel the unit
covered with protective doors and panels to may be damaged if conditions, practices, or
prevent fingers or hands from coming into contact procedures are not observed.
with moving and heated parts. Opening a door or
When training operators, take the time to
removing a panel immediately stops all rotating
review, understand, and locate all areas where
parts.
labels are posted.
Safety Interlock Switches

NOTE: Do not remove safety
Safety interlock switches (Figure 3-4) are labels at any time. If a label
located inside each endframe and behind the needs to be replaced, contact
protective panels at the rear of the unit. If any of Chicago Dryer Company for free
these is opened or removed, the interlock switch replacements.
at that location is disconnected, all rotating parts
stop moving.
These switches are not intended to lockout

the unit. Site management is responsible for
developing and implementing procedures that
follow government standards for lockout/tagout
when servicing the unit.
Figure 3-4: Never operate the unit unless all Figure 3-5: Safety labels remind operators and
safety interlock switches are working maintenance personnel that care must
correctly. be taken when working near these areas.
TOC INDEX 3-3

Right Endframe Controls

3.2 Operating Controls
The following operating controls (Figure 3-6)
All operating controls are externally mounted
are located at the front of the right endframe:
on the front of the endframes and clearly marked
with functional names. References to these • CHI Panel (A)
functions are capitalized in this instruction manual
for easy identification. Detailed descriptions are • ALARM (B)
given in the following paragraphs. • SPEED knob (C)
Control locations include: • JOG switch (D)
• Right Endframe Controls • Red Safety STOP button (E)
• CHI Panel • START/STOP buttons (H)
CHI Panel (A)
Allows fully automatic operation of the folding

section under a wide range of conditions. For an
over of the panel’s buttons, refer to CHI Panel
on page 3-6; for a complete description of the
CHI Panel control system’s functions, refer to
CHI PANEL OPERATION.
ALARM (B)
B A Sounds or beeps when there is a problem with
the unit. The CHI panel should give a diagnostic
reading.
SPEED knob (C):
Controls the speed of the unit. Turning the

SPEED knob clockwise causes flatwork to be
C D
processed at a faster speed. Turning the SPEED
knob counterclockwise causes flatwork to be
processed at a slower speed.
E F For more information on determining the

proper operating speeds for different types of
flatwork, refer to Processing Standards on
Figure 3-6: Right endframe control panel. page 3-17.
3-4 TOC INDEX

JOG switch (D): Red Safety STOP button (E)
Provided to help ensure operator safety and

CAUTION to prevent damage to the unit. There are four red
Turn the SPEED knob to the safety STOP buttons—one on the front and back
slowest speed before using of each endframe.
the JOG switch. Failure to
Pressing any of the four red safety STOP
do so may result in unsafe
buttons immediately stops all rotating parts,
conditions or damage to leaving the unit in the standby state.
the unit.
To reset a pressed STOP button, twist the
button.
Moves the ironing cylinder and all ribbons
forward and backward in small increments. To restart the unit:
Turning the JOG switch to JOG FWD will move
these elements forward a few inches. a) Turn the Steam switch OFF.
Turning the JOG switch to JOG REV will b) Push the START button.
move these elements in reverse a few inches.
When released, the JOG switch will spring back START/STOP buttons (F)
to the center position for normal start‑up and
operation. Initiate and pause general machine operation.
The green START button starts all moving parts
This feature should only be used in the while the red STOP button pauses operation of
following situations: the unit.
• To clear jams
• For maintenance at the slowest speed
• For repair at the slowest speed
TOC INDEX 3-5

CHI Panel The ADJUST button (A) is used for adjusting

the preset timings for the primary fold section.
The fold system is centrally operated through
the CHI fold system control panel making it easy The CD programming button (B) is used to set
to operate as well as to program and adjust the the minimum length for a piece to receive two
folding system. For a complete description of primary folds.
the CHI Panel control system’s functions, refer
to CHI PANEL OPERATION. The TEST button (C) is used during
troubleshooting. The fold system must be off in
The CHI fold system control panel (Figure order to access the test functions.
3-7) is located in the right front endframe and
features these controls: The CHI panel Display (D) varies depending
upon which mode is currently selected. It shows
the various fold system settings, diagnostic
NOTE: The standard display is messages, etc.
the ironer/folder’s speed and the
item count. The CURSOR button (E) moves the cursor
to various positions 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.
A B C
The ENTER button (H) confirms a selection
D from a menu, or to store new information.
The CHI button (J) turns ON (or OFF) the

E F G H automatic folding control system. The number
of folds for different size pieces are determined
by the program. The CHI button overrides the
J MANUAL button.
The MANUAL button (K) overrides the CHI

button and turns ON (or OFF) the Primary fold
section. The MANUAL button overrides the CHI
K L M N button.
The PRIMARY button (L) selects the number

Figure 3-7: The Chicago High Intelligence (CHI) of primary folds when in manual mode. The lights
control panel. show the number of folds selected.
The CROSS button (M) is not used.
The STACKER button (N) is not used.
3-6 TOC INDEX

Start-Up
3.3 Standard Operating
The following steps are suggested for starting
Procedures the unit at the beginning of each day.
In the daily operation of the unit, it is desirable
to follow consistent operational procedures. 1. Perform all of the daily preventive main-
By training operators to follow the same set of tenance procedures, except for waxing the
guidelines for daily procedures, operator safety ironing cylinder. For more information,
and efficiency are maximized. refer to Daily PM on page 4-3.
2. Have flatwork fully washed and extracted,

NOTE: Following consistent sorted, and ready to process.
operating routines optimizes
operator safety and operating 3. Turn ON the compressed air supply to
efficiency. the unit.

switch.
General routines include:
• Start-Up 5. Press the green START button. The but-
ton’s lamp should light and the rotating
• Waxing elements begin moving.
• Flatwork Handling 6. Turn the SPEED knob to the slowest
• Clearing a Jam Safely speed.
• Fold Operation 7. Make sure the ironing cylinder, feed,

return, and delivery ribbons are moving.
• Shut-Down
8. Perform a safety check:
For information on processing specific types
of flatwork, refer to Processing Standards on • Press a red safety STOP button. All
page 3-17. moving parts should stop.
• Restart the unit.

WARNING
Never run a unit when • Test each of the 3 remaining red safety
ribbons are missing or STOP buttons in the same manner.
broken. Serious damage and • Restart the unit.
injury could result.
• Press the red safety finger guard at
the front of the unit. All moving parts
should stop.
9. Restart the unit.
TOC INDEX 3-7

10. Restart the unit and let it run. The CHI Waxing
Panel completes its diagnostics and initial
display.
Standard Ironing Cylinder
11. The CHI panel then displays: Daily waxing of the ironing cylinder ensures it
is coated correctly, allowing the flatwork to slide
easily across the cylinder surface.
SPEED COUNT
XXFPM XXXXX This produces the best flatwork finish,
eliminates creases, prolongs return ribbon life,
prevents the flatwork from sticking to the ironing
12. Start the folding system by pressing either
cylinder.
the CHI or MANUAL button on the CHI
panel.
Chrome Ironing Cylinder
CAUTION Chrome-plated ironing cylinders do not require

It is essential that the regular waxing. However, if excessive static
ironing cylinder is heated build-up is causing flatwork to stick to the return
up gradually. Failure to do ribbons or is affecting machinery down-stream of
so can permanently damage the ironer, occasional waxing may be beneficial.
the rotary union joint and/or
siphon tube. Required Tools
Chicago Dryer Company powdered
wax or pure Karagami equivalent
13. Slowly open the STEAM SUPPLY SHUT- Gloves
OFF valve one half turn to allow steam to Waxing cloth
gradually enter the ironing cylinder. This
valve is connected to the steam supply line Perform only when the unit is
on the back of the of the left endframe. RUNNING and HOT.
14. Fully open the CONDENSATE SHUT-
OFF valve. This valve is connected to the
steam return line on the back of the left NOTE: If a folder is attached to
endframe. the unit, turn OFF the static bar.
15. At intervals, continue to open the STEAM
SHUT-OFF valve another half turn to
1. If the unit is not running, perform Start-
gradually allow steam to enter the ironing
Up on page 3-7.
cylinder.
2. Turn the SPEED knob to a low speed.
16. Repeat Step 15 until the steam SUPPLY
SHUT-OFF valve is fully opened. It 3. It is best to wax at an ironer temperature
should take approximately 20 minutes to of about 300° F (150° C).
completely open the valve.
3-8 TOC INDEX

NOTE: Use only a standard NOTE: If waxing a chrome

sheet or table cloth dedicated ironing cylinder, do not add
solely to waxing the ironing additional wax.
cylinder.
5. Use a waxing cloth the width of the ironer

4. Check the condition of the waxing cloth. and 90” (230 cm) long:
If the waxing cloth feels:
a) Make a fold in the middle of the piece
• Stiff when it is cool, it is sufficiently but do not complete the fold.
waxed. Skip to Step 7.
b) On the inside section of the sheet, ap-
• Limp when it is cool, more wax is ply powdered wax, using from 1/4 to
needed. Go to the next step. 1/2 lb (115-230 g). Use only Chicago
Dryer Company powdered wax (or
pure Karagami equivalent).
CAUTION
Abrasive chest type cleaners, c) Spread the wax in a thin, uniform layer.
pads, and paste wax can
permanently damage the d) Complete the fold, laying the unwaxed
portion over the waxed portion.
ironing cylinder and return
ribbons, and void the factory
warranty. WARNING
The waxing cloth will be hot
Never sprinkle wax directly when it comes out of the unit
on ribbons, compression roll, and may burn your hands.
or ironing cylinder. This will Protect your hands.
shorten the expected life of
the return ribbons.
6. Holding the waxing cloth tight from side
to side, feed the folded end into the ironer.
DO NOT over wax. The return
ribbon drive roll cover will • While feeding, lift the cloth off of the
become smooth and the feed ribbons to keep them as wax free
return ribbons will slip. as possible.
• Also hold the trailing edge of the wax-

ing cloth so wax does not drop onto the
canvas feed ribbons.
• Run it through the ironer two or three

times.
TOC INDEX 3-9

Flatwork Handling
WARNING
The waxing cloth must It is very important how operators use the unit.
always be cool when it is By following these guidelines, operators can
stored. A hot, folded waxing increase productivity, extend the life of the unit,
and most importantly-promote safety.
cloth can catch fire by
spontaneous combustion.
Safety
7. When done with waxing, hang up the wax- • Remove the flatwork only after it has
ing cloth to cool. Extend it completely; do cleared the unit. Do not pull on the
not fold it up. finished flatwork while still in the unit.
8. After the waxing cloth is completely cool, • Parts of the unit can be hotter than 300°
store it in an appropriate manner. F (150° C). Severe burns can result.
Maximum Efficiency
• Follow the posted standards for the type

of flatwork being processed.
• Place the flatwork straight and square on
the feed ribbons.
• Stretch the flatwork slightly to the sides
when feeding the flatwork into the unit.
• Do not process flatwork with frayed
edges or loose threads as these can cause
jams.
• Feed pillowcases lengthwise with the
closed end first.
• Leave a small gap between each item
being processed when feeding flatwork.
• Larger pieces, such as sheets, should
be fed by two operators and hand
crossfolded for easier handling.
• Smaller flatwork, such as napkins, should
be hand folded.
3-10 TOC INDEX

Ironing Cylinder Clearing a Jam Safely

• Use the entire length of the heated
ironing cylinder. This is especially WARNING
important when finishing pillowcases. The ironing cylinder will burn
you on contact.
• Work from side to side to prevent dirt
and heat buildup at the ends of the
Never reach in, on, or near
ironing cylinder. This preserves padding the ironing cylinder.
life.
• Rewax the ironing cylinder before If a piece of flatwork becomes jammed, use
ironing thicker flatwork such as the following procedure to clear the jam safely:
tablecloths. This will result in a better
1. Stop feeding flatwork.
finish quality. This is not necessary for
chrome ironing cylinders. 2. Wait for flatwork already in the unit to exit.
3. Turn SPEED knob to the slowest speed.
WARNING
DO NOT attempt to remove
jammed linen while unit is
jogging or moving.
4. Stop the unit by pressing a red safety

STOP button.
5. If the jammed linen can be removed easily,

clear the jam.
TOC INDEX 3-11

6. If the jammed flatwork cannot be removed Fold Operation

easily:
The Duo-Star fold system is centrally operated
a) Announce the unit is being started. through the CHI (Chicago High Intelligence)
Make sure everyone is a safe distance control panel. The CHI Panel (Figure 3-7),
away from the unit. located on the front right endframe, makes it easy
to operate, program, adjust and test the folding
b) Turn the JOG switch forward or back- system.
ward and jog the unit briefly, then
pause 2‑3 seconds before jogging the Fold operations include:
unit again.
• Folding Accuracy
c) Continue jogging the unit forward or • Automatic Operation
backward in brief increments until the
jammed flatwork can be safely and • Manual Operation
easily removed.
• Item Counter
d) Do not start the unit until the jam is • Self-Diagnostics
cleared.
• Programming, Adjustment, Testing
NOTE: I f j a m m i n g o c c u r s
regularly, tell the maintenance or
service people so they can fix the
problem.
3-12 TOC INDEX

Folding Accuracy Self-Diagnostics
To obtain accurate folds, the fold section must The Duo-Star fold control system continuously
receive flatwork that was fed into the ironer monitors itself for sensing and folding errors. If
accurately and squarely. an error is detected, a flashing message appears
in the CHI panel display and an audible alert is
1. Place each piece of flatwork straight on heard.
the ironer’s feed ribbons.
2. Flatwork must be centered from left to JAMMED AT PRIMARY /

right when fed into the ironer to ensure SHUTDOWN BEFORE REMOVING
accurate folding.
Automatic Operation The problem should be addressed immediately,

and if necessary, be brought to the attention
The maximum benefits of the fold section’s of maintenance or service personnel. The fold
advanced microprocessor control are obtained system may still be operational depending upon
when the Duo-Star is operated in CHI automatic the nature of the error and where it occurred.
mode.
In automatic mode, the Duo-Star’s fold system Programming, Adjustment, Testing

automatically determines the size of the flatwork The fold section’s operations are centrally
piece, along with the correct number of primary operated through the CHI (Chicago High
folds. Intelligence) control panel. The CHI Panel makes
For more information, refer to Automatic it easy to operate, program, adjust and test the
Operation on page C-4. folding system.
The unit is pre-programmed at the factory

Manual Operation to accommodate standard flatwork sizes and to
automatically determine the number of primary
The automatic folding system can be folds necessary. However, the unit can also
overridden at any time in order to accommodate be reprogrammed to handled small and large
special needs, such as a short run of linen which flatwork pieces as desired.
needs a special number of folds.
In addition, various specific settings in each
For more information, refer to Manual section of the Duo-Star fold system can be
Operation on page C-4. electronically adjusted to deliver accurate and
consistent packages. These include delays and
Item Counter timings in each primary folding station.
The CHI control panel displays the count of Finally, the fold control system allows service
flatwork pieces processed since the counter was personnel to test the various sections of the fold
last reset. system to ensure they are operating properly.
Each section is individually selected for testing.
To reset the counter, press the Cursor button
to move it under COUNT; then, press and hold For complete details, refer to CHI PANEL
the - button until the count zeros out. OPERATION.
TOC INDEX 3-13

Shut-Down
3.4 Operating Techniques
The following steps are suggested for shutting
The following factors are involved in producing
down the unit at the end of each day:
the best flatwork finish possible with the unit:
1. Close the STEAM SUPPLY SHUT-OFF • Conditioning Flatwork Before Ironing
valve.
• Unit Settings
2. On Type R units, turn the DELIVERY
switch to the center OFF position. • Processing Standards
• Maximum Productivity
3. Turn the SPEED knob to the slowest
speed. The conditioning of flatwork before processing
and the control settings on the unit will affect the
4. Allow the unit to run for approximately
processing standards. The processing standards
20 minutes to cool down.
ensure that flatwork is processed in a consistent
5. Close the CONDENSATE (steam return) and efficient manner.
SHUT-OFF valve
6. Stop the unit by pressing any of the red

safety STOP buttons.

switch.
WARNING
Never leave the unit
unattended without first
following the Shut-Down
procedure above.
Temporary Shut-Down
At times it is necessary for operators to shut

down the unit for a short time. The following
steps are suggested for temporarily stopping
operation.
WARNING
Never leave the
unit unattended while
it is running.

speed.
3-14 TOC INDEX

Conditioning Flatwork Before Final Rinse

Ironing
The final rinse can affect the quality of
There are several characteristics of flatwork flatwork finishing. It is important all flatwork be
which are determined by processes before drying thoroughly rinsed before entering the unit to keep
and ironing, including: flatwork from sticking to the ironing cylinder. A
pH level of 7.2 is recommended.
• Wash Load
Add a fabric softener to prevent static
• Final Rinse
electricity from causing the flatwork to stick.
• Moisture Retention Never use starch in the final rinse.
• Timing Between Washing and Ironing A warm rinse allows more water to be extracted
from the material. Thus, the unit needs to remove
Wash Load less moisture from the flatwork. This produces
flatwork with a dry, high quality finish—more
The wash load should consist of flatwork efficiently.
with the same fabric blend. Mixing different
fabric blends in the same wash load can create
Moisture Retention
inconsistent results because different fabrics
retain different levels of moisture during the Another important factor in delivering a high
extraction process. Such mixing can also create quality finish is the amount of moisture retained
excess lint on flatwork. The unit works most (MR) in the flatwork. The correct MR helps to
efficiently when one type of flatwork is processed determine the ironing speed and temperature—
at a time. drying flatwork after just one run through the
ironer.
CAUTION A few important factors in moisture retention
Starch only according to (MR) before ironing are:
a proper starch program.
• Wash formula–write down the standard
Improper levels of starch will for consistency
build a residue on the ironing
surface and reduce the unit’s • Extraction process–write down the
ability to finish flatwork. standard for consistency
• Tumble dry condition time–write down
the standard for consistency
• Type of fabric–higher percentage of
cotton, the more moisture retained
• Thickness of fabric–thinner material
retains less moisture
With too little moisture, flatwork can cause

static buildup problems. If too much moisture
is left in the flatwork, the ironing section must
work harder in order to process the work, by
either slowing down the speed or increasing the
temperature.
TOC INDEX 3-15

After extraction, the optimum MR is 30% - Unit Settings

35% for polyester/cotton fabrics and 45% - 50%
for cotton fabrics. The following three unit settings affect the
final flatwork finish:
1. Use a precise scale to measure the “still
• Ironing Cylinder Temperature
wet, but extracted” flatwork; then weigh
again after the same flatwork is “com- • Ironing Speed
pletely dry”.
• Compression Roll Pressure
2. Subtract the weight of the “completely
dry” flatwork from the “still wet, but This information contributes to achieving the
extracted” flatwork. Divide the weight best quality finished flatwork. Once processing
difference by the “completely dry” flat- tests have been run on the different types of
work weight. Finally, multiply the result- flatwork, write down the results on the Operating
ing weight by 100 to determine the MR Standard form and post by the unit.
percentage.
Refer to APPENDIX: Operating Standard
The optimum MR after ironing is 4% or less. form, for an authorized person to photocopy,
Ironing is not intended to remove 100% of the indicate, approve, and post the settings per
moisture from the flatwork. Therefore, feel the flatwork type.
flatwork when it first comes out of the unit; there
should be a slight moisture content. NOTE: It is important to write
down the ironing settings that
Allow the flatwork to sit for a few minutes to
produce the best quality finish
allow excess steam and heat to dissipate in the
for each type of flatwork being
air. Check the flatwork again; it should now feel
processed. These standards
dry to the touch.
should be posted. This removes
If the flatwork does not feel dry or to improve “guesswork” from the daily routine
the quality of finish and productivity, repeat and maximizes the efficiency and
Conditioning Flatwork Before Ironing on consistency of the entire laundry
page 3-15. operation. Consistent washing
and ironing habits are the key to
quality results.
Timing Between Washing and Ironing
The amount of time delayed between washing

and ironing/drying reduces the flatwork finish
Ironing Cylinder Temperature
quality due to fabric cooling and MR. Flatwork
needs to be ironed directly from the washer/ In general, the lower the operating temperature,
extractor whenever possible. the slower the unit must be run in order to produce
a quality flatwork finish.
Start up the unit when the second load of wash
is entering the final extract cycle. Flatwork may
be put into carts from the washer and sorted out
as desired.
Be aware that flatwork that sits overnight or

longer will have uneven MR, and the operating
speed must be adjusted accordingly.
3-16 TOC INDEX

Ironing Speed Processing Standards

The ironing speed should be standardized Processing standards should be adopted for
based on MR, fabric content and thickness for both the:
flatwork to be properly dried and ironed.
• Ironing System
Thin, single layer material can be processed • Fold System
at higher speeds. Double thickness items such as
pillowcases, and thicker material like tabletop
flatwork must be finished at lower speeds. CAUTION
This unit is NOT designed
to process folded flatwork.
NOTE: Processing excessively Processing folded flatwork
dry flatwork at too low a speed
could void the
may result in scorched flatwork.
Excessively moist flatwork, manufacturers warranty.
processed at too high a speed will
result in a damp, poorly finished
piece of flatwork. Ironing System
For each type of flatwork processed, follow

the steps below. Once the best temperature
Compression Roll Pressure and speed settings for that flatwork type have
been found, the standards should be posted and
Another factor dictating the amount of followed by all operators.
residual moisture removed in the flatwork is the
compression roll pressure. The pressure also sets 1. The wash loads should consist of one type
the calendering effect—the stretching and sliding of flatwork only.
of the flatwork to remove wrinkles and achieve a
better quality finish. 2. Use the posted Operating Standards form
for unit settings per fabric type. For more
For more information, refer to Compression information, refer to Unit Settings on
Roll Pressure Adjustment on page 7-21. page 3-16.
3. The final rinse should be as warm as possi-

ble. Add a fabric softener. Never use starch
in the final rinse.
4. Flatwork should be ironed directly from

the washer/extractor. For more informa-
tion, refer to Timing Between Washing
and Ironing on page 3-16.
TOC INDEX 3-17

Fold System
CAUTION
This unit is not designed to
CAUTION
process nylon or rubberized
Do not fold flatwork with
fabrics. Processing these
frayed edges.
fabrics could result in a fire
The loose threads hanging
or damage the ribbons and
from this flatwork often
ironing cylinder surface.
become tangled in the
ribbons, causing jams
VISA® material has a high
and other problems.
polyester content and can
Only process flatwork in
melt when ironed at too high
good condition.
a temperature, or too slow
a speed. This can cause
damage to the return ribbons Processing standards developed for the fold
and require a thorough system takes full advantage of the advanced
cleaning of the capabilities of the CHI fold system and produces
ironing cylinder. the best possible folded flatwork. These standards
help make sure flatwork is processed in a
consistent and efficient manner.
5. Turn the SPEED knob to the fastest speed.
While developing processing standards, it
6. Process a few pieces of the flatwork. The may be useful to make some changes to the fold
flatwork might feel slightly damp when programming to match local conditions, i.e.,
it first comes out of the unit. Set the item differences in flatwork size due to shrinkage
aside and feel it again in five minutes. The or manufacturing inconsistencies. This is most
flatwork should feel dry. likely to happen if the size of a piece happens
to fall just at a break-point, causing erratic
7. If the flatwork is still damp, decrease the results. Reprogram the break-point so this
speed slightly. size is consistently in one zone or the other.
For more information, refer to CHI PANEL
8. Repeat Steps 7 and 8 until the finish on the
OPERATION.
flatwork is correct.
Once the best procedures for each size have
9. This is the standard speed for processing
been found, the standards should be posted and
this type of flatwork. For more informa-
followed by all operators.
tion, refer to Ironing Speed on page 3-17.
The CHI manual operation gives extra flexibility
for special applications or requirements, including,
manual selection of 1 or 2 primary folds.
Maximum Productivity
It is important to follow consistent, standard
operating procedures in the daily operation of the
unit for both safety and productivity. Operator
safety and efficiency are maximized by training
operators to always follow the same set of
guidelines for daily procedures.
3-18 TOC INDEX

Duo-Star 20 Steam Preventive Maintenance
Chapter 4
PREVENTIVE MAINTENANCE
Various components of the Duo-Star 20™ Steam require scheduled attention to ensure long life and
trouble-free operation. The Preventive Maintenance (PM) Schedule below and on the next page outlines
all of the PM tasks required at regular intervals. All tasks are the responsibility of maintenance personnel
unless otherwise indicated.
Since operators run the machines, they should be trained on site to visually inspect common areas daily
and notify maintenance personnel when problems are found, such as worn or broken ribbons. All PM
intervals are based on 8-hour/day operation. Increase the PM frequency for two- or three-shift operations.
Preventive maintenance should only be done when the power is turned OFF at the main disconnect
switch. Specific preventive maintenance that requires the unit to be running should be done with extreme
caution and attention to detail.
FREQUENCY OF TASKS BASED ON HOURS OF OPERATION
Preventive Maintenance Tasks Operator Maintenance Ironer Condition
4.1 Daily (8 Hours)

PM Task Tables
Watch and Listen for Anything Abnormal X Running/Hot
Daily, Weekly Tasks

General Cleanliness X Off/Disconnect Power/Cool
Check and Clean Photosensors X Off/Disconnect Power/Cool
Check Guide Tapes X Off/Disconnect Power/Cool

Preventive Maintenance Schedule beginning
Check Safety Equipment X X Running/Cool
Wax Ironing Cylinder X Running/Hot
4.2 Weekly (50 hours)
Check Ironing Cylinder X Off/Disconnect Power/Cool
Clean Behind Service Panels X Off/Disconnect Power/Cool
Inspect Air Filter/Auto Drain X Off/Disconnect Power/Cool
Check Air Pressure Settings X Off/Disconnect Power/Cool
Check and Clean Inverter X Off/Disconnect Power/Cool
Grease “Weekly” Bearings X Off/Disconnect Power/Cool
Oil Roll Bearing Pivots X Off/Disconnect Power/Cool
Check and Clean Motors X Off/Disconnect Power/Cool
Check and Clean Exhaust Blower Wheel X Off/Disconnect Power/Cool
Check Ribbon Condition and Tension X Running/Cool
TOC INDEX 4-1

Preventive Maintenance Duo-Star 20 Steam
Preventive Maintenance Tasks Operator Maintenance Ironer Condition
4.3 Monthly (200 hours)

Monthly, Semi-Annual Tasks
Grease Bearings X Off/Disconnect Power/Cool
Check Setscrews X Off/Disconnect Power/Cool
Oil Drive Chain and Tension Springs X Off/Disconnect Power/Cool
Check Compression Roll Pressure and Cover

X Running/Cool
Condition
4.4 Semi-Annual (1000 Hours)
Clean Air Filter/Auto Drain X Off/Disconnect Power/Cool
Grease Flatwork Transfer Guide X Off/Disconnect Power/Cool
Check Mechanical and Electrical Connections X Off/Disconnect Power/Cool
4-2 TOC INDEX

Watch and Listen for Anything

4.1 Daily PM (8 Hours) Abnormal
WARNING Perform only when the unit is

Do not repair or correct any RUNNING.
of these conditions without Use Extreme Caution.
reading and understanding
the Repair chapter. Operators and maintenance personnel should
learn to understand the usual sights and sounds
Only qualified personnel around a unit. For example, when there is a
should troubleshoot and noise at a roll, the bearings may be worn or other
mechanical problems may exist. Stop the unit
repair this unit.
immediately and follow-up with the necessary
maintenance or repair.
Make sure the unit is
completely cooled down and
power is turned OFF at the General Cleanliness
Required Tools
Follow lockout/tagout Vacuum cleaner or compressed air
procedures approved for
your site. Follow local Perform only when the unit is OFF
regulations. Failure to do so with power disconnected and COOL.
It is important that lint, dirt, dust, and
foreign material do not enter the unit during
operation. General cleanliness prevents damage
to components, jamming, and soiling of flatwork.

switch.
2. Use a vacuum cleaner or compressed air

supply to clean the following:
• Front receiving shelf
• All conveyor ribbons
• General components as required
CAUTION
damage them.
TOC INDEX 4-3

Check and Clean Photosensors Check Safety Equipment
Required Tools Perform only when the unit is

Cloth: soft, lint free RUNNING and COOL.
Perform only when the unit is OFF The machine should never be operated without
all safety guards in place and all safety devices
working properly.
Most control problems can be avoided by
keeping the photosensors clean. Check that all four red safety STOP buttons,
and the red safety finger guard all bring the
Clean the photosensors with a soft, lint free operation of the machine to a complete halt. For
cloth. For more information on photosensor more information, refer to Start-Up on page
locations, refer to Sensors on page 5-8. 3-7.
Check Guide Tapes NOTE: Repair any faulty safety

devices before continuing to
Perform only when the unit is OFF operate the unit.
Guide tapes are used to prevent flatwork from

sticking to the compression roll. Wax Ironing Cylinder
1. Turn power OFF at the main disconnect Perform only when the unit is
switch. RUNNING and HOT.
2. Inspect for broken or missing guide tapes
and for wear or fraying of the edges.
Daily waxing of the ironing cylinder is
3. Make sure the ends of the guide tapes are necessary to produce a finer flatwork finish, to
properly stapled together. prolong return ribbon life, and to prevent the
flatwork from sticking to the ironing cylinder.
4. Replace any guide tapes that are damaged, Note that chrome ironing cylinders do not require
broken, or missing. For more information, daily waxing.
refer to Guide Tape Replacement on
page 7-11. For waxing instructions, refer to Waxing on
page 3-8.
4-4 TOC INDEX

Check Ironing Cylinder

4.2 Weekly PM (50 Hours)
WARNING with power disconnected and COOL.
Do not repair or correct any
of these conditions without Performance of the unit depends on the
reading and understanding condition of the ironing cylinder.
the Repair chapter.
switch.
should troubleshoot and 2. Inspect the cylinder by carefully looking
repair this unit. under the feed ribbons at the front of the
unit.
Make sure the unit is
3. Check for buildup of chemicals or debris
which discolor the cylinder.
power is turned OFF at the
main disconnect switch. 4. For information on restoring the fine
polished finish of the cylinder, refer to
Follow lockout/tagout Ironing Cylinder Reconditioning on
procedures approved for page 7-27.
your site. Follow local
regulations. Failure to do so
TOC INDEX 4-5

Clean Behind Service Panels Inspect Air Filter/Auto Drain

The machine has an air filter/regulator with
Required Tools automatic drain (Figure 4-1) which should be
Clean cloth inspected on a weekly basis.
Wrench: 7/16”
Vacuum cleaner
switch.
CAUTION
2. Check the filter/drain. A visible coating of
Never use compressed air dirt of condensate on the filter element or
on or around electronic excessive pressure drop is an indication
components. Doing so may that cleaning is necessary.
damage them.
3. For instructions on cleaning the air filter/
regulator, refer to Clean Air Filter/Auto
1. Turn power OFF at the main disconnect Drain on page 4-18.
switch.
2. Open and clean the inside and outside

surfaces of both endframe doors.
3. Remove and clean the rear protective

backplate. Make sure at least two workers
are available to handle this piece as it is
heavy and awkward to handle.
4. Clean any lint and wax vapor buildup

inside the unit.
5. Clean the top and bottom surface of the

feed table and the inside surface of the
exhaust canopy. Figure 4-1: To ensure proper operation, inspect
the bowl weekly for build-up.
6. Replace the protective backplate.
4-6 TOC INDEX

Check Air Pressure Settings

The machine has three standard air gauges/
pressure regulators. Each must be checked to
verify it has the correct initial pressure setting.
C
WARNING
B
Wear eye protection when
working with compressed
air components. A
1. Turn ON the compressed air supply to the

unit. The compressed air system pressur-
izes as soon as the air is turned on.
2. Locate the pressure regulators/gauges

at the rear of the right endframe (Figure
4-2). The table below the picture shows
the correct air pressure settings.
Figure 4-2: Air pressure regulators at the rear of
the right endframe.
One Lane Models
Must be at least
A Incoming
80 psi (550 kPa)
B Primary Fold Air Blast 45 psi (310 kPa)
C Transfer Guide 42 psi (290 kPa)
TOC INDEX 4-7

Check and Clean Inverter

Check and clean the inverter and its cooling
fins (Figure 4-3) weekly with a vacuum cleaner.
Failure to do so may void your warranty.
Required Tools
Vacuum cleaner


switch.
2. Open the right endframe door and locate

the main drive motor inverter (Figure 4-3).
Figure 4-3: Check and clean the inverter and its
cooling fins weekly.
CAUTION
Failure to clean the inverter
and its cooling fins could
void the warranty.

damage them.
3. Check and clean the inverter and its cool-

ing fins with a vacuum cleaner.
4. Make sure the dust covers are in place on

both sides of the inverter.
4-8 TOC INDEX

Grease “Weekly” Bearings Failure to use the correct lubricant will void
the factory warranty.
The grease fittings for the ironing cylinder
bearings (Figure 4-4, A), and compression roll
bearings (B) in both endframes, are marked with CAUTION
yellow “GREASE WEEKLY” tags and need to Before using a grease
be greased weekly. other than specified, check
with the factory service
Other bearings that are identified with the
department to verify that
yellow “GREASE” tags should also be greased
the grease meets
weekly if the unit is continuously run for long
periods. specifications and is
compatible with the grease
A special high temperature lubricant is already in the bearings.
required to properly grease all bearings. It is
important that only an EP, bentonite clay, NLGI
2, 1000 cSt viscosity grease be used.
If any other grease is being considered:
Use of unsuitable grease can cause bearing 1. Check with the Chicago Dryer Company
lockup or failure. Problems can also result if the service department to verify that the grease
new grease is incompatible with the grease that meets specifications and is compatible
is already in the bearings. with the grease already in the bearings.
2. Follow directions on the grease gun pack-

aging for other filling methods (dispenser,
B suction).
Figure 4-4: Add grease weekly to the fittings for

the ironing cylinder and compression
roll bearings in each endframe.
TOC INDEX 4-9

To fill the grease gun: To use the grease gun:
1. Remove the barrel (Figure 4-5, B) from

the end cap (A) by twisting it counter- Required Tools
clockwise. Clean cloth
Grease gun
2. Hold the barrel (Figure 4-5, B). Pull the Grease: EP, bentonite clay, NLGI 2,
plunger rod handle (C) all the way back 1000 cSt viscosity
and lock it in the keyhole slot at the end
of the barrel. Perform only when the unit is OFF
3. Remove the plastic cap from the grease
cartridge and smooth the inside edge for 1. Turn power OFF at the main disconnect
easy entry of the plunger. switch.
4. Insert the opened edge of the cartridge 2. Open both endframe doors.
completely into the barrel. Remove the
flip-top seal from the exposed cartridge 3. Wipe the old grease from the bearings.
end.
4. Insert the grease gun nozzle firmly onto
5. Screw the end cap (Figure 4-5, A) onto the the grease fitting.
barrel (B) by twisting it clockwise.
6. Release the plunger rod (Figure 4-5, C) CAUTION

from the keyhole slot and push it into the Over-lubrication will destroy
cartridge. the bearing seals and cause
premature failure.
7. To vent air pockets, loosen the end cap
(Figure 4-5, A) 1/2 turn and tighten.
5. Add lubricant slowly until a slight bead of
lubricant forms at the seal. As soon as the
bead forms, stop adding grease to prevent
A damage from over-lubrication.
B
C
CAUTION
Failure to wipe off excess
lubricant will cause lint to
adhere to the bearings and
may cause premature failure.
Figure 4-5: A grease gun is supplied with each
unit.
6. Immediately wipe off the grease from the
bearing. Failure to do so can cause lint ac-
cumulation and premature bearing failure.
7. Leave the endframe doors open for the

next procedure.
4-10 TOC INDEX

Oil Roll Bearing Pivots

The bearing pivots for the compression roll
(Figure 4-6) inside each endframe, return ribbon
guide assembly roll (Figure 4-7) outside each rear
endframe, and doffer roll (Figure 4-8) outside
each front endframe, need to be oiled weekly to
allow the bearings to pivot smoothly.
Required Tools
Clean cloth
SAE 90 grade oil
Figure 4-6: Oil the pivot for the compression roll

bearing in each endframe weekly.

switch.
2. If necessary, open both endframe doors.
3. Use a clean cloth to remove any lint or

buildup from each of the bearings and
pivots.
4. Add a few drops of a good quality SAE 90

grade oil to each of the pivots.
5. Manually raise and lower the compression

roll, the return ribbon guide assembly roll,
and the doffer roll to lubricate the pivots.
Figure 4-7: The return ribbon guide assembly
6. Wipe off any excess oil from each of the bearing pivots at the rear of the ironer.
pivots.
Figure 4-8: The doffer roll bearing pivots at the

front of the ironer.
TOC INDEX 4-11

Check and Clean Motors Check and Clean Exhaust Blower

Wheel
The drive motor, and exhaust blower motor
require weekly cleaning to ensure proper The exhaust blower wheel needs to be
operation. inspected and cleaned to ensure proper operation.
Required Tools CAUTION

Vacuum cleaner Operation of the unit with
foreign material (lint, threads,
Perform only when the unit is OFF wax particles, hair, etc.) in
with power disconnected and COOL. the blower wheel between
the blades can cause
1. Turn power OFF at the main disconnect overheating, especially
switch. of the endframe controls,
2. Open both endframe doors. and possible premature
component failure.
3. Use a vacuum to clean out lint and dirt
from the intake side (Figure 4-9) of each
specified motor. Required Tools
4. Make sure the motors are free to turn Clean cloth
Flashlight
without excessive binding.
Screwdriver
5. Close and secure both endframe doors. Vacuum cleaner


switch.
2. Remove the inlet elbow (Figure 4-10)

from the blower.
Figure 4-9: Removing lint and dirt from the intake

side of the motor ensures proper Figure 4-10: The inlet elbow must be removed to
operation. access the exhaust blower wheel.
4-12 TOC INDEX

3. Inspect the inside of the blower housing Check Ribbon Condition and
with the help of a light to observe any lint Tension
buildup between the blower wheel blades.
High temperature synthetic material is used for
4. Use a vacuum to remove lint and foreign the feed and return ribbons. Preshrunk canvas is
material from the blower. used for the primary fold and delivery ribbons.
NOTE: Fibers left on the blower NOTE: Ribbons that break

wheel allow lint and foreign should be replaced immediately.
material to accumulate more Return ribbons move and hold the
frequently. linen in proper contact with the
heated cylinder, ensuring quality
flatwork finish.
5. Make sure the blower wheel is free to turn
without excessive binding.
6. Position the inlet elbow on the blower. Perform only when the unit is
RUNNING and COOL.
WARNING
Never touch any part of the
unit while it is moving.

switch.
2. Press the green START button.
3. Check all ribbons for proper placement,

tracking, tension (no visual sagging), and
general condition (smoothness, scorching,
fraying, and tears).
4. For more information on adjusting and re-

placing various ribbons, refer to REPAIR
and the appropriate section.
TOC INDEX 4-13

Grease Bearings
4.3 Monthly PM
(200 Hours) Required Tools
Clean Cloth
WARNING Grease gun
Do not repair or correct any Grease: EP, bentonite clay, NLGI 2,
1000 cSt viscosity
of these conditions without Screwdriver
the Repair chapter.
should troubleshoot and Bearings marked with yellow “GREASE”
repair this unit. tags are not subjected to as much stress and high
temperatures as the bearings that require weekly
Make sure the unit is greasing.
power is turned OFF at the Therefore, the bearings with yellow “GREASE”
tags do not need to be greased as frequently as
the bearings with yellow “GREASE WEEKLY”
tags. Use the same high temperature grease for
Follow lockout/tagout all the bearings.
your site. Follow local For instructions on greasing the bearings
regulations. Failure to do so labeled with yellow “GREASE” tags, refer to
could result in serious injury. Grease “Weekly” Bearings on page 4-9.
4-14 TOC INDEX

Check Setscrews
Setscrews are used to secure sprockets,
bearings, pulleys, and other rotating parts.
Required Tools
Allen wrench set


switch.
2. Open both endframe doors.
3. Make sure all setscrews are correctly

tightened.
NOTE: To a l l o w f o r h e a t Figure 4-11: Do NOT put setscrews into left

expansion, bearings in the left endframe bearings.
endframe (Figure 4-11) do not
have setscrews. Do NOT put
setscrews into these bearings.
However, any shaft collars do
have setscrews that must be
secured.
TOC INDEX 4-15

Oil Drive Chain and Tension Springs

The drive chains in the left endframe (Figure
4-12, A, B, C) and compression roll tensioning
springs (D) in both endframes require monthly D
maintenance.
D
Required Tools
Clean cloth
SAE 90 grade oil A
Wrench: 7/16”
C
1. Turn power OFF at the main disconnect Figure 4-12: The drive chains are located inside the
switch. right endframe.
3. Remove the protective cover at the right

rear of the machine (Figure 4-13).
4. Clean off old lubricant from the drive

chain.
5. Lightly lubricate the chain with a good

quality SAE 90 grade oil.
6. Repeat Steps 3 and 4 for the compression

roll tensioning springs.

Figure 4-13: Remove the protective cover at the
8. Replace and secure the right rear cover. right rear of the machine.
WARNING
working correctly.
4-16 TOC INDEX

Check Compression Roll Pressure

and Cover Condition 4.4 Semi-Annual PM
(1000 Hours)
Regularly inspect the compression roll cover
and tie tapes to help ensure maximum lifetime.
WARNING
Do not repair or correct any
with power disconnected and COOL. of these conditions without
1. Turn power OFF at the main disconnect the Repair chapter.
switch.
2. Inspect the compression roll to confirm should troubleshoot and
that the roll cover is securely held against repair this unit.
the roll.
3. In addition, check the cover’s overall Make sure the unit is

condition for wear, discoloration or dis- completely cooled down and
placement. Consider cover replacement as power is turned OFF at the
necessary; for more information refer to main disconnect switch.
Compression Roll Cover Replacement
on page 7-21. Follow lockout/tagout
4. Make sure none of the tie tapes are missing
to prevent the cover from flapping during your site. Follow local
operation. Replace as necessary. regulations. Failure to do so
5. Make sure the tie tapes are positioned at
equal intervals across the length of the roll.

RUNNING and COOL.
Uneven compression roll pressure can shorten

the life of the compression roll cover. Regular
pressure checks and adjustments as necessary can
help extend padding life. For more information,
refer to Compression Roll Pressure Check on
page 7-20.
TOC INDEX 4-17

Clean Air Filter/Auto Drain 7. Unscrew the filter assembly and separate
the components (Figure 4-15, C, D, E).
The air filter/automatic drain unit requires
complete cleaning periodically to maintain 8. Discard the filter element (D).
maximum filtering efficiency and to avoid
excessive pressure drop. 9. Clean the other components (B, C, E) with
ONLY water and household soap; then,
The weekly inspection will indicate how dry with a clean soft cloth.
frequently cleaning is required. The cleaner the
compressed air supply, the less maintenance will 10. Re-assemble the clean components, in-
be required. A visible coating of dirt or condensate serting a new filter element, and install the
on the filter element surface or excessive pressure filter assembly back on the base.
drop is an indication that cleaning is necessary.
11. Re-attach the clean bowl, lining up the
marks as in Step 3.
WARNING
Before disassembling the air 12. Press up on the bowl and twist left or right
filter/regulator, turn off the air until the plastic tab snaps into position.
supply and depressurize the 13. Close and secure the right endframe door.
system and filter.
A
Required Tools
Clean, soft cloth
B
Mild detergent solution

Figure 4-14: Press the plastic tab and twist the
casing to line up the marks to remove
1. Turn off the compressed air supply and the filter bowl from the machine.
depressurize the unit.

switch. A
3. Open the right endframe door.
B
4. Press the black plastic tab on the side of
the bowl case down (Figure 4-14, A) and
rotate it left or right until the two marks C
on the bowl case light up with the single
mark on the filter base (B).
D
5. Pull down on the bowl case to remove
it. The filter base does not need to be re-
moved from the machine.
E
6. Take the bowl (Figure 4-15, A) and rinse
with ONLY water and household soap; Figure 4-15: Replace the filter element and clean
then, dry with a soft, clean cloth. the other components using only soap
and water.
4-18 TOC INDEX

Grease Flatwork Transfer Guide Check Mechanical and Electrical

Connections
Required Tools
Clean cloth Required Tools
Grease gun Clean cloth
Grease: EP, bentonite clay, NLGI 2, Screwdriver
1000 cSt viscosity Voltmeter
Wrench set
with power disconnected and COOL. Perform only when the unit is OFF
The flatwork transfer guide bearings, located
in each endframe (Figure 4-16), are not subjected Heating, cooling, and normal vibrations
to as much stress and high temperatures as other may cause connections to loosen over time.
bearings in the machine. They do, however, Perform this procedure to check and tighten the
require the same high temperature grease for all mechanical and electrical connections.
the bearings.
For instructions on greasing these bearings, switch.
refer to Grease “Weekly” Bearings on page
4-9. 2. Open both endframe doors.
3. Check and tighten all mechanical fasten-

ers.
4. Check the electrical components in both

endframes.
5. Check all electrical connections in the

main electrical panel.
WARNING
Only a qualified electrician
should make or correct any
electrical connections in or
to the unit.
Figure 4-16: A flatwork transfer guide grease fitting
is located in each endframe. 6. Connect a voltmeter between the unit’s
frame and a separate, known earth ground.
7. If there is a reading on the voltmeter, check

and repair the ironer’s ground connection.
TOC INDEX 4-19

Duo-Star 20 Steam Operating Principles
Chapter 5
OPERATING PRINCIPLES
In order to maintain and troubleshoot the Duo-Star 20™ Steam safely and effectively, it is necessary
to understand how the unit works. This chapter is divided into four operating systems and a review of
how these system are controlled to iron flatwork:
5.1 Electrical System
5.2 Compressed Air System
5.3 Mechanical System
5.4 Heating and Exhaust Systems
5.5 Sequence of Operation
Electrical System: This section reviews incoming power requirements, how power is
distributed throughout the ironer/folder, and the controls, sensors
and switches operating the unit.
Compressed Air System: This section reviews compressed air requirements, how air is
distributed throughout the unit, and the controls and mechanisms
operating the pneumatic system.
Mechanical System: This section reviews the drive mechanisms which power all rotating
and moving parts and how they enable the ironing cylinder to
produce the flatwork finish as well as fold the flatwork.
Heating and Exhaust Systems: This section reviews incoming steam requirements and how steam
is used to heat the ironing cylinder. It also explains how the exhaust
blower works in the exhaust canopy to provide ventilation for the
unit.
Sequence of Operation: This section provides a step-by-step guide to each of the ironer’s
phases of operation: Stand-By, Jog Operation; Mechanical
Start-Up and Heating System Operation. Refer to the schematic
diagrams in the SCHEMATIC PARTS LIST to follow the
timing and sequence of events.
TOC INDEX 5-1

Operating Principles Duo-Star 20 Steam
Safety 5.1 Electrical System

The equipment described here has been The electrical components of the unit are
designed to work together to give a safe and divided into two areas:
reliable machine. Changing the equipment or
• Power System
controls may cause a malfunction that could
injure someone. Do not bypass any of the safety • Control System
features or controls. Do not replace components
except with factory-approved repair parts. The power system moves the ribbons, activates
the air valves, etc. The control system decides
Questions about the operation of the unit can be when all these activities should occur.
answered by your local authorized CHICAGO®
dealer, or by the Chicago Dryer Company service
department.
Power System
The majority of the protectors and distribution
items are in the main electrical panel. Some steam
system electrical components are located in the
left endframe.
Electrical system components include:

• Disconnect Switch and Fuses
• Step-Down Transformers
• Main Electrical Panel
5-2 TOC INDEX

Disconnect Switch and Fuses
The unit comes equipped with a disconnect

switch (DSC1). This switch (Figure 5-1, A) is
in the electrical panel inside the right endframe.
Included as a part of the disconnect switch are B

a set of fuses (Figure 5-1, B), which will isolate
the unit from the mains if necessary. See the
SCHEMATIC PARTS LIST for the rating of
these fuses, which is dependent on line voltage. A
NOTE: The power supplied to the

unit must match the requirements Figure 5-1: The disconnect switch and fuse set in
the electrical panel inside the right
listed on the nameplate.
endframe.
Step-Down Transformers
If the ironer/folder is installed in a property with

line voltage higher than 240VAC, transformers
T1 and T2 are provided (Figure 5-2) on the outer
wall of the right endframe.
Figure 5-2: Transformers for high voltage units.
TOC INDEX 5-3

Main Electrical Panel
The main electrical panel (Figure 5-3) is

located inside the right endframe. The table on
the next page provides an explanation of each
item indicated in the picture.
DISC1
INV1
FILT1
CB1
CON1
CB0
CB5
CR2
PWS1
CR1 CR4 CR6
CR0 CR3 CR5
Figure 5-3: Main electrical panel power system components-inside right endframe.
5-4 TOC INDEX

MAIN ELECTRICAL PANEL COMPONENTS
Schematic Description
CB0 Circuit Breaker - PWS1
CB1 Circuit Breaker - CON1
CB5 Circuit Breaker - 24VDC Interlock Circuit
CR0 (A-D) Control Relay - Start Circuit
CR1 (A/B) Control Relay - Control Latch Circuit
CR2 Control Relay - EStop Circuit
CR3 Control Relay - Interlocks
CR4 Control Relay - Inverter Breaker/Inverter Fault/Motor Protector Faults
CR5 (A-C) Control Relay - Run
CR6 Control Relay - Run Latch
CON1 Contactor - INV1, CON3, CON4, CB2
DSC1 Main Disconnect Switch
FILT1 Filter - Incoming Power
INV1 Inverter - Main Drive Motor
PWS1 Power Supply - 24VDC Interlock/Control Circuits
TOC INDEX 5-5

Control System Inside the panel is MPC2. This board accepts

the operator inputs from the membrane switches
Various components work together to control on the front of the panel and sends them to the
the work of the folding system. I/O control panel in the right endframe.
This control system includes: In addition, the MPC1 control board sends
• CHI Panel operation and diagnostic messages to the CHI
Panel. These are shown in the display at the top
• Junction Block of the panel.
• Electrical Panel I/O Control Panel
Communications and the Control Panel
• Sensors
Inside the right endframe is the I/O control
Control of the folding is done in two areas.
panel. A serial cable provides communication
Input from the operator takes place at the CHI
between the microprocessor and the I/O control
Panel, located on the front outside endframe.
panel. Two LED’s on the communications head
These commands are combined with internal
of the control panel show when it is receiving
signals in the MPC1 control board.
information from the microprocessor (RX) and
sending data to it (TX).
CHI Panel
All the input signals from the sensors go
Operators control the fold system with the through the I/O control panel, which also powers
Chicago High Intelligence (CHI) panel located on the sensors. When the appropriate LED on the
the front of the right endframe (Figure 5-4). For I/O control panel come on, it means that a signal
more information, refer to CHI Panel on page has been received from a sensor. Each LED is
3-6 and CHI PANEL OPERATION. numbered for easy identification.
Output signals from the I/O control panel go

directly to the output devices. These devices are
also powered via the I/O control panel.
Most output devices like air valves, relays, and

indicators run on the 24 VDC that comes right
from the I/O control panel. For other devices that
require a different voltage, the I/O control panel
sends an open collector output signal to drive the
logic input on a separate driver board.
When the appropriate LED on the I/O control

panel comes on, it shows that a signal has been
sent to a device. The LED on the I/O control panel
comes on to show that the panel is functioning
properly.
For open collector output, the LED means that

the I/O control panel is sending the signal to the
output device. Each LED is numbered for easy
identification.
Figure 5-4: CHI Panel.
5-6 TOC INDEX

Junction Block
The junction block (Figure 5-5) provides the

I/O (input/output) connection points for primary
fold sensors and air valves. Refer to Sensors/
Valves on page SC-10 to identify the components
connected to each block.
Electrical Panel I/O Control Panel
All control components are located in the

I/O control panel (Figure 5-6) in the lower Figure 5-5: Primary fold junction block at the
right endframe. The table below provides an right rear of the fold section.
explanation of each item indicated in the picture.
For details about each component’s function,
refer to Control Circuit on page SC-8.
OC2 - OC3
OC1
CC1
SC1
EC1
IC1
IC2 - IC4
COMM
Figure 5-6: Control components in the electrical panel.
ELECTRICAL PANEL CONTROL COMPONENTS

Module Description
CC1/SC1 DC Power Supplies
COMM Communications Head - CHI Panel Interface
EC1 Terminator Block
IC1 Interlock Inputs/Encoders/Flags
IC2 - IC4 Input Card - Fold Inputs
OC1 Output Card - Control Outputs
OC2 - OC3 Output Card - Fold Outputs
TOC INDEX 5-7

Sensors The machine speed sensor uses proximity

sensors use a magnetic field to detect the
The photosensors use a high-powered LED movement of the ironing cylinder. As the ironing
pulse output to detect items. When an item cylinder turns, this creates a disturbance of the
is present, this beam is reflected back into a magnetic field. A signal is then sent to the control
sensitive detector built into the photosensor. A system.
signal is then sent to the appropriate MPC1 board.
There are numerous photosensor located at

various places around the unit (Figure 5-7). The
table on page 5-9 provides information about
each photosensor.
PE101
PX4
PE102
PE103
Figure 5-7: Ironer/primary fold photosensor location.
5-8 TOC INDEX

PHOTOSENSORS
Control Board
Sensor Name Function Type & Setting Red LED (Sensor
NOT triggered)
PE101 Ironer Inlet Detects when an item first enters the

ironer. The control system begins counting
pulses from PX4. When the photosensor Diffused Dark
ON
turns off, counted pulses are used to Operate
determine length and calculate timing for
first primary fold.
PE102 Fold A Detects leading edge of piece and triggers

Diffused Dark
first primary fold air blast based on delay ON
Operate
setting.
PE103 Fold B Detects leading edge of piece and triggers

Diffused Dark
second primary fold air blast based on ON
Operate
delay setting.
PROXIMITY SENSORS
PX4 Machine Speed Generates a magnetic field which is

Sensor disturbed by each passing tooth of the
sprocket. This signal is used to verify
12 mm OFF
rotation and determine speed. This
information is also used in timing primary
folds.
TOC INDEX 5-9

Air Filter/Regulators
5.2 Compressed Air
Because the condition of the compressed air
System is so important, the machine includes a filter unit
It is essential that the supply of compressed air equipped with an automatic drain (Figure 5-8,
be clean and dry, and between 80 to 125 PSI (550 A). This helps keep the air clean and dry. This
to 860 kPa). All air is filtered before it is used. unit must be serviced weekly for peak efficiency.
The major components of the pneumatic Air pressure regulators (Figure 5-8, B) are used
system are: to control the air pressure used to perform various
• Air Filter/Regulators functions. The table below lists the recommended
setting for each regulator. These can be adjusted
• Air Reservoirs to meet specific processing needs.
• Air Valves
One Lane Models
• Air Cylinder Must be at least
Incoming
80 psi (550 kPa)
• Air Bars
Primary Fold Air Blast 45 psi (310 kPa)
Transfer Guide 42 psi (290 kPa)
Air Reservoirs
Select crossbeams running down the length or
B across the width of the machine (Figure 5-8, C)
are sealed and used as air reservoirs. These hold a
C supply of compressed air for use in various parts
of the machine as required.
Air Valves
A D
The machine uses a number of air valves
which are actuated electronically by signals from
the MPC1 control board. These valves (Figure
5-8, D) control the flow of compressed air to the
Figure 5-8: Compressed air components inside the various air cylinders and air bars incorporated
right endframe.
into the unit.
5-10 TOC INDEX

Air Cylinder Air Bars

The machine has one air cylinder (Figure The machine has two air bars (Figure 5-9, B,
5-9, A) which uses compressed air to create the C) which use compressed air to help create the
mechanical movement of the flatwork transfer primary folds.
guide.
1st Primary Fold

Air Bar (B)
Flatwork Transfer Guide

Air Cylinder (A) 2nd Primary Fold
Air Bar (C)
Figure 5-9: Ironer/primary fold section air bars and air cylinders.
TOC INDEX 5-11

Ironer Drive System

Use the drawing below (Figure 5-10) to
Components that make up the mechanical
identify the mechanical components of the ironer
system include the following:
drive system.
• Ironer Drive System
A shaft from the main drive motor (A) extends
• Transfer/Primary Fold/Delivery Drive directly into the main gear reducer (B). The output
System shaft of the main gear reducer is connected to a
• Ribbon Sets drive sprocket (C) which powers the drive chain
(D).
The chain passes around a fixed idler arm

(E) and then powers drives the return ribbon
drive roll sprocket (F) and feed ribbon drive roll
sprocket (G).
It then passes over a positioning idler sprocket

(H) and drives the compression roll sprocket (I)
and the ironing cylinder sprocket (J). The fixed
idler arm (E) maintains proper tension on the
drive chain. Tension on the compression roll is
maintained by a spring (K).
I
H
G
F K
D
A/B
C
Figure 5-10: Ironer drive system—right endframe.
5-12 TOC INDEX

Transfer/Primary Fold/Delivery Drive

System
Use the picture below (Figure 5-11) to identify
the mechanical components of the transfer,
primary fold, and delivery drive system.
A second sprocket (B) is connected to the main

drive motor gear reducer output (A).
This sprocket drives a power transfer chain

(C) which is connected to a sprocket (D) on a
jack shaft.
A second sprocket on this jack shaft power

a chain (E) which drives the transfer (F) and
delivery (G) ribbons. An adjustable idler sprocket
(H) is used to keep tension on this drive chain.
E
F
A
C
G
B
H
Figure 5-11: Transfer/primary fold drive system—right endframe.
TOC INDEX 5-13

Ribbon Sets To keep the flatwork tight against the ironing

cylinder (H), a set of return ribbons (I) is rotated
Two sets of ribbons are used in ironing and by the return ribbon drive roll (J) and guided by
one for delivery. Use the cross-section below the return ribbon guide assembly (K) and idler
(Figure 5-12) to follow the path of the flatwork. rolls (L).
Note the function of each roll and set of ribbons
as the flatwork moves through the unit. The flatwork then passes over the return ribbon
drive roll (L) and onto the transfer ribbons (N).
The feed ribbon drive roll (A) rotates the set of These ribbons are driven by the transfer ribbon
feed ribbons (B). These move the flatwork under drive roll (O) and idler rolls (M) and move the
the doffer roll (C) and the safety finger guard (D) flatwork to the rear of the unit.
toward the ironing cylinder (H).
The primary fold air blast directs the flatwork
The flatwork is then carried under the between the transfer (N) and intermediate (P)
compression roll (G), which smooths the ribbons, whose rolls (Q) are driven by friction
flatwork. Guide tapes (E) are wrapped around with the transfer ribbons. The second primary fold
the doffer roll (C), the rear tie bar (F) and the air blast directs the flatwork between the transfer
compression roll (G) to prevent the flatwork from (O) and delivery (R) drive rolls.
sticking to the compression roll.
The delivery ribbons (S), rotated by the
delivery drive roll (R) and idler rolls (T), carry
the piece to the front receiving shelf.
F
L
D L
E G
I
C
H
B
A K
J
M
N M
M Q
O P
S
T R Q
Figure 5-12: Various rolls and ribbons move the flatwork through the ironing and primary fold sections.
5-14 TOC INDEX

The exhaust blower (Figure 5-14) is the only

5.4 Heating and Exhaust component of the exhaust system and it is located
Systems on the exhaust canopy. It draws used air from
under the canopy and discharges it through an
The steam heating system consists of the attached vent duct at the required rate.
following components (Figure 5-13):
• Steam supply (A)
• Condensate return (B)
• Rotary Union (C)
• Siphon Tube (not shown)
These components work together to provide
reliable, consistent heating within the ironing
cylinder.
A B
Figure 5-14: The exhaust blower is located on top

of the exhaust canopy.
Figure 5-13: Steam system components in the left
endframe.
TOC INDEX 5-15

Rotary Union
Provides the connection between fixed steam
piping and the rotating ironing cylinder. Figure
5-15 provides a detailed illustration of the rotary
union and identifies its key components.
A *G D *H *E B *F C
Steam Inlet
Connection
Siphon Tube
(not part of rotary union)
A - HEAD *E - GUIDE
B - BODY *F - SEAL RING
C - NIPPLE *G - SPRING
D - HEAD BOLTS *H - GASKET
Figure 5-15: Cross-section of the rotary union.
5-16 TOC INDEX

Siphon Tube
As the steam gives up its heat, condensate
collects in the bottom of the ironing cylinder. The
siphon tube draws this condensate out through the
rotary union and into the condensate return line.
Figure 5-16 provides a detailed illustration of the
siphon tube and identifies its key components.
Place Chain
Wrench Here
Rotary Union Body
Siphon Tube
(must point down)
Nipple
Threads
Rotary Union Head
Steam Supply Hose
Steam Return
(condensate) Hose
Figure 5-16: External view of the rotary union showing major components.
TOC INDEX 5-17

Stand-By Stage
5.5 Sequence of Operation
During this stage, the incoming power is
The unit has four main stages of operation:
connected to the unit, but the unit is not operating.
• Stand-By Stage
1. Line voltage is present the high-voltage
• JOG Operation Stage contacts for CON1.
• Mechanical Start-Up Stage 2. One stage of the incoming power supplies
the DC power supply PWS1, converting
• Heating System Operation Stage
the line voltage to 24VDC. The 24VDC
• Primary Fold Operation Stage supply is terminated at the START button.
Each stage requires several components to

accomplish its job. The sequencing and timing JOG Operation Stage
of stages are critical.
When the ironer is in Stand-By Stage, the JOG
The following steps describe the logical switch is active. The NC auxiliary contact of CR5
progression of events allowing the unit to work in the INV1 communication circuit is closed.
safely and efficiently.
3. If the JOG switch is turned to FORWARD,
the INV1 communication circuit is closed
NOTE: T h e l e t t e r s a n d as if the NO CR5 contacts are closed.
numbers in parentheses are
schematic references. For 4. If the JOG switch is turned to REVERSE,
more information, refer to the the communication circuit is completed to
SCHEMATIC PARTS LIST. the INV1’s reverse terminals and the main
drive motor runs in reverse.
5. The setting of the speed control is active.

The control should always be set to mini-
mum before using the JOG switch.
6. When the ironer is running normally,

the NC auxiliary contacts of CB5 open,
locking out operation of the JOG switch.
5-18 TOC INDEX

Mechanical Start-Up Stage 9. With CON1 energized, the following

events also occur:
This stage contains the sequence that occurs
when the unit begins operating without heating • The normally-closed auxiliary contact
the ironing cylinder. in the AC frequency inverter motor
control circuitry opens and disables
7. The green START button is pressed: operation of the JOG switch.
• Control relay CR0 is temporarily en- • Simultaneously, a second contact in the
ergized. motor control circuitry closes, signal-
ing the inverter to provide power to the
• Contactor CON1 is energized.
main drive motor.
• The green START button indicator
• The ironing cylinder, feed ribbons, and
lamp comes on.
return ribbons begin to rotate.
• With CR0 energized, CR1 is energized,
• Power is connected to the exhaust
latching the control circuit; at the same
blower motor (MTR3), which rotates
time, CR5 is energized, which sends
the exhaust blower fan and moves air
power to OC1 (Run), allowing CR6
through discharge duct.
to energize, latching the machine in
operating mode.
• Also, when CR5 is energized, its NC

contacts open, disabling the JOG
switch.
• When the START button is released,

CR0 is de-energized.
8. The control system has a built-in 5-second

delay, allowing the unit to start and come
up to speed. After 5 seconds:
• If the sprocket sensor (PX4) is trig-

gered by rotation of the ironing cylin-
der, input 104 of IC2 stays energized,
allowing the machine to operate.
• If the sprocket sensor (PX4) is not

triggered by rotation of the ironing cyl-
inder, input 104 of IC2 is not energized.
The start circuit is disabled, shutting
the machine down.
TOC INDEX 5-19

Heating System Operation Stage During start-up, heat is transferred from the
steam to the cylinder and heats it to operating
temperature. Flatwork is dried and ironed as it
CAUTION moves across the ironing cylinder surface.
It is essential that the
cylinder be heated up The steam condenses into water when it gives
gradually. Failure to do so up its heat. This water, called condensate, runs
can permanently damage down the inside of the cylinder and collects in
the rotary union and/or the bottom.
siphon tube. The condensate (Steam Return) shut-off valve
can be opened fully, because the steam trap will
The ironing cylinder is a pressure vessel built isolate the cylinder from the return piping.
to ASME standards. It must be heated gradually The condensate siphon is adjusted so that its
so that all portions change temperature at the inlet is 1/2” to 1” (12.2 mm to 25.5 mm) from
same time. the bottom of the cylinder. Condensate enters this
If heating is uneven, cracks can develop which siphon and is piped through the rotary union to
will permanently damage the ironing cylinder. the external steam trap.
Heating too rapidly can also cause excessive The steam trap periodically dumps condensate
vibration in the siphon tube and may cause it to into the return line, while sealing steam inside the
break off. cylinder. The condensate is returned to the boiler
The heat used to iron the flatwork is supplied to be heated again.
by the fuel burned in the external boiler. This This cycle of steam to condensate and back to
heat is transferred to water in the boiler, which steam is repeated over and over again to supply
changes into steam. The steam is carried through heat to the unit.
the external steam supply piping to the unit.
See Start-Up on page 3-7. It is important
Steam enters the ironing cylinder through the that each start-up be done carefully and in a
rotary union and fills the cylinder at the pressure consistent manner.
supplied by the boiler. This pressure determines
the temperature at which the ironing cylinder
will operate.
5-20 TOC INDEX

Primary Fold Operation Stage The air blast for the first primary fold pushes
the center of the piece of flatwork into the
The single lane control system uses input space between the drive rolls for the input and
from photosensors and the machine speed sensor intermediate ribbons.
to automatically operate the fold section. Refer
to the SCHEMATIC PARTS LIST to see the The piece of flatwork, now with its first
components involved. Figure 5-7, and Figure 5-9 primary fold, is carried by the intermediate
show the locations of the components. ribbons toward the second primary fold station.
As sensor PE103 turns on, an automatic delay is
Each of the primary fold air manifolds extends begun for the second primary fold.
across the full width of the unit. There is an air
valve at each end of these manifolds. When the When the sensors turn off, the length of the
signal to fold is given, both these valves open piece is known, and a calculation is made to
together. activate the second primary air blast. The signal
to fold is sent by the control system, which opens
The piece enters the fold section on the transfer air valves SV216/SV218.
ribbons. When the piece activates sensor PE101,
the control system begins counting the pulses The air blast for the second primary fold
from machine speed sensor PX4. pushes the center of the piece of flatwork into
the space between the intermediate and lower
When PE101 turns off, the length is known, delivery ribbons.
and a calculation is made to determine when to
activate the first primary fold air blast. When The piece is then carried on the delivery
PE102 turns on, an automatic delay is begun ribbons to the front receiving shelf.
for the first primary fold. At the proper time, the
signal to fold is sent by the control system, which
opens air valves SV215/SV217.
TOC INDEX 5-21

Duo-Star 20 Steam Troubleshooting
Chapter 6
TROUBLESHOOTING
This chapter includes troubleshooting for the Duo-Star 20™ Steam in the areas listed below:
6.1 LED Diagnostics 6.6

Exhaust System
6.2 Electrical 6.7

Primary Folding
6.3 Mechanical System 6.8

CHI Panel
6.4 Ironing Quality 6.9

Sensor Function
6.5 Heating System 6.10

Compressed Air System
Unusual operating symptoms that occur during the checkout or operation of the unit must be diagnosed
and corrected immediately. Mechanical problems can often be detected by visual inspection, while
diagnosis of electrical malfunctions requires maintenance personnel familiar with electrical/electronic
circuitry. Electrical component diagrams are located in the SCHEMATIC PARTS LIST.
Several systems work together to provide consistent, high quality results. It is important to consider
each system when troubleshooting the unit. Each troubleshooting section in this chapter lists issues,
possible causes, and solutions. If an issue occurs that is not addressed in this chapter, please contact your
local authorized CHICAGO® dealer or the Chicago Dryer Company factory Service Department. For a
list of common issues that can occur in each system, refer to Troubleshooting Symptoms on page 6-2.
To better understand a component’s function or how components work together, refer to OPERATING
PRINCIPLES. A complete understanding of the electrical operation will be of value when troubleshooting
this unit.
Any remedy beyond the capability of the users requires repair by trained and experienced personnel.
Please contact your local authorized CHICAGO® dealer or the Chicago Dryer Company factory Service
Department.
WARNING
Never bypass any of the safety devices. This could result in serious
injury to operators and maintenance personnel.
Only trained personnel with experience in steam, electrical, and

mechanical repair should troubleshoot and repair the unit.
Unless otherwise indicated, perform troubleshooting, maintenance,

and repair only when the unit is OFF, with power disconnected,
and completely cooled down.
TOC INDEX 6-1

Troubleshooting Duo-Star 20 Steam
Troubleshooting Symptoms
6.1 LED Diagnostics............................................................................................. 6-6
6.2 Electrical
Unit Does Not Start or JOG, Blank Display......................................................................... 6-8
Unit Does Not Start, Display reads:
Ready to Start/Jog........................................................................................................ 6-8
Unit Does Not Jog, Display reads:
Ready to Start/Jog........................................................................................................ 6-9
Unit Does Not Jog or Start, Display reads:
INVERTER/MOTOR FAULT
!SERVICE/ CLEAR FAULT!.......................................................................................... 6-9
CIRCUIT BREAKER TRIPPED
!SERVICE/ CLEAR FAULT!.......................................................................................... 6-9
FINGER GUARD
!SERVICE/ CLEAR FAULT!
ESTOP
DOOR/COVER OPEN
!SERVICE/ CLEAR FAULT!........................................................................................ 6-10
Unit Starts for a Few Seconds, Then Stops or Stops During Normal Operation,
Display reads: ENCODER 1 FAILED......................................................................... 6-10
No Speed Adjustment....................................................................................................... 6-10

Noisy Operation.................................................................................................................6-11
Ribbons Do Not Track Straight..........................................................................................6-11
Ribbon Set Not Working....................................................................................................6-11
Rotating Elements Stop.................................................................................................... 6-12
Drive System Mechanical or Electrical Error..................................................................... 6-13
6-2 TOC INDEX

6.4 Ironing Quality

Flatwork Feeds Poorly into Ironing Section...................................................................... 6-14
Flatwork Jams or Sticks to Ironing Cylinder; Poor Ironing Quality.................................... 6-14
Flatwork Wraps Around Compression Roll....................................................................... 6-15
Flatwork Scorched or Discolored...................................................................................... 6-15
Flatwork Does Not Dry Correctly...................................................................................... 6-15
Poor Flatwork Finish......................................................................................................... 6-16
Flatwork Sticks to Return Ribbons/Exits Ironer with Excessive Static.............................. 6-16
6.5 Heating System

Dripping Water.................................................................................................................. 6-17
Excessive Leakage at the Rotary Union........................................................................... 6-17
Unit Heats Poorly.............................................................................................................. 6-17
Excessive Steam Use....................................................................................................... 6-17
6.6 Exhaust System

Exhaust Poor or None....................................................................................................... 6-18
6.7 Primary Folding

Flatwork Not Moving Onto Transfer Conveyor Ribbons.................................................... 6-19
Transfer Conveyor Ribbons Do Not Work......................................................................... 6-19
Intermediate Conveyor Ribbons Do Not Work.................................................................. 6-19
Primary Folding Does Not Work, No Message Displayed................................................ 6-19
Primary Folding Does Not Work, Message reads:
COMMUNICATION ERROR
FAULTY CODE RETURNED...................................................................................... 6-20
Primary Folding Does Not Work, NO RX LED, Message reads:
COMMUNICATION ERROR
NO RESPONSE FROM CONTROL........................................................................... 6-20
Primary Folding Does Not Work, Sensor failure message................................................ 6-20
Primary Folding Does Not Work, Jam Message Displayed, No Flatwork Jammed.......... 6-20
Primary Folding is Erratic.................................................................................................. 6-21
Jam Error Message, Message reads:
JAMMED AT PRIMARY
SHUTDOWN BEFORE REMOVING
JAMMED AT SECONDARY
SHUTDOWN BEFORE REMOVING.......................................................................... 6-21
TOC INDEX 6-3

6.8 CHI Panel

CHI Panel is Not Functioning, No error message............................................................. 6-22
CHI Panel is Not Functioning, Message reads:
COMMUNICATION ERROR
FAULTY CODE RETURNED...................................................................................... 6-22
CHI Panel is Not Functioning, Message reads:
COMMUNICATION ERROR
NO RESPONSE FROM CONTROL........................................................................... 6-22
CHI Panel Doesn’t Change Programs.............................................................................. 6-22
Parameter Error Message, Message reads:
MEMORY ERROR
PARAMETERS WILL DEFAULT................................................................................. 6-22
Parameter Error Message, Message reads:
MEMORY INITIALIZED
ADJUST ALL PARAMETERS..................................................................................... 6-22
6.9 Sensor Function

Photosensor is Dirty.......................................................................................................... 6-23
Photosensor is “Seeing a Ribbon”.................................................................................... 6-23
Photosensor Not Working................................................................................................. 6-23
Machine Speed Sensor Not Working................................................................................ 6-23
Sensor Function Issue, Message Reads:
SENSOR FAILED/MISALIGNED
FIRST FOLD
SECOND FOLD LANE
FIRST FOLD ENTRY CENTER
FIRST FOLD DRAPE CENTER................................................................................. 6-23

Compressed Air Issues..................................................................................................... 6-24
No or Poor Air Supply to Air Devices................................................................................ 6-24
6-4 TOC INDEX

This page intentionally left blank.
TOC INDEX 6-5

5. For the component/function that doesn’t

6.1 LED Diagnostics work, check the appropriate LEDs (Figure
Most of the control circuits on the unit operate 6-1) against the chart below:
in a similar way. If there is a malfunction, use
• SET 1—Input LEDs.
this procedure to trace each of the components
to find the problem. • SET 2—Microprocessor control board
input LEDs.
switch. • SET 3—Microprocessor control board
output LEDs.
switch and open the lower right endframe • SET 4—Output board LEDs.
door.
LEDs CHECK
WARNING
Set 1 - OFF - Component. Make sure it is properly
This safety interlock switch aligned and functional.
is only to be defeated
Set 1 - ON - Input board connection to
temporarily while performing microprocessor control board.
this procedure. Set 2 - OFF - Input board.
Never operate the unit Sets 1 & 2 - ON - Microprocessor control board.
unless all safety systems are Set 3 - OFF*
working correctly. Sets 1,2 & 3-ON - Microprocessor control board
Serious Injury Could Result. connection to output board.
Set 4 - OFF - Output board.
All LED’s are - Open circuit between output board

3. The unit will not operate while a safety ON. Device not and device.
interlock is open. As a temporary measure functioning. - Device faulty.
during this work,use a crescent wrench to
*This means that the control board is receiving input but
manually turn ON the main disconnect is not generating proper output.
switch.
4. To diagnose the problem, start the unit, 6. Once the problem is diagnosed, manually
feed a piece and observe the problem area. turn OFF the main disconnect switch and
close the lower right endframe door.
Use the information in the:
• Control System on page 5-6, WARNING

• Testing on page C-11, and all safety covers are in place
• SCHEMATIC PARTS LIST, and all safety equipment is
working correctly.
to determine which LEDs to monitor
during a given operation.
switch.
8. Repair/replace the component and then

retest.
6-6 TOC INDEX

Figure 6-1: The I/O modules located in the electrical panel in the lower right endframe.
TOC INDEX 6-7

WARNING WARNING
Only trained personnel with experience
in steam, electrical or mechanical repair Troubleshooting Read the REPAIR chapter and make
sure that the power is disconnected
should troubleshoot and repair the unit. before doing any repairs.
6.2 Electrical
ISSUE POSSIBLE CAUSE SOLUTION

1. Main disconnect switch is • Turn the main disconnect switch to ON.
OFF.
2. One or more legs of the • Test and repair as necessary.

main power source is dead.
3. Incoming power is incorrect. • Check for fluctuating or incorrect incom-

ing voltage. The power requirements are
shown on the unit’s nameplate.
4. Main disconnect switch • Replace blown fuse.

fuse FU1 or FU2 is blown
so power is not available to • If fuse continues to blow:
PWS1. • Check the wiring for a short or open
Unit Does Not Start or JOG
circuit.
Blank Display
• Replace defective components(s) as
required.
5. DC power supply circuit • Reset tripped circuit breaker.

breaker CB0 is tripped,
• If circuit breaker continues to blow:
-- Check the wiring for a short or open
circuit.
-- Replace defective component(s) as
required.
6. Start button is defective. • Check for 24 VDC at the START button.

Replace the switch if 24 VDC is present
and the switch does not operate.
1. Start button is defective. • Check for 24 VDC at the START button.

Unit Does Not Start and the switch does not operate.
Display reads: 2. CON1 is defective. • Check/test. Replace as necessary

Ready to Start/Jog 3. CR5 or CR6 is defective. • Check/test. Replace as necessary
4. INV1 is defective. • Contact Factory Service Department.
6-8 TOC INDEX

WARNING WARNING

1. JOG switch is defective. • Check for 24 VDC at the JOG switch.
Unit Does Not Jog and the switch does not operate.
Display reads:
2. CR5 is defective • Check/Test. Replace if necessary.
Ready to Start/Jog
3. Diode Terminal Block D1, • Chest/test. Replace if necessary.
D2 or D3 is faulty.
1. Circuit breaker CB1 is • Reset tripped circuit breaker.

tripped.
-- Check the wiring for a short or open
circuit.
-- Replace defective component(s) as
required.
2. Inverter needs to be reset. • Reset the inverter:

-- Turn power OFF at the main discon-
Unit Does Not Jog or Start nect switch.
-- Wait one minute.
Display reads:
-- Turn power ON at the main disconnect
INVERTER/MOTOR FAULT switch.
• If the fault repeats:
-- Input voltage is too high or low.
-- Open circuit between the inverter and
MTR1.
-- Main drive motor MTR1 is bad.
3. Drive system is overload- • Check all sprockets and rolls driven by

ed. Mechanical problem is drive chains for binding. Refer to Drive
causing excessive motor System Mechanical or Electrical Error
loading. on page 6-13.
1. 24VDC Circuit breaker CB5 • Reset tripped circuit breaker.

Unit Does Not Jog or Start is tripped.
Display reads: -- Check the wiring for a short or open
CIRCUIT BREAKER TRIPPED circuit.
!SERVICE/ CLEAR FAULT! -- Replace defective component(s) as
required.
TOC INDEX 6-9

WARNING WARNING

WARNING
Never operate the unit unless all safety devices are working correctly.
Unit Does Not Jog or Start
1. Red safety finger guard is • Release guard.
Display reads: pushed in.
• If message continues to display, check
FINGER GUARD for faulty switch. Replace as necessary.
2. A red safety STOP button is • Twist to reset pressed button.
ESTOP pushed in.
!SERVICE/ CLEAR FAULT! • If message continues to display, check
for faulty switch. Replace as necessary.
DOOR/COVER OPEN
3. Endframe door, back panel • Close/replace open door/missing panel.
or fold system cover panel
is open/removed. • If message continues to display, check
for faulty switch. Replace as necessary.
1. Machine speed sensor is • Refer to Machine Speed Sensor Posi-

too far from the ironing tion Adjustment on page 7-61.
cylinder sprocket.
2. Machine speed sensor is • Check/Replace. Refer to Machine

bad. Speed Sensor Replacement on page
Unit Starts for a Few Seconds,
7-62.
Then Stops or Stops During
Normal Operation
3. Open between the machine • Check/repair connection.
Display reads: speed sensor and the I/O
control module or I/O mod- • Check I/O Module.
ENCODER 1 FAILED ule is bad. • Replace defective component(s) as
necessary.
4. Ironing cylinder is not • Check for broken or loose drive chain.

turning fast enough, or not
at all.
1. Short or open circuit in the • Inspect the wiring for a short or open
wiring. circuit. Replace any defective wires.
2. Loose connection at • Tighten all connections at the SPEED

SPEED knob or inverter. knob and the AC frequency inverter.
No Speed Adjustment 3. SPEED knob potentiom- • Replace the SPEED knob potentiometer.
eter is bad if it will not vary
the speed.
4. AC frequency inverter mo- • Call the factory Service Department for

tor control is malfunctioning instructions.
if there is no motion.
6-10 TOC INDEX

WARNING WARNING

1. Mechanical components • Lubricate. Refer to Grease “Weekly”
need lubrication. Bearings on page 4-9, Grease Bear-
ings on page 4-14, and/or Oil Drive
Chain and Tension Springs on page
4-16.
• Replace any bearing that does not

operate smoothly and quietly after being
lubricated.
2. Drive chain is loose. • Adjust tension. Refer to REPAIR and

the appropriate section for the specific
Noisy Operation procedure.
3. Sprockets are loose, worn, • Inspect the sprockets and the drive
or misaligned, or the drive chain. Repair/replace as necessary.
chain has excessive play.
4. Inverter frequency setting • Adjust frequency. For more information,

is causing noisy motor contact the factory Service Department.
operation.
5. Drive train system error. • Refer to Drive System Mechanical or

Electrical Error on page 6-13.
1. Ribbon tension needs to be • Adjust/Replace. Refer to REPAIR and

adjusted. the appropriate section for the specific
procedure.
2. Ribbons are broken or • Replace. Refer to REPAIR and the

Ribbons Do Not Track Straight missing. appropriate section for the specific
procedure.
3. Roll Tracking tape or friction • Replace. Refer to REPAIR and the

material is worn smooth. appropriate section for the specific
procedure.
1. Improper tension on rib- • Adjust/Replace. Refer to REPAIR and

bons. the appropriate section for the specific
procedure.
Ribbon Set Not Working 2. Roll tracking tape or • Adjust/Replace. Refer to REPAIR and
friction material is worn the appropriate section for the specific
smooth. procedure.
3. Refer to Rotating Elements Stop on page 6-12.
TOC INDEX 6-11

WARNING WARNING

1. Drive chain is slipping or • Adjust tension or replace if broken or
broken. worn.
2. Idler pulley loose or frozen. • Adjust tension or replace.
3. A motor protector has • Reset the motor protector. If it continues

tripped. to trip, check the setting.
4. There is an open circuit be- • Check for an open connection in one of

tween the contactor and the the wires on a 3-phase motor.
motor protector, or between
the motor protector and the • Motor protector is defective and needs
Rotating Elements Stop to be replaced.
motor.
• Motor is defective and needs to be
replaced.
• Check inverter and connections to the

motor.
5. If one rotating element • Replace as necessary.

is stationary, check for a
broken shaft, bad bearing
or a loose or worn drive
sprocket.
6-12 TOC INDEX

WARNING WARNING

NOTE: Several drive trains are used on the machine. They share common features and can be diagnosed
using the information below. Check the components for the particular drive train being troubleshot.
1. Chain loose or broken. • Check the chain.
• Adjust or replace. Refer to REPAIR and

the appropriate section for the specific
procedure.
2. Mechanical component • Check that sprocket is properly secured

loose, misaligned or bro- to shaft:
ken. -- Tighten setscrews as necessary.
-- Replace shaft key as necessary.
-- Replace roll if shaft damaged.
-- Check to see if sprocket is missing
teeth. Replace.
• Check and correct any alignment errors.

Replace any component that does not
work smoothly and quietly after align-
ment.
3. An inverter, motor protector • For inverter problem, turn machine off

Drive System Mechanical or or motor thermal overload for one minute.
Electrical Error has tripped. -- For motor protector, reset tripped
device.
-- For thermal overload, motor must be
allowed to cool until automatic reset.
4. There is an open some- • Check for an open connection in one of

where in the motor circuit or the wires on a 3-phase motor.
a component is defective.
• Check for an open connection between
motor and inverter or motor protector.
• Check for an open connection between

the contactor and inverter or motor
protector.
• Check for defective component such as

contactor or motor protector and replace
if necessary.
• Inverter fault. Call factory for service.
• Motor is defective and needs to be

replaced.
TOC INDEX 6-13

WARNING WARNING
6.4 Ironing Quality

1. Unit is not properly waxed • Refer to Waxing on page 3-8.
(Does not apply to chrome
ironing cylinders).
2. Feeding technique is im- • Refer to Flatwork Handling on page

proper. 3-10.
3. Compression roll is not • Make sure the compression roll is

down. engaged; the spring-loaded handles
must be in their bracket slots in each
endframe.
4. Compression roll tension is • Check/Adjust. Refer to Compression

inadequate or uneven. Roll Pressure Check on page 7-20
Flatwork Feeds Poorly into
and/or Compression Roll Pressure
Ironing Section
Adjustment on page 7-21.
5. Compression roll pad is • Replace. Refer to Compression Roll

worn. Cover Replacement on page 7-21.
6. Return ribbon tension out of • Adjust Refer to Return Ribbon Tension

adjustment. Adjustment on page 7-37.
7. Feed ribbon drive roll cover • Replace. Refer to Feed Ribbon Drive
is worn smooth. Roll Friction Material Replacement on
page 7-8
8. Feed table out of adjust- • Adjust. Refer to Feed Table Alignment

ment. and Positioning on page 7-16.
1. Feeding technique is im- • Refer to to Flatwork Handling on page

proper. 3-10.
2. Return ribbon drive roll cov- • Replace. Refer to Return Ribbon Drive
er material is worn smooth. Roll Friction Material Replacement on
page 7-41.
3. Return ribbons are worn • Replace. Refer to Return Ribbon Re-

Flatwork Jams or Sticks to
smooth. placement on page 7-38.
Ironing Cylinder; Poor Ironing
Quality 4. Ironing cylinder has a build- • Check for buildup of chemicals or debris
up of chemicals or debris. which discolor the ironing cylinder. For
cleaning instructions, refer to Ironing
Cylinder Reconditioning on page
7-27.
5. For additional possible causes and solutions, refer to Flatwork Feeds

Poorly into Ironing Section above.
6-14 TOC INDEX

WARNING WARNING

Flatwork Wraps Around Com- 1. Missing or damaged guide • Replace. Refer to Guide Tape Replace-
pression Roll tapes. ment on page 7-11.
1. If flatwork rinses clean with • Adjust the settings of the washer.

a small amount of soap, a
chemical residue is left over
from the wash cycle.
2. If flatwork does not rinse • Refer to Operating Techniques on

clean, the temperature is page 3-14.
set too high, the ironing
Flatwork Scorched or Discol- speed is too slow, and/or
ored moisture retention from the
washer/extractor is incor-
rect.
3. If rust-colored spots occur • Check and clean any condensed wax

on the flatwork, there is a buildup under the canopy and the feed
condensed wax buildup table.
under the canopy and/or
the feed table.
1. Processing standards are • To review the directions for setting up

not being followed. these standards, refer to Processing
Standards on page 3-17.
2. Flatwork left in a hamper • Increase heat or decrease ironing speed

for a long time will have an SLIGHTLY for linen that feels more
uneven moisture content. damp.
Flatwork Does Not Dry Cor-
rectly 3. Flatwork run through wash- • Increase final flatwork temperature
er/extractor with cold water from extractor. Refer to Conditioning
will have less moisture Flatwork Before Ironing on page
extracted. 3-15.
4. Extractor is not removing • To review the extraction process, refer to

enough moisture. Conditioning Flatwork Before Ironing
on page 3-15.
TOC INDEX 6-15

WARNING WARNING

1. Feeding technique is im- • Use correct feeding techniques. Refer to
proper. Flatwork Handling on page 3-10.
2. Ironing section controls are • Check the setting of SPEED knob. Refer
incorrectly set for the linen to Processing Standards on page
being processed. 3-17.
3. Ironing cylinder is not being • Refer to Waxing on page 3-8.

waxed at least once a day
(Does not apply to chrome
ironing cylinders).
4. Missing or damaged guide • Refer to Guide Tape Replacement on

tapes. page 7-11.
Poor Flatwork Finish
5. Return ribbon drive roll • Replace. Refer to Return Ribbon Drive
friction material is worn Roll Friction Material Replacement on
smooth. page 7-41.
6. Return ribbons are exces- • Replace. Refer to Return Ribbon Re-

sively worn and are not placement on page 7-38.
moving flatwork correctly.
7. Compression roll pressure • Check/Adjust. Refer to Compression

is not even from side to Roll Pressure Check on page 7-20
side. and/or Compression Roll Pressure
Adjustment on page 7-21.
8. Compression roll padding • Replace. Refer to Compression Roll

is worn. Cover Replacement on page 7-21.
Flatwork Sticks to Return Rib- 1. Chrome ironing cylinder • Refer to Waxing on page 3-8.
bons/Exits Ironer with Exces- needs waxing.
sive Static
6-16 TOC INDEX

WARNING WARNING
6.5 Heating System

1. Normal operation. • Some leakage (“weeping”) at the rotary
union is normal. Steam entering the
rotary union provides the necessary
lubrication.
2. Some connections may be • Tighten the fittings or component hard-

loose. ware. If this does not stop leakage, refer
Dripping Water
to Excessive Leakage at the Rotary
Union below.
3. Piping strains can force • Align piping to relieve strain on the

the carbon-graphite seal rotary union.
ring and guide in the rotary
union out of alignment.
1. The metal parts (body and • Repair or replace the rotary union. Refer
nipple) mating with the seal to Rotary Union Maintenance on page
rings are worn. 7-30.
Excessive Leakage at the Ro-
tary Union
2. The body and nipple may • Repair or replace the rotary union. Refer
be corroded or worn. to Rotary Union Maintenance on page
7-30.
1. Steam supply shut-off valve • Open slowly. Refer to Start-Up on page

not properly open. 3-7.
2. Loss of steam pressure. • Check supply to ironer. Correct steam

pressure or lower ironing speed.
Unit Heats Poorly 3. Condensate water has • Siphon tube may be broken off or it has
backed up in the cylinder moved from the 6 o’clock position. Re-
and produced a cooling pair or replace siphon. Refer to Rotary
effect. Union Maintenance on page 7-30.
4. Steam trap sluggish or • Verify that trap(s) are level and working
stuck closed. correctly. Repair/replace as necessary.
1. Steam leaks around fittings. • Tighten the fittings or component hard-

ware. If this does not stop leakage, refer
to Excessive Leakage at the Rotary
Excessive Steam Use Union above.
2. Steam trap stuck in open • Verify that trap(s) are level and working
position. correctly. Repair/replace as necessary.
TOC INDEX 6-17

WARNING WARNING
6.6 Exhaust System

1. Exhaust blower motor pro- • Reset the motor protector.
tector is tripped.
2. Exhaust blower motor is • Inspect the exhaust blower motor. Refer

binding. to Check and Clean Motors on page
4-12.
3. Exhaust blower wheel is • Check for lint build up on the exhaust

dirty. blower wheel. Refer to Check and
Clean Exhaust Blower Wheel on page
4-12.
Exhaust Poor or None
4. Wire connections for the • Check the wire connections from the
exhaust blower motor are exhaust blower to the main electrical
loose or disconnected. panel. Refer to Exhaust Blower Motor
Rotation Checkout on page 2-19.
5. Screens are blocking the • Remove any screens from the end of
end of the exhaust duct the ductwork. Refer to Exhaust Blower
work. Installation on page 2-5.
6. Exhaust duct work in the • Clean out the exhaust duct work.
canopy is dirty or blocked.
6-18 TOC INDEX

WARNING WARNING
6.7 Primary Folding

1. Flatwork transfer guide air • Adjust. Refer to Flatwork Transfer
Flatwork Not Moving Onto
cylinder stroke too short. Guide Mechanical Adjustment on
Transfer Conveyor Ribbons
page 7-45.
1. Sprocket and shaft are • Refer to Drive System Mechanical or

damaged, or the drive chain Electrical Error on page 6-13.
is loose.
Transfer Conveyor Ribbons 2. Ribbon tension needs to be • Refer to Transfer Ribbon Tension
Do Not Work adjusted. Adjustment on page 7-45.
3. Tracking tape on the drive • Refer to Transfer, Intermediate and

roll is worn smooth. Delivery Rolls Tracking Tape Replace-
ment on page 7-55.
1. Ribbons are loose, worn or • Refer to Intermediate Ribbon Replace-

clipper lacing is broken. ment on page 7-48.
Intermediate Conveyor Rib-
bons Do Not Work 2. Tracking tape on the drive • Refer to Transfer, Intermediate and
roll is worn smooth. Delivery Rolls Tracking Tape Replace-
ment on page 7-55.
1. Fold system is turned off. • Press the CHI or MANUAL button to

activate.
2. The flatwork transfer guide • Check/adjust.

is malfunctioning, returning
the flatwork to the front of
the unit.
3. Compressed air system • Refer to Compressed Air System on

Primary Folding Does Not issue. page 6-24.
Work
No Message Displayed 4. Flatwork is not detected by • Refer to Sensor Function on page

the input sensor (PE101) 6-23.
causing the piece to fall
behind the unit.
5. Flatwork is not being fed • Refer to Flatwork Handling on page

properly. 3-10.
6. Primary fold system error. • Test the primary fold section. Refer to
Primary Fold Tests on page C-13.
TOC INDEX 6-19

WARNING WARNING

NOTE: During start-up, the CHI panel communicates with the fold control
circuit board MPC1; the RX and TX LEDs blink for about one-second as
communication begins.
1. Four-wire communication • Make sure the connection is tight at both

Primary Folding Does Not cable from CHI panel to the ends.
Work fold control board is loose.
Message reads: 2. Communications cable is • Turn the connector over to check and
attached backward. correct.
COMMUNICATION ERROR
FAULTY CODE RETURNED 3. Two-wire power cable from • Make sure the connection is tight; re-
MPC1 to the CHI panel is place if worn.
loose or defective.
4. Fold control circuit board • Replace if necessary.

MPC1 is defective.
1. Four-wire communications • Make sure the connection is tight at both

Primary Folding Does Not cable from the CHI panel ends.
Work, NO RX LED to the fold controller has
come off.
Message reads:
2. Communications cable has • Repair or replace if necessary.
COMMUNICATION ERROR a broken wire.
NO RESPONSE FROM CON-
TROL 3. Fold controller circuit board • Replace.
is defective.
Primary Folding Does Not 1. Sensor may be dirty or • Clean and/or adjust. Refer to Sensor
Work defective. Function on page 6-23.
Sensor failure message
Primary Folding Does Not 1. Ironer exit sensor (PE103) • Clean and/or adjust. Refer to Sensor
Work issue. Function on page 6-23.
Jam Message Displayed, No

Flatwork Jammed
6-20 TOC INDEX

WARNING WARNING

1. Incorrect flatwork feeding. • Operator is feeding flatwork incorrectly.
Refer to Flatwork Handling on page
3-10.
2. One or more of the pho- • Clean and/or adjust. Refer to Sensor

tosensors may be dirty or Function on page 6-23.
defective.
3. Compressed air system • Refer to Compressed Air System on

issue. page 6-24.
Primary Folding is Erratic
4. Too much static electricity • Change processing standards to
causing the flatwork to increase moisture retention slightly or
stick. change the amount of fabric softener
used. Refer to Operating Techniques
on page 3-14.
5. One or more stations need • Use the TEST mode of the CHI panel to
adjustment. find the station(s) needing adjustment.
Refer to Primary Fold Tests on page
C-13.
WARNING
Never reach into the fold section when the unit is powered. Turn
power OFF at the main disconnect switch before manually clearing
a jam. Make sure everyone is clear of the unit before restarting the
unit.
1. Random jam error. • Remove the jam. Refer to Clearing a

Jam Safely on page 3-11.
2. Feeding error. • Flatwork must be placed straight on

Jam Error Message
ribbons and centered in lane. Refer to
Message reads: Folding Accuracy on page 3-13.
JAMMED AT PRIMARY 3. Compressed air problem. • First or Second primary fold air blast set-
SHUTDOWN BEFORE REMOV- tings need adjustment. Refer to Primary
ING Fold Adjustments on page C-10.
JAMMED AT SECONDARY • Air bar needs alignment or air valve

SHUTDOWN BEFORE REMOV- requires service. Refer to Air Bar
ING Alignment on page 7-63.
4. Problem with sensor. • Sensor is dirty or is failing. Refer to

Sensor Function on page 6-23.
5. Mechanical Problem. • Ribbon set not working. Refer to Rib-

bon Set Not Working on page 6-11.
• Pinch point positioning needs adjust-

ment. Contact the factory Service
Department.
TOC INDEX 6-21

WARNING WARNING
6.8 CHI Panel

CHI Panel is Not Functioning 1. 2-wire power cable from • Reconnect; replace if necessary.
MPC1 for power to the CHI
No error message Panel is not connected.
1. 4-wire communications • Check and repair connection at both

cable from the CHI Panel to ends.
CHI Panel is Not Functioning MPC1 is loose.
Message reads:
2. Communication cable is • Turn the connector over.
COMMUNICATION ERROR attached backward.
FAULTY CODE RETURNED
3. MPC1 Machine Controller • Replace.
circuit board is bad.
1. 4-wire communications • Check and repair connection at both

CHI Panel is Not Functioning cable from the CHI Panel to ends.
MPC1 is loose.
Message reads:
2. Communication cable has • Repair or replace.
COMMUNICATION ERROR broken wire.
NO RESPONSE FROM CON-
TROL 3. MPC1 Machine Controller • Replace.
1. Ironer is not started. • Start.
2. Folder not started. • Start folder unit.

CHI Panel Doesn’t Change
Programs 3. CHI Panel is faulty. • Check and replace.
4. MPC1 Machine Controller • Replace.

Parameter Error Message 1. CHI Panel component is • CHI Panel contains a static memory with
missing or bad. the laundry’s specific programming se-
Message reads: lections. Contact an authorized service
MEMORY ERROR outlet for instructions.
PARAMETERS WILL DEFAULT
Parameter Error Message 1. After replacement, the CHI • All programs need to be reset. Refer
Panel chip only recognizes to Programming on page C-6 and
Message reads: factory defaults. Adjustment on page C-8.
MEMORY INITIALIZED
ADJUST ALL PARAMETERS
6-22 TOC INDEX

WARNING WARNING
6.9 Sensor Function

1. Insufficient preventive main- • Clean. Refer to Check and Clean Pho-
Photosensor is Dirty
tenance. tosensors on page 4-4.
1. Ribbons are not tracking • Adjust tension so ribbons track straight.

properly or photosensor is Refer to Ribbons Do Not Track
Photosensor is “Seeing a
misaligned. Straight on page 6-11 and/or First
Ribbon”
Primary Fold Photosensor Position
Alignment on page 7-59.
1. Photosensor or other • Refer to LED Diagnostics on page

Photosensor Not Working control component is failing 6-6 to determine source of problem
or bad. and take appropriate corrective action.
1. Sensor is not properly • Adjust. Refer to Machine Speed Sensor

positioned. Position Adjustment on page 7-61.
2. Sensor is failing or bad. • Check component. Replace as neces-

Machine Speed Sensor Not
sary. Refer to Machine Speed Sensor
Working
Replacement on page 7-62.
• Check wiring and connections. Tighten/

repair as necessary.
1. Photosensor/reflector is • Clean. Refer to Check and Clean Pho-

dirty. tosensors on page 4-4.
2. Incorrect adjustment. • Check/adjust. Refer to Ironer Inlet and

Second Primary Fold Photosensor
Sensitivity Adjustment on page 7-57
and/or First Primary Fold Photosensor
Sensor Function Issue
Sensitivity Adjustment on page 7-58.
Message Reads:
3. There is an open circuit • Check connections between the sensor
SENSOR FAILED/MISALIGNED between the sensor and the and input card.
FIRST FOLD input card. -- Main control circuit board is defective.
Replace.
-- Sensor is defective. Replace.
SECOND FOLD LANE
4. Sensor is activated and the • I/O module is defective and needs to be
SENSOR FAILED/MISALIGNED control system does not replaced.
FIRST FOLD ENTRY CENTER respond.
SENSOR FAILED/MISALIGNED 5. Damaged sensor cable. • Replace the sensor. Refer to Photosen-
FIRST FOLD DRAPE CENTER sor Replacement on page 7-60.
6. Component is bad or • Check wiring and connections. Tighten/

failing. repair as necessary.
• Check component. Replace as neces-

sary. Refer to Photosensor Replace-
ment on page 7-60.
TOC INDEX 6-23

WARNING WARNING

1. Air supply error. • Make sure the valve between the unit
and the air supply is open.
• Turn air supply on.
• Pressure must be set correctly. Refer to

Check Air Pressure Settings on page
4-7.
• Air supplied must be clean and dry.
2. Compressed air supply • Test the system using the CHI panel.
system error. Refer to Testing on page C-11.
-- Look at the I/O module for each air
valve. An LED lights for each valve.
Refer to the SCHEMATIC PARTS
Compressed Air Issues LIST. When the LED does not come
on when the valve is supposed to
open, the I/O module is defective and
must be replaced.
-- There is an open circuit between the
I/O module and the actuator
-- Actuator on the valve is defective and
must be replaced
3. Air filter with auto drain is • Clean the air filter with auto drain. Refer
dirty. to Clean Air Filter/Auto Drain on page
4-18.
4. A supply hose is obstructed • Check the hose to the valve in ques-

or detached tion. Reattach, clear the obstruction or
replace.
1. Compressed air tubing • Make sure connections are secure.

problem.
• Check tubing for leaks, kinks or plugs.
2. Air valve malfunction. • Make sure coil is properly connected to

air valve.
No or Poor Air Supply to Air
Devices • Make sure coil is receiving electrical
signal.
• Replace coil/air valve.
3. Air supply hose/piping too • Make sure supply lines are 1/2” (DN 15)
small. inside diameter.
6-24 TOC INDEX

Duo-Star 20 Steam Repair
Chapter 7
REPAIR
Although designed for long service life, some individual consumable parts of the Duo-Star 20™ Steam
eventually wear during normal use and must be cleaned, adjusted, or replaced. This chapter includes
the following sections:
7.1 Safety Considerations 7.6

Rotary Union Maintenance
7.2 Parts Availability 7.7

Return Section
7.3 Feed Section 7.8

Primary Fold/Delivery Sections
7.4 Compression Roll 7.9

Sensors
7.5 Ironing Section 7.10

Compressed Air System
As a general rule:
• Replace ribbons when they are worn or broken, when tension can no longer be adjusted, or
when flatwork does not feed smoothly into the ironing section.
• Replace roll covers when they are worn smooth, when the ribbons slip in place, or when the
general finish of the flatwork is unsatisfactory after other causes have been ruled out.
• Replace tracking tape when it is worn smooth or when ribbons slip in place.
• Clean the ironing cylinder when deposits or debris affect the finish of processed flatwork.
• Follow Preventive Maintenance Schedule beginning on page 4-1.
WARNING
Do not try to repair or correct any condition without reading and
understanding this Repair Chapter.
Only qualified personnel should troubleshoot and repair the machine.
WARNING
Always ensure the unit is completely cooled down and the power is
shut OFF at the main disconnect switch before servicing the unit.
TOC INDEX 7-1

Repair Duo-Star 20 Steam
• Only work on the unit when it has

7.1 Safety Considerations been completely cooled. For more
Before attempting any repair work, review information, refer to Shut-Down on
these safety steps and precautions to protect page 3-14.
yourself and the unit. • All maintenance procedures should
• Safety should be the primary concern of be handled by at least two qualified
anyone performing repair work on the persons. Using the “buddy system”
unit. facilitates a quicker procedure and
decreases the risk of an accident.
• Except where specifically directed, make
sure the power is turned OFF at the main • Always keep hands and clothing away
disconnect switch. from the moving parts of the machine
when it must be running to make repairs
or adjustments.
WARNING
Always use extreme caution • Never bypass any of the unit’s safety
when performing any repair features. Only operate the unit with
endframe doors and all guards in
procedure requiring the unit
place and all safety features operating
to be operating. correctly.
Take every precaution • Never stand, sit, or kneel on a receiving

to keep hands and loose shelf.
clothing from coming into • Your site should have lockout/tagout
contact with any of the procedures in place that comply with
moving rolls or other government standards for performing
moving parts. maintenance and repair. Ask your
Serious Injury Could Result. supervisor for specific information.
• The JOG switch remains powered
Whenever the unit is running, even when one of the safety interlock
one person should be ready switches is open. This keeps it available
at a red safety STOP button for emergency use. It is very important
at all times to stop the unit that the unit is properly tagged according
if necessary. to the site’s government-approved
procedures whenever repair work is
being done.
7-2 TOC INDEX

WARNING 7.2 Parts Availability

Know the proper lockout/ Replacement and repair parts can be ordered
tagout procedures for through your local authorized CHICAGO ®
equipment during repair. distributor. Questions about the operation,
Follow the rules of your work maintenance, troubleshooting, or repair of the unit
site. Failure to do so could can also be directed to your distributor.
result in serious injury.
In addition, questions may be directed to
the Chicago Dryer Company factory Service
Do not repair or correct any Department by calling (773) 235-4430.
condition without reading
and understanding the
repair procedure. NOTE: Use only factory warranty
tested and approved replacement
Only qualified personnel parts when repairing a Chicago®
unit. They are designed for each
should troubleshoot and
specific machine model and serial
repair this unit. number. Overnight shipment of
parts is available.
Always make sure that the
machine is cooled down and
that power is disconnected
before servicing the unit.
TOC INDEX 7-3

Feed Ribbon Tension Adjustment

7.3 Feed Section
Adjust the tension of the feed ribbons when
Flatwork is directed into the unit through the
they sag or track to one side of the ironing section.
feed section, which consists of the following
Both conditions cause excessive wear on the
components (Figure 7-1):
ribbons and shorten their life.
• Feed Table (A)
• Feed Ribbon Drive Roll (B)
Required Tools
Wrenches:
• Feed Ribbons (C) 3/8”
9/16”
• Doffer Roll (D)
• Guide Tapes (E) Perform only when the unit is OFF
Various of these components require periodic
adjustment, replacement, or occasional repair. 1. Turn power OFF at the main disconnect
switch.
These procedures include:
• Feed Ribbon Tension Adjustment 2. Open both endframe doors.
• Feed Ribbon Replacement 3. Locate the feed ribbons drive roll tension
adjustment bolts (Figure 7-2, A). There is
• Feed Ribbon Drive Roll Friction one on each side of the machine.
Material Replacement
4. While holding each adjustment bolt in
• Guide Tape Replacement
place, loosen its locknut (Figure 7-2, B).
• Doffer Roll Cover Replacement
• Feed Table Alignment and Positioning
A B C D E
Figure 7-1: Feed section components. Figure 7-2: Feed ribbon tension adjustment in the
left endframe.
7-4 TOC INDEX

9. Run the unit briefly and make sure the

CAUTION ribbons track straight and do not rub on
Do not over tension the the ribbon guides under the feed table.
ribbons. Too much tension
can cause excessive motor 10. If tension on the ribbons is uneven, ribbons
track toward the end of the drive roll where
amperage and premature
the tension is highest.
ribbon wear.
5. Adjust each bolt the same number of turns
clockwise until the ribbons are snug. Test 12. Either turn the adjusting bolt counter-
the tension by pulling up lightly on the clockwise at the high tension end, or turn
ribbon. Resistance should be felt within the adjusting bolt clockwise at the low
1/4” to 1/2” (6 to 13 mm). tension end.
13. Repeat Steps 7 to 12 until the ribbons have

WARNING the correct tension and track evenly.
This safety interlock switch
is only to be defeated 14. Stop the unit and turn power OFF at the
temporarily while performing main disconnect switch.
this procedure.
Never operate the unit place, secure its locknut.
unless all safety systems are
working correctly. 16. Remove the interlock switch keys; then,
Serious Injury Could Result. close and secure both endframe doors.
6. The machine will not operate while a safe- WARNING

ty microswitch is open. As a temporary Never operate the unit unless
measure during this work, defeat each all safety covers are in place
endframe interlock switch by inserting and all safety equipment is
one of the switch keys that shipped with working correctly.
the unit.

switch.

speed.
TOC INDEX 7-5

Feed Ribbon Replacement 5. While holding each adjustment bolt in

Feed ribbons stretch and flatwork moves
unevenly and improperly into the ironing section. 6. Turn each bolt the same number of turns
When tension on these ribbons can no longer be counterclockwise until the ribbons are
adjusted, the entire set must be replaced. easily moved by hand.
7. Place the wooden wedges under each end

NOTE: Read the FEED RIBBON of the doffer roll to hold it above the feed
REPLACEMENT section on the ribbons.
Pink Operator Safety Reminder
in the front of this manual.
WARNING
Never start the unit while
installing the feed ribbons.
Replacing Worn Ribbons It is dangerous
Use this procedure to replace ribbons that are and unnecessary.
still in place, but are worn out.
8. Pull the worn ribbons around their tracks
Required Tools until all the lacing clips are accessible and
Pliers aligned at the front of the unit.
Wooden wedges
Wrenches:
3/8” NOTE: Make sure the rough
9/16” side of the ribbon faces down.

with power disconnected and COOL. 9. Remove the connecting pin from an old
ribbon and attach a new ribbon to one end,
1. Verify the replacement ribbons are the rough side down.
correct size and there is sufficient quantity
10. Pull the old ribbon through until the new
to complete the procedure. See Rolls and
ribbon is in place.
Ribbons on page PL-6.
11. Disconnect the old ribbon and connect the
ends of the new ribbon with a new pin.
switch.
12. Repeat Steps 9 to 11 to replace additional
worn ribbons. Stagger the positions of the
4. Locate the feed ribbons drive roll tension lacing clips to give the flatwork a smooth
adjustment bolts (Figure 7-2, A). There is flow.
one on each side of the machine.
13. Remove the wooden wedges from the
ends of the doffer roll, allowing it to rest
on the ribbons.
14. Adjust ribbon tension; refer to Feed Rib-

bon Tension Adjustment on page 7-4.
7-6 TOC INDEX

Replacing Broken or Missing Ribbons

WARNING
Ribbons that break should be replaced Never start the unit while
immediately. To avoid excessive stress on only installing the feed ribbons.
one new, slightly shorter ribbon, the entire set of It is dangerous
ribbons should be replaced. At a minimum, it is
and unnecessary.
recommended that ribbons be replaced in pairs.
Required Tools
Pliers NOTE: Make sure the rough
Screwdriver: long shaft side of the ribbon faces down.
Wooden wedges
Wrenches:
3/8” 9. Position a replacement feed ribbon, rough
9/16” side down, on the feed table. Push the
ribbon under both the doffer roll and the
Perform only when the unit is OFF red safety finger guard.
10. Using a long-shafted screwdriver or simi-
1. Verify the replacement ribbons are the lar tool, push the leading edge of the ribbon
correct size and sufficient quantity for down the back edge of the feed table. Be
completing the procedure. See Rolls and careful not to scratch the ironing cylinder.
11. Reach under the feed table and pull the
2. Turn power OFF at the main disconnect end of the ribbon toward the front of the
switch. unit. Make sure the ribbon end is below the
rod and between the feed ribbon guides.
3. Open both endframe doors. Verify that the replacement ribbon follows
the path of the other ribbons.
4. Locate the feed ribbons drive roll tension
adjustment bolts (Figure 7-2, A). There is 12. Bring the ends of the ribbon together and
one on each side of the machine. connect the ends with a new pin.
5. While holding each adjustment bolt in 13. Repeat Steps 9 to 12 to replace additional
place, loosen its locknut (Figure 7-2, B). missing ribbons. Stagger the positions
of the lacing clips to give the flatwork a
6. Turn each bolt the same number of turns smooth flow.
counterclockwise until the ribbons are
easily moved by hand.
NOTE: If the remaining ribbons
7. Place the wooden wedges under each end are being replaced, refer to
of the doffer roll to hold it above the feed Replacing Worn Ribbons on
ribbons. page 7-6.
8. Remove a ribbon from each end of the
unit and use one or both as replacement
ribbons. These end ribbons can then be
ends of the doffer roll, allowing it to rest
replaced by a pair of new ribbons.
on the ribbons.
15. Adjust ribbon tension; refer to Feed Rib-

bon Tension Adjustment on page 7-4.
TOC INDEX 7-7

Feed Ribbon Drive Roll Friction 4. Locate the feed ribbons drive roll tension
Material Replacement adjustment bolts (Figure 7-2, A). There is
The friction material on the feed ribbon drive
roll must be replaced if the feed ribbons slip in 5. While holding each adjustment bolt in
place when the tension is adjusted correctly. place, loosen its locknut (Figure 7-2, B).
6. Turn each bolt the same number of turns

NOTE: This procedure requires counterclockwise until the ribbons are
at least two workers: One to turn easily moved by hand.
the roll and apply the cement, and
one to apply the friction material. It 7. Place the wooden wedges under each end
is preferable to use three workers, of the doffer roll to hold it above the feed
each performing a single task. ribbons.
8. Pull the feed ribbons around their tracks

until all the lacing clips are accessible and
Required Tools aligned at the front of the unit.
Chain puller
Clean cloth 9. Remove all the connecting pins from the
Contact cement: 3M #10 or feed ribbons. Position the feed ribbons
equivalent away from the drive roll.
Filament tape
Marker 10. The friction material must be applied while
Masking tape the feed ribbon drive roll turns freely:
Paint brush: natural bristle
Pliers a) Release tension on the drive chain (Fig-
Protective clothing ure 7-3, A); refer to Main Drive Chain
Protective covering Tension Adjustment on page 7-26.
Scraper/sandpaper/steel brush
Screwdriver b) Locate the clips that secure the ends of
Solvent (low VOC) the drive chain together.
Utility knife
Wooden wedges c) Use a chain puller to relieve tension at
Wrenches: the site of the clips and remove them.
3/8”
9/16” d) Remove the chain from the feed ribbon
11/16” drive roll sprocket (B).
1-3/8” or Crescent

A
1. Verify the correct replacement parts are

available, including the friction material, B
cement, and filament tape. See Rolls and

switch.
Figure 7-3: Remove the drive chain from the feed
3. Open both endframe doors. ribbon drive roll.
7-8 TOC INDEX

11. Place a tarp, plastic drop cloth, heavy pa-

per, or another temporary protective cover- CAUTION
ing over the ironing cylinder, compression You must be down to bare
roll, return ribbons, and receiving shelf. metal before installing the
new cover or it may not
12. Cut and remove the filament tape located
adhere properly.
at each end of the drive roll.
13. Pull or cut off the old feed ribbon drive

roll friction material. NOTE: Spiral-wind the friction
14. Remove old cement/debris from the material at a 45° angle (Figure 7-4,
compression roll with a scraper, coarse A). To ensure this, the material
sandpaper, or a steel brush. edges must be aligned with no
gaps.
15. Wipe away remaining residue with a clean
cloth.
17. Spiral wind the new cover over the roll
without cement to make sure there is
WARNING enough material to cover the roll. Put it on
Make sure there is adequate in the same spiral pattern as before.
ventilation and wear
protective clothing before 18. Starting from the drive side of the ma-
working with any solvent. chine, dry fit two or three full turns of the
material to establish the correct angle.
Follow manufacturer’s
Make sure the material edges align with
directions for safe usage.
no gaps. Secure with masking tape.
19. Use a paint brush to apply an even coat of

16. Wipe the entire surface of the compression
cement over a short section of the exposed
roll with a solvent (low VOC). Make sure
roll (about two turns worth), making sure
the roll’s surface is down to bare metal,
the entire surface is covered (Figure 7-5).
and that it is completely clean and dry.
Sprial Wound
Friction Material (A)
Filament Tape (B)

Figure 7-5: Apply an even coat of cement.
Figure 7-4: Friction material is secured with glass
filament tape.
TOC INDEX 7-9

20. Carefully continue to turn the roll, making 27. Carefully remove the masking tape.
sure the material goes on smoothly without
any gaps. 28. Secure the friction material at each end of
the drive roll with several wraps of glass
21. Continue working down the length of the filament tape. Tape from the top while
roll applying the friction material quickly turning the roll in its normal rotational
after the cement is spread. direction (Figure 7-4, B).
22. After the roll is covered, wrap the other 29. Remove the temporary protective covering
end of the roll with masking tape. and clean up the area.
23. Go back to the drive side of the roll, 30. Reinstall the drive chain on its sprocket
remove the masking tape and carefully and adjust its tension; refer to Main
unwind the un-cemented portion of the Drive Chain Tension Adjustment on
material. page 7-26.
24. Using the same technique, apply the ce- 31. Refasten the feed ribbons. Make sure the
ment and carefully rewind the material ribbon end is below the rod and between
onto the roll. the feed ribbon guides. Stagger the posi-
tions of the lacing clips to give the flatwork
25. Secure the end with masking tape. a smooth flow.

NOTE: If any cement gets onto ends of the doffer roll, allowing it to rest
the friction material surface, use a on the ribbons.
piece of masking tape to lift if off.
33. Allow the cement to harden for about 2
hours before operating the unit.
26. Wait about 10 minutes for the glue to
harden; then, trim the ends of the friction 34. After the cement hardens, adjust ribbon
material so it is even with the edges of tension; refer to Feed Ribbon Tension
the roll. Adjustment on page 7-4.
7-10 TOC INDEX

Guide Tape Replacement

The guide tapes (Figure 7-6) that go around
the guide tape bar, compression roll, and doffer
roll keep flatwork from sticking to and wrapping
around the compression roll. These tapes wear
through at the staples or break over time,
requiring replacement.
NOTE: Replace any missing or

broken guide tapes immediately.
Figure 7-6: Guide tapes help keep flatwork from

wrapping around the compression roll.
Replacing the First Guide Tape
If at least one guide tape is still in place, go to

Replacing Subsequent Guide Tapes on page
7-13. If all the guide tapes have been removed,
follow these steps to position the first tape.
Required Tools
Stapler/staples
Utility knife
Wrench: 9/16”

1. Make sure a sufficient length of replace- Figure 7-7: Unscrew the knurled nut securing the
ment guide tape is available. photosensor cable to the photosensor.

switch.
3. Unscrew the knurled nut which secures

the photosensor cable to the photosensor
(Figure 7-7).
5. D i s e n g a g e t h e c o m p r e s s i o n r o l l
spring-loaded handles from their bracket
slots in each endframe (Figure 7-8).
Figure 7-8: The spring-loaded handles are located

in each endframe.
TOC INDEX 7-11

6. Remove the red safety finger guard:

WARNING
a) Note the positioning of the spacers and/ Never start the unit while
or washers at the front left and right of installing the guide tapes.
the guard. It is dangerous
b) In the left endframe, remove the lower and unnecessary.
bolt which pushes against the safety
microswitch (Figure 7-9, A).
7. Pass the guide tape over the top of the
c) Have a worker support the left side of compression roll (Figure 7-10, A) and loop
the guard and then remove the upper it around the guide tapes support bar (B);
bolt (B). then, pass it under the compression roll
and the doffer roll (C).
d) In the right endframe, remove the
upper bolt. 8. Align and overlap the ends of the replace-
ment guide tape 5 to 6” (120 to 150 mm),
leaving a small amount of slack. Cut the
CAUTION tape from the roll. Do not staple the ends
Take care not to damage of the tape at this time.
the safety switch that rides
9. Repeat Steps 6 and 7 to position the rest
on the lower bolt in the
of the guide tapes, or go to Replacing
endframes.
Subsequent Guide Tapes on page 7-13.
10. Replace red safety finger guard by revers-

e) The bottom right bolt will slide out of
ing Step 5.
the left endframe with the guard. Care-
fully remove the guard. Make sure to 11. Place the spring-loaded handles in their
keep track of all spacers and washers. bracket slots inside each endframe to add
tension to the compression roll.
13. Screw the photosensor cable into the pho-

tosensor receptacle.
D A
B
C B
Figure 7-9: Red safety finger guard and Figure 7-10: The guide tapes help keep flatwork
microswitch. from sticking to the compression roll.
7-12 TOC INDEX

14. Pull the leading edge of the first replace- Replacing Subsequent Guide Tapes
ment guide table through the bars in the
red safety finger guard (Figure 7-6/Figure If at least one guide tape is in place on the unit,
7-10, D) it is possible to use this procedure to replace all
of the guide tapes. This procedure is easier than
Replacing the First Guide Tape on page 7-11
CAUTION since it is not necessary to remove the red safety
The trailing edge of each finger guard.
guide tape must be on top or
the tape edge can be caught Required Tools
on the feed ribbons, causing Stapler/staples
it to break. Staple puller
Utility knife
15. Align and overlap the ends of the guide Perform only when the unit is OFF
tape 5 to 6” (120 to 150 mm). Be sure with power disconnected and COOL.
the trailing edge of the guide tape is on
top and the leading edge is on the bottom
1. Make sure a sufficient length of replace-
(Figure 7-10).
ment guide tape is available.
16. Staple the ends together, placing a staple
near each end of the tape with one to three
switch.
additional staples spaced evenly between
(Figure 7-11). 3. Open both endframe doors.
17. Repeat Steps 12 to 14 for the remaining 4. D i s e n g a g e t h e c o m p r e s s i o n r o l l
guide tapes. spring-loaded handles from their bracket
5. Cut the guide tape to be replaced at any
convenient position.
6. Using a roll of replacement guide tape,

Trailing end staple the leading edge of the new guide
overlaps by 5-6” tape onto the old guide tape being replaced
(125-150 mm) using one or two staples.
WARNING
Staples
installing the guide tapes.
It is dangerous and
unnecessary.
7. Pull the old guide tape through until the

new guide tape is in place.
Figure 7-11: The trailing edge of the guide tape 8. When both ends of the replacement guide
must be on top, and the leading edge tape are accessible, remove the staple(s)
must be on the bottom. and discard the old guide tape.
TOC INDEX 7-13

9. Repeat Steps 5 to 8 to replace additional Doffer Roll Cover Replacement

guide tapes.
Follow this procedure to replace a worn doffer
roll cover.
CAUTION
The trailing edge must be on Required Tools
top or the edge may catch on
Chalk/pencil/marker
the feed ribbons, causing it Filament tape
to break. Protective clothing
Protective covering
Putty knife
10. Align and overlap the ends of the first Scraper/sandpaper/steel brush
replacement guide tape 5 to 6” (120 to Solvent (low VOC)
150 mm), leaving a small amount of slack. Stapler/staples
Be sure the trailing edge is on top and the Staple puller
leading edge on the bottom (Figure 7-10). Utility knife
Cut the tape from the roll. Wooden wedges
11. Staple the tape together, placing a staple Perform only when the unit is OFF
near each end of the tape with one to three with power disconnected and COOL.
additional staples spaced evenly between
(Figure 7-11). 1. Verify the correct replacement parts are
available, including the replacement cover
12. Repeat Steps 10 and 11 for the remaining size, cement, and filament tape. See Rolls
guide tapes. and Ribbons on page PL-6.
13. Place the spring-loaded handles in their 2. Turn power OFF at the main disconnect
bracket slots inside each endframe to add switch.
14. Close and secure both endframe doors. of the doffer roll to raise it.
4. Use a staple puller to remove the staples

holding the ends of the guide tapes togeth-
er. Move the guide tapes out of the way.
5. Place a tarp, plastic drop cloth, heavy

paper, or another temporary protective
covering over the ironing cylinder, com-
pression roll, and feed ribbons.
6. Pull or cut off the old doffer roll cover.
7. Remove old cement/debris from the

compression roll with a scraper, coarse
sandpaper, or a steel brush.

cloth.
7-14 TOC INDEX

11. Mark and cut the cover at the start of the

WARNING winding, parallel to the end of the roll
Make sure there is adequate (Figure 7-12 and Figure 7-13).
ventilation and wear
protective clothing before 12. In a strip along the full length of the doffer
roll, apply the cement evenly on 1/4 to 1/3
working with any solvent.
of the roll. Smooth it out with a putty knife.
Follow manufacturer’s
directions for safe usage. 13. Position the starting edge at the end of the
roll and secure it with several wraps of fil-
ament tape (Figure 7-13 and Figure 7-14).
9. Wipe the entire surface of the compression
roll with a solvent (low VOC). Make sure 14. Carefully spiral-wind the cover onto the
the roll’s surface is down to bare metal, roll, making sure it goes on smoothly
and that it is completely clean and dry. without any gaps.
15. Trim off any excess cover material from

CAUTION the end of the doffer roll. Secure the end
You must be down to bare of the cover to the doffer roll with several
metal before installing the wraps of filament tape (Figure 7-14).
new cover or it may not
adhere properly. 16. Remove the temporary protective cover-
ing from the feed ribbons and clean up
the area.
NOTE: Spiral-wind the friction

material at a 45° angle. To ensure
this, the material edges must be
aligned with no gaps.
10. Spiral wind the new cover over the roll

without cement to make sure there is
enough material to cover the roll. Put it on
in the same spiral pattern as before.
Figure 7-13: When properly cut and positioned, the

cover should be flush with the end of
the doffer roll.

Figure 7-12: Mark and cut the cover at the start of

the winding, parallel to the end of the Figure 7-14: Secure the end of the cover to the
roll. doffer roll with filament tape.
TOC INDEX 7-15

17. Align and overlap the ends of the first Feed Table Alignment and
guide tape. Be sure the trailing edge of the Positioning
guide tape is on top and the leading edge
is on the bottom (Figure 7-10). The feed table is an important component in
the feed section and must be properly aligned and
18. Staple the ends together, placing a staple positioned. If the feed table becomes bowed out
near each end of the tape with one to three of shape or is positioned too far from the ironing
additional staples spaced evenly between cylinder, flatwork may not feed properly into the
(Figure 7-11). ironing section.
19. Repeat this process for the remaining
guide tapes. Checking Alignment and Positioning
20. Remove the wooden wedges from the ends Improper handling of the unit during shipping
of the doffer roll, allowing it to rest on the can cause too much tension on the feed table,
feed ribbons. making it bow upward excessively. A feed table
that is in poor alignment is usually due to heavy
21. Turn power ON at the main disconnect items being set on it, or people standing on it.
switch and start the unit to make sure the Over time, normal daily use also causes the table
cover is secure and smooth against the to sag slightly. Any of these conditions may cause
doffer roll. flatwork to feed improperly.
22. If any adjustment to the cover is necessary, When properly aligned and positioned, the
stop the unit and turn power OFF at the feed table will bow slightly upward in the middle.
main disconnect switch before making the The leading edge should be 1/4” (6 mm) from the
adjustment. ironing cylinder at either end and 3/8” (9 mm)
from the ironing cylinder in the middle (Figure
7-15).
IRONING CYLINDER
1/4" (6 mm) GAP 1/4" (6 mm) GAP

3/8" (9 mm) GAP
FEED TABLE
BOTTOM VIEW
Figure 7-15: Proper feed table positioning is important for flatwork to feed properly into the ironing section.
7-16 TOC INDEX

7. Pull the feed ribbons around their tracks

Required Tools
Bar stock:
aligned at the front of the unit.
1/4”
3/8” 8. Remove all the connecting pins from the
Wooden wedges
feed ribbons. Position the feed ribbons
away from the drive roll.
with power disconnected and COOL. 9. Use a small piece of 1/4” bar stock to
check the spacing between the feed table
1. Turn power OFF at the main disconnect and ironing cylinder at each end. There
switch. should be a snug fit. Use a small piece of
3/8” bar stock to check the spacing at the
2. Open both endframe doors. center of the unit.
3. Locate the feed ribbons drive roll tension 10. If the feed table is:
one on each side of the machine. a) Not properly positioned, perform Ad-
justing Alignment and Positioning
4. While holding each adjustment bolt in on page 7-18.
b) Properly positioned, reconnect the feed
5. Turn each bolt the same number of turns ribbons. Make sure the ribbon end is
counterclockwise until the ribbons are below the rod and between the feed
easily moved by hand. ribbon guides. Perform Feed Ribbon
Tension Adjustment on page 7-4.
of the doffer roll to hold it above the feed
ribbons.
TOC INDEX 7-17

Adjusting Alignment and Positioning 5. Check the spacing between the feed table
and the cylinder at the center of the unit
Required Tools (Figure 7-15). The correct spacing is 3/8”.
Bar stock: • If the spacing is more than 3/8” (9 mm),
1/4”
loosen the locknuts equally on each
3/8”
side of the threaded adjusting rod (Fig-
Drill
Drill bit: 1/4” ure 7-16) until the middle of the feed
Wrenches: table is 3/8” from the ironing cylinder.
9/16” (2)
1-1/8” • If the spacing is less than 3/8” (9 mm),
tighten the locknuts equally on each
Perform only when the unit is OFF side of the threaded adjusting rod (Fig-
with power disconnected and COOL. ure 7-16) until the middle of the feed
table is 3/8” from the ironing cylinder.
1. From each end of the feed table, remove
6. At each end of the feed table, drill a new
the 1/4” roll pins connecting the table ends
1/4” (6 mm) hole through the table and the
to their support brackets. These pins are
supporting bracket. Insert a 1/4” roll pin
used to help keep the feed table in position.
into the hole to maintain the new position
2. Starting at one end of the unit, loosen of the feed table.
the locknuts in the slotted holes on the
7. Reconnect the feed ribbons. Make sure
underside of the feed table (Figure 7-16),
the ribbons go between the feed ribbon
and position the end 1/4” (6 mm) from the
guides under the table. Stagger the posi-
ironing cylinder. Tighten the locknuts to
tions of the lacing clips to give flatwork
secure the table.
a smooth flow.
3. Repeat Step 2 at the other end of the unit.
4. Make sure the spacing at each end of the ends of the doffer roll, allowing it to rest
unit is 1/4” (6 mm) and that the locknuts on the ribbons.
are securely tightened.
9. Perform Feed Ribbon Tension Adjust-
ment on page 7-4.
FEED TABLE
SLOTTED HOLES
ROLL PIN THREADED ADJUSTING ROD ROLL PIN
LOCK NUT 1" DIA. PIPE
(BOTTOM DETAIL VIEW)

Figure 7-16: The slotted holes and threaded adjusting rod are used to properly align and position the feed table.
7-18 TOC INDEX

7.4 Compression Roll

The compression roll (Figure 7-17) improves
flatwork finish. Some of compression roll
components require periodic adjustment,
replacement or occasional repair.

• Compression Roll Pressure Check
• Compression Roll Pressure Adjustment
• Compression Roll Cover Replacement
Figure 7-17: The compression roll helps to move the

flatwork into the ironing section.
TOC INDEX 7-19

Compression Roll Pressure Check 7. Turn power ON at the main disconnect

switch.
When flatwork does not feed smoothly into the
ironing section, the pressure of the compression 8. Press the green START button. Turn the
roll may need to be adjusted. SPEED knob to the slowest speed.
It is important that there is sufficient pressure 9. Feed the piece of paper under the com-
and that pressure is even from side to side. Too pression roll (Figure 7-17) on the left side
little pressure will cause poor ironing quality; too about one-quarter of the distance from the
much pressure will cause premature wear of the endframe. Immediately pull back gently
compression roll covers and padding. on the paper.
10. You should feel the compression roll

WARNING pulling the paper into the ironing section,
Specific procedures that but be able to pull back the paper without
require the unit to be running tearing it. If there is uneven or no pressure
should be done with extreme placed on the paper, or if the paper tears, the
caution and attention compression roll pressure must be adjusted.
to detail.
11. Repeat Steps 9 and 10 at the middle of the
unit and on the right side about one quarter
of the distance from the endframe.
Required Tools
Brown packing paper
Utility knife NOTE: Too little pressure in the
Wooden wedges middle may indicate too much
pressure at the ends.
RUNNING and COOL.
Use Extreme Caution. 12. If pressure is uneven or nonexistent on
the paper, compression roll pressure must
1. Make sure the unit is completely cool. For be adjusted; refer to Compression Roll
more information, refer to Shut-Down on Pressure Adjustment on page 7-21.
page 3-14.
13. Remove the wooden wedges from under
2. Cut a piece of brown packing paper ap- each end of the doffer roll.
proximately 9” wide and 4’ long (230 mm
x 1200 mm).
4. Make sure that the compression roll is

engaged; the spring-loaded handles must
be in their bracket slots in each endframe
(Figure 7-18).
6. Place wooden wedges under each end of

the doffer roll to raise it.
Figure 7-18: The spring-loaded handles are located
in each endframe.
7-20 TOC INDEX

Compression Roll Pressure Compression Roll Cover

Adjustment Replacement
The cover on the compression roll must
Required Tools be replaced when the cover material is worn
Wrench: 9/16” smooth or if flatwork does not move easily into
the ironing section. Be sure the compression roll
Perform only when the unit is OFF pressure has been adjusted correctly first.
NOTE: Read the REPLACING

1. Turn power OFF at the main disconnect COMPRESSION ROLL PADS
switch. AND COVERS section on the
2. Open both endframe doors. Pink Operator Safety Reminder
in the front of this manual.
3. D i s e n g a g e t h e c o m p r e s s i o n r o l l
spring-loaded handles from their bracket
WARNING
4. Locate the flat washer, adjusting nut, lock Do not attempt to replace
washer, and locknut on the spring-loaded the compression roll
handle in each endframe. These parts are covers without experienced
used to adjust the tension of the compres- personnel. This procedure
sion roll. When the handle is placed in
requires skill.
the bracket slot, it applies tension to the
compression roll springs.
5. Turn the adjustment nut clockwise to NOTE: Take the time to read
increase the tension; counterclockwise through and understand the entire
to decrease. Tighten the locknut once the procedure before replacing the
adjustment has been made. compression roll cover.
6. Place the spring-loaded handles in their
bracket slots inside each endframe to add
8. Perform Compression Roll Pressure

Check on page 7-20.
9. Make further adjustments as necessary.
TOC INDEX 7-21


Required Tools
Cement 6. D i s e n g a g e t h e c o m p r e s s i o n r o l l
Clean cloth spring-loaded handles from their bracket
Nomex tie tape slots in each endframe (Figure 7-18).
Putty Knife
Protective covering 7. Remove the red safety finger guard:
Scraper/sandpaper/steel brush
Stapler/Staples/Staple puller a) Note the positioning of the spacers and/
Utility knife/scissors or washers at the front left and right of
Wooden wedges
the guard.
Wrenches:
7/16”?? b) In the left endframe, remove the lower
9/16”
bolt which pushes against the safety
microswitch (Figure 7-20, A).
with power disconnected and COOL. c) Have a worker support the left side of
the guard and then remove the upper
1. Make sure power is turned OFF at the bolt (B).
main disconnect switch, and that the unit
is completely cool. For more information, d) In the right endframe, remove the
refer to Shut-Down on page 3-14. upper bolt.
2. Verify the replacement cover is the correct

CAUTION
size. See Rolls and Ribbons on page
Take care not to damage
PL-6.
the safety switch that rides
3. Use a staple puller to remove the staples on the lower bolt in the
holding the ends of the guide tapes togeth- endframes.
er. Move the guide tapes out of the way.
4. Unscrew the knurled nut which secures e) The bottom right bolt will slide out of
the photosensor cable to the photosensor the left endframe with the guard. Care-
(Figure 7-19). fully remove the guard. Make sure to
keep track of all spacers and washers.
Figure 7-19: Unscrew the knurled nut securing the Figure 7-20: Red safety finger guard and
photosensor cable to the photosensor. microswitch.
7-22 TOC INDEX

8. Use wedges in each endframe to lift the

compression so it can be turned by hand
with some ease.
Compression
Roll Return Ribbon
9. Place a tarp, plastic drop cloth, heavy Idler Roll

covering over the feed ribbons, ironing
cylinder, and return ribbons.
10. Working at the front of the unit: Padding
• Cut the Nomex tie tapes securing the Heated

cover. Cylinder
• Pull off the old compression roll cover. Feed

Table
11. Remove old cement/debris from the

compression roll with a scraper, coarse Figure 7-21: Let the trailing edge of the new cover
rest on the feed table.
sandpaper, or a steel brush.

cloth.
13. Remove the protective covering and clean

up the work area as necessary.
14. Hand feed the leading edge of the cover

under the compression roll and let is rest
on the return ribbon idler roll (Figure
7-21). Let the trailing edge rest on the
feed ribbons.
Cement
Strip
15. Along the full length of the compression
roll, apply a 2” (50 mm) wide strip of the
cement (Figure 7-22) and smooth with a Padding
putty knife.
Figure 7-22: Cement is used to bond the pad to the

compression roll.
TOC INDEX 7-23

CAUTION Leading edge
The leading edge of the cover

must be positioned straight
across the compression roll
or the entire procedure will
need to be repeated. Cement
Strip
Padding
16. Position and smooth the leading edge of
the padding straight across the length of
the compression roll and overlapping the
cement (Figure 7-23). Make sure the cover
is straight, smooth, and tight against the
compression roll for a good bond with Figure 7-23: A smooth, tight fit is required to
the cement. correctly secure the compression roll
padding.
17. Position one worker on each side of the
compression roll.
18. Slowly hand rotate the roll to wrap the

cover material around it:
• Make sure the padding edges are

straight and even with each end of the
compression roll. Direction of rotation
• Keep the material as smooth as pos-
sible.
• When finished, the padding should

wrap around the roll just short of three
times, leaving about a 1/2” (12 mm)
gap between the leading and trailing
edges (Figure 7-24). Ironing Roll
• This gap should be even across the
length of the compression roll. If it 1/2”
is not:
a) Unwind the compression roll Padding

cover.
b) Pull the end free from the cement. Figure 7-24: There should be a short, even gap
between the leading and trailing edges of
c) Repeat this procedure beginning the compression roll cover.
with Step 14; note that it may be
necessary to add more cement in
Step 15.
7-24 TOC INDEX

19. Cut seven lengths of tie tape, each approx- 25. Reposition the guide tapes; refer to Guide
imately 6’ (2 m) long. Tape Replacement on page 7-11.
20. Evenly space the tie tapes along the 26. Replace and secure both endframe panels.
length of the compression roll (Figure
7-25). Tuck one end of each tape into the
unsecured trailing edge. Make sure each WARNING
is centered between a pair of feed ribbon Never operate the unit unless
guide fingers. all safety covers are in place
21. Hand rotate the compression roll to wrap working correctly.
the tape around the cover until both ends
of each tape are positioned at the front of
the unit: 27. Turn power ON at the main disconnect
switch.
• Tie the tapes with a square knot.
28. Start the unit and test the red safety finger
• Stagger the positions of the knots to guard to make sure the unit comes to a
provide a smoother flatwork flow. complete stop when the red safety finger
guard is pushed.
• Make the ties tapes snug against the
compression roll padding, but do not 29. Stop the unit.
over-tighten the tie tapes. There should
be no indentations in the compression 30. Turn power OFF at the main disconnect
roll padding switch.
• Cut off any extra length of tape. 31. Turn OFF the compressed air supply to
the unit.
22. Place the spring-loaded handles in their
bracket slots inside each endframe to add 32. Check and adjust compression roll pres-
tension to the compression roll. sure following Compression Roll Pres-
sure Check on page 7-20 and Com-
23. Re-install the red safety finger guard by pression Roll Pressure Adjustment on
reversing Step 7. Make sure the spacers page 7-21.
and washers are correctly positioned.
33. The ironing cylinder must be waxed before
24. Reconnect the inlet photosensor. resuming operation. For more information,
refer to Waxing on page 3-8. Note this
step is not necessary for chrome ironing
cylinders.
Tie Tape
Cover Compression
Roll
Figure 7-25: Tuck one end of each tie tape into the
flap of the compression roll cover.
TOC INDEX 7-25

Main Drive Chain Tension

7.5 Ironing Section Adjustment
The following procedures should be used
to keep the ironing cylinder and other ironing The drive chain in the right endframe powers
section components operating properly: the feed ribbon and return ribbon drive rolls as
well as the ironing cylinder. The chain has an
• Main Drive Chain Tension Adjustment adjustable tensioning arm.
• Ironing Cylinder Reconditioning Over time, the drive chain may stretch
slightly from the effects of heat and stress. If the
unit becomes excessively noisy, or if the drive
mechanisms work unevenly because of chain
slippage, it will be necessary to adjust the tension
on the chain.
Required Tools
Wrenches:
11/16”

B
switch.
A 2. Open the right endframe door.
3. Check the drive chain (Figure 7-26, A)

for excessive movement. There should be
very little free play in the chain.
Drive Chain
4. Tension on the drive chain is kept by an

idler arm chain tensioner (Figure 7-26, B).
Tension Idler Arm When tension on the chain becomes loose,
adjust the idler arm tensioner.
Mounting Bolt
NOTE: A stretched chain that
has been adjusted may not fit the
sprocket correctly and may need
to be replaced.
C D
5. Locate the idler arm mounting bolt (Figure
7-26, C) on the inside of the endframe.
Endframe 6. Loosen the idler arm mounting bolt just

enough to allow turning of the idler arm
Figure 7-26: The drive chain is adjusted using the
base with a crescent wrench.
tensioning idler arm.
7-26 TOC INDEX

Ironing Cylinder Reconditioning

CAUTION
Tighten chain so the machine The following procedure gives instructions
runs smoothly. Too much for removing dirt, rust, alkali deposits, and other
tension will cause a jerking similar contaminants from the fine polished
ironing cylinder surface. No chemicals can be
motion and can
used to clean the ironing cylinder. Mechanical
damage bearings.
cleaning, described below, must be done very
carefully. Important: Contact the Factory
7. Turn the idler arm base (Figure 7-26, D) to Service Department before attempting to clean
apply adequate tension to the chain. a chrome ironing cylinder.
8. Tighten the mounting bolt to hold the

adjustment.
CAUTION
For units with a chrome
9. Close and secure the right endframe door. ironing cylinder: Do NOT
attempt mechanical cleaning
of the ironing cylinder. The
switch. Start the unit to check the adjust-
chrome surface will
ment.
be damaged.
Do NOT use any cleaning or

polishing products unless
specifically instructed
to do so by the Factory
Service Department.
WARNING
To avoid the possibility
of severe injury, clean the
ironing cylinder only when
the unit is off (with the power
disconnected) and cool. All
cleaning should be done at
the rear of the unit.
Never attempt to clean the

cylinder while it is moving.
TOC INDEX 7-27

6. Pull the return ribbons around their tracks

Required Tools
Belt sander
aligned at the back of the unit.
Clean cloth
Masking tape 7. Remove the ribbon connecting pins. Re-
Pliers
move the ribbons from the idler rolls on top
Protective coverings
Sandpaper: 220-350 grit
and let the ribbons hang from the guide as-
Wire/string/guide tape sembly onto the protective floor covering.
Wrench: 7/16”
covering over the return ribbons and guide
assembly.

switch. CAUTION
Avoid gouging or leaving any
2. Remove the protective backplate covering flat spots on the cylinder.
the rear of the unit. Make sure at least two The unit will work properly
workers are available to handle the piece,
only if the fine polished
as it is heavy and awkward to handle.
surface of the cylinder is
preserved.
WARNING
This safety interlock switch Clean the cylinder using
is only to be defeated vertical motions, not a
temporarily while performing sideways motion, to preserve
this procedure. the fine polished surface of
Never operate the unit the cylinder.
working correctly. 9. Clean the exposed part of the ironing cyl-
Serious Injury Could Result. inder. Use a belt sander with 220 to 350
grit sandpaper. Use only light movements
3. The unit will not operate while a safety of the sander, not heavy pressure.
interlock switch is open. As a temporary
measure during this work, defeat the
protective backplate interlock switch
by inserting one of the switch keys that
shipped with the unit.
4. Release tension on the return ribbons. Se-

cure the return ribbon guide assembly in a
high position by tying off from above with
wire or string or guide tape (Figure 7-27).

covering on the floor at the rear of the unit. Figure 7-27: Use wire, string or guide tape to
secure the return ribbon guide
assembly in a high position.
7-28 TOC INDEX

10. Do not use any other tools as these will 14. Use the JOG switch to access another por-
permanently damage the cylinder. Work tion of the cylinder. Do not use the JOG
across the entire length of the cylinder. switch more than necessary.
Never gouge or leave flat spots on the
cylinder, and work only in an up and down 15. Turn power OFF at the main disconnect
motion. switch.
11. After removing any contaminants, wipe 16. Repeat Steps 9 to 15 to clean the entire
away any remaining residue on the surface surface of the ironing cylinder.
with a clean cloth.
17. Remove the temporary protective cov-
12. Now it is time to move on the next section. ering.
18. Reposition the return ribbons around the

WARNING idler rolls and reconnect the return ribbons.
The ironing cylinder will Stagger the positions of the lacing clips to
be moving without the give the flatwork a smooth flow.
protective backplate in 19. Remove the wire/string/guide tape holding
position. Make sure everyone the return ribbon guide assembly in the
is at a safe distance high position.
from the unit.
20. Check tension on the return ribbons; refer
Take every precaution to Return Ribbon Tension Adjustment
to keep hands and loose on page 7-37.
clothing from coming into 21. Remove the tape holding down the pro-
contact with any of the tective backplate switch; then, replace and
moving rolls. secure the protective backplate at the rear
Serious Injury Could Result. of the unit. Make sure at least two workers
are available to handle the piece, as it is
One person should be ready heavy and awkward to handle.
at a red safety STOP button
at all times to stop the unit WARNING
if necessary. Never operate the unit unless
13. Turn power ON at the main disconnect and all safety equipment is
switch and turn the SPEED knob to the working correctly.
slowest speed.
TOC INDEX 7-29

Areas of Wear
7.6 Rotary Union
Two conditions can cause a rotary union to
Maintenance leak excessively.
Parts in the rotary union will wear during
normal use and may begin to leak steam or water. 1. Leakage can occur from normal wear of
This section describes how to determine which the carbon graphite guides and seal ring.
parts are the cause of leakage and how to correct If wear on these parts is the cause of the
the condition. leakage, it can be corrected by installation
of the parts in a repair kit. The siphon tube
Repair may involve installation of a repair may also have to be replaced.
parts kit, replacement of the siphon tube, or
replacement of the entire unit. 2. Leakage can also be caused by wear on the
metal parts of the body or nipple. If this
The parts of the rotary union are shown in is the cause of the leakage, the complete
Figure 7-28. An asterisk (*) indicates the parts rotary union must be replaced. The siphon
which are part of the repair kit: the gasket, tube may also have to be replaced.
spring, seal ring, inboard and outboard guides,
and retaining ring. Determine the cause of the leakage by
disassembling the unit with the following
procedures.
H B
G F E D C
I
J
A
A Hex Head Bolts F Nipple
B Head Casing G* Seal Ring
C* Gasket H Union Body
D* Spring I* Outboard Guide
E* Inboard Guide J* Retaining Ring
Figure 7-28: Components in a typical rotary union.
7-30 TOC INDEX

Required Tools Disassembling the Rotary Union

Brush The rotary union has an internal spring that
Chain wrench is under pressure. This procedure requires two
Drill maintenance personnel to safely remove the head
Gloves
casing from the union body.
Lapping compound: 250-300 grit
Retaining ring tool
Rotary union repair kit (pn: 3801-345) CAUTION
Scraper
Screwdriver
Have the repair kit on hand
Suction cup before performing this
Teflon tape/pipe thread compound procedure. A new gasket will
Torque wrench be required once the head is
Wrenches: disconnected from
11/16”
Pipe
the union body.
Perform only when the unit is OFF In addition, it may be advisable to have a
with power disconnected and COOL. new siphon tube on hand in case the old one is
damaged or otherwise cannot be reused.
person. The “buddy system” is WARNING
the safest system. Only qualified personnel
should attempt these repairs.
Make sure the machine is
The following procedures should be handled completely cooled down and
by at least two qualified persons. Using the power is OFF at the main
“buddy system” facilitates a quicker procedure disconnect switch before
and decreases the risk of an accident. servicing the unit.

switch.
2. Make sure the unit is completely cool. For

more information, refer to Shut-Down on
A page 3-14.
B 3. Open the left endframe door.
4. Break the steam supply (Figure 7-28, A)

and condensate (B) unions. Leave the
steam supply flexible hose and condensate
piping connected to the rotary union.
Figure 7-29: Steam system rotary union in the left

endframe.
TOC INDEX 7-31

5. Remove the stop rod from the rotary union 7. Using a chain wrench or pipe wrench, un-
(Figure 7-30, A). screw the nipple of the rotary union from
the trunnion shaft of the ironing cylinder
(Figure 7-30, B; Figure 7-31).
CAUTION
Be careful when removing 8. Carefully remove the rotary union with
the rotary union. The its attached siphon tube from the ironing
attached siphon tube can be cylinder.
damaged by rough handling.
9. Unscrew the siphon tube from the head of
the rotary union.
6. A siphon tube is threaded into the head of
10. Check the threads on the siphon tube:
the rotary union and can be damaged if the
rotary union is not properly supported or • If the threads are worn, damaged, or
removed carefully. Support the union so not full size, a new siphon tube should
that it will not drop when it comes free. be installed.
• If the siphon tube itself is worn,

cracked, or damaged, a new siphon
tube should be installed.
WARNING
There is an internal spring
force present. Use care
B during disassembly to avoid
A injury. Two workers should
perform the following step.
Figure 7-30: The stop rod helps keep the rotary 11. Remove the head bolts (Figure 7-28, A)
union stable during operation. which fasten the head casing (B) to the
union body (H).
12. Remove the spring (Figure 7-28, D), in-

board guide (E), seal ring (F), and nipple
(G).
Place Chain
Wrench Here
Rotary Union Body
Siphon Tube
(must point down)
Nipple
Threads
Figure 7-31: External view of the rotary union showing major components and correct position of siphon tube.
7-32 TOC INDEX

13. Use a retaining ring tool to remove the Inspecting the Rotary Union
retaining ring (Figure 7-32, A) from the
back of the union body. Leakage can be caused by wear on the metal
parts of the body and/or nipple.
14. Remove the outboard guide (Figure 7-32,
B). 1. Spread the disassembled parts of the union
out for inspection/cleaning.
2. Look at the raised portion of the nipple

which fits between the guide and seal
A ring to see if it is pitted, worn or damaged
(Figure 7-33, A).
3. Check the front interior portion of the

body where the seal ring rides against the
body for pitting, wear or damage (Figure
B 7-33, B).
4. Inspect the portion of the head with the

threads (Figure 7-33, C) for the siphon
tube to see if the threads are in good
condition.
Figure 7-32: The outboard guide is secured in place
with a retaining ring. 5. As appropriate:
• If any of the areas described above has

wear or damage, the entire rotary union
must be replaced. Refer to Replacing
the Rotary Union on page 7-34.
• If all of these areas are sound, perform

Repairing the Rotary Union on page
7-34.
C B
Figure 7-33: Inspect the nipple and the union body

for pitting, wear or other damage.
TOC INDEX 7-33

Repairing the Rotary Union Replacing the Rotary Union

1. Use a scraper to remove the old gasket 1. If a new rotary union is being installed,
from the head casing and/or union body. remove the components directly connect-
Make sure it is completely removed and ed to the old union and, using the same
the gasket seat is clean. configuration, securely connect them to
the new one using Teflon tape.
2. Clean all parts thoroughly.
2. A new siphon tube should be used unless
3. Install the new outboard guide using the inspection has found that the old one is
new retaining ring. in good condition. Carefully screw the
siphon tube into the head. Do not damage
4. Install the new seal ring. Make sure the
the tube.
convex side faces the back of the union
body. 3. Make sure that when the rotary union in-
stalled, the end of the siphon is pointing
5. Lap the seal ring to its mating metal parts
down. Refer to Figure 7-31.
using a 250 to 300 grit lapping compound.
The surfaces will have a dull matte finish
when they are sufficiently lapped. CAUTION
The siphon tube must be
NOTE: Polishing these surfaces treated carefully to avoid
with the lapping compound helps damage. The end of the
prevent further leakage. siphon tube must be pointing
at the bottom of the ironing
cylinder when the installation
6. Install the new inboard guide, new spring, is complete.
and new gasket. Make sure the spring
groove on the inboard guide faces out.
4. Use Teflon tape or pipe thread compound
7. Bolt the body and the head casing back to- on the threaded end of the nipple of the
gether. This is easiest and safest using two rotary union. Do NOT use Permatex or
persons: One applying force to compress anything similar.
the spring and the other installing the bolts.
5. Carefully insert the siphon tube into the
ironing cylinder. Screw the nipple of the
CAUTION rotary union into the trunnion of the iron-
Finger tighten the bolts ing cylinder. Make sure it is secure.
only. They will be torqued
as required during the 6. Reinstall the stop rod removed in Step 6
of Disassembling the Rotary Union on
Replacing the Rotary Union
page 7-31.
procedure which follows.
7. Connect the steam supply and condensate
unions, reversing Step 5 of Disassembling
8. Finger tighten all the bolts.
the Rotary Union. Do NOT use any
9. Go to Step 3 of Replacing the Rotary kind of thread compound, pipe dope or
Union which follows. Permatex.
7-34 TOC INDEX


RUNNING and HOT.
CAUTION
Use Extreme Caution. It is essential that the ironing
cylinder be heated up
gradually. Failure to do so
WARNING can permanently damage the
This safety interlock switch cylinder and/or siphon tube.
11. Start and begin heating the ironer. For
this procedure.
more information, refer Start-Up on
Never operate the unit page 3-7.
working correctly.
Serious Injury Could Result. CAUTION
If the bolts are tightened
unevenly, parts will not seat
8. The machine will not operate while a safe- properly and leakage
ty microswitch is open. As a temporary will result.
measure during this work, defeat the left
endframe interlock switch.
12. As the ironer heats, partially tighten the
head bolts using the pattern shown in
WARNING
Figure 7-32.
The machine will be
operating with an 13. Repeat Step 13 until the head bolts are
open endframe. tightened to the required torque of 60 ft-lb
Use Extreme Caution. (81 Nm) is reached.
14. Continue heating the unit until it has

9. Turn power ON at the main disconnect reached operating temperature.
switch.
15. Allow the unit to run as to the new parts
10. Turn the SPEED knob to the slowest to wear in. There will initially be some
speed. steam/water leakage which should disap-
pear in approximately one-half hour.
4 5
6 3
Figure 7-34: Rotary union head bolt tightening

pattern.
TOC INDEX 7-35

16. Once steam leakage stops, remove the

interlock switch keys; then, replace and 7.7 Return Section
secure the left endframe panel. Flatwork is directed around the ironing
cylinder by the return section (Figure 7-35),
WARNING which consists of the following components:
Never operate the unit unless • Return ribbons (A)
and all safety equipment is • Return ribbon guide assembly (B)
working correctly. • Return ribbon drive roll (C)
• Idler rolls (D1, D2)
17. Immediately restart the ironer.
The return ribbons hold the flatwork in proper
18. The machine is now ready for normal use contact with the heated cylinder, ensuring quality
or can be cooled off and shut down. For flatwork finish.
more information, refer to Shut-Down on
page 3-14. Various components of the return section
require periodic adjustment, replacement, or
occasional repair.

• Return Ribbon Tension Adjustment
• Return Ribbon Replacement
• Return Ribbon Drive Roll Friction
Material Replacement
D1
D2
B
C
Figure 7-35: Return section components.
7-36 TOC INDEX

Return Ribbon Tension Adjustment

WARNING
Adjust the tension of the return ribbons when This safety interlock switch
they sag or track to one side of the ironing section. is only to be defeated
Both conditions cause excessive wear on the temporarily while performing
ribbons and shorten their life.
this procedure.
Required Tools unless all safety systems are
Wrenches: working correctly.
3/8”
9/16”
Perform only when the unit is OFF 6. The machine will not operate while a safe-
with power disconnected and COOL. ty microswitch is open. As a temporary
measure during this work, defeat each
1. Turn power OFF at the main disconnect endframe interlock switch by inserting
switch. one of the switch keys that shipped with
the unit.
3. Locate the return ribbons idler roll tension switch.
one on each side of the machine. 8. Turn the SPEED knob to the slowest
speed.
place, loosen its locknut (Figure 7-36, B). 9. Run the unit briefly and make sure the
ribbons track straight and do not rub on the
ribbon guides on the guide assembly roll.
CAUTION
Do not over tension the 10. If tension on the ribbons is uneven, ribbons
ribbons. Too much tension will track toward the end of the ironing
can cause excessive motor cylinder where the tension is highest.
ribbon wear.
5. Adjust each bolt the same number of turns

clockwise until the ribbons are snug. Test
the tension by pulling up lightly on the
ribbon. Resistance should be felt within
1/4” to 1/2” (6 to 13 mm).
B
Figure 7-36: Return ribbon tension adjustment in

the left endframe.
TOC INDEX 7-37

11. Stop the unit and turn power OFF at the Return Ribbon Replacement
Return ribbons stretch and flatwork moves
12. Either turn the adjusting bolt counter- unevenly and improperly through the ironing
clockwise at the high tension end, or turn section. When tension on these ribbons can no
the adjusting bolt clockwise at the low longer be adjusted, the entire set must be replaced.
tension end.
13. Repeat Steps 7 to 12 until the ribbons have NOTE: R e a d t h e R E T U R N

the correct tension and track evenly. RIBBON REPLACEMENT OR
ADJUSTMENT section on the
14. Stop the unit and turn power OFF at the Pink Operator Safety Reminder
main disconnect switch. in the front of this manual.
place, secure its locknut.
Replacing Worn Ribbons
16. Remove the interlock switch keys; then,
close and secure both endframe doors. Use this procedure to replace ribbons that are
WARNING
Never operate the unit unless Required Tools
all safety covers are in place Pliers
Wire/string/guide tape
Wrenches:
working correctly. 3/8”
7/16”
9/16”

1. Verify the replacement ribbons are the

correct size and sufficient quantity for
completing the procedure. See Rolls and
NOTE: HI-LYFE™ extended

wear ribbons are available. These
ribbons provide superior quality
flatwork finish. Specify HI-LYFE
extended wear ribbons when
reordering.

switch.
7-38 TOC INDEX

3. Remove the protective backplate from the 7. Pull the old ribbon through until the new
rear of the unit. Make sure at least two ribbon is in place.
as it is heavy and awkward to handle. 8. Disconnect the old ribbon and secure the
replacement ribbon with a new pin.
cure the return ribbon guide assembly in a 9. Repeat Steps 6 to 8 to replace additional
high position by tying off from above with worn ribbons. Stagger the positions of the
wire or string or guide tape (Figure 7-37). lacing clips to give the flatwork a smooth
flow.
WARNING 10. Remove the wire/string/guide tape holding

Never start the unit while the return ribbon guide assembly in the
installing the return ribbons. high position.
It is dangerous 11. Check tension on the return ribbons; refer
and unnecessary. to Return Ribbon Tension Adjustment
on page 7-37.
5. Pull the worn ribbons around their tracks 12. Reinstall the protective backplate at the
until all the lacing clips are accessible and rear of the unit. Make sure at least two
aligned at the back of the unit. workers are available to handle the piece,
NOTE: Whether using Nomex
or HI-LYFE ribbons, make sure Replacing Broken or Missing Ribbons
the darker side of the ribbon will
face the ironing cylinder. Ribbons that break should be replaced
immediately. To avoid excessive stress on only
one new, slightly shorter ribbon, the entire set of
6. Remove the connecting pin from an old ribbons should be replaced. At a minimum, it is
ribbon and attach a new ribbon to one end, recommended that ribbons be replaced in pairs.
making sure the darker side will face the
ironing cylinder. Required Tools
Pliers
Wire/string/guide tape
Wrenches:
3/8”
7/16”
9/16”


completing the procedure. See Rolls and
Figure 7-37: Use wire, string or guide tape to
secure the return ribbon guide
assembly in a high position.
TOC INDEX 7-39

NOTE: HI-LYFE™ extended NOTE: Whether using Nomex

wear ribbons are available. These or HI-LYFE ribbons, make sure
ribbons provide superior quality the darker side of the ribbon will
flatwork finish. Specify HI-LYFE face the ironing cylinder.
extended wear ribbons when
reordering.
7. Place one end of the replacement ribbon
over the return ribbon drive roll and one
2. Turn power OFF at the main disconnect end beneath, making sure the slightly
switch. darker side will face the ironing cylinder.
3. Remove the protective backplate from the 8. Move to the back of the unit where both
rear of the unit. Make sure at least two ends of the ribbon are now exposed.
workers are available to handle the piece, Wrap the top end of the ribbon around
as it is heavy and awkward to handle. the cylinder.
4. Release tension on the return ribbons. Se- 9. Pass it under and around the top idler roll;
cure the return ribbon guide assembly in a next, pass it over the second idler roll so
high position by tying off from above with it is hanging down the back of the unit.
10. Pull the bottom end of the ribbon under
5. Remove a ribbon from both ends of the the return ribbon guide assembly. Bring it
unit and use one or both as replacement up to meet the other end and connect the
ribbons. These end ribbons can then be ends of the ribbon with a new pin.
replaced by a pair of new ribbons.
ribbons. Stagger the positions of the lacing
WARNING clips to give the flatwork a smooth flow.
installing the return ribbons.
NOTE: If the remaining ribbons
It is dangerous
are being replaced, refer to
and unnecessary. Replacing Worn Ribbons on
page 7-38.
6. Move to the front of the unit at the posi-
tion where a ribbon is broken or missing.
Fold the replacement ribbon in half with 12. Remove the wire/string/guide tape holding
the seams on the inside. Do not crease the return ribbon guide assembly in the
the ribbon. high position.
13. Check tension on the return ribbons; refer

to Return Ribbon Tension Adjustment
on page 7-37.
14. Reinstall the protective backplate at the

rear of the unit. Make sure at least two
7-40 TOC INDEX

Return Ribbon Drive Roll Friction

Material Replacement WARNING
The chain and power must
If the friction material on the return ribbon both remain disconnected
drive roll is worn smooth, or if the return ribbons during this procedure. Do
slip in place when tension is adjusted properly, not reconnect either of these
the friction material must be replaced.
until the entire procedure
is completed.
Required Tools
Caulk Gun
Chain puller 5. The friction material must be applied while
Clean cloth the return ribbon drive roll turns freely:
Hammer
Masking tape a) Open the right endframe door and lo-
Nail cate the drive chain (Figure 7-38, A).
Pliers
Protective covering b) Release tension on the chain; refer to
Putty knife: serrated Main Drive Chain Tension Adjust-
Screwdriver ment on page 7-26.
Steel brush
Utility knife c) Locate the clips that secure the ends of
Wire/string/guide tape the drive chain together.
Wooden wedges
Wrenches: d) Use a chain puller to relieve tension at
3/8” the site of the clips and remove them.
7/16”
9/16” e) Remove the chain from the return rib-
11/16” bon drive roll sprocket (B).
f) Close and secure the right endframe
Perform only when the unit is OFF door.
1. Verify the correct replacement parts and

supplies are available, including the size
of the friction material and the cement for
the return ribbon drive roll. See Rolls and B

switch.
3. Open both endframe doors. A

cure the return ribbon guide assembly in a
high position by tying off from above with Figure 7-38: Remove the drive chain from the
return ribbon drive roll.
TOC INDEX 7-41

6. Remove the flatwork transfer guide as- 10. Remove the screws and clamps at each end
sembly: of the drive roll (Figure 7-40) that hold the
friction material in place. Set the clamps
a) In the left endframe, loosen the bolts aside for later use.
which secure the air cylinder locking
collar (Figure 7-39, A). 11. Pull or cut off the old friction material. As
you do so, note the direction of the spiral
b) Remove the shaft key (B). winding.
c) In the right endframe, loosen the set- 12. Remove the old cement from the drive
screws which hold the locking collar in roll with a scraper, coarse sandpaper, or a
place and then remove the collar. steel brush. Wipe away remaining residue
with a clean cloth. Make sure the roll’s
d) Next, loosen the bearing setscrews.
surface is down to bare metal, and that it
e) Slide the assembly completely to one is completely clean and dry.
side and then remove the entire assem-
bly from the ironer. CAUTION
f) Place all components in a safe place. You must be down to bare
metal before installing the
7. Remove the front receiving shelf. new cover or it may not
adhere properly.
8. Pull the return ribbons around their tracks
aligned at the front of the unit. Remove
the connecting pins and position the return NOTE: Spiral-wind the friction
ribbon ends away from any contact with material at a 45° angle. To ensure
the drive roll. this, the material edges must be
aligned with no gaps.
covering over the delivery ribbon drive 13. Spiral wind the new cover over the roll
roll and the floor underneath the unit. without cement to make sure there is
enough material to cover the roll. Put it on
in the same spiral pattern as before.
A Clamp & Screws
A Return Ribbon
Drive Roll
Friction Material
B
Figure 7-40: The friction material is secured to

Figure 7-39: Flatwork transfer guide assembly each end of the drive roll by screws
locking collar in the left endframe. and clamps.
7-42 TOC INDEX

14. Use a caulk gun to apply several beads of 18. Use a nail to pierce the friction material
cement across the length of the roll. and expose the holes for the end clamp
screws.
15. Use a serrated putty knife or other rough-
edged tool to spread the cement evenly 19. Remove the masking tape and then re-in-
over the entire roll (Figure 7-41). stall the end clamps and screws (Figure
7-40).
16. Starting either side of the machine:
20. Remove the temporary protective covering
• Spiral-wind two or three turns of the and clean up the area.
material onto the roll and secure it with
masking tape so the material does not 21. Refasten the return ribbons. Stagger the
unwind during installation. positions of the lacing clips to give the
flatwork a smooth flow.
• Carefully continue to spiral-wind the
cover onto the roll, making sure it goes 22. Remove the wire/string/guide tape holding
on smoothly without any gaps. the return ribbon guide assembly in the
high position.
• This procedure is easier with two peo-
ple. One person turns the drive roll by 23. Re-install the drive chain on the return
hand while a second person holds the ribbon drive roll sprocket and adjust its
roll of material and guides the material tension; refer to Main Drive Chain Ten-
onto the drive roll, pressing it firmly sion Adjustment on page 7-26.
into place.
24. Reinstall the flatwork transfer guide, re-
• Continue working down the length of versing Step 11.
the roll.
• After the roll is covered, wrap the other
end of the roll with masking tape. 26. Reinstall the front receiving shelf.
17. Use a hammer to lightly tap the friction 27. Allow the cement to harden for 5 to 6
material at each end to break it off and hours before operating the unit.
create an even edge or use a utility knife
28. After the cement hardens, check tension on
to trim it.
the return ribbons; refer to Return Ribbon
Tension Adjustment on page 7-37.
Feed Ribbons
Heated
Cylinder
Cement applied to entire

drive roll surface
Feed Ribbon Return Ribbon

Drive Roll Drive Roll
Figure 7-41: Cement secures the friction material to

the return ribbon drive roll.
TOC INDEX 7-43

Various components of the primary fold and

7.8 Primary Fold/Delivery delivery sections require periodic adjustment,
Sections replacement, or occasional repair.
The first and secondary primary folds take These procedures include:
place as the flatwork is directed through the
• Flatwork Transfer Guide Mechanical
primary section (Figure 7-42). The primary
Adjustment
section consists of the following components:
• Transfer idler roll #2 (A) • Transfer Ribbon Tension Adjustment
• Transfer tension idler (B) • Transfer Ribbon Replacement
• Transfer ribbons (C) • Intermediate Ribbon Replacement
• Transfer ribbon drive roll (D) • Delivery Ribbon Tension Adjustment
• Transfer idler roll #1 (E) • Delivery Ribbon Replacement
• Intermediate idler roll (F) • Transfer Ribbon/ Delivery Drive Chain

Tension Adjustment
• Intermediate ribbons (G)
• Transfer, Intermediate and Delivery
• Intermediate tension idler (H) Rolls Tracking Tape Replacement
Flatwork is then delivered to the front of the
machine. The delivery section (Figure 7-42)
consists of the following components:
• Delivery ribbons (I)
• Delivery idler rolls (J1, J2)
• Delivery drive roll (K)
A C
B E
D F
J1 G
I H
J2 K
Figure 7-42: Primary fold/delivery section components.
7-44 TOC INDEX

Flatwork Transfer Guide Mechanical Transfer Ribbon Tension Adjustment

Adjustment
Adjust the tension of the transfer ribbons
If flatwork is not feeding properly onto the when they sag or track to one side of the ironing
transfer ribbons, it may be necessary to lengthen section. Both conditions cause excessive wear on
the stroke of the flatwork transfer guide air the ribbons and shorten their life.
cylinder so that the fingers position closer to the
transfer ribbons. Required Tools
Wrenches:
Required Tools 3/8”
Wrenches: 9/16” (2) 9/16”

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

1. Turn power OFF at the main disconnect switch.
switch.
2. Locate the transfer ribbons idler roll ten-
2. Open the left endframe door. sion adjustment bolts on the inner wall of
3. Loosen the flatwork transfer guide air the endframe (Figure 7-44, A). There is
cylinder rod jam nut (Figure 7-43, A). one on each side of the machine.
4. Turn the air cylinder rod (Figure 7-43, B) 3. While holding each adjustment bolt in
clockwise one or two turns to lengthen place, loosen its locknut (Figure 7-44, B).
its stroke.
5. Tighten the jam nut.
6. Close and secure the left endframe door.
7. Start the machine and process several

pieces of flatwork to test the adjustment.
A
B
A
Figure 7-43: Flatwork transfer guide air cylinder Figure 7-44: Transfer ribbon tension adjustment on
rod and jam nut. the inner wall of the endframe.
TOC INDEX 7-45

Transfer Ribbon Replacement

CAUTION
Do not over tension the Transfer ribbons stretch and flatwork moves
ribbons. Too much tension unevenly and improperly into the primary fold
can cause excessive motor section. When tension on these ribbons can no
longer be adjusted, the entire set must be replaced.
ribbon wear.
4. Adjust each bolt the same number of turns Use this procedure to replace ribbons that are
clockwise until the ribbons are snug. Test still in place, but are worn out.
the tension by pulling up lightly on the
ribbon. Resistance should be felt within Required Tools
1/4” to 1/2” (6 to 13 mm). Pliers
Wrenches:
5. Turn power ON at the main disconnect 3/8”
switch. 9/16”
speed. Perform only when the unit is OFF
ribbons track straight. 1. Verify the replacement ribbons are the
8. If tension on the ribbons is uneven, ribbons completing the procedure. See Primary
will track toward the end of the where the Fold Section on page PL-16.
tension is highest.
9. Stop the unit and turn power OFF at the switch.
3. Locate the transfer ribbons idler roll ten-
10. Either turn the adjusting bolt counter- sion adjustment bolts on the inner wall of
clockwise at the high tension end, or turn the endframe (Figure 7-44, A). There is
the adjusting bolt clockwise at the low one on each side of the machine.
tension end.
11. Repeat Steps 7 to 12 until the ribbons have place, loosen its locknut (Figure 7-44, B).
the correct tension and track evenly.
12. Stop the unit and turn power OFF at the counterclockwise until the ribbons are
main disconnect switch. easily moved by hand.
7-46 TOC INDEX

6. Remove the primary fold system protec- Replacing Broken or Missing Ribbons
tive cover at the rear of the unit (Figure
7-45). Ribbons that break should be replaced
WARNING ribbons should be replaced. At a minimum, it is
Never start the unit while recommended that ribbons be replaced in pairs.
installing the transfer
ribbons. It is dangerous Required Tools
and unnecessary. Pliers
Wrenches:
3/8”
7. Pull the worn ribbons around their tracks 9/16”
aligned at the back of the unit.
8. Remove the connecting pin from an old
ribbon and attach a new ribbon to one end.
9. Pull the old ribbon through until the new correct size and sufficient quantity for
ribbon is in place. completing the procedure. See Primary
Fold Section on page PL-16.
10. Disconnect the old ribbon and secure the
replacement ribbon with a new pin. 2. Turn power OFF at the main disconnect
switch.
worn ribbons. Stagger the positions of the 3. Locate the transfer ribbons idler roll ten-
lacing clips to give the flatwork a smooth sion adjustment bolts on the inner wall of
flow. the endframe (Figure 7-44, A). There is
12. Adjust ribbon tension; refer to Transfer
Ribbon Tension Adjustment on page 4. While holding each adjustment bolt in
7-45. place, loosen its locknut (Figure 7-44, B).
13. Replace the primary fold system protec- 5. Turn each bolt the same number of turns
tive cover. counterclockwise until the ribbons are
6. Remove the primary fold system protec-

tive cover at the rear of the unit (Figure
7-45).
7. Working at the rear of the unit, remove a

ribbon from both ends of the unit and use
one or both as replacement ribbons. These
end ribbons can then be replaced by a pair
of new ribbons.
Figure 7-45: Primary fold system protective cover

at the rear of the unit.
TOC INDEX 7-47

Intermediate Ribbon Replacement

WARNING
Never start the unit while The intermediate ribbons are elastic and not
installing the transfer adjustable. Over time these ribbons stretch,
ribbons. It is dangerous causing flatwork to move unevenly and improperly
through the primary fold section.
and unnecessary.
When tension on the ribbons is no longer
adequate, the entire set must be replaced.
8. Place the ribbons between the guides and
follow the ribbon path.
9. Bring the ends of the ribbon together and
connect them with a new pin. Use this procedure to replace ribbons that are
10. Repeat Steps 9 and 10 to replace additional
ribbons. Stagger the positions of the lacing
clips to give the flatwork a smooth flow.
Required Tools
Gloves
Pliers
NOTE: If the remaining ribbons Wrenches: 7/16”
Replacing Worn Ribbons on Perform only when the unit is OFF
page 7-46. with power disconnected and COOL.

11. Adjust ribbon tension; refer to Transfer correct size and there is sufficient quantity
Ribbon Tension Adjustment on page to complete the procedure. See Primary
7-45. Fold Section on page PL-16.
12. Replace the primary fold system protec- 2. Turn power OFF at the main disconnect
tive cover. switch.
WARNING NOTE: This procedure requires

Never operate the unit unless at least two qualified personnel to
all safety covers are in place handle the fold system protective
and all safety equipment is c o v e r, wh ic h is h e a v y a n d
working correctly. awkward to handle.
Wear gloves to protect hands from

sharp edges.
3. Remove the fold system protective cover

at the rear of the unit (Figure 7-45).
7-48 TOC INDEX

4. Remove the primary fold sheet deflector Replacing Broken or Missing Ribbons
(Figure 7-46). It is secured with five bolts.
Ribbons that break should be replaced
NOTE: It may be easier to one new, slightly shorter ribbon, the entire set of
perform this procedure after ribbons should be replaced. At a minimum, it is
using Transfer Ribbon Tension recommended that ribbons be replaced in pairs.
Adjustment on page 7-45 to
relieve tension on those ribbons.
Required Tools
Gloves
Pliers
5. Pull the worn ribbons around their tracks Wrenches: 7/16”
until all lacing clips are accessible and
aligned.
WARNING
Never start the unit while 1. Verify the replacement ribbons are the
installing the intermediate correct size and sufficient quantity for
ribbons. It is dangerous completing the procedure. See Primary
Fold Section on page PL-16.
and unnecessary.
switch.
6. Remove the connecting pin and pull the
old ribbon off the roll.
NOTE: This procedure requires
7. Center the new ribbon under the idler roll,
at least two qualified personnel to
pull the two ends together over the drive
handle the fold system protective
roll, and connect them with a new pin.
c o v e r, wh ic h is h e a v y a n d
8. Stagger the positions of the lacing clips to awkward to handle.
give the flatwork a smooth flow.
Wear gloves to protect hands from
9. Replace the protective covers removed in sharp edges.
Steps 3 and 4.
3. Remove the fold system protective cover

at the rear of the unit (Figure 7-45).
4. Remove the primary fold sheet deflector

(Figure 7-46). It is secured with five bolts.
NOTE: It may be easier to

perform this procedure after
using Transfer Ribbon Tension
Adjustment on page 7-45 to
relieve tension on those ribbons.
Figure 7-46: Primary fold sheet deflector at the rear

of the unit.
TOC INDEX 7-49

5. Remove a ribbon from both ends of the Delivery Ribbon Tension Adjustment
ribbons. These end ribbons can then be Adjust the tension of the delivery ribbons
replaced by a pair of new ribbons. when they sag or track to one side of the delivery
table. Both conditions cause excessive wear on
the ribbons and shorten their life.
WARNING
Never start the unit while Required Tools
installing the intermediate
Wrenches:
ribbons. It is dangerous 3/8”
and unnecessary. 9/16”

6. Center the new ribbon under the idler roll, with power disconnected and COOL.
pull the two ends together over the drive
switch.
NOTE: If all of the ribbons
are being replaced, remove the 2. The gap between the delivery and transfer
ribbons at this time. drive rolls is adjustable. Make sure the
gap is set before adjusting ribbon tension.
3. To adjust the gap:

until all lacing clips are accessible and a) Loosen the transfer ribbon/delivery
aligned. drive chain; refer to Transfer Rib-
bon/ Delivery Drive Chain Tension
8. Remove the connecting pin and pull the Adjustment on page 7-54.
old ribbon off the roll.
b) Locate the roll position adjustment
9. Center the new ribbon under the idler roll, bolts (Figure 7-47, A). There is one on
pull the two ends together over the drive each side of the machine.
c) While holding each adjustment bolt
10. Stagger the positions of the lacing clips to in place, loosen its locknut (Figure
give the flatwork a smooth flow. 7-47, B).
11. Replace the protective covers removed in
Steps 3 and 4.
WARNING
Never operate the unit unless C
and all safety equipment is B
working correctly.
D
A
Figure 7-47: Delivery drive roll gap adjustment.
7-50 TOC INDEX

d) Adjust each bolt the same number of

turns until the gap between the rolls CAUTION
(Figure 7-47, C, D) is 0.5” to 0.75” Do not over tension the
(12-20 mm). ribbons. Too much tension
can cause excessive motor
e) While holding each adjustment bolt in
ribbon wear.
f) Re-tension the transfer ribbon/delivery
drive chain; refer to Transfer Ribbon/
6. Adjust each bolt the same number of
Delivery Drive Chain Tension Ad-
turns clockwise until the ribbons are snug.
justment on page 7-54.
Test the tension by pulling up lightly on the
4. Locate the delivery ribbons idler roll ten- ribbon. Resistance should be felt within
sion adjustment bolts on the inner wall of 1/4” to 1/2” (6 to 13 mm).
the endframe (Figure 7-48, A). There is
switch.
speed.

ribbons track straight.
A B 10. If tension on the ribbons is uneven, rib-

bons will track toward the end of the where
the tension is highest.

12. Either turn the adjusting bolt counter-

clockwise at the high tension end, or turn
the adjusting bolt clockwise at the low
Figure 7-48: Delivery conveyor tension adjustment. tension end.
13. Repeat Steps 9 to 14 until the ribbons

have the correct tension and track evenly.


TOC INDEX 7-51

Delivery Ribbon Replacement

WARNING
Delivery ribbons stretch and flatwork moves Never start the unit while
unevenly and improperly onto the delivery table. installing the delivery
When tension on these ribbons can no longer be ribbons. It is dangerous
adjusted, the entire set must be replaced.
and unnecessary.

Use this procedure to replace ribbons that are until all the lacing clips are accessible and
still in place, but are worn out. aligned at the back of the unit.
7. Remove the connecting pin from an old

Required Tools ribbon and attach a new ribbon to one end.
Pliers
Wrenches: 8. Pull the old ribbon through until the new
3/8” ribbon is in place.
9/16”
9. Disconnect the old ribbon and secure the
Perform only when the unit is OFF replacement ribbon with a new pin.
worn ribbons. Stagger the positions of the
lacing clips to give the flatwork a smooth
flow.
completing the procedure. See Primary
Fold Section on page PL-16. 11. Adjust ribbon tension; refer to Delivery
Ribbon Tension Adjustment on page
7-50.
switch.
3. Locate the delivery ribbons idler roll ten-

sion adjustment bolts on the inner wall of


7-52 TOC INDEX

Replacing Broken or Missing Ribbons 6. Remove a ribbon from both ends of the
Ribbons that break should be replaced ribbons. These end ribbons can then be
immediately. To avoid excessive stress on only replaced by a pair of new ribbons.
ribbons should be replaced. At a minimum, it is
recommended that ribbons be replaced in pairs. WARNING
Required Tools installing the delivery
Pliers ribbons. It is dangerous
Wrenches: and unnecessary.
3/8”
9/16”
7. Place the ribbons between the guides and
follow the ribbon path.
8. Bring the ends of the ribbon together and
connect them with a new pin.
correct size and sufficient quantity for 9. Repeat Steps 8 and 9 to replace additional
completing the procedure. See Primary ribbons. Stagger the positions of the lacing
Fold Section on page PL-16. clips to give the flatwork a smooth flow.

switch. NOTE: If the remaining ribbons
3. Locate the delivery ribbons idler roll ten- Replacing Worn Ribbons on
sion adjustment bolts on the inner wall of page 7-52.
10. Adjust ribbon tension; refer to Delivery
Ribbon Tension Adjustment on page
7-50.
TOC INDEX 7-53

Transfer Ribbon/ Delivery Drive

Chain Tension Adjustment
Over time, the intermediate drive chain may
stretch slightly from the effects of heat and A
stress. If the unit becomes excessively noisy, or
if the transfer drive mechanism works unevenly
because of chain slippage, it will be necessary to
adjust tension on the chain.
Required Tools
Wrenches:
7/16”
15/16” (2) B
Perform only when the unit is OFF Figure 7-49: The transfer ribbon/delivery ribbon
with power disconnected and COOL. drive chain on the right side of the
machine.
switch.
2. Remove the right rear protective cover.
3. Check the transfer ribbon/delivery ribbon

drive chain (Figure 7-49, A) for excessive
movement. There should be very little
free play.
4. If necessary, loosen the adjustment sprock-

et (Figure 7-49, B) and move it until the
chain is properly tensioned.
5. Tighten the sprockets.
6. Replace and secure the right rear pro-

tective cover.

switch. Start the unit to check the adjust-
ment.
7-54 TOC INDEX

Transfer, Intermediate and Delivery Perform only when the unit is OFF
Rolls Tracking Tape Replacement with power disconnected and COOL.
Tracking tape helps hold ribbons from moving

from side to side or overlapping each other on
switch.
their rolls during operation. It is placed under the
center of each ribbon and is wound around the 2. Verify there is enough 1” (25 mm) tracking
outside of the roll. tape available to replace the old material.
The following rolls periodically need tracking 3. Locate the roll that needs tracking tape
tape replaced (Figure 7-50): (Figure 7-50).
• Transfer ribbon drive roll (A)
4. Remove the drive chain so the roll can
• Intermediate ribbons idler rolls (B) turn freely:
• Delivery ribbon drive roll (C) a) Release tension following Transfer
Ribbon/ Delivery Drive Chain Ten-
Required Tools sion Adjustment on page 7-54.
Chain puller
b) Locate the clips that hold the chain
Drill
Drill bit: 1/16”
together.
Nail
c) Use a chain puller to relieve tension at
Permanent marker
Pliers
the site of the clips and remove them.
Pop-riveter and #34 1/16” rivets, or
d) Remove the drive chain from its
screwdriver and 1/16” self-tapping
screws sprockets.
Protective covering
Scissors/knife
5. Loosen the tension of the ribbon set asso-
Scraper/sandpaper/steel brush ciated with the roll. For more information,
Temporary protective covering refer to Transfer Ribbon Tension Ad-
Wrenches: justment on page 7-45 or Intermediate
3/8” Ribbon Replacement on page 7-48 or
1/2 (2) Delivery Ribbon Tension Adjustment
9/16” on page 7-50 as appropriate.
6. Pull the ribbons around their tracks un-

til all the lacing clips are accessible and
aligned. Remove the connecting pins from
all the ribbons and move the ends away
from the roll.

B paper, or another temporary protective
A
covering over the parts of the unit which
C B must be kept clean and below the work
area.
Figure 7-50: Primary/delivery rolls using tracking

tape.
TOC INDEX 7-55

8. Using a 1/16” bit, drill out the rivets hold- 14. Repeat Steps 11 to 13 for each tracking
ing each tracking tape in place (Figure tape location.
7-51).
15. Remove the temporary protective cov-
9. Remove the old tape. Mark the center ering.
position of each tape with chalk or a
marker so that new tapes can be properly 16. Reconnect the drive chain removed by
positioned. Mark the location of the rivet reversing Step 4 and adjust its tension
holes. following Transfer Ribbon/ Delivery
Drive Chain Tension Adjustment on
10. Scrape off any old cement which re- page 7-54.
mains on the roll using a scraper, coarse
sandpaper, or a wire brush. Wipe away 17. Reconnect the ribbons. Stagger the posi-
any remaining residue with a clean cloth. tions of the lacing clips to give the flatwork
a smooth flow.
11. To apply tape, unroll enough tape for
each placement. Remove the backing 18. Adjust the tension of the ribbon set asso-
from the tape and line up the tape with ciated with the roll. For more information,
the center mark. refer to Transfer Ribbon Tension Ad-
justment on page 7-45 or Intermediate
12. Wrap the tape so that it goes around the roll Ribbon Replacement on page 7-48 or
at least twice. The direction of the wrap Delivery Ribbon Tension Adjustment
depends on the roll (Figure 7-52). on page 7-50 as appropriate.
• Drive rolls—against the rotational 19. Replace any panels or protective covers
direction of the roll. removed for this procedure.
• Idler rolls—with the rotational direc-

tion of the roll. WARNING
13. Use a nail to pierce the tracking tape and all safety guards are in place
expose the rivet hole. Install a pop-rivet and all safety equipment is
into the hole, or a self-tapping 1/16” screw
working correctly.
if a pop-rivet is not available.
Direction of Travel
Idler Roll Drive Roll

Figure 7-51: Tracking tape is wound around the
drive roll and secured with rivets. Figure 7-52: Tracking tape application.
7-56 TOC INDEX

Ironer Inlet and Second Primary Fold

7.9 Sensors Photosensor Sensitivity Adjustment
The ironer/folder uses two types of sensors:
photosensors, which rely on visual signals, and a The ironer inlet (PE101) and second primary
machine speed sensor (proximity sensor), which fold (PE103) should always be adjusted to
rely on magnetic signals. maximum sensitivity.
The single most common source of unreliable Required Tools

photosensor operation is dirt on the lens of a Phillips screwdriver: #1
photosensor or a reflector which can cause it to
miss a piece of linen or give a false signal when
no material is there. Use a clean, soft cloth to Perform only when the unit is OFF
make sure all photosensors and reflectors are free with power disconnected and COOL.
of lint or dust.
The table below provides a quick look at each switch.
photosensor on the unit, indicating its position,
adjustment and replacement options. Note that
only the ironer exit photosensor can have its CAUTION
sensitivity adjusted. The sensitivity potentiometer
on a photosensor is a
precision electronic device.
NOTE: All photosensors are
Forcing it beyond its range
mounted in a fixed position. No
physical alignment is possible or
and/or using too large a
necessary. screwdriver may cause
irreparable damage.
The following provides a list of sensor-related

2. Use a #1 Phillips screwdriver to adjust
procedures :
photosensor sensitivity clockwise to max-
• Ironer Inlet and Second Primary Fold imum (Figure 7-53).
Photosensor Sensitivity Adjustment
3. Start the unit and process several pieces
• First Primary Fold Photosensor to test the adjustment.
Sensitivity Adjustment
• First Primary Fold Photosensor Position
Alignment
• Photosensor Replacement
• Machine Speed Sensor Position
Adjustment
• Machine Speed Sensor Replacement
Figure 7-53: The sensitivity of the ironer inlet

and second primary fold sensors are
always set to maximum.
TOC INDEX 7-57

First Primary Fold Photosensor 1. Turn power ON at the main disconnect

Sensitivity Adjustment switch.
Correct adjustment of the second primary fold

photosensor (Figure 7-54) is critical for correct WARNING
primary folding. Leave the red safety STOP
button pushed in during this
If the sensor “sees” too far or does not far entire procedure. Do not
enough, flatwork may be missed or there may be reset it until instructed.
false triggers when flatwork is not present.
Required Tools
Paper: white 2. After the unit has gone through its start-up
Phillips screwdriver: #1 routine, press a red safety STOP button.
Tape measure
3. Hold a piece of white paper about 4” (100
mm) below the top of the transfer ribbons
with power connected and COOL.
(Figure 7-54, A).
CAUTION
The sensitivity potentiometer
on a photosensor is a
precision electronic device.
B
Forcing it beyond its range
and/or using too large a
screwdriver may cause
irreparable damage.
4. Use a #1 Phillips screwdriver and adjust

A the potentiometer until the yellow LED
just lights (Figure 7-54, B).
5. Move the paper further and make sure the

Figure 7-54: Adjust the first primary fold yellow LED goes out.
photosensor to “see” about 4”.
6. Twist to reset the red SAFETY stop button.
7. Start the unit and run several pieces to

verify the adjustment.
7-58 TOC INDEX

First Primary Fold Photosensor Required Tools

Position Alignment Phillips screwdriver: #2
The alignment of the first primary fold Wrench: 3/8”
photosensors is critical to proper and productive
operation of the machine. Sensors that are Perform only when the unit is OFF
misaligned can miss a piece of flatwork or give with power connected and COOL.
a false signal when no material is there.
The first primary fold photosensors must be 8. Turn power ON at the main disconnect
aligned to view between the transfer ribbons. switch.
A damaged ribbon or one that is not tracking
correctly can accidentally activate a sensor.
WARNING
This is the most common cause of a false Leave the red safety STOP
signal. Replace damaged ribbons and properly button pushed in during this
adjust the tension to eliminate false triggering of entire procedure. Do not
sensors. For more information, refer to Transfer reset it until instructed.
Ribbon Tension Adjustment on page 7-45. Serious Injury Could Result.
9. After the unit has gone through its start-up

routine, press a red safety STOP button.
10. Second primary fold sensors are attached

to brackets. These are mounted on chan-
nels that run the full width of the machine.
The brackets have lots in them to allows
for left or right adjustment (Figure 7-55).
11. Loosen the screws and move the bracket to

that the sensor looks between the ribbons.
You should be able to see the sensor’s red
beam on the delivery table. Make sure that
Figure 7-55: Second primary photosensor position no part of the beam is showing on the top
adjustment bracket. of a transfer ribbon.
12. Tighten the screws to secure the adjust-

ment.
13. Twist to reset the red SAFETY stop button.
14. Start the unit and run several pieces to

verify the adjustment.
TOC INDEX 7-59

Photosensor Replacement
If a photosensor fails or is erratic, it should
be replaced immediately. All photosensors are
connected using either a quick-release connector B
or a simple screw connector.
Required Tools A
Phillips screwdriver: #1
Screwdriver: small

15. Make sure you have the correct type for Figure 7-56: All photosensors have screw
the photosensor to be replaced. For more connections for simple replacement.
information on sensor location and type,
refer to Sensors on page 5-8 and Sen-
sors/Valves on page SC-10.

switch.
17. Locate the photosensor to be replaced.
18. Unscrew the photosensor from its mount-

ing (Figure 7-56, A). Be careful to save the
mounting screws.
19. Unscrew the knurled nut which secures the

old photosensor cable (Figure 7-56, B).
20. Screw the new photosensor into its con-

nector receptacle. Make sure it is secure.
21. Using the hardware from Step 4, secure

the new photosensor in position.
22. If replacing an ironer inlet or second pri-

mary fold photosensor, set its sensitivity to
maximum; if replacing a first primary fold
photosensor, refer to First Primary Fold
Photosensor Sensitivity Adjustment on
page 7-58 to properly set its sensitivity.
23. Start the machine and process several

pieces of flatwork to make sure the new
photosensor is working correctly.
7-60 TOC INDEX

Machine Speed Sensor Position 5. Look at the machine speed sensor (Figure
Adjustment 7-57). The LED on the back of the sensor
should blink each time a tooth of the iron-
The machine speed sensor (Figure 7-57) is ing cylinder sprocket passes.
located inside the right endframe. It is mounted
on a bracket very close to the teeth of the ironing 6. If the LED is not blinking, the sensor
cylinder sprocket. may be located too far from the teeth of
the sprocket. The gap between the sensor
This sensor generates a magnetic field, which and the teeth should be 0.04” to 0.06” (1
is disturbed by each passing tooth of the sprocket. to 1.5 mm).
This signal is interpreted as the speed of the
flatwork. 7. Stop the unit and turn the power OFF at
the main disconnect switch.
Required Tools
Shim: 1 or 1.5 mm CAUTION
Wrenches: 11/16” (2) Adjust the position of the
machine speed sensor very
Perform only when the unit is carefully. If it is hit by the
RUNNING and COOL.
sprocket, the sensor must
be replaced.
switch. 8. Loosen the outer nut (Figure 7-57, A) and
move the sensor closer to the teeth.
9. Tighten the inner nut (Figure 7-57, B) to
WARNING hold the sensor in the new position. Do
not position the sensor closer than 0.04”
(1.0 mm) to the sprocket. The sensor must
is only to be defeated be replaced if it is hit by the teeth of the
temporarily while performing sprocket.
this procedure.
working correctly.
A B
3. The unit will not operate while a safety

interlock switch is open. As a temporary
measure during this work, defeat the door
switch in the endframe by inserting one of
the switch keys that shipped with the unit.
4. Start the unit. Turn the SPEED knob to the

slowest speed.
Figure 7-57: The machine speed sensor must be

correctly positioned near the teeth of
the ironing cylinder sprocket.
TOC INDEX 7-61

10. Turn power ON at the main disconnect Machine Speed Sensor Replacement
switch; then, repeat Steps 4 to 9 until
the machine speed sensor is operating It the machine speed sensor fails or is erratic,
correctly. it must be replaced immediately.
11. Stop the unit and turn power OFF at the Required Tools
Plastic wire ties
12. Remove the interlock switch key; then, Scissors/knife
Shim: 1 or 1.5 mm
close and secure the right endframe door.
Wrenches: 11/16” (2)
WARNING Perform only when the unit is OFF

Never operate the unit unless with power disconnected and COOL.
and all safety equipment is 1. Make sure you have the correct replace-
operating correctly. ment sensor. For more information, refer
to Sensors on page 5-8 and Sensors/
Valves on page SC-10.

switch.
4. Unscrew the knurled nut which secures

the cable to the old machine speed sensor.
5. Unscrew the sensor from its mounting

bracket. Be careful to save the nuts.
6. Using these nuts, secure the new machine

speed sensor in position.
7. Screw the cable into the machine speed

sensor receptacle.
8. Make sure the new machine speed sensor

is positioned properly; refer to Machine
Speed Sensor Position Adjustment on
page 7-61.
9. Start the unit and process several pieces

of flatwork to make sure the new sensor
is working correctly.
7-62 TOC INDEX

Air Bar Alignment

7.10 Compressed Air
It is important that the air blast manifolds, or
System air bars, used to create the primary folds point into
The unit uses air blast manifolds and air the gap between each set of pinch rolls. The air
cylinders to create the folds. It is important bar second primary fold is split into two sections.
that these components are properly aligned and Each section can be individually adjusted.
adjusted.
Use this procedure for the first primary fold
This includes: (Figure 7-58, B) and second primary fold air
• Air Bar Alignment bars (C).
• Transfer Guide Air Cylinders Air Flow

Adjustment WARNING
• Air Valve Repair working with compressed
air components
Required Tools
Allen wrench: 1/8”

1st Primary Fold with power disconnected and COOL.
Air Bar (B)
1. Make sure that power is shut OFF at the

2. Mark the original air bar position for ref-

erence before adjusting it.
3. Loosen the setscrews in the collar which

secure the air bar in position.
Flatwork Transfer Guide 4. Aim the row of air holes toward the
Air Cylinder (A) 2nd Primary Fold
Air Bar (C) center of the gap between the pinch rolls,
or slightly above this gap.
Figure 7-58: Ironer/primary fold section air bars 5. Tighten the setscrews.
and transfer guide air cylinder.
6. Start the machine and test the adjustment.
7. Repeat the adjustment as necessary.
TOC INDEX 7-63

Transfer Guide Air Cylinders Air

Flow Adjustment
The movement of the flatwork transfer guide
(Figure 7-58, A) is controlled by an air cylinder.
The cylinder has screws for adjusting the speed

of the extend (Figure 7-59, A) and retract (B)
travels of the cylinder piston.
WARNING
Wear eye protection when B
air components.
A
Required Tools
Screwdriver: small
Figure 7-59: Transfer guide air cylinder flow
controls.
RUNNING and COOL.

switch.
2. Turn ON the compressed air supply to

the unit.
3. Use the CHI panel TEST mode to test the

action of the cylinder. The transfer guide
should open and close quickly without
banging.
4. It it hits hard on the extension of the cylin-

der, use a screwdriver to adjust the extend
flow control valve (Figure 7-59, A) so the
guide just completes its extension travel.
5. It it hits hard at the retraction of the

cylinder, use a screwdriver to adjust the
retract flow control valve (Figure 7-59,
B). Set it so that the guide just completes
its retraction travel.
7-64 TOC INDEX

Air Valve Repair

Perform only when the power is disconnected
and the air system is depressurized.
A
Required Tools
Clean cloth/brush B
Phillips screwdriver: #2

WARNING Figure 7-60: Be sure to keep track of all air valve

Perform only when the air components.
system is depressurized.

air components.

switch.
2. Turn OFF the compressed air supply and

purge the compressed air from the unit.
3. Carefully disassemble the valve (Figure

7-60). Be careful with the small parts.
4. Clean off any small particles stuck to the

diaphragm with a soft cloth or brush.
5. Reassemble the valve. Make sure that both

the large (A) and small (B) O-rings are
correctly positioned.
6. Start the machine and test the valve.
7. If the diaphragm is clean, but the valve will

not operate correctly, replace the valve.
TOC INDEX 7-65

Duo-Star 3024-051
Duo-Star™ Fold Operation

CHI Panel Operation
DUO-STAR
MODEL 20-01
TOC C-TOC INDEX C-1

3024-051 Duo-Star
CONTENT
I. OPERATION..................................................................................... C-3
CHI Panel Controls and Indicators...........................................................C-3
Automatic Operation................................................................................C-4
Manual Operation.....................................................................................C-4
Item Counter............................................................................................C-5
Self-Diagnostics.......................................................................................C-5
Safety Stop Buttons.................................................................................C-5
II. PROGRAMMING............................................................................. C-6

Start Programming...................................................................................C-6
End Programming....................................................................................C-7
Primary Fold Programming......................................................................C-7
III. ADJUSTMENT................................................................................ C-8

Start Adjustment.......................................................................................C-8
End Adjustment........................................................................................C-9
Primary Fold Adjustments......................................................................C-10
IV. TESTING........................................................................................C-11
Start Testing........................................................................................... C-11
End Testing.............................................................................................C-12
Primary Fold Tests..................................................................................C-13
C-2 TOC C-TOC INDEX

Duo-Star 3024-051
I. OPERATION
CHI Panel Controls and Indicators CROSS button (E)
The CHI panel (Figure C-1) is the heart of Not used.
the operation of the Duo-Star fold system. The
following is information about the panel for all STACKER button (F)
models of the Duo-Star.
Not used.
Panel Display (A)
CURSOR button (G)
Shows current operating information (e.g.
speed and item count), fault messages, and Moves the flashing underline to the desired
in programming mode, selectable functions. display menu item.
Some messages are abbreviated due to space
constraints. Within this bulletin display messages Programming buttons (H)
and CHI Panel markings are shown and referred
Used in programming, adjusting, and testing
to as they actually appear. When necessary,
the unit. These include the ADJUST, CD, TEST,
abbreviations will be explained.
ENTER, +, and – buttons.
CHI ON/OFF button (B) Each of these buttons will be explained

in context later in this section as well as in
Sets the machine for automatic mode Programming on page C-6, Adjustment on
operation. When operating in automatic mode, page C-8, and Testing on page C-11.
the unit automatically determines the number of
primary folds. Pressing this button overrides the
MANUAL ON/OFF button.
MANUAL ON/OFF button (C)

Allows the operator to turn off folding
operations or to set the unit to Manual mode to
control large piece primary folding. Pressing this A H
button overrides the CHI ON/OFF button.
G
PRIMARY button (D)
When in Manual mode, selects the number of
folds for large pieces. An indicator will light to
show the number of primary folds selected. B
C D E F
Figure C-1: The Duo-Star CHI Panel.
TOC C-TOC INDEX C-3

3024-051 Duo-Star
Automatic Operation Manual Operation

The Chicago High Intelligence (CHI) system It may be desirable to override the automatic
uses all pre-programmed settings for automatic folding system at times in order to accommodate
operation. Press the CHI button to show the ON a short run of flatwork which require a special
light. The folder operates in automatic 1 or 4 lane number of folds.
operation, depending on the model configuration.
1. Press the MANUAL button.
Panel Display 2. Press the PRIMARY button to select either

one or two primary folds.
Shows the SPEED of the folder, in FPM
(feet-per-minute) and the total running COUNT
of all pieces processed since the last reset of the Panel Display
counter.
The standard message screen on the CHI
control panel shows the SPEED of the folder,
SPEED COUNT in FPM (feet-per-minute) and the total running
XXFPM XXXXX COUNT of all pieces processed since the last
reset of the counter.
This counter is also used when the unit is first

NOTE: This display also appears turned on and the folding system is turned off.
when the stacker is turned on in
MANUAL operation.
SPEED COUNT
The stack height can be adjusted XXFPM XXXXX
using the +/- buttons.
SINGLE LANE OPERATION
Flatwork Length
Number of Primary
0 - 16” 16” - 25” 25 “- 120”
Folds
0 1 2
* Pieces less than 46” wide should be run in manual.
C-4 TOC C-TOC INDEX

Duo-Star 3024-051
Item Counter Self-Diagnostics

The CHI control panel displays the count of The CHI system continuously monitors
flatwork pieces processed since the counter was itself for sensing and folding errors. If an error
last reset. is found, a flashing message appears on the
display and an audible alert sounds. For more
To reset the counter: information on diagnostic messages, refer to
TROUBLESHOOTING.
1. Make sure that either the CHI or MANU-
AL button is ON. The problem should be addressed immediately.
If necessary, bring the problem to the attention
2. Press the CURSOR button until the cursor
of maintenance or service personnel. The fold
is positioned under the item COUNT.
system may still be operational depending on the
3. Press and hold down the — button until type of error and where it happened.
the count is reset to all zeros.
WARNING
Keep clear of moving parts.
SPEED COUNT
30FPM 0000 Never reach into a machine
when the power is on.
The supervisor may want to do this at the
beginning of each shift.
Safety Stop Buttons
Using any of the red STOP buttons will cause
the folder to shut-down and reset. The panel
display will indicate INTERLOCK CIRCUIT
OPEN. This also indicates that a door is open,
or a motor is overloaded.
TOC C-TOC INDEX C-5

3024-051 Duo-Star
II. PROGRAMMING
The CHI Panel is programmed at the factory Start Programming
to accommodate standard flatwork sizes and
automatically determine the number of primary To program any of the CHI panel’s functions,
folds that result in a neat, stackable package. follow these first steps:
Any setting can be changed in order to 1. Press and hold the CD button; then, press
accommodate the particular needs of the laundry. the ENTER button. Release both buttons.
This is done by using the CD button to enter The SELECT PROGRAM menu displays
programming mode as explained below. as follows:
In addition to programming changes,

adjustments can also be made. For more SELECT PROGRAM
information, refer to Adjustment on page C-8. IRON PRIM CROSS SORT REJ
NOTE: In order to eliminate The flashing cursor is under PRIM.

accidental changes, only qualified
supervisors should access the 2. Press the CURSOR button until the flash-
programming section of the CHI ing cursor is under the desired program
control panel. area.
3. Press the ENTER button. The appropriate

programming menu displays:
WARNING • PRIM is used to determine the mini-
Never touch any part of the mum length for an item to receive two
machine while it is running. primary folds.
• The IRON, CROSS, SORT and REJ
Only trained repair personnel selections are not currently used.
should work on the unit. 4. With the desired programming menu dis-
Always think carefully played, press the CURSOR button until
around moving machinery. the flashing cursor is under the program
setting to be changed.
5. Press “+” or “-” to change the setting. Each

NOTE: W o r k w i t h a n o t h e r of the following programming sections
person. The “buddy system” is has a table to use as a guide in determin-
the safest system. ing settings.
6. Repeat Steps 4 and 5 for each setting to

be changed.
C-6 TOC C-TOC INDEX

Duo-Star 3024-051
End Programming Primary Fold Programming

When finished changing program settings, The Primary menu settings appear for display
follow these steps to save or discard changes. purposes only. Changing either of these settings
will have no effect on machine operation.
Saving changes
1. Press the ENTER button to save. The SE- PRIMARY NUMBER OF FOLDS
LECT PROGRAM menu displays. 2 > 60" LONG
2. Press the CD button to leave program-

ming mode. The range is from 22” to 60”.
Canceling changes
1. Press the CD button without pressing

ENTER. The following message displays:
ENTER TO SAVE
MINUS TO QUIT
2. Press the - button. The programming menu

re-displays with all changes removed.
3. Press the CD button again to leave the

specific programming menu and display
the SELECT PROGRAM menu.
4. Press the CD button once more to leave

programming mode.
TOC C-TOC INDEX C-7

3024-051 Duo-Star
III. ADJUSTMENT
Sometimes it may be necessary to adjust various Start Adjustment
settings in order to fine tune the performance of
the unit. In addition, adjustments can be made to To adjust any of the CHI panel’s functions,
better coordinate ironer and folder speeds. follow these first steps:
1. If the fold system is off, press the CHI ON/

NOTE: In order to eliminate OFF button to turn it on (button LED is
accidental changes, only qualified lit). This will make it possible to immedi-
supervisors should access the ately test the results of changing a setting.
adjustment section of the CHI
control panel. 2. Press and hold the ADJUST button; then,
press the ENTER button. Release both
buttons. The SELECT ADJUSTMENT
menu displays as follows:
WARNING
SELECT ADJUSTMENT
machine while it is running. PRIM 12 CROSS 123 STK 12
Only trained repair personnel The flashing cursor is under PRIM 12.
should work on the unit.
3. Press the CURSOR button until the flash-
Always think carefully
ing cursor is under the desired adjustment
around moving machinery. area.
4. Press the ENTER button. The appropriate

adjustment menu displays:
person. The “buddy system” is • PRIM12 is used to make adjustments
the safest system. to large piece and small piece fold set-
tings. See Primary Fold Adjustments
on page C-10.
• CRS123 and STK12 are not used.
5. With the desired adjustment menu dis-

played, press the CURSOR button until
the flashing cursor is under the setting to
be adjusted.
6. Press “+” or “-” to change the setting. Each

of the following adjustment sections has
a table to use as a guide in determining
settings.
7. Repeat Steps 5 and 6 for each setting to

be changed.
C-8 TOC C-TOC INDEX

Duo-Star 3024-051
End Adjustment
When finished making adjustments, follow
these steps to save or discard changes.
Saving changes
1. Press the ENTER button to save. The

SELECT ADJUSTMENT menu displays.
2. Press the ADJUST button to leave adjust-

ment mode.
Cancelling changes
1. Press the ADJUST button without pressing

ENTER. The following message displays:
ENTER TO SAVE
MINUS TO QUIT
2. Press the “-” button. The adjustment menu

re-displays with all changes removed.
3. Press the ADJUST button again to leave

the specific adjustment menu and display
the SELECT ADJUSTMENT menu.
4. Press the ADJUST button once more to

leave adjustment mode.
TOC C-TOC INDEX C-9

3024-051 Duo-Star
Primary Fold Adjustments

NOTE: T h e d e l a y s e t t i n g
The delay and air blast time for each primary controls edge separation, which
fold can be individually adjusted. In addition, two is the distance between the edges
sets of adjustments can be made, one for large of a folded piece.
piece folding and one for small piece folding.
The desired size of this separation
When PRI12 is selected from the SELECT depends on the overall size of the
ADJUSTMENT menu, the SELECT PRIMARY piece being folded.
MODE menu displays:
A piece the size of a sheet should
have an edge separation around
SELECT PRIMARY MODE
2” (50 mm). Smaller pieces should
1LANE 2LANE 3LANE 4LANE
have smaller edge separations.
NOTE: Only 1LANE is available.

The remaining are not accessible. 1st Primary Fold Edge Separation
Press "-"to move Press "+"to move
edge thisway edge thisway
Press ENTER. The Primary Fold Adjustment
menu displays:
FOLD#1 (1LANEMODE) FOLD#2

1.4"/.10SEC 2.4"/.10 SEC
2nd Primary Fold Edge Separation
The numbers displayed under FOLD#1 and Press "+"to move Press "-"to move
FOLD#2 are the delay and air blast length edge thisway edge thisway
respectively. The flashing cursor is under the

Fold#1 Delay adjustment.
PRIMARY FOLD ADJUSTMENT
Range
Adjustment Function High Range Select Low Range Select Default
(Increment)
The distance the piece travels 0.2–7.0” Fold will be too Fold will be too See
DELAY
before the air blast. (.02”) short. long. below.
The air blast length. A longer .06–.20 sec May cause wrinkles, May not fold, or See
AIR
blast is for heavier pieces. (.02 sec) inefficient air use. fold inaccurately. below.
C-10 TOC C-TOC INDEX

Duo-Star 3024-051
IV. TESTING
The testing function should only be used to see Start Testing
and hear the operation of the unit to verify proper
functioning or as an aid during troubleshooting. To test any of the CHI panel’s functions, follow
these first steps:
When the TEST mode is active, stay clear of
moving parts. Watch the unit from a safe distance. 1. Locate the appropriate schematic. For
Do not touch any part of the unit when it is in more information, refer to the SCHE-
TEST mode. Serious injury may result. MATIC PARTS LIST.

WARNING switch.
3. Access the right endframe, open the folder
machine while it is running.
electrical box and locate the fold I/O mod-
Serious Injury Could Result. ules. During the test, the LED’s on the
output side of the control boards will light
Only trained repair personnel to indicate status of ON.
should work on the unit.
Always think carefully
around moving machinery. WARNING
NOTE: W o r k w i t h a n o t h e r this procedure.
person. The “buddy system” is Never operate the unit
the safest system.
working correctly.
4. The folder will not operate while a safety

microswitch is open. As a temporary
measure during testing, defeat the door
interlock switch by inserting one of the
switch jumpers that shipped with the unit.

RUNNING and COOL.

switch. Start the unit.
TOC C-TOC INDEX C-11

3024-051 Duo-Star
6. Test mode can only be entered if the fold 11. Look at the fold control boards to confirm
system is off. If necessary press the CHI the correct LEDs light. If a component
ON/OFF button or the MANUAL ON/ fails to operate or an LED fails to trigger
OFF button to turn off the fold system. properly, refer to TROUBLESHOOT-
The CHI Panel should display as follows: ING for possible causes.
SPEED COUNT NOTE: The numbers appearing

XXFPM XXXXX in the messages correspond to the
hardware output LED’s. Refer to
the SCHEMATIC PARTS LIST.
7. Press and hold the TEST button; then,
press the ENTER button. Release both
buttons. The SELECT TEST menu dis-
plays. End Testing
To leave test mode, follow these steps:
SELECT TEST 1. When finished running a test, press the
PRIM12 CROSS123 STK12 TEST button once to return to the SE-
LECT TEST menu.
The flashing cursor is under 1 of PRI12. 2. Press the TEST button again to leave test
8. Press the CURSOR button to select the mode.
desired test. The appropriate testing menu 3. Press the red START/STOP button to shut
displays: down the unit. Turn the power OFF at the
• PRIM12 is used to test primary folding main disconnect switch.
air valves. See Primary Fold Tests on 4. Remove the interlock switch jumper;
page C-13. then close/replace and secure the right
• CROSS123 and STK12 are not cur- endframe door/panel.
rently used.
WARNING
9. Press the ENTER button. The test
function message displays.
The numbers in the display correspond to and all safety equipment is
the fold control output LEDs that trigger working correctly.
with each operation. Each of the follow-
ing sections has a table to use as a guide
in running the test.
10. The fold control system automatically

begins to operate each of the components
involved in the test.
C-12 TOC C-TOC INDEX

Duo-Star 3024-051
Primary Fold Tests

The FOLD#1 TEST message displays:
FOLD#1TEST
215/217/216/218
The fold control system automatically begins

to operate each of the air valves involved in the
first and second primary folds, rotating through
each in sequence, where 215 is first primary fold
left half, and 217 is first primary fold right half;
216 is second primary fold left half and 218 is
second primary fold right half.
TOC C-TOC INDEX C-13

Duo-Star 20 Steam 3035-010
NOTE: When ordering parts, please provide the serial number and
a complete description of the machine, including any non-
standard features. Electrical part numbers can be found in the
SCHEMATICS section (when available).
Duo-Star 20 Steam
Picture Parts List
Content
General Components
Front View...................................................................................................................................PL-2
Rear View...................................................................................................................................PL-4
Rolls and Ribbons.......................................................................................................................PL-6
Endframe Components
Left Side Bearings.......................................................................................................................PL-8
Right Side Bearings....................................................................................................................PL-9
Drive Side Detail.......................................................................................................................PL-10
Right Indication Panel...............................................................................................................PL-13
Heating System Components

Steam Piping Assembly............................................................................................................PL-14
Primary Fold Components

Primary Fold Section.................................................................................................................PL-16
Primary Fold Air Bar Detail - Single Lane.................................................................................PL-18
TOC PL-TOC INDEX PL-1

3035-010 Duo-Star 20 Steam
Front View
9
* *
10 11
8 12 *
13 **
4 ** 5
7
14
15
3
16 **
17
2 18
1 23 22 21 ** 20 19
PART NUMBERS SHOWN ARE FOR 120” MACHINE.

REFER TO CHART FOR CORRESPONDING MACHINE LENGTH
PL-2 TOC PL-TOC INDEX

Front View continued...
ID Part Number Qty Description

1 2001-368 1 DOOR MODEL 20
2 4019-633 1 BUMPER ,DOOR 28-1/4” W/2 END CAPS
3 1411-560-01 1 SWITCH STOP 22 MM W/1 N/C CONTACT BLOCK
4** 4801-203 1 CANOPY COMPLETE SO 16, 20 -120” STEAM
5 E18-100 3 MINERALLAC HANGER 1/2” IP
6 4805-100 1 COLLAR 9” START 4” LONG
7 4819-220 1 ELBOW 9” DIA 90 DEG
8 4803-451 1 CANOPY BLOWER ONLY FOR 1 HP MOTOR
9 4819-222 1 ADAPTOR PIECE
10* 2801-845 1 MOTOR 1 HP 3/60/208-230/460 1730 RPM
11* 2801-875 1 MOTOR 1 HP 3/50/220/440 1440 RPM FR 143T
12* 2801-825 1 MOTOR 1 HP 1/60/115/230 1730 RPM FR 143T
13** 3210-089 1 SAFETY FINGER GUARD ASSY MODEL 20-120”
14 3006-062 1 RIGHT INDICATION PANEL COMPLETE
15 0402-767 2 BEARING HANGER 1” BORE
16** 3401-255 1 FEED TABLE 136” MODEL 20-120”
17 1402-572 1 SWITCH WORK DELIVERY
18 0603-442 1 ANGLE IRON R.H. 2” x 2” x 21” x 3/16 GA
19 2001-531 1 ENDFRAME ASSY R.H. MODEL 20
20 2809-275 1 GEARMOTOR, 3/4HP 40.81:1 RATIO INLINE
21** 3407-110 1 DELIVERY TABLE 137” x 24” x 14 GA
22 0603-431 1 ANGLE IRON L.H. 2” x 2” x 21” x 3/16 GA
23 2001-532 1 ENDFRAME ASSY L.H. MODEL 20
* = Voltage Dependent
** = 120” Machine Only

Rear View
8 * 9 *10 * 11
6 ** 7 12 15 **
13
14
5
16
4
3 5
17
2
18
1
20
19
PART NUMBERS SHOWN ARE FOR 120” MACHINE.

REFER TO CHART FOR CORRESPONDING MACHINE LENGTH

Rear View continued...

1 2001-531 1 ENDFRAME ASSY R.H. MODEL 20
2 1413-477 1 SWITCH
3 3004-273 1 ELECTRIAL CONNECTION HERE 3/1-60/110-220
4 0608-419 1 R.H. HOOD SHIELD SUPPORT BRKT
5 1411-560-01 2 SWITCH STOP 22 MM W/1 N/C CONTACT BLOCK
6** 3403-126 1 REAR COVER INSULATING MODEL 20-120”
7 E18-100 1 MINERALLAC HANGER 1/2” IP
8* 2801-825 1 MOTOR 1 HP 1/60/115/230 1730 RPM FR 143T
9* 2801-875 1 MOTOR 1 HP 3/50/220/440 1440 RPM FR 143T
10* 2801-845 1 MOTOR 1 HP 3/60/208-230/460 1730 RPM
11 4819-222 1 ADAPTOR PIECE
12 4803-451 1 CANOPY BLOWER ONLY FOR 1 HP MOTOR
13 4819-220 1 ELBOW 9” DIA 90 DEG
14 4805-100 1 COLLAR 9” START 4” LONG
15** 4801-100 1 CANOPY COMPLETE MODEL 16, 20-120”
16 0608-420 1 L.H. HOOD SHIELD SUPPORT BRKT
17 4019-633 1 BUMPER ,DOOR 28-1/4” W/2 END CAPS
18 2001-368 1 DOOR MODEL 20
19 2001-532 1 ENDFRAME ASSY L.H. MODEL 20
20 2809-275 1 GEARMOTOR, 3/4HP 40.81:1 RATIO INLINE
* = Voltage Dependent
** = 120” Machine Only

Rolls and Ribbons
4 5 6
5
14
3
13
2
11 12
7
1
10 9
8
NOTES: Parts on BOM are for 120” Long Machine.

Refer to chart for other machine lengths.

Rolls and Ribbons continued...

1 3209-417 1 DRIVE ROLL 5-1/2”x126”x11 GA W/RED COVER
2 1003-086 38 POLYESTER RIBBON 3” x 40” W/PIN
3 3211-216 1 DOFFER ROLL 1-1/4” x126”x16 GA W/FELT
4 3209-237 1 RAW DRIVE ROLL 5-1/2” x120” x11 GA
5 3203-206 3 RAW IDLER ROLL 3-1/2” x 126” x 11 GA
6 1002-250 20 NOMEX RIBBON 6” x 124” W/PIN
7 3201-721 1 STEAM HEATED ROLL MODEL 20-120”
8 3208-041 1 RETURN RIBBON GUIDE ASSY MODEL 16,20-120
9 3209-239 1 DRIVE ROLL 5-1/2” x126” x11 GA W/FLEXTRA
10 3208-042 1 FEED RIBBON GUIDE ASSY MODEL 16, 20-120
11 3208-028 1 S/S GUIDE TAPE BAR ASSY 3/4” x 137-1/2”
12 0607-228 1 R.H. GUIDE TAPE SUPPORT MOUNT ASSY
13 0607-229 1 L.H. GUIDE TAPE SUPPORT MOUNT ASSY
14 1007-723 6 IMPREGNATED GUIDE TAPE 1/2” 36 YD ROLL
NOTES: Parts on BOM are for 120” Long Machine.
Refer to chart for other machine lengths.

Left Side Bearings
9 9
1
8
Item# Part Number Qty Description

1 0402-792 3 BEARING 1” BORE PIVOT MNT GF NEXT PIVOT
2 0402-784 1 BEARING BALL 2-15/16” BORE
3 0402-793 2 BEARING 1” BORE PIVOT MNT GF OPPOSITE
4 0402-767 1 BEARING HANGER 1” BORE
5 0402-019 1 BEARING 1-1/4” BORE PIVOT MOUNT
7 0402-768 1 BEARING 1-1/4” BORE STAT MOUNT
8 0402-762 1 BEARING HANGER 1” BORE ARM CUT TO 1-1/2”
9 0402-774 1 BEARING 1” BORE STAT MOUNT”

Right Side Bearings

1 OR 2 3 OR 4 3 OR 4
13 6
7
12
OR 8
11
9
10 * 3
OR
14
* 4 14
* 3 15
OR
* 4
Item# Part Number Qty Description

1 0402-786 1 BEARING 1-1/4” BORE PIVOT MOUNT CNTRSUNK
2 0402-787 1 BEARING 1-1/4” BORE PIVOT MOUNT CNTRSUNK
3 0402-792 5 BEARING 1” BORE PIVOT MNT GF NEXT PIVOT
4 0402-793 5 BEARING 1” BORE PIVOT MNT GF OPPOSITE
5 4003-075 1 GREASE FITTING 1/4-28 90 DEG
6 4003-650 1 GREASE EXTENSION PIECE 5”
7 5002-505 1 ELBOW STREET 45 DEG 1/8”
8 0402-780 1 BEARING BALL 2-1/4” BORE
9 0403-763 2 BEARING CAM FOLLOWER 1-3/4” BORE ASSY
10 0402-768 1 BEARING 1-1/4” BORE STAT MOUNT
13 0402-007 1 BEARING HANGER 1” BORE W/WELDED BRKT
14 0402-774 1 BEARING 1” BORE STAT MOUNT

Drive Side Detail
2 3
1
4
17
6
15 16
2 7
18 8
14
19 9
13 20
12
11
10

Drive Side Detail continued...

1 1206-350 1 BEARING SPROCKET #50 17T 5/8” BORE
2 1201-450 2 SPROCKET #50 20T 1-1/4” BORE KWAY 2 STSC
3 5005-600 1 COUPLING 1/2” STEEL X-HEAVY
4 2212-825 1 UV SCANNER W/3 FT LEADS W/BUL 3023-437
5 1201-591 1 SPROCKET 50B 60T 2-1/4” BORE
6 0601-023 1 BURNER TAIL SUPPORT 3” x 2” x 14 GA
7 4203-655 1 SLEEVE INFRARED THERMOCOUPLE, HIGH LIMIT
8 4203-000 1 TOUCHLESS THERMOCOUPLE SCANNER ASSY
9 0205-260 1 ELBOW 1/8” NPT x 3/8” OD
10 1201-405 1 SPROCKET #50 12T 1” BORE KWAY 2 STSCRW
11 2809-275-01 1 GEARMOTOR, 3/4HP 40.81:1 RATIO INLINE
12 1211-005 1 IDLER ARM FOR CHAIN RIDER
13 1211-006 1 CHAIN RIDER SET #40 CHAIN
14 1201-430 1 SPROCKET #50 16T 1-1/4” BORE KWAY 2 STSC
15 1204-421 1 CHAIN #50 154 LINKS W/CONN LINK
16 3603-225 1 SPRING 3/4” x 8”
17 0607-200 1 SPRING BRACKET
18 0603-401 1 MACHINE SPEED SENSOR BRACKET
19 1608-004 1 MACHINE SPEED SENSOR ASSY
20 0607-129 1 COMPRESSION ROLL TENSION HANDLE ASSY

This page intentionally left blank.

Right Indication Panel
8
1
5
5
2
3 7
6 5 5

1 1417-550 1 ALARM AUDIBLE
2 1402-550 1 SPEED CONTROL POT 5K
3 1414-510 1 KNOB FOR SPEED CONTROL SWITCH
4 1411-700 1 RED STOP BUTTON TURN RELEASE 1 N/C
5 1414-260-01 6 CONTACT BLOCK 1 N/O
6 1414-140-01 1 START BUTTON GREEN ILLUMW/O CONTACT BLK
7 1414-410-01 1 SELECTOR SWITCH 3 POS RED
8 1612-658 1 CHI PANEL CONTROLLER
9 3006-122 1 PANEL RIGHT CONTROL SUREFIRE W/CHI PANEL

Steam Piping Assembly

8 9
10
11
5
3
1
12
2
13
15
14

Steam Piping Assembly continued...

1 5001-258 1 NIPPLE 1” x 7”
2 5002-110 1 ELBOW 90 DEG 1”
3 5001-256 1 NIPPLE 1” x 6”
4 5019-403 1 UNION 1” 250 LB BLK
5 3803-175 1 STEAM HOSE 1” x 12”
6 3819-210 1 GUIDE FOR ROTARY UNION
7 5002-585 1 ELBOW STREET 90 DEG 1”
8 3802-150 1 SIPHON PIPE 1/2” x 35” LONG
9 3801-340-01 1 ROTARY UNION RIGHT HAND W/BUL 3010-289
10 5002-575 1 ELBOW STREET 90 DEG 1/2”
11 3803-125 1 STEAM HOSE 1/2” x 18”
12 5019-100 1 1/2” 250LB BLK UNION
13 5001-164 1 NIPPLE 1/2” x 8”
14 5002-185 1 ELBOW RED 90 DEG 3/4” x 1/2”
15 5001-223 1 NIPPLE 3/4” x 13-1/2”

Primary Fold Section
6 7 8 9 10 11
1
2
12 14
3 13
26 15
4 5 5
16
17
18
23
25 19
24 22 21
20

Primary Fold Section continued...

1 2010-132 1 RETURN RIBBON GUIDE FINGER SUPPORT
2 2006-189 3 PRE-CROSSFOLD FINGERS RIBBON GUIDE
3 0608-364 1 RETURN RIBBON GUIDE PIECE MOUNT
4 2006-074 1 RETURN RIBBON GUIDE PIECE 138” LONG
5 3203-104 4 IDLER ROLL 3” x 126” x 11G
6 0607-163 1 1ST PRIMARY PHOTOEYE CHANNEL 127-1/2”
7 1001-025 40 CANVAS RIBBON 2” x 101” W/PIN”
8 0608-297 2 MOUNTING BRKT, 1st PRIM PHOTOEYE CHANNEL
9 2006-078 1 1-1/2” SQ TUBING 139-3/4” LONG
10 2006-080 3 1ST PRIMARY FOLD GUIDE FINGERS
11 0607-161 1 1ST PRIMARY FOLD GUIDE ASSEMBLY 139-3/4”
12 2006-081 1 2ND PRIMARY FOLD GUIDE FINGERS
13 3209-136 1 DRIVE ROLL 3” x 126” x 11G W/40 RINGS
14 0209-094 1 1ST PRI-FOLD AIR BAR ASSY SINGLE LANE
15 3203-067 1 IDLER ROLL 3” x 126” x 11 GA
16 3203-081 1 IDLER ROLL 3” x 126” x 11G W/20 RINGS
17 3203-315 1 LH IDLER ROLL 2-1/4”x61-1/2” W/10 RINGS
18 3203-316 1 RH IDLER ROLL 2-1/4”x61-1/2” W/10 RINGS
19 1807-013 1 PRIMARY FOLD SHEET DEFLECTOR
20 0209-096 2 2ND PRI-FOLD AIR BAR ASSY W/59 HOLES
21 2007-167 1 CONNECTING TUBING 1-1/2” x3” x162”
22 1003-018 20 ELASTIC RIBBON 2” x 14” W/PIN
23 3209-138 1 DRIVE ROLL 3-1/2” x126” x11GA W/23 RINGS
24 1001-024 22 CANVAS RIBBON 2” x 119” W/PIN
25 3203-066 1 IDLER ROLL 3-1/2” x 126” x 11 GA
26 2006-207 22 FINGER 7” x 3/4” x 3/32” NYLON DELIVERY

Primary Fold Air Bar Detail -

Single Lane
5
4 6
3
2
1
7
8
11
11
9
10
14 11
13 12
10
15
26 25 24
11
10 19 18
9 10 21 20
26 23 21 22
14 18
14 13

Primary Fold Air Bar Detail - Single Lane continued...

1 0605-027 1 BRACKET INTERLOCK 4” x 7/8” x 14 G
2 1607-277-02 1 PHOTOSENSOR DARK OPERATE W/CONN
3 1819-152 1 BUMPER RUBBER
4 0607-163 1 1ST PRIMARY PHOTOEYE CHANNEL 127-1/2”
5 0608-297 2 MOUNTING BRKT, 1st PRIM PHOTOEYE CHANNEL
6 0607-161 1 1ST PRIMARY FOLD GUIDE ASSEMBLY 139-3/4”
7 0209-094 1 1ST PRI-FOLD AIR BAR ASSY SINGLE LANE
8 1807-013 1 PRIMARY FOLD SHEET DEFLECTOR
9 0205-220 2 STRAIGHT CONNECTOR 1/2” NPT x 1/2” OD
10 0202-960 4 VALVE AIR 1/2” 24 VAC
11 5001-149 6 NIPPLE 1/2” x CLOSE
12 5006-020 2 TEE MALL 1/2 x 1/2 x 1/2
13 0202-165 4 PLUG FOR AIR VALVE COIL
14 0205-365 3 ELBOW SWIVEL 1/2” NPT x 1/2” OD
15 0207-015 1 SINGLE LANE AIR RESERVOIR PRIMARY FOLD
18 0209-096 2 2ND PRI-FOLD AIR BAR ASSY W/59 HOLES
19 3203-315 1 LH IDLER ROLL 2-1/4”x61-1/2” W/10 RINGS
20 0607-177 3 7/8” SET COLLAR BRACKET ASSEMBLY
21 0607-162 4 7/8” SET COLLAR ASSY CUT TO 1-1/8” OD
23 3203-316 1 RH IDLER ROLL 2-1/4”x61-1/2” W/10 RINGS
24 2006-080 3 1ST PRIMARY FOLD GUIDE FINGERS
25 2006-081 3 2ND PRIMARY FOLD GUIDE FINGERS
26 1413-500 2 SWITCH INTERLOCK

Duo-Star 20 Steam 3210-506b
NOTE: When ordering parts, please provide the serial number and
a complete description of the Duo-Star, including any non-
standard features.
Duo-Star 20 Steam
Schematic Parts List
Content
Motor Circuits
208-240V Motor Circuit.............................................................................................................. SC-2
460V Motor Circuit..................................................................................................................... SC-4
Interlock Circuit
24V Interlock Circuit................................................................................................................... SC-6
Control Circuits
Control Circuit............................................................................................................................ SC-8
Sensors/Valves........................................................................................................................ SC-10
Low Voltage Interconnect......................................................................................................... SC-13
Pneumatic Diagrams
Pneumatic Diagram 1 Lane..................................................................................................... SC-14
Pneumatic Diagram 4 Lane..................................................................................................... SC-16
Electrical Panel
Main Electrical Panel............................................................................................................... SC-18
TOC SC-TOC INDEX SC-1

208-240V Motor Circuit
SC-2 TOC SC-TOC INDEX

208-240V Motor Circuit (622802)

Reference Part No. Description
CB0 1410-230-01 CIRCUIT BREAKER 3 A 2 POLE
CON1 1404-472 CONTACTOR 18 AMP 24VDC
CON1A 1414-705 AUX CONTACT 2 N/O FOR CONTACTOR
DISC1 1402-645 SWITCH DISCONNECT ASSY TYPE J
DISC1H 1402-646 HANDLE OPERATING
DISC1S 1402-647 KIT OPERATING SHAFT
FILT1 1615-950 5 HP LINE FILTER
FU1 1407-710 FUSE 10 A TYPE J 600 V
FU2 1407-710 FUSE 10 A TYPE J 600 V
FU3 1407-710 FUSE 10 A TYPE J 600 V
INV1 1615-185 INVERTER 1 HP AC 230V W/BUL 3023-393
MP3 1405-405 MOTOR PROTECTOR 2.5-4 AMP
MP5 1405-235 MOTOR PROTECTOR 1-1.6 AMP
MTR1 2809-275-01 GEARMOTOR, 3/4HP 40.81:1 RATIO INLINE
MTR3 2801-845 MOTOR 1 HP 3/60/208-230/460 1730 RPM
MTR4 2801-250 MOTOR 1/3 HP 3/60/208-230/460 3450 RPM
PWS1 1418-640 POWER SUPPLY OSP
T3 1412-380 TRANSFORMER 250 VA 208/230/460 TO 120 V
T4 1412-125 TRANSFORMER CL-2 75VA 120/208/240V TO 24

460V Motor Circuit

460V Motor Circuit (6220803)

FU1 1407-710 FUSE 10 A TYPE J 600 V
FU2 1407-710 FUSE 10 A TYPE J 600 V
FU3 1407-710 FUSE 10 A TYPE J 600 V
MTR1 2809-275-01 GEARMOTOR, 3/4HP 40.81:1 RATIO INLINE
MTR3 2801-845 MOTOR 1 HP 3/60/208-230/460 1730 RPM
MTR4 2801-250 MOTOR 1/3 HP 3/60/208-230/460 3450 RPM
T1 1412-950 TRANSFORMER 1.5 KVA 240 x 480 120 x 240
T2 1412-950 TRANSFORMER 1.5 KVA 240 x 480 120 x 240

24V Interlock Circuit

24V Interlock Circuit (6230435)

CB5 1410-105-01 CIRCUIT BREAKER 0.5 A 1 POLE
CR2 1406-780 E-STOP RELAY
LS1 1413-535 LIMIT SWITCH ADJ LEVER
LS2 1413-535 LIMIT SWITCH ADJ LEVER
LS3 1413-509 SWITCH WITH ACTUATOR
LS5 1413-477 SWITCH
LS6 1413-500 SWITCH INTERLOCK
LS7 1413-500 SWITCH INTERLOCK
PB1C1 1411-545 RED MUSHROOM BUTTON STOP TURN RELEASE
PB5C1 1411-017 RED/GREEN ILLUMINATED PUSHBUTTON
Rollerfeed Option
RF-CR10 1401-513 RELAY 24 VDC 2 POLE
RF-CR10B 1401-503 SOCKET FOR 2 POLE RELAY
RF-CR10H 1401-504 HOLD DOWN SPRING FOR 2 POLE RELAY
RF-T5 1412-125 TRANSFORMER CL-2 75VA 120/208/240V TO 24

Control Circuit

Control Circuit (6270481)

AH1 1417-550 ALARM AUDIBLE
CABLE1 1716-716 16’ DATA CABLE ASSEMBLY
CC1 1406-736 COUPLER 232-115 KBAUD
CR5B 1401-275 RELAY 1 POLE 24VAC/DC
CR5C 1401-275 RELAY 1 POLE 24VAC/DC
D1 1406-623 4 COND. DIODE TERMINAL 2.5 SQMM GREY
DISP1 2605-100 VACUUM FLUORESCENT DISPLAY
EC1 1406-760 TERMINATOR
IC1 1406-744 INPUT (8x24VDC-HI)
IC3xx 1406-744 INPUT (8x24VDC-HI)
IC4x 1406-744 INPUT (8x24VDC-HI)
KYBD1 1611-018 CHI BARE
MPC1 1612-690 CHI DISPLAY/CONTROL BOARD
OC1 1406-750 OUTPUT (8x24VDC-HI)
OC3x 1406-750 OUTPUT (8x24VDC-HI)
PB7C2 1401-275 RELAY 1 POLE 24VAC/DC
POT2 1402-550 SPEED CONTROL POT 5K
POT2A 1414-510 KNOB FOR SPEED CONTROL SWITCH
PX4 1607-430 12mm N.C. PROX (XNC)
PX4C 1607-433 3 WIRE 90 DEG FEMALE M8 TO M12, 2M
S2 1716-712 KEYSWITCH DPDT W/ CONNECTOR
SC1 1406-762 SUPPLY INTERMEDIATE

Sensors/Valves

Sensors/Valves (6270482)
JB1 1607-695 WIRING BLOCK 8 PORT
JB3 1607-695 WIRING BLOCK 8 PORT
P218-C 1607-376 CABLE DIN TYPE A TO MALE M12, 1M
PE101 1607-965 SENSOR, 120mm RANGE
PE101-C 1607-491 4 WIRE CABLE 90 DEG FEMALE M8, 5M FLYING
PE101-CO 1607-486 M12 4 PIN FIELD WIREABLE CONNECTOR
PE101-PC 1607-488 4 WIRE CABLE STRAIGHT M12 UNFINISHED
PE102-C 1607-356 CABLE M12 MALE /M8 FEMALE 90 DEG 3m
PE103-C 1607-489 4 WIRE CABLE STR. FEMALE M8, 5M FLYING
PE111-PC 1607-384 4 WIRE CABLE STRAIGHT M12, 2M
SV212 0202-450 “VALVE IN LINE SPRING RETURN 1/4” OD
SV212-C 1607-386 CABLE DIN TYPE C TO MALE M12, 5M
SV212-PC 1607-488 4 WIRE CABLE STRAIGHT M12 UNFINISHED
SV215 0202-080 VALVE SOL 24VDC / SCH:25
SV215-C 1607-378 CABLE DIN TYPE A TO MALE M12, 5M
continued...

3210-506b Duo-Star 20 Steam
Sensors/Valves (6270482) continued...


Low Voltage Interconnect

Pneumatic Diagram 1 Lane

Pneumatic Diagram 1 Lane (6300058)

CYL1 0208-100 AIR CYLINDER 1-1/4” BORE 1 1/2” STROKE
FC1E 0203-200 ELBOW FLOW CONTROL 1/8” NPT
FC1R 0203-200 ELBOW FLOW CONTROL 1/8” NPT
FILT1 0203-170-01 FILTER DRAIN 1/2” NPT
PG1 0203-135 GAUGE 160 PSI 1/8” NPT 1-3/4” DIA
REG2 0203-195-02 REGULATOR 1/2” NPT
SV212 0202-450 VALVE IN LINE SPRING RETURN 1/4” OD

Pneumatic Diagram 4 Lane

Pneumatic Diagram 4 Lane (6300068)

CYL1 0208-100 AIR CYLINDER 1-1/4” BORE 1 1/2” STROKE
FC1E 0203-200 ELBOW FLOW CONTROL 1/8” NPT
FC1R 0203-200 ELBOW FLOW CONTROL 1/8” NPT
FILT1 0203-170-01 FILTER DRAIN 1/2” NPT
SV212 0202-450 VALVE IN LINE SPRING RETURN 1/4” OD

Main Electrical Panel

Main Electrical Panel (6260602)

CC1 1406-736 COUPLER 232-115 KBAUD
CON1A 1414-705 AUX CONTACT 2 N/O FOR CONTACTOR
CR5B 1401-275 RELAY 1 POLE 24VAC/DC
CR5C 1401-275 RELAY 1 POLE 24VAC/DC
EC1 1406-760 TERMINATOR
FU1 1407-710 FUSE 10 A TYPE J 600 V
FU2 1407-710 FUSE 10 A TYPE J 600 V
FU3 1407-710 FUSE 10 A TYPE J 600 V
IC3xx 1406-744 INPUT (8x24VDC-HI)
IC4x 1406-744 INPUT (8x24VDC-HI)
OC3x 1406-750 OUTPUT (8x24VDC-HI)
PB7C2 1401-275 RELAY 1 POLE 24VAC/DC
SC1 1406-762 SUPPLY INTERMEDIATE
Rollerfeed Option
RF-CR10 1401-513 RELAY 24 VDC 2 POLE
RF-CR10B 1401-503 SOCKET FOR 2 POLE RELAY
RF-CR10H 1401-504 HOLD DOWN SPRING FOR 2 POLE RELAY
RF-T5 1412-125 TRANSFORMER CL-2 75VA 120/208/240V TO 24

TOC INDEX
TOC INDEX
DuoStar-120 TECHNICAL SPECIFICATIONS 07/30/14
Steam 6500-054 App:GW
Production
Variable Speed Drive Output
APPENDIX:
Feet per Minute (m/min) Technical Specifications
Minimum 8 (2.5)
Maximum 50 (15.0)
Heating
Steam
Maximum Boiler Horsepower 9.0
Maximum ASME PSI rating (kPa) 125 (860)
Operating Pressure , PSI (kPa) 100-125 (690-860)
Steam Supply Connection , inch (DN) 1 (25)
Condensate Return Connection , inch (DN) 3/4 (20)
Motors
Total 2 2/3 (1.675)
D r iv e , H P ( k W ) 3/4 (0.56)
Exhaust Blower 1 , HP (kW) 1 (0.75)
Primary Fold Motor 1 /2 (0.375
Electrical Frequency : All Models 50 / 60 Hz

Total Amps 11.0 10.0 6.0 5.0
Three Phase Voltage 208 230 380 460
Total Amps 30.0 26.0

Single Phase Voltage 115 230
Exhaust
Air Discharge Main
CFM , (m3/min) max. at 1” S.P. 1450 (41)
Vent Diameter , inches (mm) 10 (255)
Compressed Air
Maximum Air use , CFM (l/min) 7
Operating Pressure , PSI (kPa) 80-120
Inlet Size , inch ½
Drain Size , inch ¼
Rolls
Number of Rolls 1
Roll Diameter , inch (mm) 20 (711)
Usable Length , inch (mm) 120 (3050)
Approximate Shipping Weight Ironer

Domestic , lb (kg) 4710 (2130)
Export , lb (kg) 5140 (2335)
* Based on operation with natural gas at less than 1,500ft.(450m)altitude. BTU input will vary slightly on other types of
gas and will be reduced at higher altitudes.
** Depends on speed, temperature, moisture retention, demand, production, and other local factors.
Specifications subject to change without notice.
TOC INDEX
MANUFACTURER’S BULLETINS ON THE CD
The following manufacturer’s bulletins are included in the interactive version of this manual,
provided on the CD that shipped with the machine. If viewing the interactive version, click
on any of the items listed below to go directly to that information. If an interactive version is
not available, contact the Factory Parts Department to order one.
3045-001: Dayton High Volume Direct Drive Blowers

3045-063: Installation Instructions for Type SX Joints
3045-240: Clena Powdered Wax MSDS
TOC INDEX
3045001a
TOC MB-TOC INDEX

TOC MB-TOC INDEX
TOC MB-TOC INDEX
TOC MB-TOC INDEX
IS-3000SX-2
Effective July 2005
Replaces IS-3000SX-1
Installation Instructions 3045063
for Type SX Joints

Anti-rotation 8Q
rod hole
4
55
For stationary syphon, distribution pipe and through-flow applications Type SXBPQ-1
NOTE: Please follow your company's safety procedures when- tight, there may be 1/8˝ – 3/16˝ space between the two flanges.
ever working on Kadant Johnson rotary joints and read all of If the rotary joint has a threaded nipple connection for attach-
the instructions completely before proceeding. ment to your roll, simply thread it into the journal.
Please refer to the assembly drawings supplied with your STEP 4.

Kadant Johnson rotary joint for part identification. If you have Connect piping to joint using Kadant Johnson flexible metal
any further questions, please contact your Representative or hose. The hose(s) should be long enough so there is no bind-
Kadant Johnson. ing or tension tending to move the joint off the journal cen-
terline of the roll. The joint must be reasonably free to move
STEP 1. outward to compensate for carbon seal ring wear. (See rec-
Check to make sure that all core sand, dirt, weld beads, pipe ommended flexible metal hose length chart in this instruction
turnings, metal dust and other foreign matter has been sheet.)
removed from the piping, roll, dryer or cylinder before installing
joint. This will help eliminate carbon seal ring scoring and dam- IMPORTANT: CONNECT THE HOSE DIRECTLY TO THE
age to internal joint parts which could cause unnecessary JOINT. MINIMIZE THE USE OF FITTING AND PIPE, AS THE
downtime and maintenance. INCREASED WEIGHT CAN AFFECT THE PERFORMANCE
OF THE JOINT. PROVIDE SUITABLE SUPPORT FOR THE
STEP 2. PIPE AND FITTING BEYOND THE HOSE.
Thread the horizontal pipe into the rotary joint head (2).
STEP 5.
IMPORTANT: THE INNER PIPE MUST BE STRAIGHT AND Install stop rods in the anti-rotation rod holes using Schedule 80
TRUE. THIS WILL PREVENT EXCESSIVE PIPE WEAR AND pipe. It is recommended that no more than two joints be joined
PIPE BREAKAGE. with one rod. Secure the rod in the rod hole of one joint using
cotter pins and let the rod float in the rod hole of the second
STEP 3. joint. This will absorb the torque generated by the joint, and pre-
For quick release style connections to your journal; place a new vent premature hose failure by reducing stresses.
copper gasket (8Q) into the journal flange. Slide the quick
release nipple flange (5) over the rotary joint nipple (4) with its NEVER APPLY OIL OR GREASE TO KADANT JOHNSON
taper facing outward. Place the two split taper wedges (55) into JOINTS. THE SATURATED STEAM, CONDENSATE OR LIQ-
recess of the nipple and then slide the quick release flange UID PASSING THROUGH IS THE ONLY LUBRICATION
over them. Lift the joint up and slide the nipple (4) into the jour- REQUIRED FOR THE CARBON-GRAPHITE PARTS.
nal flange recess and secure to the studs with nuts provided,
tightening evenly. Note that the quick release nipple flange (5) MINIMIZE RUNNING KADANT JOHNSON JOINTS DRY.
will not seat tightly against the face of the journal flange. When EXCESSIVE CARBON SEAL WEAR MAY OCCUR.
TOC MB-TOC INDEX

LUGS FOR ANTI-ROTATION RODS
CAUTION
Check the rotary joint regularly for carbon seal ring wear. The use of a anti-rotation rod is a common method with self-sup-
Should the carbon seal ring wear away completely, the metal porting joints, especially with higher speeds and pressures. It is
nipple can wear into the joint body, and eventually through it. assurance that the joint will not turn should it bind or seize for
This will result in significant leakage, creating a possibly haz- any reason. Furthermore, the anti-rotation rod greatly increases
ardous condition, and may require replacement of the entire the life of the connecting hose by relieving it of all strains and
joint instead of just the seal ring. tension.
TABLE 1 Anti-rotation
Joint Size Seal Wear rod hole
3/4˝ 1/4˝
1˝ 3/8˝
1-1/4˝ 3/8˝
1-1/2˝ 3/8˝
2˝ 3/8˝
2-1/2˝ 3/8˝
3˝ 7/16˝
Anti-rotation rod
Flexible
hose
X Anti-rotation rod
PROCEDURE FOR DETERMINING

CARBON SEAL RING WEAR
Measure the distance for dimension (X) as shown above when
the joint is new. Reference Table 1 for your particular joint size.
Remember that as the carbon seal ring begins to wear, the joint Flexible
moves (due to pressure) away from the cylinder journal end. hose
Add dimension “X” to the number you found in Table 1. As the
seal wears dimension “X” will increase. Refer to Table 1. When
“X” has increased the thickness of seal wear indicated you RECOMMENDED SIZES FOR ANTI-ROTATION RODS
should replace the seal ring. Joint Size Joint Number Use Schedule 80 Pipe Size
3/4˝ 3200 1/8˝
1˝ 3300 1/8˝
ALTERNATIVE PROCEDURE FOR
1-1/4˝ 3400 1/4˝
DETERMINING SEAL WEAR
1-1/2˝ 3500 3/8˝
Reference the groove machined into the end of the nipple. The
2˝ 3550 1/2˝
width (Z) of this groove is equivalent to the amount of seal wear
2-1/2˝ 3600 1/2˝
available. As the seal ring wears, the rotary joint will automati-
3˝ 3700 3/4˝
cally move away from the cylinder journal end. When the
groove is as far from the outboard (dry) carbon guide as it is
wide (Y = Z), the seal ring should be replaced.
RECOMMENDED MINIMUM HOSE LENGTHS
Outboard
Hose Size Minimum Length
Dry Guide
Y 1/4˝ 8˝
Y
3/8˝ 10˝
Z 1/2˝ 10˝
Z 3/4˝ 12˝
1˝ 15˝
1-1/4˝ 18˝
1-1/2˝ 18˝
2˝ 21˝
New installation Nipple groove is fully exposed 2-1/2˝ 24˝
and seal should be replaced 3˝ 27˝
The Kadant Johnson Warranty

Kadant Johnson products are built to a high standard of quality. Performance is what you desire: that is what we
provide. Kadant Johnson products are warranted against defects in materials and workmanship for a period of one
year after date of shipment. It is expressly understood and agreed that the limit of Kadant Johnson’s liability shall,
at Kadant Johnson’s sole option, be the repair or resupply of a like quantity of non-defective product. www.kadantjohnson.com
IS-3000SX-2 © 2005 Kadant Johnson Inc.
TOC MB-TOC INDEX

3045240
Material Safety Data Sheet
CLENACORP
1200 industrial Road #3, San Carlos, CA 94070
Product: CLENA POWDERED WAX JANUARY 2011

SECTION 1
Product: CLENA POWDERED WAX
Manufacturers Name/Address: Emergency Phone Numbers

Clenacorp (650) 591-1733
1200 Industrial Road #3 Information Phone Number
San Carlos, CA 94070 (650) 591-1733
SECTION II – HAZARDOUS INGREDIENTS

Hazardous Components-specific Chemical Identity: (Common Names) OSHAACGIH TLVOTHER LIMITS % OPTIONAL
NO HAZARDOUS INGREDIENTS
SECTION III - PHYSICAL/CHEMICAL CHARACTERISTICS

o
Boiling Point: 600 F Specific Gravity (H20=1): 0.55
o
Vapor Pressure (mm Hg): Negligible Melting Point: 130 F
Vapor Density (Air=1): Non-volatile Evaporation Rate (Butyl Acetate=1) Negligible
Solubility in Water: Insoluble
Appearance and Odor: Off white solid, mild fatty odor
How to Detect this Substance: (Warning properties of substance as a gas, vapor, dust, or mist)
Not Applicable
SECTION IV - FIRE AND EXPLOSION HAZARD DATA

o
Flash point (Method Used): 565 F (C.O.C.) Flammable Limits in Air, Volume %
Autoignition temperature: Unknown LEL: Unknown
UEL: Unknown
Extinguishing Media:
____ Water Spray __X_Carbon Dioxide __X _Foam __X_ Dry Chemical __X_ Other: Water Fog
Special Fire Fighting Procedures: Do not use water stream, material floats.
Unusual Fire and Explosion Hazards: Only usual hazards associated with organic dust.
SECTION V - HEALTH HAZARD DATA
Symptoms of Overexposure for each potential route of exposure.

Inhaled: May cause slight irritation to nose and throat
Contact with skin or eyes: May cause slight irritation
Absorbed through skin: May cause slight irritation
Swallowed: Unlikely to occur
Health Hazards:
Acute: Swallowed Powdered Wax has a mild laxative effect which can lead to nausea, vomiting and diarrhea.
Chronic: Prolonged skin contact, along with poor personal hygiene, can lead to mild skin dermatitis.
Powdered Wax 1
TOC MB-TOC INDEX

Carcinogenicity:
X__ No This product’s ingredients are not found in the lists below.
____NTP? ___IARC Monographs? ___Osha regulated?
Signs and Symptoms of Exposure: Molten material can cause thermal burns
Medical Conditions Generally Aggravated by Exposure: None
Emergency First Aid Procedures:

Eye Contact: Flush with water for 15 minutes, contact physician
Skin: Wash hands with soap and water after each use and at the end of work shift .
Inhaled: None
Swallowed: Contact physician, hospital or poison control center for information
SECTION VI - REACTIVITY DATA
Stability: Unstable Conditions to Avoid: None

X Stable
Incompatibility (Materials to Avoid): Strong Oxidizing Agents
Hazardous Decomposition or Byproducts: Carbon Dioxide, Carbon Monoxide
Hazardous
Polymerization: X Will Not Occur
Will Occur
Conditions to Avoid: None
SECTION VII - SPILL, LEAK, AND DISPOSAL PROCEDURES
Steps to Be Taken in Case Material is Released or Spilled: Material is non-hazardous. Use normal housekeeping
procedures.
Waste Disposal Method: No special measures necessary. Dispose of all wastes in accordance with federal, state, and local
regulations.
Precautions to Be Taken in Handling and Storing: No special precautions necessary.
Other Precautions:
SECTION VIII - SPECIAL HANDLING INFORMATION
Respiratory Protection (Specify Type): Disposal dust respirator. 3M model 8710 is recommended.
Ventilation: Local Exhaust: If needed for heated fumes Special: No special equipment
Mechanical (General): None required
Other Handling and Storage Requirements: Material is combustible. Do not store near strong oxidizing agents.
Protective Gloves: None required Eye Protection: Chemical safety glasses
Other Protective Clothing or Equipment: None required
Work/Hygienic Practices: Use good personal hygiene practices when handling. Wash hands after using product. Ensure
eye wash or clean running water is readily available.
Powdered Wax 2
TOC MB-TOC INDEX

3010-025
GENERAL TORQUE SPECIFICATION CHART
These torque values are approximate and should not be accepted as accurate limits. Indeterminate
factors (surface finish, type of plating and lubrication) in specific applications preclude the publication
of accurate values for universal use.
DO NOT USE the below values for gasketed joints or joints of soft materials.
DO NOT USE your torque wrench for values greater than its maximum scale reading.
FOR ENGLISH FASTENERS (In Foot Pounds)

Socket Head Stainless
SIZE 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 55 85 86 23 25
7/16-20 41 60 95 95 25 28
1/2-13 57 85 125 130 32 37
1/2-20 64 95 140 145 34 40
9/16-12 80 125 175 180 44 50
9/16-18 91 140 195 210 48 54
5/8-11 111 175 245 255 68 75
5/8-18 128 210 270 290 73 80
FOR METRIC FASTENERS (In Newton Meters)

SIZE 4.6 4.8 5.8 8.8 9.8 10.9 12.9
M5 3 4 5 7 8 11 12
M6 5 6 8 12.5 14 17 20
M8 12 16 20 30 34 44 50
M 10 23 32 40 60 70 85 100
M 12 40 56 70 103 120 150 180
M 14 65 90 110 167 190 240 280
M 16 100 140 170 270 290 380 440
M 20 200 330 520 740 860
TOC INDEX
OPERATING STANDARD
STEAM IRONER
Model: Serial #: Date: / / Approved by:
APPENDIX: Operating Standard form
FLATWORK / FABRIC CONTENT OPERATING SPEED
/
/
/
/
/
/
/
/
/
/
Tip - Flatwork
Warm Rinse
A warm rinse allows more water to be extracted from the material. This means the ironer needs to
remove less moisture from the flatwork to produce a dry, high quality finish. Furthermore, the ironer can be
run faster if the final rinse is warm.
Moisture Retention (MR)
After extraction, the optimum MR is 30% - 35% for mixed- fiber-content fabrics and 45% - 50% for cotton
fabrics. To determine the MR after extraction, use a precise scale to measure the “still wet, but extracted”
flatwork; then weigh again after the same flatwork is “completely dry”. Subtract the weight of the “still wet, but
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 optimum MR after ironing is 4% or less. Ironing is not intended to remove 100% of the moisture
from the flatwork. Therefore, feel the flatwork when it first comes out of the unit; there should be a slight
moisture content. Allow the flatwork to sit for a few minutes to allow excess steam and heat to dissipate in the
air. Check the flatwork again; it should now feel dry to the touch. For more information, review the Instruction
Manual, Flatwork Handling procedure.
NOTE: This Operating Standard form needs to be completed and approved by the laundry manager at each facility. Each laundry facility
uses different means to accomplish a quality finish, including wash formulas, extraction, number of personnel, etc.; the Chicago Dryer
Company does not assume any responsibility how this form is completed or used.
3010906
TOC INDEX
Duo-Star 20 Steam Index
INDEX
A Check and Clean
Exhaust Blower Wheel 4-12
Adjustment, CHI Panel 3-13, C-8 Inverter 4-8
End Adjustment C-9 Motors 4-12
Primary Fold C-10 Photosensors 4-4
Start Adjustment C-8 CHI Panel
Air Bar Alignment 7-63 About 3-6, 5-6, C-3
Air Components, About Adjustment C-8
Air Bars 5-11 End Adjustment C-9
Air Cylinders 5-11 Primary Fold C-10
Air Filter/Regulators 5-10 Start Adjustment C-8
Air Reservoirs 5-10 Operation C-3
Air Valves 5-10 Automatic Operation C-4
Air Cylinders Controls and Indicators C-3
Air Flow Adjustment, Transfer Guide 7-64 Manual Operation C-4
Air Filter/Auto Drain Safety Stop Buttons C-5
Cleaning 4-18 Self-Diagnostics C-5
Inspect 4-6 Programming C-6
Air Pressure Settings, Check 4-7 End Programming C-7
Air System. See Compressed Air System Primary Fold Programming C-7
Air Valve Repair 7-65 Start Programming C-6
Alignment and Positioning, Feed Table 7-16 Testing C-11
Automatic Operation, CHI Panel 3-13, C-4 End Testing C-12
Primary Fold C-13
B
Start Testing C-11
Bearings, Greasing Troubleshooting 6-22
Monthly 4-14 Clean
Weekly 4-9 Air Filter/Auto Drain 4-18
Broken or Missing Ribbon Replacement Behind Service Panels 4-6
Delivery 7-53 Clearing a Jam Safely 3-11
Feed 7-7 Communications and the Control Panel, Control
Intermediate 7-49 System 5-6
Return 7-39 Compressed Air Supply
Transfer 7-47 Checkout 2-18
Connection 2-8
C Compressed Air System 5-10
Air Bars
Check
About 5-11
Air Pressure Settings 4-7
Alignment 7-63
Compression Roll
Air Cylinders
Pressure and Cover Condition 4-17
About 5-11
Guide Tapes 4-4
Air Flow Adjustment, Transfer Guide 7-64
Ironing Cylinder 4-5
Air Filter/Auto Drain
Mechanical and Electrical Connections 4-19
Cleaning 4-18
Ribbon Condition and Tension 4-13
Inspect 4-6
Safety Equipment 4-4
Air Filter/Regulators 5-10
Setscrews 4-15
Air Pressure Settings, Check 4-7
Air Reservoirs 5-10
Topic continued on next page...
TOC INDEX I-1

Index Duo-Star 20 Steam
Compressed Air System (cont) Disassembling the Rotary Union 7-31

Air Valves Disconnect Switch and Fuses 5-3
About 5-10 Doffer Roll Cover Replacement 7-14
Repair 7-65 Drive Chain
Repair 7-63 Oil 4-16
Troubleshooting 6-24 Tension Adjustment
Compression Roll 7-19 Main 7-26
Check Pressure and Cover Condition 4-17 Transfer Ribbon/Delivery Ribbon 7-54
Cover Drive Roll Friction Material Replacement
Replacement 7-21 Feed Ribbon 7-8
Pressure Return Ribbon 7-41
Adjustment 7-21 Ductwork 2-5
Check 7-20
Unit Settings 3-17 E
Condensate (Steam Return) Piping Installation 2-13 Electrical
Conditioning Flatwork Before Ironing 3-15 Check Mechanical and Electrical Connections
Final Rinse 3-15 4-19
Moisture Retention 3-15 Checkout Connection 2-19
Timing Between Washing and Ironing 3-16 Exhaust Blower Motor Rotation Checkout 2-19
Wash Load 3-15 Connection 2-8
Control Function Check 2-21 Exhaust Blower Motor 2-9
Controls and Indicators, CHI Panel 3-6, C-3 Main Power Connection 2-11
Controls, Operating. See Operating Controls Electrical System
Control System, Electrical 5-6 About 5-2
CHI Panel 5-6 Control System 5-6
Communications and the Control Panel 5-6 CHI Panel 5-6
I/O Control Panel 5-7 Communications and the Control Panel 5-6
Junction Block 5-7 I/O Control Panel 5-7
Sensors 5-8 Junction Block 5-7
Cover Replacement Sensors 5-8
Compression Roll 7-21 Disconnect Switch and Fuses 5-3
Doffer Roll 7-14 Main Electrical Panel 5-4
Feed Ribbon Drive Roll Friction Material 7-8 Power System 5-2
Return Ribbon Drive Roll Friction Material 7-41 Step-Down Transformers 5-3
D Troubleshooting 6-8
Endframe Controls. See Operating Controls
Daily Operating Procedures. Exhaust Blower
See Standard Operating Procedures Installation 2-5
Daily Operation Safety 1-3 Ductwork 2-5
Daily PM (8 Hours) 4-3 Electrical Connection 2-9
Check Installing the Exhaust Blower 2-6
Guide Tapes 4-4 Locating the Exhaust Blower 2-6
Safety Equipment 4-4 Ventilating the Work Area 2-7
Check and Clean Photosensors 4-4 Motor Rotation Checkout 2-19
General Cleanliness 4-3 Exhaust System
Watch and Listen for Anything Abnormal 4-3 About 5-15
Wax Ironing Cylinder 4-4 Troubleshooting 6-18
Delivery Drive System 5-13
Delivery Ribbon
Drive Chain Tension Adjustment 7-54
Drive Roll Tracking Tape Replacement 7-55
Replacement 7-52
Tension Adjustment 7-50
I-2 TOC INDEX

F H
Feed Section 7-4 Heating Operation Checkout 2-22
Doffer Roll Cover Replacement 7-14 Heat Ironing Cylinder 2-24
Drive Roll Friction Material Replacement 7-8 Inspect Steam Piping System 2-22
Feed Table Alignment and Positioning 7-16 Heating System 5-15. See also Steam System
Guide Tape Replacement 7-11 Operation Stage 5-20
Ribbon Rotary Union, About 5-16
Replacement 7-6 Siphon Tube 5-17
Tension Adjustment 7-4 Troubleshooting 6-17
Fill Grease Gun 4-10
Final Protective Wrapper Removal 2-15 I
Final Rinse, Conditioning Flatwork Before Ironing Inspect
3-15 Air Filter/Auto Drain Units 4-6
First Primary Fold Installation 2-3
Photosensor Position Adjustment 7-59 Rotary Union 7-33
Photosensor Sensitivity Adjustment 7-58 Steam Piping System 2-22
Flatwork Handling 3-10 Installation Procedures 2-3
Ironing Cylinder 3-11 Compressed Air Supply Connection 2-8
Maximum Efficiency 3-10 Electrical Connection 2-8
Safety 3-10 Exhaust Blower Installation 2-5
Flatwork Transfer Guide Final Protective Wrapper Removal 2-15
Air Cylinders Air Flow Adjustment 7-64 Inspection 2-3
Grease 4-19 Receiving Shelf Set-Up 2-15
Mechanical Adjustment 7-45 Steam Connection 2-12
Folding Accuracy 3-13 Uncrating and Positioning 2-4
Fold System Installing the Exhaust Blower 2-6
Checkout 2-24 Intermediate Ribbon
Fold Operation 3-12 Drive Roll Tracking Tape Replacement 7-55
Automatic Operation 3-13 Replacement 7-48
Folding Accuracy 3-13 I/O Control Panel 5-7
Item Counter 3-13, C-5 Ironer Drive System 5-12
Manual Operation 3-13 Ironer Inlet Photosensor Sensitivity Adjustment
Programming, Adjustment, Testing 3-13 7-57
Self-Diagnostics 3-13 Ironing Cylinder
Processing Standards 3-18 Check 4-5
Friction Material Replacement Flatwork Handling 3-11
Feed Ribbon Drive Roll 7-8 Heating 2-24
Return Ribbon Drive Roll 7-41 Paper Removal 2-22
G Reconditioning 7-27
Temperature, Unit Settings 3-16
General Cleanliness 4-3 Waxing 4-4
Grease Ironing Quality Troubleshooting 6-14
Flatwork Transfer Guide 4-19 Ironing Section 7-26
Monthly Bearings 4-14 Ironing Cylinder Reconditioning 7-27
Using Other 4-9 Main Drive Chain Tension Adjustment 7-26
Weekly Bearings 4-9 Ironing Speed, Unit Settings 3-17
Grease Gun Ironing System, Processing Standards 3-17
Filling 4-10 Item Counter, CHI Panel 3-13, C-5
Using 4-10
Guide Tape
Check 4-4
Replacement 7-11
TOC INDEX I-3

J O
Jams, Clearing Safely 3-11 Oil
JOG Operation Stage, Sequence of Operation 5-18 Drive Chain and Tension Springs 4-16
Junction Block 5-7 Roll Bearing Pivots 4-11
Operating Controls 3-4
L CHI Panel 3-6, C-3
LED Diagnostics, Troubleshooting 6-6 Right Endframe Controls 3-4
Locating the Exhaust Blower 2-6 Operating Techniques 3-14
Conditioning Flatwork Before Ironing 3-15
M Maximum Productivity 3-18
Processing Standards 3-17
Machine Speed Sensor Unit Settings 3-16
Position Adjustment 7-61 Operation, CHI Panel C-3
Replacement 7-62 Automatic C-4
Main Disconnect Switch 1-4, 3-2 Controls and Indicators C-3
Main Electrical Panel 5-4 Manual C-4
Main Power Connection 2-11 Safety Stop Buttons C-5
Maintenance and Repair Safety 1-3 Self-Diagnostics C-5
Manual Operation, CHI Panel 3-13, C-4
Manual Scope 1-2 P
Maximum Efficiency, Flatwork Handling 3-10
Maximum Productivity 3-18 Parts Availability, Repair 7-3
Mechanical Start-Up Stage, Sequence of Operation Photosensors. See also Sensors
5-19 About 5-8
Mechanical System Check and Clean 4-4
About 5-12 Position Adjustment
Ironer Drive System 5-12 First Primary Fold 7-59
Ribbon Sets 5-14 Replacement 7-60
Transfer/Primary Fold/Delivery Drive System Sensitivity Adjustment
5-13 First Primary Fold 7-58
Troubleshooting 6-11 Ironer Inlet/Second Primary Fold 7-57
Missing or Broken Ribbon Replacement PM Task Tables
Delivery 7-53 Daily, Weekly Tasks 4-1
Feed 7-7 Monthly, Semi-Annual Tasks 4-2
Intermediate 7-49 Positioning the Unit 2-4
Return 7-39 Power System, Electrical 5-2
Transfer 7-47 Step-Down Transformers 5-3
Moisture Retention, Conditioning Flatwork Before Pre-Operational Checkout 2-16
Ironing 3-15 Checkout Completion 2-25
Monthly PM (200 Hours) 4-14 Cleaning the Unit 2-25
Check Compressed Air Supply Checkout 2-18
Compression Roll Pressure and Padding Condi- Electrical Connection Checkout 2-19
tion 4-17 Fold System Checkout 2-24
Setscrews 4-15 Heating Operation Checkout 2-22
Grease Bearings 4-14 Ironing Cylinder Paper Removal 2-22
Oil Drive Chain and Tension Springs 4-16 Safety Device and Control Function Checkout
2-20
Security of Hardware 2-16
Pressure Adjustment, Compression Roll 7-21
Pressure Check, Compression Roll 7-20
I-4 TOC INDEX

Preventive Maintenance Ribbon

Daily PM (8 Hours) 4-3 Condition and Tension Check 4-13
Monthly PM (200 Hours) 4-14 Replacement
Semi-Annual PM (1000 Hours) 4-17 Delivery 7-52
Task Tables Feed 7-6
Daily, Weekly Tasks 4-1 Intermediate 7-48
Monthly, Semi-Annual Tasks 4-2 Return 7-38
Weekly PM (50 Hours) 4-5 Transfer 7-46
Primary Fold Sets 5-14
Adjustments, CHI Panel C-10 Tension Adjustment
Operation Stage 5-21 Delivery 7-50
Programming, CHI Panel C-7 Feed 7-4
Testing, CHI Panel C-13 Return 7-37
Troubleshooting 6-19 Transfer 7-45
Primary Fold/Delivery Sections 7-44 Right Endframe Controls 3-4
Delivery Ribbon Rotary Union
Replacement 7-52 About 5-16
Tension Adjustment 7-50 Areas of Wear 7-30
Flatwork Transfer Guide Disassembly 7-31
Air Cylinders Air Flow Adjustment 7-64 Inspection 7-33
Grease 4-19 Maintenance 7-30
Mechanical Adjustment 7-45 Repair 7-34
Intermediate Ribbon, Replacement 7-48 Replacement 7-34
Tracking Tape Replacement, Transfer, Intermedi-
ate and Delivery Rolls 7-55 S
Transfer Ribbon Safety 1-3, 5-2
Replacement 7-46 Flatwork Handling 3-10
Tension Adjustment 7-45 Repair Safety Considerations 7-2
Transfer Ribbon/Delivery Ribbon Drive Chain Safety Features 1-4
Tension Adjustment 7-54 Safe Work Habits 1-3
Primary Fold Drive System 5-13 Safety Considerations, Repair 7-2
Processing Standards 3-17 Safety Device and Control Function Checkout 2-20
Fold System 3-18 Control Function Check 2-21
Ironing System 3-17 Safety Device Check 2-21
Programming, CHI Panel 3-13, C-6 Safety Features 1-4, 3-2
End Programming C-7 Main Disconnect Switch 1-4, 3-2
Primary Fold C-7 Safety Guards 1-5, 3-3
Start Programming C-6 Safety Interlock Switches 1-5, 3-3
Proximity Sensors Safety Labels 1-5, 3-3
About 5-8 Safety Messages in this Manual 1-6
R Safety Stop Buttons 1-4, 3-2
Safety Guards 1-5, 3-3
Receiving Shelf Set-Up 2-15 Safety Interlock Switches 1-5, 3-3
Reconditioning, Ironing Cylinder 7-27 Safety Labels 1-5, 3-3
Repair Safety Messages in this Manual 1-6
Parts Availability 7-3 Safety Stop Buttons 1-4, 3-2, C-5
Safety Considerations 7-2 Safe Work Habits 1-3
Repairing the Rotary Union 7-34 During Daily Operation 1-3
Replacing the Rotary Union 7-34 Maintenance and Repair 1-3
Return Section 7-36 Scope of the Manual 1-2
Drive Roll Friction Material Replacement 7-41
Ribbon
Replacement 7-38
TOC INDEX I-5

Second Primary Fold Steam System 5-15. See also Heating System

Photosensor Sensitivity Adjustment 7-57 Connection
Security of Hardware 2-16 Condensate (Steam Return) Piping 2-13
Self-Diagnostics, CHI Panel 3-13, C-5 Supply Piping 2-14
Semi-Annual PM (1000 Hours) 4-17 Piping Inspection 2-22
Check Rotary Union
Mechanical and Electrical Connections 4-19 About 5-16
Clean Air Filter/Auto Drain 4-18 Areas of Wear 7-30
Grease Disassembly 7-31
Flatwork Transfer Guide 4-19 Inspection 7-33
Sensors 7-57. See also Photosensors Maintenance 7-30
About 5-8 Repair 7-34
Function, Troubleshooting 6-23 Replacement 7-34
Machine Speed Sensor Siphon Tube 5-17
Position Adjustment 7-61 Step-Down Transformers 5-3
Replacement 7-62
Photosensor T
Check and Clean 4-4 Task Tables, PM
Position Adjustment Daily, Weekly Tasks 4-1
Second Primary Fold 7-59 Monthly, Semi-Annual Tasks 4-2
Replacement 7-60 Temporary Shut-Down 3-14
Sensitivity Adjustment Tension Adjustment
Ironer Inlet/Second Primary Fold 7-57 Delivery Ribbon 7-50
Second Primary Fold 7-58 Feed Ribbon 7-4
Sequence of Operation 5-18 Main Drive Chain 7-26
Heating System Operation Stage 5-20 Return Ribbon 7-37
JOG Operation Stage 5-18 Transfer Ribbon 7-45
Mechanical Start-Up Stage 5-19 Transfer Ribbon/Delivery Ribbon Drive Chain
Primary Fold Operation Stage 5-21 7-54
Stand-By Stage 5-18 Tension Spring
Setscrews, Check 4-15 Oil 4-16
Shut-Down 3-14 Testing, CHI Panel 3-13, C-11
Temporary Shut-Down 3-14 End Testing C-12
Siphon Tube 5-17 Primary Fold C-13
Site and Utility Requirements 2-2 Start Testing C-11
Spring Timing Between Washing and Ironing, Conditioning
Oil Tension 4-16 Flatwork Before Ironing 3-16
Standard Operating Procedures 3-7 Tracking Tape Replacement
Clearing a Jam Safely 3-11 Transfer, Intermediate and Delivery Rolls 7-55
Flatwork Handling 3-10 Transfer Drive System 5-13
Fold Operation 3-12 Transfer Guide, Flatwork
Shut-Down 3-14 Air Cylinders Air Flow Adjustment 7-64
Start-Up 3-7 Grease 4-19
Waxing 3-8 Mechanical Adjustment 7-45
Stand-By Stage, Sequence of Operation 5-18 Transfer Ribbon
Start-Up 3-7 Drive Chain Tension Adjustment 7-54
Drive Roll Tracking Tape Replacement 7-55
Replacement 7-46
I-6 TOC INDEX

Troubleshooting
CHI Panel 6-22
Compressed Air System 6-24
Electrical 6-8
Exhaust System 6-18
Heating System 6-17
Ironing Quality 6-14
LED Diagnostics 6-6
Mechanical System 6-11
Primary Folding 6-19
Sensor Function 6-23
Symptoms 6-2
U
Uncrating and Positioning 2-4
Unit Settings 3-16
Compression Roll Pressure 3-17
Ironing Cylinder Temperature 3-16
Ironing Speed 3-17
V
Ventilating the Work Area 2-7
W
Warranty 1-2
Wash Load, Conditioning Flatwork Before Ironing
3-15
Watch and Listen for Anything Abnormal 4-3
Waxing 3-8
Wax Ironing Cylinder 4-4
Weekly PM (50 Hours) 4-5
Check
Air Pressure Settings 4-7
Ironing Cylinder 4-5
Ribbon Condition and Tension 4-13
Check and Clean
Exhaust Blower Wheel 4-12
Inverter 4-8
Motors 4-12
Clean
Behind Service Panels 4-6
Grease Weekly Bearings 4-9
Inspect Air Filter/Auto Drain 4-6
Oil Roll Bearing Pivots 4-11
Worn Ribbon Replacement
Delivery 7-52
Feed 7-6
Intermediate 7-48
Return 7-38
Transfer 7-46
TOC INDEX I-7

DUO - STAR 20 (Steam Heater) Manual

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DUO - STAR 20 (Steam Heater) Manual

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Dear Customer,

 Manual Body (Chapters 1-7)  Stacker Section (Folders Only)

 Schematics (for following reasons)  Stacker Schematics

If you require assistance during installation and start-up or have any

CHICAGO DRYER COMPANY

CHICAGO DRYER COMPANY

Chapter 3 - Operating Guidelines

Chapter 4 - Preventive Maintenance

Chapter 5 - Operating Principles

CHI PANEL OPERATION

PICTURE PARTS LIST

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

1.3 Safety....................................................................................................... 1-3

2.2 Installation Procedures............................................................................. 2-3

2.3 Pre-Operational Checkout...................................................................... 2-16

TOC INDEX iii

CHAPTER 3 OPERATING GUIDELINES

3.2 Operating Controls................................................................................... 3-4

3.3 Standard Operating Procedures.............................................................. 3-7

3.4 Operating Techniques............................................................................ 3-14

CHAPTER 4 PREVENTIVE MAINTENANCE

4.1 Daily PM (8 Hours)................................................................................... 4-3

4.2 Weekly PM (50 Hours)............................................................................. 4-5

4.3 Monthly PM (200 Hours)........................................................................ 4-14

4.4 Semi-Annual PM (1000 Hours).............................................................. 4-17

CHAPTER 5 OPERATING PRINCIPLES

5.1 Electrical System...................................................................................... 5-2

5.2 Compressed Air System......................................................................... 5-10

5.3 Mechanical System................................................................................ 5-12

5.4 Heating and Exhaust Systems............................................................... 5-15

5.5 Sequence of Operation.......................................................................... 5-18

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

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

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

6.4 Ironing Quality........................................................................................ 6-14

6.5 Heating System...................................................................................... 6-17

6.6 Exhaust System..................................................................................... 6-18

6.7 Primary Folding...................................................................................... 6-19

6.8 CHI Panel............................................................................................... 6-22

6.9 Sensor Function..................................................................................... 6-23

6.10 Compressed Air System......................................................................... 6-24

TOC INDEX vii

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

7.3 Feed Section............................................................................................ 7-4

7.4 Compression Roll................................................................................... 7-19

7.5 Ironing Section....................................................................................... 7-26

7.6 Rotary Union Maintenance..................................................................... 7-30

7.7 Return Section....................................................................................... 7-36

Repair topics continued on the next page...

viii TOC INDEX

7.8 Primary Fold/Delivery Sections.............................................................. 7-44

7.9 Sensors.................................................................................................. 7-57

7.10 Compressed Air System......................................................................... 7-63

1.2 Scope of the Manual

 Chicago Dryer Company  (773) 235-4430

TOC INDEX 1-1

Follow these procedures to keep the unit

Updates Chapter 7 - Repair

1-2 TOC INDEX

Maintenance and Repair

Keep hands and loose

• Your site should have procedures that

TOC INDEX 1-3

The main disconnect switch is located on the