Comet Executive Exec56g

INSTRUCTION MANUAL
COMET EXECUTIVE™
Gas Heated
Flatwork Ironer
Instruction Manual #3011-102f
MAXI Companies
4317 E. Genessee Street, Dewitt, New York 13214 USA
Phone: 315-446-2180 Fax: 315-446-2403
E-mail: sales@maxico.com
Comet Executive Gas 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
PICTURE PARTS LIST
SCHEMATIC PARTS LIST
APPENDIX
Floor Plans
Technical Specifications
Manufacturer’s Bulletins
Torque Specifications
Operating Standard
INDEX
TOC INDEX i
Table of Contents Comet Executive Gas
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
Electrical Connection............................................................................... 2-8
Gas Connection..................................................................................... 2-12
Receiving Shelf Set-Up.......................................................................... 2-14
Final Protective Wrapper Removal......................................................... 2-15
2.3 Pre-Operational Checkout...................................................................... 2-15

Security of Hardware.............................................................................. 2-16
Exhaust Blower Motor Rotation Checkout............................................. 2-17
Safety Device and Control Function Checkout...................................... 2-18
Ironing Cylinder Paper Removal............................................................ 2-19
Gas Connection Checkout..................................................................... 2-20
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.......................................................................................... 3-2
Safety Interlock Switch............................................................................. 3-3
Safety Labels........................................................................................... 3-3
3.2 Operating Controls................................................................................... 3-4

Right Endframe Controls.......................................................................... 3-4
Left Endframe Controls............................................................................ 3-5
3.3 Standard Operating Procedures.............................................................. 3-6

Start-Up.................................................................................................... 3-6
Waxing..................................................................................................... 3-7
Flatwork Handling.................................................................................... 3-9
Clearing a Jam Safely............................................................................ 3-10
Shut-Down..............................................................................................3-11
3.4 Operating Techniques............................................................................ 3-12

Conditioning Flatwork Before Ironing..................................................... 3-12
Unit Settings........................................................................................... 3-14
Processing Standards............................................................................ 3-15
Maximum Productivity............................................................................ 3-15
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 Temperature Sensor Contact Shoes............................ 4-4
Check Guide Tapes.................................................................................. 4-4
Check Safety Equipment.......................................................................... 4-5
Wax Ironing Cylinder................................................................................ 4-5
4.2 Weekly PM (50 Hours)............................................................................. 4-6

Clean Behind Service Panels................................................................... 4-6
Check Ironing Cylinder............................................................................. 4-7
Check and Clean Inverter........................................................................ 4-7
Grease “Weekly” Bearings....................................................................... 4-8
Oil Roll Bearing Pivots........................................................................... 4-10
Check and Clean Motors.........................................................................4-11
Check and Clean Sail Switch and Exhaust Blower Wheel......................4-11
Check Ribbon Condition and Tension.................................................... 4-12
4.3 Monthly PM (200 Hours)........................................................................ 4-13

Check Setscrews................................................................................... 4-13
Grease Bearings.................................................................................... 4-14
Oil Drive Chain and Tension Springs...................................................... 4-14
Check Compression Roll Pressure and Padding Condition................... 4-15
4.4 Semi-Annual PM (1000 Hours).............................................................. 4-15

Check Gas Pressure.............................................................................. 4-16
Check Mechanical and Electrical Connections...................................... 4-16
4.5 Annual PM (2000 Hours)........................................................................ 4-17

Check and Clean Pilot Assembly........................................................... 4-18
TOC INDEX v
CHAPTER 5 OPERATING PRINCIPLES

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

Disconnect Switch and Fuses.................................................................. 5-3
Step-Down Transformer........................................................................... 5-3
Electrical Panel........................................................................................ 5-4
5.2 Mechanical System.................................................................................. 5-5

Drive System............................................................................................ 5-5
Ribbon Sets.............................................................................................. 5-6
5.3 Exhaust System....................................................................................... 5-7

Exhaust Blower........................................................................................ 5-7
Sail Switch................................................................................................ 5-7
5.4 Heating System........................................................................................ 5-7

Burner System......................................................................................... 5-9
Temperature Control.............................................................................. 5-10
Temperature Sensor Contact Shoes...................................................... 5-10
5.5 Sequence of Operation...........................................................................5-11

Stand-By Stage.......................................................................................5-11
JOG REVERSE Operation Stage...........................................................5-11
Mechanical Start-Up Stage.................................................................... 5-12
Burner Operation Stage......................................................................... 5-12
vi TOC INDEX
CHAPTER 5 TROUBLESHOOTING
Troubleshooting Symptoms................................................................................ 6-2
6.1 Electrical................................................................................................... 6-4
6.2 Mechanical System.................................................................................. 6-6
6.3 Ironing Quality.......................................................................................... 6-9
6.4 Heating System...................................................................................... 6-12

Pilot Ignition............................................................................................ 6-12
Burner Ignition........................................................................................ 6-13
Burner Operation.................................................................................... 6-14
6.5 Exhaust System..................................................................................... 6-16
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............................................................. 7-5
Feed Ribbon Replacement...................................................................... 7-6
Feed Ribbon Drive Roll Friction Material Replacement........................... 7-8
Guide Tape Replacement....................................................................... 7-10
Feed Table Alignment and Positioning................................................... 7-13
7.4 Compression Roll................................................................................... 7-16

Compression Roll Pressure Check........................................................ 7-17
Compression Roll Pressure Adjustment................................................. 7-18
Compression Roll Cover Replacement.................................................. 7-19
7.5 Ironing Section....................................................................................... 7-23

Drive Chain Tension Adjustment............................................................ 7-23
Ironing Cylinder Reconditioning............................................................. 7-24
Ironing Cylinder Hardened Ring Replacement....................................... 7-27
7.6 Burner System....................................................................................... 7-29

Burner Removal/Replacement............................................................... 7-29
Burner Tip Maintenance......................................................................... 7-32
Temperature Sensor Contact Shoe Replacement.................................. 7-33
Temperature Control or High Temperature Limit Control Replacement. 7-34
7.7 Return Section....................................................................................... 7-36

Return Ribbon Tension Spring Replacement......................................... 7-37
Return Ribbon Replacement.................................................................. 7-38
Return Ribbon Drive Roll Friction Material Replacement....................... 7-40
viii TOC INDEX

Comet Executive Gas Introduction
Chapter 1
INTRODUCTION
This chapter contains the following sections:
1.1 Warranty
1.2 Scope of the Manual
1.3 Safety
The Comet Executive™ Gas-Heated Flatwork Ironer (Figure 1-1) is a one-piece unit that dries and
irons sheets, pillowcases, table linen, and other types of flatwork. The unit processes 100% polyester,
polyester/cotton blends or all-cotton fabrics. This unit is available with an ironing cylinder length of
56” (1400 mm), 66” (1600 mm), or 80” (2000 mm). This unit is not designed to process anything other
than flatwork.
Like the rest of the CHICAGO® product line, the Comet Executive Gas 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 Comet Executive Gas 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 Comet Executive Gas provides high quality flatwork finishing.
TOC INDEX 1-1

Introduction Comet Executive Gas
Chapter 4 - Preventive Maintenance

1.1 Warranty
Contains procedures for Daily, Weekly,
A full page warranty statement is included Monthly, Semi-Annual, and Annual
in this Instruction Manual. Please take the maintenance. Follow these procedures to keep the
time to review this warranty and understand its unit operating safely and at maximum efficiency.
provisions. A Preventive Maintenance Schedule is located at
the front of this chapter.
1.2 Scope of the Manual
Chapter 5 - Operating Principles
This instruction manual will help you keep
your CHICAGO ® product operating safely, Describes the operation of the unit in detail. A
efficiently, and with minimum expense. Individual good understanding of this chapter will help avoid
chapters in this manual provide the necessary operation errors and assist with troubleshooting
information required for safe installation, and maintenance.
operation, maintenance, troubleshooting, and
repair of the Comet Executive Gas ironer. Chapter 6 - Troubleshooting
Contains issues, possible causes, and solutions
Updates in all areas of operation.
Occasionally, new information about the unit
becomes available after the publication of this
Chapter 7 - Repair
manual. If you receive a CHICAGO® FYI Service Contains procedures for making adjustments,
Bulletin pertaining to your unit, insert the bulletin repairs and parts replacement for the unit. Please
in the front of the manual. follow all safety recommendations carefully.
Chapter 1 - Introduction Parts List

Contains detailed drawings and part
Provides an overview of the unit and its key
specifications to assist in ordering replacement
features, of this manual, and of important safety
parts. It is divided into views in which the parts
features.
are grouped by function.
Chapter 2 - Installation Schematics

Describes recommended procedures for Contains electrical drawings showing power
determining a suitable location for the unit and and motor circuits, control and interlock circuits,
connecting the utilities. This chapter also includes gas control and safety circuits, and other relevant
checkout procedures to ensure all systems are drawings, including part specifications.
working properly. Local requirements often vary,
so follow local codes at all times. Appendix
Contains Technical Specifications, a Floor
Chapter 3 - Operating Guidelines Plan, manufacturer’s bulletins, and other relevant
information for the unit.
Gives recommendations for operating the unit
at maximum efficiency. This chapter includes
instructions for operators and suggestions for Index
work organization. Contains an alphabetical listing/cross-
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 “O” (horizontal position), the main disconnect
and understanding the switch shuts off the incoming electrical power
REPAIR chapter. to the unit.
Unless otherwise indicated, turn the main

Only qualified personnel
disconnect switch to off before performing any
should troubleshoot and maintenance or repair work.
repair this unit.
Safety Stop Buttons
The preferred method of stopping the operation

of the unit is by pressing any of the four red safety
STOP buttons located at each corner of the unit.
Pressing any of these buttons immediately

stops the heating system and all rotating parts.
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 immediately stops the heating system WARNING labels alert personnel that
and all rotating parts. personal injury may result from not following
recommended procedures.
Both endframes and the rear of the unit are
covered with protective doors and panels to CAUTION labels alert personnel the unit
prevent fingers or hands from coming into contact may be damaged if conditions, practices, or
with moving and heated parts. Removing the rear procedures are not observed.
panel immediately stops the heating system and
When training operators, take the time to
all rotating parts.
locate, review, and understand all areas where
labels are posted.
Safety Interlock Switch
A safety interlock switch is located behind NOTE: Do not remove safety

the protective backplate. If it is removed, the labels at any time. If a label
interlock switch is disconnected, all rotating parts needs to be replaced, contact
stop moving, and the heating system shuts off. Chicago Dryer Company for free
replacements.
This safety interlock switch is not intended to
lockout the unit. Site management is responsible
for developing and implementing lockout/
tagout procedures that comply with government
standards for use when servicing the unit.
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
WARNING
Never operate the unit
unless all safety systems
are working correctly and all
access panels are in place.
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
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

Comet Executive Gas Installation
Chapter 2
INSTALLATION
This chapter contains installation instructions for the Comet Executive™ Gas 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 Comet Executive Gas
The site should have a relatively level,

2.1 Site and Utility sturdy floor capable of supporting the unit’s
Requirements weight without significant flexing. For weight
specifications, refer to APPENDIX: Technical
Figure 2-1 shows the clearance requirements Specifications.
for the unit. These are the minimum dimensions
recommended for efficient production, service, Shimming of the endframes is generally
and maintenance access. needed to level the unit. No special foundation,
floor grouting, or installation of anchors is
required. However, floor grouting or installation
NOTE: The location of the unit
of anchors may be required to comply with local
is extremely important.
codes or aboard a ship.
A short run of 8” (203 mm) diameter vent

It is strongly recommended that sufficient ducting must be supplied locally for the exhaust
clear space be provided to allow for removal of blower and canopy. Adequate ventilation
the gas burner assembly from the left endframe is required. For more information, refer to
for service, if necessary. If this clearance is not Ventilating the Work Area on page 2-7.
possible, additional clearance to the front or rear
of the unit should be provided so the unit can be
rotated.
18”
(460 mm)
Ironing Cylinder Length 18”

plus 24” (610 mm) (460 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 front of the left 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 gas requirements; verify
the local gas supply matches the gas requirements • Electrical Connection
specified on the unit’s nameplate. For more • Gas Connection
information, refer to APPENDIX: Technical
Specifications. • Receiving Shelf Set-Up
Note that the nature of the atmospheric burner • Final Protective Wrapper Removal
used in the machine prevents it from operating
at full capacity when in use above an altitude of Inspection
approximately 2000 feet (609 meters). For use
at higher elevations, contact the factory service Carefully inspect all shipments before they are
department. 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
Figure 2-2: The nameplate contains important been done to the unit during
information, including information shipment.
about altitude usage.
TOC INDEX 2-3

Uncrating and Positioning 3. Remove the exhaust blower assembly

from the crate and set aside.
Required Tools 4. Open both endframe doors and remove
Crowbar any materials shipped with the unit. Close
Forklift and secure the doors.
Screwdriver
Sledgehammer
Wire cutter/knife CAUTION
Wrenches:
The unit should only be
9/16” or 3/4”
moved by qualified riggers
1. Before unpacking the unit, make sure the using proper equipment.
proposed site is acceptable and necessary
foundations have been prepared. For more
5. With the unit still on its skid, move it into
information, refer to Site and Utility Re-
approximate position. Remove the bolts
quirements on page 2-2.
which secure the unit to the skid.
2. Remove the crating, strapping, and other
packaging materials except guide tapes CAUTION
(Figure 2-3), the protective plastic cover Do not drop or twist the unit.
and the brown paper on the ironing cyl-
inder. These protective coverings should
be left in place so the unit remains clean 6. As appropriate, using care not to drop or
until it is ready to use. twist the unit:
• 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.
7. 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
Figure 2-3: Do not remove the guide tapes when
removing the shipping materials. conditions. For use aboard a ship, the unit
may be welded at the foot pads.
2-4 TOC INDEX

8. After the unit is placed and secured, re- Exhaust Blower Installation
move the plastic covers from the unit. Do
not remove the guide tapes or the brown The exhaust canopy includes a blower to expel
paper on the ironing cylinder. excess heated air and moisture. This system
contributes to the safety and comfort of operating
9. Remove the following items (Figure 2-4) personnel, proper operation of the unit, and
from the box removed from the endframe: reduction of maintenance time.
• One 1 lb. (450 g) can of powdered wax All labor and materials required for venting
(A)--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 (B)

Ductwork
• One 8” exhaust collar and one blower
outlet adaptor (C) The 8” (203 mm) diameter ductwork for the
exhaust blower and all associated hardware for
• One manual gas shut-off valve (D) the exhaust system must be locally supplied.
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.
B
Check the canopy nameplate for the maximum
length of ductwork. For longer runs, a booster
A C 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

D to a larger duct for outside venting, consult a
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 Determined locally
applicable certification labels to be
valid. Call the factory if you have 1. Install the provided 8” collar in the open-
any questions. ing on the top of the exhaust canopy
(Figure 2-6). Bend the tabs back to secure
in position.
CAUTION 2. Install the provided blower outlet rect-

Do not change the mounting angle-to-round adaptor to the blower
position of the sail switch discharge (Figure 2-5, A).
and do not reverse the
blower housing.
The exhaust blower is designed for wall A

mounting. Find a good location close to both the
outside discharge point and the unit.
It is particularly important that a straight

section of ductwork be attached directly to the
blower discharge (Figure 2-5, A).
B
When installed, a blower can be rotated up to
45° to the left or right of vertical to help make
this configuration.
NOTE: Exceeding a 45° rotation

from vertical for the blower may Figure 2-5: The exhaust blower assembly is
not maintain proper air movement designed for remote mounting.
and may cause the sail switch to
operate incorrectly.
Figure 2-6: Connect the ducting to the opening on

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

3. The exhaust blower assembly must be Ventilating the Work Area

mounted VERTICALLY within 15 ft
(5 m) of the unit to maintain proper air
movement.
WARNING
The room housing the unit
4. Mount the exhaust blower assembly using must be provided with
heavy anchors or mountings screws. adequate make-up air to
ensure operator safety as
5. Extend 8” (203 mm) round exhaust duct-
well as the proper operation
ing from the canopy discharge (Figure 2-6)
to the exhaust blower inlet (Figure 2-5, B). of the ironing section and
other fuel-burning equipment
6. Extend the 8” (203 mm) round exhaust in the area.
ducting from the exhaust blower output
to the outside discharge point, making
the length of the run as short and straight A permanent fresh air supply or natural air
as possible. ventilation is required for the unit. In general, one
square inch is required for each 4,000 BTU/H up
The discharge must be properly designed to to 400,000 BTU/H, plus one square inch for each
maintain the required air flow: 10,000 BTU/H in excess of 400,000 BTU/H.
• To ensure proper operation of the Based on these standards, the makeup air
exhaust canopy sail switch and the required for the unit is approximately as follows:
correct removal of by-products, it is
• 56” cylinder: 19 sq. in. (123 cm2)
recommended that the unit be connected
to a separate exhaust system. • 66” cylinder: 23 sq. in. (148 cm2)
• The discharge must be protected from • 80” cylinder: 26 sq. in. (168 cm2)
backdrafts and precipitation.
However, local requirements may differ.
• No screen or filter should be connected Check local regulations to determine the exact
at the discharge unless it is connected to makeup air requirements. Follow local codes at
a commercial lint collector. all times.
TOC INDEX 2-7

Electrical Connection Sail Switch and Exhaust Blower Motor

Connection
CAUTION
The incoming electric NOTE: All material for wiring
power service must match the exhaust blower motor and sail
the specific electrical switch must be locally supplied.
requirements shown Check local regulations to
determine requirements. Follow
on the nameplate.
local codes at all times.
The nameplate (Figure 2-2), located on the

front of the left endframe, shows the electrical
Required Tools
requirements of the unit. All labor and materials
Screwdriver
required to bring the electrical service to the unit
Wire cutter/stripper
are a local responsibility.
All electrical wiring must comply with local 1. Remove the sail switch and wiring box
codes, and a qualified electrician should size the covers.
wiring.
2. Connect a wire to each of the upper two
Refer to the nameplate to determine the power terminals, labeled R and B (Figure 2-7, A)
supply requirements. If high or low voltage and route them through the greenfield and
is suspected, check the electrical service to into the wiring box (B).
determine the actual voltage conditions.
3. Replace the sail switch cover.
Improper or fluctuating voltage will cause
the safety systems to interrupt the burner system
operation, possibly damage motors and other
electrical system components, and void the
factory warranty.
NOTE: A fused, main disconnect A

switch has been incorporated into
the right endframe door. Check
local regulations to determine
whether a separate external fused
disconnect switch is still required. B
Follow local codes at all times.
Figure 2-7: Connect the sail switch wires to the
terminals labeled R and B and bring
into the wiring box.
2-8 TOC INDEX

4. Remove the wiring box cover to the ex-

haust blower motor (Figure 2-8, A/Figure NOTE: If local codes permit,
2-9, A). consider routing the exhaust
blower wires into the sail switch
5. Bring the wires for the sail switch into the wiring box and then bringing a
wiring box and attach the electrical con- single connection over to the
nection to the box. ironer.
6. Use wire nuts to securely connect to each
sail switch wire; then, replace the wiring
7. Bring the wires for the exhaust blower into
box cover.
the wiring box and attach the electrical
connection to the box.
8. Follow the label on the motor case (Figure

2-8, B for single phase; Figure 2-9, B for
3-phase) to wire for high or low voltage
as appropriate. Make sure to connect the
grounding wire to the lug (C).
9. Replace the wiring box cover(s).
Low Voltage High Voltage

C Blue Line
1 Blue Line
1 Brown
Red 4 Brown
Orange 3
5 Red
4
B Black
Orange
White Line White 5
6
A Yellow Black
Line
Yellow 6
To reverse: Interchange
Red and Black Leads
Figure 2-8: Wiring for single phase exhaust

blower motor.
Low Voltage High Voltage
6 5 4 6 5 4
9 8 7
C
9 8 7
3 2 1 3 2 1
A
Line Line
Interchange any two line wires

to reverse rotation. Figure 2-9: Wiring for 3-phase exhaust blower
motor.
TOC INDEX 2-9

10. The main disconnect switch is located on Main Power Connection

the right endframe door. Turn it to the OFF
position (Figure 2-10, A).
WARNING
11. Turn the door latch (Figure 2-10, B) on Only a qualified electrician
the right endframe door and open the door. should make the electrical
connections to the unit.
12. Route the electrical connections for the Improper installation could
sail switch and exhaust blower motor to
result in serious injury.
the electrical box.
13. Properly secure the electrical connections.

Required Tools
14. The electrical connections for the exhaust
Allen wrench: 3/16”
blower motor are made in the electrical Screwdriver
panel: Wire cutter/stripper
a) Connect the power wires for the ex-
haust blower motor to the terminals at
the bottom of the canopy motor protec-
tor (Figure 2-11, A) as follows:
• 3-Phase: 2, 4, and 6. D
B
• Single phase, 230V: 2 and 6
• Single phase, 115V: 4 and 6.
b) Connect the green ground wire to the

grounding block at the top of the elec-
trical panel (Figure 2-11, B)
c) Remove the jumper wire connected

to terminals 5 and 6 (Figure 2-11, C) A
and connect the two red wires for the
exhaust blower sail switch.
B Figure 2-11: Exhaust blower connections.
Figure 2-10: The main disconnect switch is located

on the right endframe door.
2-10 TOC INDEX

3-Phase Machines Single Phase Machines-230V

1. Bring the supply lines to the electrical 1. Bring the supply lines to the electrical
panel. Use three wires for the power sup- panel. Use two wires for the power supply
ply and a green fourth wire for ground. and a green third wire for ground.
2. Extend the lines following local codes and 2. Extend the lines following local codes and
properly secure the conduit or greenfield. properly secure the conduit or greenfield.
3. Connect the three power supply wires to 3. Connect the two power supply wires to
terminals L1, L2, and L3 at the top of the terminals L1 and L2 at the top of the main
main disconnect switch (Figure 2-11, D). disconnect switch (Figure 2-11, D).
4. Connect the green fourth wire to the 4. Connect the green third wire to the
grounding block next to it (B). grounding block next to it (B).
WARNING WARNING
The machine must be The machine must be
properly grounded to ensure properly grounded to ensure
operator safety. operator safety.
5. Make sure the other end of the ground 5. Make sure the other end of the ground
wire is connected to a proper earth ground. wire is connected to a proper earth ground.
6. Close and secure the right endframe door. 6. Close and secure the right endframe door.
CAUTION CAUTION
Do not attempt to start the Do not attempt to start the
machine at this time. Leave machine at this time. Leave
the disconnect switch OFF. the disconnect switch OFF.
TOC INDEX 2-11

Single Phase Machines-115V Gas Connection

1. Bring the supply lines to the electrical
panel. Use two wires for the power supply CAUTION
and a green third wire for ground. The gas supply must
2. Extend the lines following local codes and match the specific gas
properly secure the conduit or greenfield. requirements shown on
the nameplate.
3. Connect one power wire to terminal L1
at the top of the main disconnect switch
(Figure 2-12, A) and the other power wire The nameplate (Figure 2-2), located on the
to the neutral block to its right (B). front of the left endframe, specifies the gas
requirements of the unit. The unit requires gas
4. Connect the green third wire to the ground- supplied at the correct pressure.
ing block to its left (Figure 2-12, C).
Note that the nature of the atmospheric burner
used in the machine prevents it from operating
WARNING at full capacity when in use above an altitude of
The machine must be approximately 2000 feet (609 meters). For use
properly grounded to ensure at higher elevations, contact the factory service
operator safety. department.
If the incoming gas pressure is too high or too

5. Make sure the other end of the ground low, the unit will work improperly or not at all.
wire is connected to a proper earth ground. Confirm the pressure of the gas supply meets the
requirements shown on the nameplate.
6. Close and secure the right endframe door.
If a high pressure gas supply is used, an
additional regulator, mounted outside the unit,
CAUTION is required. The following are based on using a
Do not attempt to start the water column manometer connected upstream of
machine at this time. Leave the supplied pressure regulator. A high pressure
the disconnect switch OFF. gas supply is:
• For natural gas: more than 11” (2.75
kPa) of pressure.
• For LP gas, more than 12” (3.0 kPa).
• For manufactured gas, contact the
Factory Service Department.
For more information on checking the pressure

of the gas supply, refer to Gas Connection
Checkout on page 2-20.
C B All labor and materials required for the gas
A
connection to the unit, except those items shipped
with the unit, are a local responsibility. Local
codes and regulations must be followed for proper
installation.
Figure 2-12: Single phase connections.
2-12 TOC INDEX

Shut-Off Valve Installation

WARNING
Only qualified personnel Required Tools
should make the gas Pipe thread compound
connections to the unit. Pipe wrench
Improper installation could
result in serious injury. The gas line to the unit should be routed so it
does not interfere with any service panel or block
access to the back of the unit.
The gas connection to the unit is made at the
back of the left endframe. A 1/2” (DN 15) gas inlet 1. Check all internal gas connections in the
connection (Figure 2-13) is provided to connect unit. Tighten any unions that became loose
the incoming gas line. A manual gas shut-off during shipment.
valve is supplied with the unit. Other components
must be locally supplied. 2. Connect a short nipple (Figure 2-14, A)
to the coupling at the back of the left
endframe (Figure 2-13).
NOTE: Pipe thread compound is
required on all gas line connections 3. Connect the gas shut-off valve (Figure
to ensure a leakproof installation. 2-14, B) to the short nipple (A). Make
Comply with local codes. sure that the arrow is neither upside down
nor vertical.
4. Connect a short nipple (C) to the other side

of the gas shut-off valve (B).
5. Connect the branch of a tee (D) to the

other side of the nipple (C). Install the tee
vertically.
Gas In
E
D C B A
Gas Cock Ironer

F Rear
Figure 2-14: Install the hardware for the gas

Figure 2-13: The 1/2” gas supply connection is at
connection as shown.
the rear of the left endframe.
TOC INDEX 2-13

6. Attach a dirt leg nipple (F) with a cap to Receiving Shelf Set-Up
the lower run of the tee (D).
Required Tools
NOTE: A dirt leg in the gas Screwdriver
line upstream of the ironer helps Wrench: 7/16”
prevent malfunctions resulting
from rust, grit, dirt, and other solid 1. As necessary, loosen the screws which
particles in the gas supply. secure the receiving shelf in position
(Figure 2-15).
2. Position the receiving shelf in its operat-

7. Make sure the manual gas valve (B) is
ing position.
closed by rotating the handle to a 90° angle
from the direction of the gas pipe. 3. Tighten the screws to secure in position.
8. Extend the gas supply line to the top of
the tee (E).
NOTE: If possible, extend the

gas supply line directly from the
gas meter to the unit without any
other equipment connected to this
line.
CAUTION
Do not open any gas
valves at this time.
Figure 2-15: The front receiving shelf can be
repositioned during installation.
2-14 TOC INDEX

Final Protective Wrapper Removal

2.3 Pre-Operational
1. Carefully remove any remaining plastic
protective coverings from the unit. Do
Checkout
not remove the guide tapes (Figure 2-3).
NOTE: For more information
2. Remove any wooden wedges used to about the controls mentioned in
hold the ironing cylinder in place during the following procedures, refer
shipment, and save the wedges for main- to Operating Controls on page
tenance and repair work. 3-4.
3. The brown paper covering the ironing

cylinder will be removed after machine Before the unit can be placed into full
phasing is verified, and safety and control operation, perform the following procedures:
functions have been checked.
• Security of Hardware
• Exhaust Blower Motor Rotation
Checkout
• Safety Device and Control Function
Checkout
• Ironing Cylinder Paper Removal
• Gas Connection Checkout
• Checkout Completion
• 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.
TOC INDEX 2-15

Security of Hardware
Required Tools
Allen wrench set
Wrench set
1. Open both endframe doors.
2. Check all hardware connections and

tighten as necessary. Make sure all set-
screws are sufficiently tightened to hold
their respective components in position.
NOTE: To a l l o w f o r h e a t
expansion, bearings in the left Figure 2-16: Do NOT put setscrews into left
endframe (Figure 2-16) do not endframe bearings.
have setscrews. Do NOT put
setscrews into these bearings.
However, if there are any shaft
collars, these do have setscrews
that must be secured.
3. Make sure all protective wrappers and

wooden wedges holding the ironing
cylinder are removed. For more informa-
tion, refer to Final Protective Wrapper
Removal on page 2-15.
4. Close and secure both endframe doors.
2-16 TOC INDEX

Exhaust Blower Motor Rotation 5. As appropriate:

Checkout
• If the motor is rotating in the correct
After all utility connections are completed, direction, go to the next procedure.
the unit can be energized and checked to verify
the correct rotation of the exhaust blower motor. • If the rotation of the motor is not in the
correct direction, go to the next step.
All maintenance procedures should be handled
by at least two qualified persons. Using the
WARNING
“buddy system” facilitates a quicker procedure
and decreases the risk of an accident. Only a qualified electrician
should make or correct any
electrical connections in or
Required Tools
to the unit.
Screwdriver
1. Turn power ON at the main disconnect 6. Turn power OFF at the main disconnect
switch. switch.
2. Start the unit by pressing the green START 7. Open the right endframe door.
button.
8. As appropriate:
3. IMMEDIATELY press a red safety STOP
• For 3-phase machines, disconnect
button.
and interchange any two of the three
4. Look at the vented cap of the exhaust exhaust blower electrical supply wires
blower motor as it slows down. The rota- connected to the bottom of the canopy
tion direction should be clockwise (Figure motor protector (Figure 2-11, A).
2-17).
• For single phase machines, remove
the wiring box cover to the exhaust
blower motor and interchange the red
and black leads.
NOTE: Make sure the electrical

supply wires are securely
connected.
10. Repeat Steps 1 to 4 to make sure the

exhaust blower motor is rotating in the
correct direction.
Figure 2-17: The exhaust blower motor should be

turning in the direction of the arrow.
TOC INDEX 2-17

Safety Device and Control Function Safety Device Check

Checkout
1. Turn power ON at the main disconnect
The machine can now be checked for proper switch.
safety device and control function operation.
After that, the brown paper covering the ironing 2. Press the green START button (Figure
cylinder can be removed. 2-18, A). All rotating and conveying ele-
ments of the machine should operate.
NOTE: W o r k w i t h a n o t h e r 3. There are four red safety STOP buttons

person. The “buddy system” is on the unit, one on each endframe of the
the safest system. machine (Figure 2-18, B).
• With the unit running, test each button

in turn to make sure the unit comes to
All test procedures should be handled by at a complete stop.
least two qualified people. Using the “buddy
system” facilitates a quicker procedure and • Restart the unit after each red safety
decreases the risk of an accident. STOP button test.
4. Restart the unit.

WARNING
Do not place the machine 5. Test the red safety finger guard at the front
into service until all controls of the ironer (Figure 2-18, C) by pushing
are functioning properly. in on it. Make sure that all moving ele-
Failure to follow this rule ments stop.
may cause serious injury
to operators or
maintenance personnel.
D
E
Figure 2-18: All rotating parts should stop when

you press the red safety finger guard.
2-18 TOC INDEX

Control Function Check Ironing Cylinder Paper Removal

1. Press the green START button.
2. Turn the SPEED knob (Figure 2-18, D) with power connected and COOL.
Use Extreme Caution.
clockwise to increase the speed.
3. Make sure the ironing cylinder, feed rib-

bons, and return ribbons change speed as CAUTION
the knob is turned. Do not use sharp objects
to remove the brown paper
4. Turn the SPEED knob counterclockwise protecting the ironing
to decrease the speed.
cylinder. Avoid scratching
5. Make sure the ironing cylinder, feed rib- the cylinder surface during
bons, and return ribbons change speed as paper removal.
the knob is turned.
There are two temperature
6. Set the ironer to its slowest setting. sensor contact shoes (Figure
7. Press a red safety STOP button. 2-19) seated against the
front of the ironing cylinder.
Be careful not to move
WARNING either sensor, which may
Make sure the SPEED control cause the ironing section to
knob is turned to the slowest malfunction.
speed before pressing the
JOG REVERSE button.
Failure to do so may result in 1. Remove the brown paper from the ironing
unsafe conditions or damage cylinder. Tear away a strip across the full
to the unit. length at the front of the cylinder, under
the feed table.
8. Press the JOG REVERSE button (Figure 2. Turn power ON at the main disconnect
2-18, E) for a few seconds and release it. switch.
The rotating elements should move slowly
in reverse while the button is pressed.
9. Stop the unit and turn power OFF at the

main disconnect switch.
Figure 2-19: Do not disturb the positioning of the

temperature sensors when removing
the brown paper.
TOC INDEX 2-19

3. Turn the SPEED knob fully counterclock- Gas Connection Checkout

wise to set the machine to its slowest
speed.
Gas Supply
4. Press the green START button.
Required Tools
WARNING Pipe thread compound
Never attempt to remove Water column manometer
debris from the cylinder
while it is moving. The burner system requires gas supplied at
the correct pressure. If the gas pressure supplied
to the unit is either too high or too low, the
5. Allow the paper to discharge onto the burner system will work improperly or not at all.
front receiving shelf. Make sure it does not Confirm the gas pressure meets the requirements
affect the positioning of the temperature shown on the nameplate of the unit.
sensor contact shoes.
6. Wait until it is clear of the machine before WARNING

removing. Only a qualified and
7. Stop the unit and turn power OFF at the experienced Combustion
main disconnect switch. Service Technician should
install and adjust any
8. Check to make sure that all paper has been gas components.
removed.
9. Repeat Steps 2 to 8 as necessary.

The gas supply must
match the specific gas
requirements shown on
the nameplate.
It is important to check the available gas

pressure to the unit during periods of peak
demand by other gas-heated equipment in the
laundry room or elsewhere at the facility. Gas
pressure to the unit may be reduced significantly
at these times, which will interfere with the proper
operation of the burner.
2-20 TOC INDEX

Follow the procedure below for the type of gas For Liquefied Petroleum Gas
being used—natural gas, liquefied petroleum gas, (Propane, Butane):
or manufactured gas.
For Natural Gas: with power disconnected and COOL.
Perform only when the unit is OFF 1. Turn power OFF at the main disconnect
with power disconnected and COOL. switch.
1. Turn power OFF at the main disconnect WARNING

switch. Do not adjust or test gas
components unless you are
WARNING qualified to do so.
Do not adjust or test gas
components unless you are 2. Connect a U-tube or other water column
qualified to do so. manometer upstream of the gas connec-
tion, and measure the static gas pressure.
2. Connect a U-tube or other water column 3. If the pressure is:
manometer upstream of the gas connec-
tion, and measure the static gas pressure. • Less than 11” (2.75 kPa): Burner may
not work reliably. Correct the gas pres-
3. If the pressure is: sure before proceeding.
• Less than 5” (1.25 kPa): Burner may • 11” - 12” (2.75 - 3.0 kPa): Proper op-
not work reliably. Correct the gas pres- erating range.
sure before proceeding.
• 5” - 11” (1.25 - 2.75 kPa): Proper op-

erating range.
• More than 11” (2.75 kPa): This is a

high pressure gas supply. Installation
of an additional regulator is necessary:
1) The additional regulator must be

mounted according to the manu-
facturer’s specifications.
C
2) Open the left endframe door and
measure the incoming gas pressure
to gas valve (Figure 2-20) to make
sure it is now in the proper range
(connect the manometer to the “in” B
A
port on the gas valve, A).
3) When replacing the plug, use pipe

thread compound to avoid leaks. Figure 2-20: Make sure to check gas operating
Teflon tape is not recommended. pressure (B) as well as upstream
pressure (A).
TOC INDEX 2-21

• More than 12” (3.0 kPa): This is a high Inspect Gas Piping
pressure gas supply. Installation of an
additional regulator is necessary: Required Tools
1) The additional regulator must be Leak detection equipment or
soap & water solution
mounted according to the manu-
Pipe wrench
facturer’s specifications.
2) Open the left endframe door and Perform only when the unit is OFF
measure the incoming gas pressure with power disconnected and COOL.
to gas valve (Figure 2-20) to make
sure it is now in the proper range
(connect the manometer to the “in” WARNING
port on the gas valve, A). Only qualified personnel
should adjust or service gas
3) When replacing the plug, use pipe controls or components.
thread compound to avoid leaks.
Teflon tape is not recommended. It is essential to check all
internal and external gas
For Manufactured Gas: connections for leakage
before proceeding.
Contact the Factory Service Department.
1. Make sure the external manual gas supply

valve is turned off and the power is turned
OFF at the main disconnect switch.
2. Prepare to inspect the piping using com-

bustible gas leak detection equipment or
a soap and water solution.
CAUTION
Be sure to check all unions
which may have loosened
during shipment.
3. Check and tighten all connections that may

have loosened during shipment or were
not properly secured during installation.
4. Turn on the gas supply. Check all internal

and external connections with combustible
gas leak detector, or apply a soap and water
solution to all joints to make sure there
are no leaks.
5. If a leak is found, turn off the gas supply.

Tighten the leaky connection.
6. Repeat Steps 4 and 5 until all joints are

tight and verified leak free.
2-22 TOC INDEX

Ignition Test 11. Turn the TEMPERATURE control dial

to OFF.
1. Make sure the external manual gas supply
valve is turned off. 12. Wait a few seconds and then turn the con-
trol back to 300º F (150º C).
2. Make sure the TEMPERATURE control
dial is turned to OFF. 13. It may take several attempts before all of
the air is purged from the gas line.
3. Open the left endframe door.
14. Once the burner is successfully lit, im-
4. Remove the “out” port plug to the gas mediately check the manometer pressure
valve (Figure 2-20, B) and connect a water indication.
column manometer.
15. There must be sufficient, steady gas pres-
5. Turn power ON at the main disconnect sure of 3-1/2” (.9 kPa) for natural gas, or
switch. 10” to 11” (2.5 kPa to 2.75 kPa) for LP
gas as indicated on the manometer (if us-
6. Open the gas shut-off valve at the rear of
ing manufactured gas, contact the Factory
the ironer.
Service Department).
7. Press the green START button and turn the
16. As appropriate:
SPEED knob to the slowest speed.
• If the gas pressure is within limits, go
8. Set the TEMPERATURE control dial
to Step 18.
(Figure 2-21, A) to 300º F (150º C).
• If the gas pressure is not within these
9. After 15 seconds, listen for sounds indicat-
limits, recheck the supply pressure.
ing the pilot ignition sequence has started
Refer to Gas Supply on page 2-20.
and the pilot burner is igniting. The HEAT-
ING indicator lamp should be lit. • If necessary, adjust the gas valve’s
built-in pressure regulator (Figure
10. If the burner does not fire properly, the
2-20, C). Go to the next step.
ignition control will go into a lock out
condition. This is indicated by a flashing
LED on the control (Figure 2-22).
A
B
Figure 2-21: Left endframe control panel. Figure 2-22: Ignition control in the left endframe.
TOC INDEX 2-23

17. To adjust the gas pressure to the burner: 19. Turn the TEMPERATURE control dial
to OFF.
NOTE: The gas valve’s internal 20. Stop the unit and turn power OFF at the
regulator should only be adjusted main disconnect switch.
after the upstream gas pressure
is acceptable. 21. Disconnect the manometer and reinstall
the plug When replacing the plug, use pipe
thread compound to avoid leaks. Teflon
a) Turn the TEMPERATURE control dial tape is not recommended.
to OFF.
22. Close and secure the left endframe door.
b) Stop the unit and turn power OFF at
the main disconnect switch. WARNING
c) Remove the cap to the gas valve’s Never operate the unit unless
internal regulator to access the adjust- all safety covers are in place
ment screw. and all safety equipment is
working correctly.
d) Turn the adjustment screw clockwise/
in to increase pressure or counterclock-
wise/out to decrease pressure.
e) Replace the pressure regulator cap.
f) Repeat Steps 5 to 16.
NOTE: If burner ignition is not

successful after several attempts,
refer to Heating System on
page 6-12. If the problem
cannot be solved, contact a local
CHICAGO® distributor or Chicago
Dryer Company’s Factory Service
Department.
18. Once the burner flame is maintained, ob-

serve the appearance of the flames along
the burner. A normal flame extends to the
top of the inside of the cylinder and bends
back slightly (Figure 2-23). If the flame
does not match this, contact the Factory Figure 2-23: A normal burner flame should extend
Service Department. to the top of the ironing cylinder and
bend slightly.
2-24 TOC INDEX

Checkout Completion
If any of the checkout steps are unsuccessful,
refer to TROUBLESHOOTING for additional
information.
If the problem cannot be determined/solved,

contact your local CHICAGO® distributor or
Chicago Dryer Company’s factory service
department.
Cleaning the Unit

During shipment and installation of the unit,
dirt or other contaminants may accumulate that
will soil or mark processed flatwork.
Clean the unit by running old pieces of

flatwork using the entire width of the unit.
For information on processing flatwork, refer

to Flatwork Handling on page 3-9.
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 3-7.
TOC INDEX 2-25

Comet Executive Gas Operating Guidelines
Chapter 3
OPERATING GUIDELINES
In order to operate the Comet Executive™ Gas 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 bulletin (Figure 3-1). This bulletin must be posted at the operating site.
Operator Safety Reminders for Chicago ® Flatwork Ironer

POST AND READ
1. NEVER TRY TO REMOVE OR ADJUST JAMMED LINEN OR MATERIAL

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 .
If something is jammed, SHUT THE IRONER OFF at the power source before trying to remove
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
remove jammed linen or service the irone r. ALWAYS AVOID CONTACT WITH HEATED PARTS.
2. NEVER reach over, under, or behind safety finger guard or into any area near heated roll or
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
ironer’s heat or pressure. This rule should be followed whether you are working at the front, side,
or rear of the ironer.
3. CHECK operation of safety fi nger guard at the beginning of every shift. Touching the safety
guard should activate a switch which will stop the irone r. If this safety feature is not working prop -
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
ALL other safety guards and end panels are in place before operating the ironer .
4. ALWAYS make sure that all ribbons and tapes are in place and working properly . They are
designed to hold linen so it is properly ironed and to prevent jamming. NEVER REPLACE OR
ADJUST TAPES, RIBBONS, OR PADDING WHILE IRONER IS RUNNING. Keeping your ironer
well-waxed also helps to prevent jams
5. DO NOT iron anything except flatwork because damage to the ironer or injury can result. Your
ironer is designed for processing flatwork only.
6. DO NOT stand, sit, or kneel on any shelf at the front or rear of the ironer . These are not de-
signed to support a person ’s weight.
7. USE the “Buddy System” when servicing the ironer to make sure no one else accidentally turns
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
WHILE IRONER IS RUNNING OR HOT. Serious injury can result. Never try to service an ironer
while it is running.
8. PROTECT yourself and your fellow workers by making sure that everyone follows these simple
rules. Read and follow all safety labels. Learn which parts are hot and how your ironer works
- 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
him/her prevent serious injury to themselves or others, by seeing that he or she follows the rules
and shuts the ironer o ff first. You can help prevent accidents by explaining these rules to employ -
ees who do not read English.
9. IF IN DOUBT, ask your supervisor or contact our Service Department for instructions. They
will be glad to show you how to safely and ef ficiently operate or service the irone r. Only qualified
personnel should service the irone r.
6371
Figure 3-1: The Operator Safety Reminders for CHICAGO® Flatwork Ironer bulletins must be read by all
personnel.
TOC INDEX 3-1

Operating Guidelines Comet Executive Gas
Safety Stop Buttons

3.1 Safety Features
The preferred method of stopping the operation
The unit is manufactured with several built-in
of the unit is by pressing any of the four red safety
features to promote safety and proper operating
STOP buttons located at each corner of the unit
procedures.
(Figure 3-3, A). Pressing any of these buttons
immediately stops the heating system and all
WARNING rotating parts.
Never bypass any of the
safety devices. Safety Guards
Serious Injury Could Result.
A red safety finger guard (Figure 3-3, B)
covers the moving parts at the front of the unit.
There are five general categories of safety It runs the entire length of the unit’s working area
features: and physically restricts hands from coming into
contact with moving and heated parts. Pushing the
• Main Disconnect Switch safety finger guard immediately stops the heating
• Safety Stop Buttons system and all rotating parts.
• Safety Guards
• Safety Interlock Switch
• Safety Labels
Main Disconnect Switch
CAUTION
The main disconnect switch
must be set to “O” (OFF)
when opening and closing
the endframe door. Figure 3-2: The main disconnect switch is located
on the right endframe door.
The main disconnect switch (Figure 3-2) is

located on the right endframe door. When turned
to “O” (horizontal position), the main disconnect A
switch is off, and shuts off the incoming electrical
power to the unit.
Unless otherwise indicated, turn the main

disconnect switch to off before performing any
maintenance or repair work.
Figure 3-3: The red safety STOP buttons (A) and

red safety finger guard (B) provide
immediate shut-down capability.
3-2 TOC INDEX

Both endframes and the rear of the unit are

covered with protective doors and panels to
prevent fingers or hands from coming into contact
with moving and heated parts. Removing the rear
panel immediately stops the heating system and
all rotating parts.
Safety Interlock Switch

A safety interlock switch is located behind
the protective backplate (Figure 3-4). If it is
removed, the interlock switch is disconnected,
all rotating parts stop moving, and the heating
Figure 3-4: Never operate the unit unless all
system shuts off.
safety interlock switches are working
correctly.
This safety interlock switch is not intended to
lockout the unit. Site management is responsible
for developing and implementing lockout/
tagout procedures that comply with government
standards for use when servicing the unit.
Safety Labels
WARNING (orange) and CAUTION (yellow)
labels are placed at locations around the unit to
keep operators and maintenance personnel alert
in particular areas (Figure 3-5).
WARNING labels alert personnel that

personal injury may result from not following
CAUTION labels alert personnel the unit

may be damaged if conditions, practices, or
procedures are not observed.
When training operators, take the time to

locate, review, and understand all areas where
labels are posted.
NOTE: Do not remove safety

labels at any time. If a label
needs to be replaced, contact
Chicago Dryer Company for free
replacements. Figure 3-5: Safety labels remind operators and
maintenance personnel that care must
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 • STOP button (A)
functions are capitalized in this instruction manual
for easy identification. Detailed descriptions are • START button (B)
given in the following paragraphs. • SPEED CONTROL knob (C)
Control locations include: • JOG REVERSE button (D)
• Right Endframe Controls

STOP button (A):
• Left Endframe Controls
Provided to help ensure operator safety and
to prevent damage to the unit. There are four red
safety STOP buttons—one on the front and back
of each endframe.
Pressing any of the four red safety STOP

A buttons immediately stops the heating system
and all rotating parts, leaving the unit in the
standby state.
START button (B):
B Begins the start-up and operation of the unit.

A green indicator lamp, located under the switch
surface, lights when the green START button is
pushed.
This indicates that power is connected to the

C motors. All rotating parts, including the ironing
D cylinder, feed ribbons, and return ribbons begin
to move.
Figure 3-6: Right endframe control panel.
SPEED CONTROL knob (C):
Controls the speed of the unit. Turning the

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

proper operating speeds for different types of
flatwork, refer to Processing Standards on
page 3-15.
3-4 TOC INDEX

JOG REVERSE button (D): Left Endframe Controls

The following operating controls and indicator
CAUTION lamps are located at the front of the left endframe
Turn the SPEED CONTROL (Figure 3-7).
knob to the slowest speed
• TEMPERATURE control dial (A)
before using the JOG
REVERSE button. Failure to • HEATING indicator lamp (B)
do so may result in unsafe • STOP button (C)
conditions or damage
to the unit.
TEMPERATURE control dial (A):
Sets the desired operating temperature of the

Moves the ironing cylinder and all ribbons in
burner system which heats the ironing cylinder.
reverse in small increments. Only works while
When power is turned ON at the main disconnect
button is being held down.
switch, turn the control to the desired temperature.
This feature should only be used in the The red ON indicator will be lit.
following situations:
For more information on determining the
• To clear jams proper operating temperatures for different types
of flatwork, refer to Processing Standards on
• For maintenance at the slowest speed page 3-15.
• For repair at the slowest speed
HEATING indicator lamp (B):
Lights when the heat is called for in the ironing

cylinder and the gas burner system is active.
STOP button (C):
Functions the same as the red safety STOP

buttons on the right endframe. For more
information, refer to Right Endframe Controls
C on page 3-4.
B
A
Figure 3-7: Left endframe control panel.
TOC INDEX 3-5

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

contact shoes under the feed table. Gently
• Start-Up blow or wipe off lint and other contami-
• Waxing nants. Check that each shoe contacts the
cylinder surface fully and firmly.
• Flatwork Handling
3. Have flatwork fully washed and extracted,
• Clearing a Jam Safely sorted, and ready to process.
• Shut-Down
4. Make sure the TEMPERATURE control
For information on processing specific types dial is turned to OFF.
of flatwork, refer to Processing Standards on
page 3-15.
switch.
WARNING 6. Press the green START button. The but-

ton’s green lamp should light and the
Never run a unit when
rotating elements begin moving.
ribbons are missing or
broken. Serious damage and 7. Turn the SPEED CONTROL knob to the
injury could result. slowest speed.
8. Make sure the ironing cylinder, feed, and

return ribbons are moving, and the exhaust
blower is running.
9. Perform a safety check:
• Press a red safety STOP button. All

moving parts should stop.
• Restart the unit.
• Test each of the 3 remaining red safety

STOP buttons in the same manner.
• Restart the unit.
• Press the red safety finger guard at the

front of the unit (Figure 3-3, B). All
moving parts should stop.
3-6 TOC INDEX

10. Restart the unit. Waxing

11. Adjust the TEMPERATURE control dial
to waxing temperature, approximately Standard Ironing Cylinder
300° F (150° C). Daily waxing of the ironing cylinder ensures it
12. After 15 seconds, listen for sounds indicat- is coated correctly, allowing the flatwork to slide
ing the pilot ignition sequence has started easily across the cylinder surface.
and the pilot burner is igniting. The HEAT- This produces the best flatwork finish,
ING indicator lamp should be lit. eliminates creases, prolongs return ribbon life,
13. Wait approximately 5-10 minutes for the prevents the flatwork from sticking to the ironing
ironing cylinder to reach proper waxing cylinder, and protects the temperature contact
temperature. shoes from excessive wear.
Chrome Ironing Cylinder
Chrome-plated ironing cylinders may require

less frequent waxing. However, if excessive static
build-up is causing flatwork to stick to the return
ribbons or is affecting machinery down-stream of
the ironer, occasional waxing may be beneficial.
In addition, occasional waxing may help

prevent excessive wear on the temperature
contact shoes.
Required Tools
Chicago Dryer Company powdered
wax or pure Karagami equivalent
Waxing cloth
Perform only when the unit is

RUNNING and HOT.
1. If the unit is not running, perform Start-

Up on page 3-6.
2. Turn the SPEED CONTROL knob to a

low speed.
3. Set the ironer temperature to 300° F (150°

C).
NOTE: Use only a standard

sheet or table cloth dedicated
solely to waxing the ironing
cylinder.
TOC INDEX 3-7

4. Check the condition of the waxing cloth. 5. Use a waxing cloth the width of the ironer
If the waxing cloth feels: and 90” (230 cm) long:
• Stiff when it is cool, it is sufficiently a) Make a fold in the middle of the piece
waxed. Skip to Step 6. but do not complete the fold.
• Limp when it is cool, more wax is b) On the inside section of the sheet, ap-
needed. Go to the next step. ply powdered wax, using from 1/4 to
1/2 lb (115-230 g). Use only Chicago
Dryer Company powdered wax (or
CAUTION pure Karagami equivalent).
Abrasive chest type cleaners,
pads, and paste wax can c) Spread the wax in a thin, uniform layer.
permanently damage the
d) Complete the fold, laying the unwaxed
ironing cylinder and return
portion over the waxed portion.
ribbons, and void the
factory warranty.
WARNING
Never sprinkle wax directly The waxing cloth will be hot
on ribbons, compression roll, when it comes out of the unit
or ironing cylinder. This will and may burn your hands.
shorten the expected life of Protect your hands.
the return ribbons.
6. Holding the waxing cloth tight from side
DO NOT over wax. The return to side, feed the folded end into the ironer.
ribbon drive roll cover will
become smooth and the • While feeding, lift the cloth off of the
return ribbons will slip. feed ribbons to keep them as wax free
as possible.
• Also hold the trailing edge of the wax-

NOTE: If waxing a chrome ing cloth so wax does not drop onto the
ironing cylinder, do not add canvas feed ribbons.
additional wax.
• Run it through the ironer two or three
times.
3-8 TOC INDEX

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
store it in an appropriate manner. 300° 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.
• Two operators should feed and receive
flatwork. While one operator is manually
folding flatwork, the other can prepare
the next piece of flatwork for processing.
TOC INDEX 3-9

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 CONTROL 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. Turn the TEMPERATURE control dial

to OFF.
6. If the jammed linen can be removed easily,

clear the jam.
3-10 TOC INDEX

7. If the jammed flatwork cannot be removed Shut-Down

easily:
The following steps are suggested for shutting
a) Announce the unit is being started. down the unit at the end of each day:
Make sure everyone is a safe distance
away from the unit. 1. Turn the TEMPERATURE control dial
to OFF.
b) Press the JOG REVERSE button and
jog the unit briefly, then pause 2‑3 2. Turn the SPEED CONTROL knob to the
seconds before jogging the unit again. slowest speed.
c) Continue jogging the unit in brief in- 3. Allow the unit to run for approximately
crements until the jammed flatwork can 20 minutes to cool down.
be safely and easily removed.
4. Stop the unit by pressing any of the red
d) Do not start the unit until the jam is safety STOP buttons.
cleared.
5. Turn power OFF at the main disconnect
switch.
NOTE: I f j a m m i n g o c c u r s
regularly, tell the maintenance or
WARNING
service people so they can fix the
problem.
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.
1. Turn the TEMPERATURE control dial

to OFF.
WARNING
Never leave the
unit unattended while
it is running.
2. Turn the SPEED CONTROL knob to the

slowest speed.
TOC INDEX 3-11

Conditioning Flatwork Before

3.4 Operating Techniques Ironing
The following factors are involved in producing
the best flatwork finish possible with the unit: There are several characteristics of flatwork
which are determined by processes before drying
• Conditioning Flatwork Before Ironing and ironing, including:
• Unit Settings • Wash Load
• Processing Standards • Final Rinse
• Maximum Productivity • Moisture Retention
The conditioning of flatwork before processing • Timing Between Washing and Ironing
and the control settings on the unit will affect the
processing standards. The processing standards Wash Load
ensure that flatwork is processed in a consistent
and efficient manner. The wash load should consist of flatwork
with the same fabric blend. Mixing different
fabric blends in the same wash load can create
inconsistent results because different fabrics
retain different levels of moisture during the
extraction process. Such mixing can also create
excess lint on flatwork. The unit works most
efficiently when one type of flatwork is processed
at a time.
CAUTION
Starch only according to
a proper starch program.
Improper levels of starch will
build a residue on the ironing
surface and reduce the unit’s
ability to finish flatwork.
3-12 TOC INDEX

Final Rinse After extraction, the optimum MR is 30% -

35% for polyester/cotton fabrics and 45% - 50%
The final rinse can affect the quality of for cotton fabrics.
flatwork finishing. It is important all flatwork be
thoroughly rinsed before entering the unit to keep 1. Use a precise scale to measure the “still
flatwork from sticking to the ironing cylinder. A wet, but extracted” flatwork; then weigh
pH level of 7.2 is recommended. again after the same flatwork is “com-
pletely dry”.
Add a fabric softener to prevent static
electricity from causing the flatwork to stick. 2. Subtract the weight of the “completely
Never use starch in the final rinse. dry” flatwork from the “still wet, but
extracted” flatwork. Divide the weight
A warm rinse allows more water to be extracted difference by the “completely dry” flat-
from the material. Thus, the unit needs to remove work weight. Finally, multiply the result-
less moisture from the flatwork. Additionally, ing weight by 100 to determine the MR
with warm flatwork, the unit does not have to percentage.
work as hard to keep at set temperature. This
produces flatwork with a dry, high quality The optimum MR after ironing is 4% or less.
finish—more efficiently. Ironing is not intended to remove 100% of the
moisture from the flatwork. Therefore, feel the
Moisture Retention flatwork when it first comes out of the unit; there
should be a slight moisture content.
Another important factor in delivering a high
quality finish is the amount of moisture retained Allow the flatwork to sit for a few minutes to
(MR) in the flatwork. The correct MR helps to allow excess steam and heat to dissipate in the
determine the ironing speed and temperature— air. Check the flatwork again; it should now feel
drying flatwork after just one run through the ironer. dry to the touch.
A few important factors in moisture retention If the flatwork does not feel dry or to improve
(MR) before ironing are: the quality of finish and productivity, repeat
Conditioning Flatwork Before Ironing on
• Wash formula–write down the standard page 3-12.
for consistency
• Extraction process–write down the Timing Between Washing and Ironing
standard for consistency
The amount of time delayed between washing
• Tumble dry condition time–write down and ironing/drying reduces the flatwork finish
the standard for consistency quality due to fabric cooling and MR. Flatwork
needs to be ironed directly from the washer/
• Type of fabric–higher percentage of
extractor whenever possible.
cotton, the more moisture retained
• Thickness of fabric–thinner material Start up the unit when the second load of wash
retains less moisture is entering the final extract cycle. Flatwork may
be put into carts from the washer and sorted out
With too little moisture, flatwork can cause static as desired.
buildup problems. If too much moisture is left in the
flatwork, the ironing section must work harder in Be aware that flatwork that sits overnight or
order to process the work, by either slowing down longer will have uneven MR, and the operating
the speed or increasing the temperature. speed must be adjusted accordingly.
TOC INDEX 3-13

Unit Settings Ironing Speed
The following three unit settings affect the The ironing speed should be standardized
final flatwork finish: based on MR, fabric content and thickness for
flatwork to be properly dried and ironed.
• Ironing Cylinder Temperature
• Ironing Speed Thin, single layer material can be processed
at higher speeds. Double thickness items such as
• Compression Roll Pressure pillowcases, and thicker material like tabletop
flatwork must be finished at lower speeds.
This information contributes to achieving the
best quality finished flatwork. Once processing
tests have been run on the different types of NOTE: Processing excessively
flatwork, write down the results on the Operating dry flatwork at too low a speed
Standard form and post by the unit. may result in scorched flatwork.
Excessively moist flatwork,
Refer to APPENDIX: Operating Standard processed at too high a speed will
form, for an authorized person to photocopy, result in a damp, poorly finished
indicate, approve, and post the settings per piece of flatwork.
flatwork type.
NOTE: It is important to write Compression Roll Pressure

down the ironing settings that
produce the best quality finish Another factor dictating the amount of
for each type of flatwork being residual moisture removed in the flatwork is the
processed. These standards compression roll pressure. The pressure also sets
should be posted. This removes the calendering effect—the stretching and sliding
“guesswork” from the daily routine of the flatwork to remove wrinkles and achieve a
and maximizes the efficiency and better quality finish.
consistency of the entire laundry
operation. Consistent washing For more information, refer to Compression
and ironing habits are the key to Roll Pressure Adjustment on page 7-18.
quality results.
Ironing Cylinder Temperature
In general, the lower the operating temperature,

the slower the unit must be run in order to produce
a quality flatwork finish.
3-14 TOC INDEX

Processing Standards 5. Set the temperature of the TEMPERA-

TURE control dial for the fabric being
processed.
CAUTION
This unit is NOT designed • 100% polyester: 250-300° F (121-
to process folded flatwork. 149° C)
Processing folded flatwork
• All cotton or polyester/cotton blends:
could void the
325-370° F (163-188° C).
manufacturers warranty.
CAUTION
For each type of flatwork processed, follow Material with a high
the steps below. Once the best temperature
polyester content can melt
and speed settings for that flatwork type have
been found, the standards should be posted and
when ironed at too high a
followed by all operators. temperature, or too slow
a speed. This can cause
1. The wash loads should consist of one type damage to the return ribbons
of flatwork only. and require a thorough
cleaning of the
2. Use the posted Operating Standard form
for unit settings per fabric type. For more ironing cylinder.
information, refer to Unit Settings on
page 3-14. 6. Turn the SPEED CONTROL knob to the
3. The final rinse should be as warm as pos- fastest speed.
sible. Add a fabric softener. Never use 7. Process a few pieces of the flatwork. The
starch in the final rinse. flatwork might feel slightly damp when
4. Flatwork should be ironed directly from it first comes out of the unit. Set the item
the washer/extractor. For more informa- aside and feel it again in five minutes. The
tion, refer to Timing Between Washing flatwork should feel dry.
and Ironing on page 3-13. 8. If the flatwork is still damp, decrease the
speed slightly.
CAUTION
9. Repeat Steps 7 and 8 until the finish on the
This unit is not designed to flatwork is correct.
process nylon or rubberized
fabrics. Processing these 10. This is the standard speed for processing
fabrics could result in a fire this type of flatwork. For more informa-
or damage the ribbons and tion, refer to Ironing Speed on page 3-14.
ironing cylinder surface.
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.
TOC INDEX 3-15

Comet Executive Gas Preventive Maintenance
Chapter 4
PREVENTIVE MAINTENANCE
Various components of the Comet Executive™ Gas 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
WatchTask Tables
and Listen for Anything Abnormal X Running/Hot
General Cleanliness X Off/Disconnect Power/Cool

Daily, Weekly Tasks
Check and Clean Temperature Sensor
X Off/Disconnect Power/Cool
Contact Shoes
Check Guide Tapes Preventive Maintenance

X Schedule beginning
Off/Disconnect Power/Cool
Check Safety Equipment X X Running/Cool
Wax Ironing Cylinder X Running/Hot
4.2 Weekly (50 hours)
Clean Behind Service Panels X Off/Disconnect Power/Cool
Check Ironing Cylinder 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 Sail Switch and Exhaust

Blower Wheel
Check Ribbon Condition and Tension X Running/Cool
TOC INDEX 4-1

Preventive Maintenance Comet Executive Gas
FREQUENCY OF TASKS BASED ON HOURS OF OPERATION
Preventive Maintenance Tasks Operator Maintenance Ironer Condition
4.3 Monthly (200 hours)
Check Setscrews X Off/Disconnect Power/Cool

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

X Running/Cool
Padding Condition
4.4 Semi-Annual (1000 Hours)
Check Gas Pressure X Off/Disconnect Power/Cool
Check Mechanical and Electrical

Connections
4.5 Annual (2000 Hours)
Check and Clean Pilot Assembly 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.
could result in serious injury.
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 Temperature Check Guide Tapes

Sensor Contact Shoes
Required Tools with power disconnected and COOL.
Soft cloth
Vacuum cleaner or compressed air Guide tapes are used to prevent flatwork from
sticking to the compression roll.
Perform only when the unit is OFF 1. Turn power OFF at the main disconnect
switch.
Two spring-loaded temperature contact shoes, 2. Inspect for broken or missing guide tapes
located under the feed ribbons (Figure 4-1), are and for wear or fraying of the edges.
used to sense and transmit the ironing cylinder
temperature. 3. Make sure the ends of the guide tapes are
properly stapled together.
The one at the center relays information to the
temperature control; the one toward the left end of 4. Replace any guide tapes that are damaged,
the cylinder relays information to the high limit broken, or missing. For more information,
temperature control. refer to Guide Tape Replacement on
page 7-10.
Cleanliness of the contact shoes and firm
pressure on the cylinder are necessary for proper
operation of the ironing section.
Gently blow or wipe off line and other

contaminants. Check that each shoe contacts
the cylinder surface fully and firmly. If contact
shoes are worn down, they must be replaced
immediately.
For more information, refer to Temperature

Sensor Contact Shoe Replacement on page
7-33.
Figure 4-1: Temperature shoes must be clean

and correctly placed for the ironing
cylinder to heat properly.
4-4 TOC INDEX

Check Safety Equipment Wax Ironing Cylinder
Perform only when the unit is Perform only when the unit is
RUNNING and COOL. RUNNING and HOT.
Use Extreme Caution. Use Extreme Caution.
The machine should never be operated without Daily waxing of the ironing cylinder is
all safety guards in place and all safety devices necessary to produce a finer flatwork finish,
working properly. to prolong return ribbon life, to prevent the
flatwork from sticking to the ironing cylinder,
Check that all four red safety STOP buttons, and to protect the temperature contact shoes
and the red safety finger guard all bring the from excessive wear. Note that chrome ironing
operation of the machine to a complete halt. For cylinders may require less frequent waxing.
more information, refer to Start-Up on page
3-6. For waxing instructions, refer to Waxing on
page 3-7.
NOTE: Repair any faulty safety
devices before continuing to
operate the unit.
TOC INDEX 4-5

Clean Behind Service Panels

4.2 Weekly PM (50 Hours)
Required Tools
WARNING Allen wrench: 5/32”
Do not repair or correct any Clean cloth
of these conditions without Vacuum cleaner
the Repair chapter. Perform only when the unit is OFF
should troubleshoot and
CAUTION
repair this unit.
components. Damage
can result.
power is turned OFF at the
Follow lockout/tagout switch.
2. Open and clean the inside and outside
your site. Follow local
surfaces of both endframe doors.
regulations. Failure to do so
could result in serious injury. 3. Remove and clean the rear protective
backplate. This piece should be handled
by two maintenance personnel.
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.
6. Replace and secure the protective

backplate.
WARNING
Never operate the unit unless
all safety covers are in place
and all safety equipment is
working correctly.
4-6 TOC INDEX

Check Ironing Cylinder Check and Clean Inverter

Check and clean the inverter and its cooling
with power disconnected and COOL. fins weekly with a vacuum cleaner. Failure to do
so may void your warranty.
Performance of the unit depends on the
condition of the ironing cylinder. Required Tools
Vacuum cleaner
switch.
2. Inspect the cylinder by carefully looking with power disconnected and COOL.
under the feed ribbons at the front of the
unit. 1. Turn power OFF at the main disconnect
switch.
3. Check for buildup of chemicals or debris
which discolor the cylinder. 2. Open the right endframe door and locate
the main drive motor inverter (Figure 4-2).
4. For information on restoring the fine
polished finish of the cylinder, refer to
Ironing Cylinder Reconditioning on CAUTION
page 7-24. 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.
WARNING
working correctly.
Figure 4-2: Check and clean the inverter and its

cooling fins weekly.
TOC INDEX 4-7

Grease “Weekly” Bearings

The grease fittings for the ironing cylinder
bearing (Figure 4-3, A) in the right endframe,
cam follower bearings (Figure 4-4, A) in the left
endframe, and compression roll bearings (Figure
4-3, B; Figure 4-4 B) in both endframes, are
marked with yellow “GREASE WEEKLY” tags
and need to be greased weekly. B
Other bearings that are identified with the A
yellow “GREASE” tags should also be greased
weekly if the unit is continuously run for long
periods. Figure 4-3: Add grease weekly to the fitting for
the ironing cylinder bearing in the
A special high temperature lubricant is right endframe and to the fittings for
required to properly grease all bearings. It is the compression roll bearing in each
important that only an EP, bentonite clay, NLGI endframe.
2, 1000 cSt viscosity grease be used.
Use of unsuitable grease can cause bearing

lockup or failure. Problems can also result if the
new grease is incompatible with the grease that
is already in the bearings. B
Failure to use the correct lubricant will void
the factory warranty.
A A
CAUTION
Before using a grease
other than specified, check
with the factory service
department to verify that
Figure 4-4: Add grease weekly to the fittings on
the grease meets the cam follower bearings in the left
specifications and is endframe.
compatible with the grease
already in the bearings.
4-8 TOC INDEX

5. Add lubricant slowly until a slight bead of

Required Tools
lubricant forms at the seal. As soon as the
Clean cloth
bead forms, stop adding grease to prevent
Grease gun
Grease: EP, bentonite clay, NLGI 2,
damage from over-lubrication.
1000 cSt viscosity
CAUTION
Perform only when the unit is OFF Failure to wipe off excess
lubricant will cause lint to
adhere to the bearings and
1. Turn power OFF at the main disconnect may cause premature failure.
switch.
2. Open both endframe doors. 6. Immediately wipe off the grease from the
3. Wipe the old grease from the bearings. bearing. Failure to do so can cause lint ac-
cumulation and premature bearing failure.
4. Insert the grease gun nozzle firmly onto
the grease fitting. 7. Leave the endframe doors open for the
next procedure.
CAUTION
Over-lubrication will destroy
the bearing seals and cause
premature failure.
TOC INDEX 4-9

Oil Roll Bearing Pivots

The bearing pivots for the compression roll
(Figure 4-5, A) and return ribbon guide assembly
roll (B) inside each endframe need to be oiled
weekly to allow the bearings to pivot smoothly.
B
Required Tools A
Clean cloth
SAE 90 grade oil


Figure 4-5: Oil the roll bearing pivots in each
switch. endframe weekly.
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 and the return ribbon guide assembly
roll to lubricate the pivots.
6. Wipe off any excess oil from each of the

pivots.
WARNING
working correctly.
4-10 TOC INDEX

Check and Clean Motors Check and Clean Sail Switch and
Exhaust Blower Wheel
The drive motor and exhaust blower motor
require weekly cleaning to ensure proper The sail switch (Figure 4-7) must be cleaned in
operation. order for it to operate properly when the exhaust
blower is on. The exhaust blower wheel needs
Required Tools to be inspected and cleaned after the sail switch
Vacuum cleaner
is removed.
Perform only when the unit is OFF CAUTION

with power disconnected and COOL. Operation of the unit with
foreign material (lint, threads,
1. Turn power OFF at the main disconnect wax particles, hair, etc.) in
switch. the blower wheel between
the blades can cause
2. Use a vacuum to clean out lint and dirt
overheating, especially
from the intake side (Figure 4-6) of each
of the endframe controls,
specified motor.
and possible premature
3. Make sure the motors are free to turn component failure.
without excessive binding.
Required Tools
Clean cloth
Flashlight
Screwdriver
Vacuum cleaner

Figure 4-6: Removing lint and dirt from the intake

side of the motor ensures proper Figure 4-7: The sail switch must be cleaned to
operation. ensure proper operation.
TOC INDEX 4-11

1. Turn power OFF at the main disconnect Check Ribbon Condition and
switch. Tension
2. Remove the sail switch cover. High temperature synthetic material is used
for the feed and return ribbons.
3. Remove the two screws holding the sail
switch in position and gently pull it out
from the exhaust blower. Be careful not NOTE: Ribbons that break
to disconnect any wires. should be replaced immediately.
Return ribbons move and hold the
4. Remove lint and other dirt with a clean linen in proper contact with the
cloth or, if necessary, compressed air. heated cylinder, ensuring quality
flatwork finish.
5. Inspect the inside of the blower housing
with the help of a light to observe any lint
buildup between the blower wheel blades.
6. Remove the inlet elbow (Figure 4-8) from RUNNING and COOL.
the blower. Use Extreme Caution.
NOTE: Fibers left on the blower

WARNING
wheel allow lint and foreign
Never touch any part of the
material to accumulate more
frequently. unit while it is moving.
7. Use a vacuum to remove lint and foreign 1. Turn power ON at the main disconnect
material from the blower. Make sure the switch.
blower wheel is free to turn without exces-
sive binding. 2. Press the green START button.
8. Position the inlet elbow on the blower. 3. Check all ribbons for proper placement,
tracking, tension (no visual sagging), and
9. Reinstall the sail switch and the cover. 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.
Figure 4-8: The inlet elbow must be removed to

access the exhaust blower wheel.
4-12 TOC INDEX

Check Setscrews
4.3 Monthly PM
Setscrews are used to secure sprockets,
(200 Hours) bearings, pulleys, and other rotating parts.
WARNING
Required Tools
Do not repair or correct any
Allen wrench set
of these conditions without
the Repair chapter. Perform only when the unit is OFF
should troubleshoot and 1. Turn power OFF at the main disconnect
switch.
repair this unit.
completely cooled down and 3. Make sure all setscrews are correctly
power is turned OFF at the tightened.
NOTE: To a l l o w f o r h e a t
Follow lockout/tagout expansion, bearings in the left
procedures approved for endframe (Figure 4-9) do not have
your site. Follow local setscrews. Do NOT put setscrews
regulations. Failure to do so into these bearings. However, if
could result in serious injury. there are any shaft collars, these
do have setscrews that must be
secured.
WARNING
working correctly.
Figure 4-9: Do NOT put setscrews into left

endframe bearings.
TOC INDEX 4-13

Grease Bearings Oil Drive Chain and Tension Springs

The drive chain in the left endframe (Figure
Required Tools 4-10, A), and the compression roll tensioning
Clean cloth springs (B), and return ribbon tensioning
Grease gun springs (C) in both endframes require monthly
Grease: EP, bentonite clay, NLGI 2,
maintenance.
1000 cSt viscosity
Required Tools
with power disconnected and COOL. Clean cloth
SAE 90 grade oil
Bearings marked with yellow “GREASE”

tags are not subjected to as much stress and high with power disconnected and COOL.
temperatures as the bearings that require weekly
greasing.
Therefore, the bearings with yellow “GREASE” switch.
tags do not need to be greased as frequently as
the bearings with yellow “GREASE WEEKLY”
tags. Use the same high temperature grease for 3. Clean off old lubricant from the drive
all the bearings. chain and tensioning springs.
For instructions on greasing bearings labeled 4. Lightly lubricate the chain and springs
with yellow “GREASE” tags, refer to Grease with a good quality SAE 90 grade oil.
“Weekly” Bearings on page 4-8.
WARNING
working correctly.
Figure 4-10: The drive chain is located inside the

right endframe.
4-14 TOC INDEX

Check Compression Roll Pressure

and Padding Condition 4.4 Semi-Annual PM
(1000 Hours)
RUNNING and COOL. WARNING
Do not repair or correct any
of these conditions without
Uneven compression roll pressure can shorten
the life of the compression roll pad. Regular
pressure checks and adjustments as necessary
the Repair chapter.
can help extend padding life.
In addition, check the cover’s overall condition should troubleshoot and
for wear, discoloration or displacement. Consider repair this unit.
cover replacement as necessary.
For more information, refer to Compression Make sure the unit is

Roll on page 7-16. completely cooled down and
Follow lockout/tagout
TOC INDEX 4-15

Check Gas Pressure Check Mechanical and Electrical

Connections
It is important to check the available gas
pressure to the unit during periods of peak
demand by other gas-heated equipment in the Required Tools
laundry room or elsewhere at the facility. Gas Clean cloth
pressure to the unit may be reduced significantly Screwdriver
at these times, which will interfere with the proper Voltmeter
Wrench set
operation of the burner.
For more information on checking the gas Perform only when the unit is OFF
pressure, refer to Gas Connection Checkout with power disconnected and COOL.
on page 2-20.
Heating, cooling, and normal vibrations
may cause connections to loosen over time.
Perform this procedure to check and tighten the
mechanical and electrical connections.

switch.
3. Check and tighten all mechanical fasten-

ers.
4. Check the electrical components in both

endframes.
5. Check all electrical connections in the

electrical panel.
WARNING
Only a qualified electrician
should make or correct any
electrical connections in or
to the unit.
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.
4-16 TOC INDEX


4.5 Annual PM
WARNING (2000 Hours)
all safety covers are in place WARNING
and all safety equipment is Do not repair or correct any
working correctly. of these conditions without
the Repair chapter.

repair this unit.

Follow lockout/tagout
TOC INDEX 4-17

Check and Clean Pilot Assembly Perform only when the unit is OFF
Periodic inspection and cleaning of the various
pilot assembly components helps ensure trouble-
free operation. Remove Burner
In order to service the pilot assembly, it will 1. Turn power OFF at the main disconnect
be necessary to remove the burner. Make sure switch.
the unit is completely COOL before beginning
this procedure. 2. Turn OFF the gas supply to the unit.
3. Lockout and tagout both the electrical

NOTE: Ta k e t h e t i m e t o and gas supplies following local work
read through and understand rules and in compliance with government
the entire procedure before standards.
performing this work.
4. Remove the protective backplate at the
This procedure should be handled rear of the unit. This piece should be
by at least two qualified persons. handled by two maintenance personnel.
Using the “buddy system”
facilitates a quicker procedure 5. Open both endframe doors.
and decreases the risk of 6. In the left endframe, note the specific
an accident. connection point for the flame sensor wire
(Figure 4-11, A) and the ignition electrode
wire (B) to the ignition control.
Required Tools 7. Disconnect each wire.
C-clamp: large
Clean cloth
Compressed air C
Denatured alcohol
Gloves A
Pencil/marker
Pipe thread compound/Teflon
tape
Pipe wrench B
Pliers
Sandpaper: 220 grit emery
Wrenches:
7/16”
1/2”
9/16” (2) Figure 4-11: Disconnect the flame sensor and
ignition electrode wires.
4-18 TOC INDEX

8. Disconnect the pilot gas line from the gas 14. Remove the burner assembly slowly. When
valve (Figure 4-12, A). the burner has been moved about 18” (450
mm), stop moving the assembly.
9. Securely place a large C-clamp on the
burner assembly and use it as a hand-hold The tail pipe should be about ready to clear
to help balance and support the assembly. the right endframe and will drop against
the bottom of the ironing cylinder if not
10. Then, loosen the union (Figure 4-12, B)
properly supported.
between the gas valve and the burner.
15. The two people at the left end should push
down slightly on the assembly, while the
NOTE: Three maintenance
person at the right endframe reaches into the
people are required to remove
ironing cylinder and supports the tail pipe.
the burner assembly. Station one
person at the right end of the unit 16. Begin slowly pulling the burner out an-
and the other two at the left end. other few inches until the tail pipe is clear.
Be careful to avoid letting the burner tail
pipe bang against the bottom of the iron-
ing cylinder.
WARNING
The burner assembly is 17. Continue moving the burner assembly out
heavy and will rotate when it slowly. Keep downward pressure on it to
is removed. lift the tail pipe as it clears the cylinder
end and keep it from banging against the
Make sure it is adequately heat shield in the bottom of the cylinder,
supported at both ends which could cause damage.
during removal and 18. Continue sliding the burner assembly
replacement and that there slowly out of the ironing cylinder. When
are sufficient personnel/ the tail pipe reaches the left end, all three
equipment to handle it to people should lift the burner assembly so
prevent injury or damage. the tail pipe can clear the cylinder.
19. Place the burner assembly on a sturdy

11. Make sure a worker has a good hold on worktable.
the C-clamp and the burner assembly is
supported.
12. Finish disconnecting the gas union (Figure

4-12, B).
A B
13. Support the burner assembly while remov-
ing the bolts that hold the burner support
bracket in position (Figure 4-11, C).
Figure 4-12: Disconnect the pilot gas line at the gas

valve.
TOC INDEX 4-19

Service Pilot Assembly 1. Remove the pilot gas tube (Figure 4-13,
A).
NOTE: W i t h t h e b u r n e r
removed, examine the burner tips CAUTION
to determine whether they need Do not attempt to clean the
cleaning. If so, refer to Burner Tip orifice by inserting anything
Maintenance on page 7-32. into the openings. These
are precisely sized and any
alteration will affect machine
operation, necessitating
replacement of the orifice.
E D 2. Remove the pilot gas orifice (Figure 4-13,

B) and put into denatured alcohol. Allow
to soak for about 4 hours.
C 3. Remove the orifice from the alcohol and

thoroughly rinse with water; then, blow
dry with compressed air.
4. Replace the orifice and re-connect the gas

pilot tube.
B
5. Check the condition of the ignition elec-
trode (Figure 4-13, C) and the flame sensor
(D). Make sure there is no corrosion and
A F the ceramic insulation is not cracked or
otherwise damaged.
6. If necessary, lightly go over with 220-grit

Figure 4-13: Check the condition of the ignition emery paper.
electrode and the flame detector.
7. Check the gap between the electrode and
pilot gas flange (Figure 4-13, E). It should
be about the thickness of a dime (1.35-1.4
mm).
8. Make sure the flame sensor is straight

and that its wire (Figure 4-13, F) is firmly
connected.
4-20 TOC INDEX

Replace Burner 8. Reconnect the pilot gas line (Figure 4-12,

A). Use pipe thread compound or Teflon
After all maintenance/repair is completed, tape to assure a leakproof connection.
replacing the burner is generally a reversal of the
removal process with the following additional 9. Reconnect the flame sensor and ignition
guidelines: electrode wires as noted in 6 of Remove
Burner on page 4-18.
1. When the assembly has been pushed back
into the ironing cylinder, have a worker 10. Reposition and secure the protective
help guide the tail pipe into place. backplate. This piece should be handled
2. With two people at the left endframe push-
ing down slightly on the burner assembly, 11. Make sure the internal valve is in the fully
the third person reaches into the ironing ON position.
cylinder helps guide the tail pipe through
the opening in the right endframe. 12. Close and secure both endframe doors.
3. Once the tail pipe is seated in the opening,

slide it the rest of the way into position. WARNING
4. Make sure it is properly positioned in its all safety covers are in place
holding bracket. and all safety equipment is
working correctly.
5. Reinstall the burner support removed in
Step 13 of Remove Burner on page 4-18.
13. Start the unit to verify proper operation.
6. Make sure the burner is properly oriented
and physically secured.
7. Securely rejoin the gas line union for the

burner (Figure 4-12, B). Use pipe thread
compound to assure a leakproof connec-
tion.
TOC INDEX 4-21

Comet Executive Gas Operating Principles
Chapter 5
OPERATING PRINCIPLES
In order to maintain and troubleshoot the Comet Executive™ Gas 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 Mechanical System
5.3 Exhaust System
5.4 Heating System
5.5 Sequence of Operation
Electrical System: This section reviews incoming power requirements, how power
is distributed throughout the ironer, and the controls, sensors and
switches operating the unit.
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 and deliver it to the front of the unit.
Exhaust System: This section explains how the exhaust blower and sail switch work
together in the exhaust canopy to provide ventilation for the unit.
Heating System: This section reviews incoming gas requirements, how gas is used
to heat the ironing cylinder, and the control, safety buttons, and
switches used to provide a safe combustion heating system.
Sequence of Operation: This section provides a step-by-step guide to each of the

ironer’s phases of operation: Stand-By, Jog Reverse Operation;
Mechanical Start-Up, and Burner 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 Comet Executive Gas
Safety 5.1 Electrical System

The equipment described here has been The electrical components of the unit provide
designed to work together to give a safe and the power to move the ironing cylinder, the
reliable machine. Changing the equipment or various rolls and ribbons, and to control operation
controls may cause a malfunction that could of the ironer.
injure someone. Do not bypass any of the safety
Components in the electrical system are
features or controls. Do not replace components
located in the main electrical panel inside the
except with factory-approved repair parts.
right endframe.
Questions about the operation of the unit can be
The majority of the protectors and distribution
answered by your local authorized CHICAGO®
items are in the main electrical panel. Some gas
dealer, or by the Chicago Dryer Company service
system electrical components are located in the
department.
left endframe.
Electrical system components include:
• Disconnect Switch and Fuses

• Step-Down Transformer
• Electrical Panel
5-2 TOC INDEX

Disconnect Switch and Fuses

The unit comes equipped with a disconnect A
switch (DDS). This switch (Figure 5-1, A) is in
the electrical panel inside the right endframe.
Included as a part of the disconnect switch are

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

unit must match the requirements C
listed on the nameplate.
Additional fuses protect the drive motor Figure 5-1: The disconnect switch and fuse set in
inverter (Figure 5-1, C) and the transformer (D). the electrical panel inside the right
endframe.
Step-Down Transformer
If the ironer is installed in a property with line
voltage higher than 240 VAC, transformer T2 is
provided (Figure 5-2) on the inner wall of the
right endframe. This steps down the voltage to
the 240 VAC.
T2
Figure 5-2: T2 for high voltage units.
TOC INDEX 5-3

Electrical Panel
The electrical panel (Figure 5-3) is located
inside the right endframe. The table below
provides an explanation of each item indicated
in the picture.
DSC1
T1 FB2
MP1 FB1
INV1
CR1
Figure 5-3: Electrical panel power system components-inside right endframe.
ELECTRICAL PANEL COMPONENTS

Schematic Description
CR1 Control Relay - Run Latch
DSC1 Main Disconnect Switch
FB1 Fuse Block - Main Drive Motor Inverter
FB2 Fuse Block - Transformer T1
INV1 Inverter - Drive Motor
MP1 Motor Protector - Exhaust Blower Motor
T1 Transformer - 24 V Control Circuit
5-4 TOC INDEX


Components that make up the mechanical
system include the following:
• Drive System
• Ribbon Sets
Drive System
I
Use the drawing at right (Figure 5-4) to
H
identify the mechanical components of the ironer
drive system.
G J
A shaft from the main drive motor (A) extends
directly into the main gear reducer (B). The output K
shaft of the main gear reducer is connected to a
drive sprocket (C) which powers the drive chain F
(D).
The chain passes around an adjustable idler

arm (E) and then powers the return ribbon drive E
roll sprocket (F) and feed ribbon drive roll D
sprocket (G). It then drives the compression roll
sprocket (H) and the ironing cylinder sprocket (I).
A/B
The adjustable idler arm (E) maintains proper
tension on the drive chain. Tension on the C
compression roll is maintained by a spring (I).
Figure 5-4: Drive system—right endframe.
TOC INDEX 5-5

Ribbon Sets
Two sets of ribbons are used in ironing. Use
the cross-section below (Figure 5-5) to follow the
path of the flatwork. Note the function of each I
roll and set of ribbons as the flatwork moves C D I
through the unit.
F
The feed ribbon drive roll (A) rotates the set of A
B
feed ribbons (B). These move the flatwork under
the safety finger guard (C) toward the ironing E
cylinder (E).
G
The flatwork is then carried under the
compression roll (D), which smooths the flatwork.
H
To keep the flatwork tight against the ironing
cylinder (E), a set of return ribbons (F) is rotated
by the return ribbon drive roll (G) and guided by Figure 5-5: Various rolls and ribbons move the
the return ribbon guide assembly (H) and idler flatwork through the ironer.
rolls (I).
The flatwork then passes over the return ribbon

drive roll (G) and onto the receiving shelf.
5-6 TOC INDEX

5.3 Exhaust System 5.4 Heating System

Components that make up the exhaust system The heating system consists of the following
are located in the exhaust canopy. components:
These components include: • Burner System
• Exhaust Blower • Temperature Control
• Sail Switch • Temperature Sensor Contact Shoes

These systems work together to monitor and
Exhaust Blower control the operation of the heating system.
For detailed electrical information, refer to the
The exhaust blower (Figure 5-6, A) draws used SCHEMATIC PARTS LIST.
air and combustion by-products from under the
canopy and discharges them through an attached
vent duct at the required rate.
Sail Switch
The sail switch (Figure 5-6, B) is located in
the discharge of the exhaust blower. The sail
switch contacts are closed when air, exhaust
combustion by-products, and excess heat are
being vented through the exhaust ductwork.
When air movement stops or is restricted in the
exhaust ductwork, the sail switch contacts open,
and the burner system shuts down.
B
A
Figure 5-6: The exhaust blower (A) with its sail

switch (B) should be wall mounted
within 15’ of the ironer.
TOC INDEX 5-7

C
A
B
Figure 5-7: Burner system components in the left endframe.
5-8 TOC INDEX

Burner System Gas Shut-Off Valve (D)
The following provides a brief summary of Shuts off the gas supply to the burner.
each component identified in Figure 5-7.
Gas Burner (E)
Gas Valve with Regulator (A)
Uses gas and atmospheric air to provide flames
Allows gas to flow to the burner. Normally along the length of the cylinder. After the pilot
closed gas valve is opened by a signal from the gas burner flame has been proven by the flame
ignition control. This valve supplies both the pilot sensor, the burner lights.
and burner gas.
In case of a failure within the heating system, Pilot Gas Orifice (F)
the burner gas valve is closed. Gas does not Provides a precisely controlled gas flow for
continue to enter the burner when there is no a the pilot flame. The pilot flame stays on when
flame. the burner is lit.
Ignition Control (B) Ignition Electrode (G)

Controls gas system operation. Responds to Powered by the ignition control, provides a
a heat signal from the TEMPERATURE control high voltage spark inside the pilot burner to ignite
and provides a high-voltage spark to the ignition the incoming gas.
electrode.
It also monitors to make sure a flame has been Flame Sensor (H)
safely established.
Powered by the ignition control, proves the
pilot gas burner flame.
High Limit Control (C)
Responds to an over-limit condition in the

ironing cylinder by opening up and preventing
further gas system operation until the cylinder
has sufficiently cooled and it has been manually
reset. See also Temperature Sensor Contact
Shoes on page 5-10.
TOC INDEX 5-9

Temperature Control
The TEMPERATURE control (Figure 5-8) is
used to set the temperature of the ironing cylinder
and to turn the gas system ON and OFF. See also
the information on the temperature sensor contact
shoes below.
Temperature Sensor Contact Shoes

The unit is equipped with two temperature
sensing devices which monitor the temperature of
the heated ironing cylinder. A oil-loaded capillary
tube and bulb is used as the sensing device. Figure 5-8: Temperature control at the front of the
left endframe.
Each sensor is housed in a spring-loaded
contact shoe which rides on the surface of the
heated ironing cylinder under the feed ribbons
(Figure 5-9):
• The one at the center (A) transfers

heat from the cylinder to the
TEMPERATURE control.
• The one toward the left end of the
cylinder (B) transfers heat to the high
temperature limit control.
B A
If either of these contact shoes wear down,
breaks off, or is incorrectly placed against the
cylinder, inaccurate information will be read
by the TEMPERATURE control and/or high
temperature limit control, and the unit will not Figure 5-9: Temperature contact shoes under the
feed ribbons.
function properly.
5-10 TOC INDEX

Stand-By Stage
5.5 Sequence of Operation
During this stage, the main disconnect switch
The unit has four main stages of operation:
is ON, but the unit is not operating.
• Stand-By Stage
1. Line voltage is present at INV1.
• JOG REVERSE Operation Stage
2. One stage of the incoming power supplies
• Mechanical Start-Up Stage the transformer T1, converting the line
voltage to 24 VAC. The 24 VAC supply is
• Burner Operation Stage
terminated at the START button and the
Each stage requires several components to CR1 contacts.
accomplish its job. The sequencing and timing
of stages are critical. 3. Power is connected to the exhaust blower
motor. The exhaust blower motor rotates
The following steps describe the logical the exhaust blower fan and moves air
progression of events allowing the unit to work through the discharge duct.
safely and efficiently.
JOG REVERSE Operation Stage
NOTE: T h e l e t t e r s a n d
When the ironer is in Stand-By Stage, the JOG
numbers in parentheses are
REVERSE button is active.
schematic references. For
more information, refer to the 1. When the button is pushed, it closes the
SCHEMATIC PARTS LIST. inverter’s reverse motion circuit, causing
the main drive motor to run in reverse.
2. When the button is released, the circuit is

opened and the motor stops.
3. The setting of the speed control is active.

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

pressing the JOG REVERSE button will
have no effect on machine operation.
TOC INDEX 5-11

Mechanical Start-Up Stage Burner Operation Stage

This stage contains the sequence that occurs This stage describes the sequence that occurs
when the unit begins operating without ignition during ignition, operation, and shut-down of the
of the burner. burner.
1. The green START button is pressed, the 24 1. With the unit running normally, power is
VAC supply energizes control relay CR1, supplied to all gas system operating and
and the green START button indicator safety controls.
lamp comes on.
2. Before ignition can begin, the sail switch
2. The CR1 contacts close: (FS1) must be closed.
• This allows START button to be re- 3. The heating phase begins when an opera-
leased without de-energizing the start tor sets the TEMPERATURE control dial
relay. to a setting that is greater than the actual
temperature of the ironing cylinder:
• In addition, the closing of the CR1
contacts makes power available to the • The ignition control opens the pilot
gas control and safety circuitry. gas valve and provides power to the
ignition electrode.
• Simultaneously, a second set of CR1
contacts in the motor control circuitry • Once the pilot flame is proven, the igni-
close, signaling the inverter to provide tion control opens the main gas valve.
power to the main drive motor.
• The system will not call for heat again
• The ironing cylinder, feed ribbons, and until temperature drops 12º F below
return ribbons begin to rotate. set point.
• The high temperature limit control

(HLT1) is energized.
• If the control senses a high tem-

perature condition, it shuts down
the heating system.
• The unit must be given time to cool

down before the high temperature
limit control can be manually reset.
5-12 TOC INDEX

Comet Executive Gas Troubleshooting
Chapter 6
TROUBLESHOOTING
This chapter includes troubleshooting for the Comet Executive™ Gas in the areas listed below:
6.1 Electrical
6.3 Ironing Quality
6.4 Heating System
6.5 Exhaust 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 gas, 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 Comet Executive Gas
Troubleshooting Symptoms
6.1 Electrical
Unit Does Not Start or Jog.................................................................................................. 6-4
Unit Jogs, Does Not Start................................................................................................... 6-5
Unit Starts, Does Not Jog................................................................................................... 6-5
No Speed Adjustment......................................................................................................... 6-5

Noisy Operation.................................................................................................................. 6-6
Ribbons Do Not Track Straight........................................................................................... 6-6
Ribbon Set Not Working..................................................................................................... 6-7
Rotating Elements Stop...................................................................................................... 6-7
Drive System Mechanical or Electrical Error....................................................................... 6-8
6.3 Ironing Quality

Flatwork Feeds Poorly into Ironing Section........................................................................ 6-9
Flatwork Jams or Sticks to Ironing Cylinder; Poor Ironing Quality...................................... 6-9
Flatwork Scorched or Discolored...................................................................................... 6-10
Flatwork Does Not Dry Correctly...................................................................................... 6-10
Poor Flatwork Finish..........................................................................................................6-11
Flatwork Sticks to Return Ribbons/Exits Ironer with Excessive Static...............................6-11
6-2 TOC INDEX

6.4 Heating System

Pilot Ignition
TEMPERATURE Control Indicator Lamp Does Not Come On When Dial is
Turned to ON.............................................................................................................. 6-12
Pilot Ignition Irregular or Absent........................................................................................ 6-12
Burner Ignition
Flame Does Not Travel Down the Entire Length of the Burner......................................... 6-13
Gas Flow: Poor, Irregular, None........................................................................................ 6-13
Burner Starts Normally, Then Shuts Down....................................................................... 6-13
Burner Operation
Ironing Cylinder Heats to SET Temperature, but Will Not Ignite a Second Time.............. 6-14
TEMPERATURE Control Erratic or Does Not Work......................................................... 6-14
Temperature Sensor Not Working Correctly..................................................................... 6-15
Flames Coming From Ends of Ironing Cylinder................................................................ 6-15
Excessive Wear on Temperature Sensor Contact Shoes................................................. 6-15
6.5 Exhaust System

Exhaust Poor or None....................................................................................................... 6-16
TOC INDEX 6-3

WARNING WARNING
Only trained personnel with experience
in gas, 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.
6.1 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 any blown fuses.

fuses are blown.
• If fuses continue to blow:
-- Check the wiring for a short or open
circuit.
-- Replace defective component(s) as
required.
5. Drive motor thermostat • Allow motor to cool and thermostat to

is tripped (motor is over- reset.
heated).
Unit Does Not Start or Jog • If the motor thermostat continues to trip:
circuit.
-- Check for excessive load on motor
which may cause an over current
condition.
-- Replace the defective motor.
6. Inverter needs to be reset. • Reset the inverter:

-- Turn power OFF at the main discon-
nect switch.
-- Wait one minute.
-- Turn power ON at the main disconnect
switch.
• If the fault repeats:

-- Input voltage is too high or low.
-- Open circuit between the inverter and
MTR2.
-- Drive motor MTR2 is bad.
6-4 TOC INDEX

WARNING WARNING

1. Fuse protecting T1 blown. • Replace any blown fuses.
• If fuses continue to blow:

circuit.
-- Replace defective component(s) as
required.
2. START button is defective. • Check for 24 VAC at the green START

button switch. Replace the switch if 24
VAC is present and the switch does not
operate.
3. CR1 is defective. • Repair or replace the auxiliary contact.
4. 24 VAC transformer T1 is • Check for 24 V output. Replace the

Unit Jogs, Does Not Start defective. transformer if there is no 24 V output.
WARNING
Never operate the unit unless all safety devices are working correctly.
5. STOP button or the red • Replace any defective STOP button.

safety finger guard is
pushed in and stuck or • Make sure the finger guard is installed
defective. correctly and not depressed.
• Check the finger guard switches inside

both endframes.
6. The protective backplate is • Push in the plungers to the safety inter-

off or the safety interlock lock switches.
switch is otherwise open.
• Close and secure the endframe doors
and the protective plate.
1. JOG REVERSE button is • Check for 24 VAC at the JOG REVERSE

Unit Starts, Does Not Jog
defective. button.
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.
TOC INDEX 6-5

WARNING WARNING

1. Mechanical components • Lubricate. Refer to Grease “Weekly”
need lubrication. Bearings on page 4-8, Grease Bear-
ings on page 4-14, and/or Oil Drive
Chain and Tension Springs on page
4-14.
• Replace any bearing that does not

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

Tension Adjustment on page 7-23.
3. Sprockets are loose, worn, • Inspect the sprockets and the drive
or misaligned, or the drive chain. Repair/replace as necessary.
Noisy Operation chain has excessive play.
4. Howling and whistling occur • Clean the burner tips. Refer to Burner
when the burner is on. Tip Maintenance on page 7-32.
5. Burner tail pipe clearance is • Check the burner tail pipe clearance
insufficient. inside hollow drive shaft of ironing
cylinder. Reposition tail pipe holder, if
necessary.
6. Inverter frequency setting is • Adjust frequency. For more information,

causing noisy motor opera- contact the factory Service Department.
tion.
7. Drive train system error. • Refer to Drive System Mechanical or

Electrical Error on page 6-8.
1. Ribbon tension needs to be • Adjust/Replace. Refer to REPAIR and

adjusted. the appropriate section for the specific
procedure.
Ribbons Do Not Track Straight 2. Ribbons are broken or • Replace. Refer to REPAIR and the ap-
missing. propriate section for specific procedure.
3. Roll friction material is • Replace. Refer to REPAIR and the ap-

worn smooth. propriate section for specific procedure.
6-6 TOC INDEX

WARNING WARNING

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 friction material is worn • Adjust/Replace. Refer to REPAIR and
smooth. the appropriate section for the specific
procedure.
3. Refer to the Rotating Elements Stop issue next.
1. Drive chain is slipping or • Adjust tension or replace if broken.

broken.
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.
TOC INDEX 6-7

WARNING WARNING

NOTE: Several drive trains are used on the machine. They share common features and can be diagnosed us-
ing 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 Drive Chain

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

or motor thermal overload for one minute.
Drive System Mechanical or has tripped.
Electrical Error -- 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.
6-8 TOC INDEX

WARNING WARNING
6.3 Ironing Quality

1. Unit is not properly waxed • Refer to Waxing on page 3-7.
(Does not apply to chrome
ironing cylinders).
2. Feeding technique is im- • Refer to Flatwork Handling on page

proper. 3-9.
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 • Adjust. Refer to Compression Roll

inadequate or uneven. Pressure Check on page 7-17 and/or
Flatwork Feeds Poorly into
Compression Roll Pressure Adjust-
Ironing Section
ment on page 7-18.
5. Compression roll pad is • Replace. Refer to Compression Roll

worn. Cover Replacement on page 7-19.
6. Return ribbon tension out of • Adjust Refer to Return Ribbon Tension

adjustment. Spring Replacement 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 7-13.
1. Feeding technique is im- • Refer to Flatwork Handling on page

proper. 3-9.
2. Return ribbon drive roll • Replace. Refer to Return Ribbon Drive

cover material is worn Roll Friction Material Replacement on
smooth. page 7-40.
Flatwork Jams or Sticks to 3. Return ribbons are worn • Replace. Refer to Return Ribbon Re-
Ironing Cylinder; Poor Ironing smooth. placement on page 7-38.
Quality
4. Ironing cylinder has a • Check for buildup of chemicals or debris
buildup of chemicals or which discolor the ironing cylinder. For
debris. cleaning instructions, refer to Ironing
Cylinder Reconditioning on page 7-24.
5. For additional possible causes and solutions, refer to Flatwork Feeds

Poorly into Ironing Section on page 6-9.
TOC INDEX 6-9

WARNING WARNING

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 3-12.
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 3-15.
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.
3. Flatwork run through • Increase final flatwork temperature

washer/extractor with cold from extractor. Refer to Condition-
Flatwork Does Not Dry Cor-
water will have less mois- ing Flatwork Before Ironing on page
rectly
ture extracted. 3-12.
4. Extractor is not removing • To review the extraction process, refer to

enough moisture. Conditioning Flatwork Before Ironing
on page 3-12.
5. TEMPERATURE control is • Replace the TEMPERATURE control.

not working properly. Refer to Temperature Control or High
Temperature Limit Control Replace-
ment on page 7-34.
6-10 TOC INDEX

WARNING WARNING

1. Feeding technique is im- • Use correct feeding techniques. Refer to
proper. Flatwork Handling on page 3-9.
2. Ironing section controls are • Check the TEMPERATURE Control and

incorrectly set for the linen the setting of SPEED knob. Refer to
being processed. Processing Standards on page 3-15
3. Ironing cylinder is not being • Refer to Waxing on page 3-7.

waxed at least once a day
(Does not apply to chrome
ironing cylinders).
4. Return ribbon drive roll • Replace. Refer to Return Ribbon Drive

Poor Flatwork Finish friction material is worn Roll Friction Material Replacement on
smooth. page 7-40.
5. Return ribbons are exces- • Replace. Refer to Return Ribbon Re-

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

is not even from side to Pressure Check on page 7-17 and/or
side. Compression Roll Pressure Adjust-
ment on page 7-18.
7. Compression roll padding • Replace. Refer to Compression Roll

is worn. Cover Replacement on page 7-19.
Flatwork Sticks to Return Rib- 1. Chrome ironing cylinder • Refer to Waxing on page 3-7.
bons/Exits Ironer with Exces- needs waxing.
sive Static
TOC INDEX 6-11

WARNING WARNING
6.4 Heating System
PILOT IGNITION
1. Switch may have a loose • Inspect/replace the TEMPERATURE
TEMPERATURE Control Indi-
connection or is bad. control.
cator Lamp Does Not Come
On When Dial is Turned to ON
2. Indicator lamp may be bad. • Inspect/replace the lamp.
1. Pilot burner assembly is • Clean. Refer to Check and Clean Pilot

dirty. Assembly on page 4-18.
2. Line voltage to the unit and/ • Line voltage to the unit must be within
or to the ignition control +5% to -10% of the voltage on the
may be too low. nameplate.
• Voltage to the ignition control may be

too low. Check the voltage at terminal It
must be within +5% to -10% of 24 V.
-- Check for fluctuating or incorrect in-
Pilot Ignition Irregular or
coming voltage. Check power require-
Absent
ments on the unit nameplate.
3. Ignition electrode wire is • Check. Refer to Check and Clean Pilot

loose or broken or gap is Assembly on page 4-18.
incorrect.
4. Ignition control is not send- • Check/replace ignition control as neces-

ing a proper spark signal. sary.
5. Pilot gas orifice is dirty. • Clean. Refer to Check and Clean Pilot
Assembly on page 4-18.
6-12 TOC INDEX

WARNING WARNING
BURNER IGNITION
1. External and/or internal • Open the manual gas valves.
manual gas valves are
closed or partially closed.
Flame Does Not Travel Down
the Entire Length of the 2. Gas pressure is wrong. • Refer to the Gas Flow: Poor, Irregular,
Burner None issue below.
3. Burner tips are clogged. • Clean. Refer to Burner Tip Mainte-

nance on page 7-32.
1. External and/or internal • Make sure the external and internal

manual gas valves are manual gas valves are open before
closed. starting the burner.
2. Incoming gas pressure is • Check the incoming gas pressure during

too high or too low due to periods of peak demand and adjust, if
an incorrect gas supply or necessary. Refer to Gas Connection
other gas-burning equip- Checkout on page 2-20.
ment in the area.
3. Gas valve coil or ignition • Check the voltage at the gas valve coil
control is bad. when the burner system calls for heat.
Gas Flow: Poor, Irregular,
None -- If 24 VAC is present but the valve
doesn’t open, the gas valve is bad and
must be replaced.
-- If the voltage is well below 24 VAC,
check the line voltage to the unit.
-- If there is no voltage at all, the ignition
control may need to be replaced.
4. On-site gas demand is • Check the incoming gas pressure during

irregular due to other equip- periods of peak demand and adjust, if
ment. necessary. Refer to Gas Connection
Checkout on page 2-20.
1. Gas flow to the burner is • Refer to the Gas Flow: Poor, Irregular,
insufficient. None issue above.
2. Exhaust system backflow • Check/clean exhaust system as neces-

has caused sail switch to sary. For cleaning instructions, refer
close. to Check and Clean Sail Switch and
Burner Starts Normally, Then Exhaust Blower Wheel on page 4-11.
Shuts Down
• Check/replace defective sail switch.
3. If no other problems are • Check. Replace, if necessary.

found and the burner will
not stay lit, the ignition
control is bad.
TOC INDEX 6-13

WARNING WARNING
BURNER OPERATION
1. High temperature limit con- • Allow ironing cylinder to cool down and
trol has tripped. then manually reset high limit control.
2. Ignition electrode wire is • Refer to Pilot Ignition Irregular or

loose or broken or gap is Absent on page 6-12.
incorrect.
3. Pilot assembly is operating • Refer to Pilot Ignition Irregular or

incorrectly. Absent on page 6-12.
Ironing Cylinder Heats to SET
Temperature, but Will Not 4. Exhaust sail switch does • Check for lint build up on the sail switch.
Ignite a Second Time not have enough air to Refer to Check and Clean Sail Switch
operate. and Exhaust Blower Wheel on page
4-11.
• With the unit running, check the circuit

for the sail switch by testing for 120 V
between terminals 5, 6 and GND in the
main electrical box. If 120 V is not pres-
ent, the sail switch is bad and must be
replaced.
1. Operators are not using • Refer to Flatwork Handling on page

the full length of the ironing 3-9.
cylinder. This causes the
cylinder ends to heat up
and temperature to fluctu-
ate up and down.
2. TEMPERATURE Control is • Replace the TEMPERATURE control.

not working properly. Refer to Temperature Control or High
Temperature Limit Control Replace-
TEMPERATURE Control Er- ment on page 7-34.
ratic or Does Not Work
3. One or both of the tempera- • Inspect the temperature sensor contact
ture sensor contact shoes shoes under the feed ribbons at the front
are operating incorrectly. of the ironing cylinder.
• Refer to Check and Clean Tempera-

ture Sensor Contact Shoes on page
4-4.
• Refer to Temperature Sensor Contact

Shoe Replacement on page 7-33.
6-14 TOC INDEX

WARNING WARNING
BURNER OPERATION
1. Dirty temperature contact • Check/clean as necessary. Refer to
shoe. Check and Clean Temperature Sensor
Contact Shoes on page 4-4
2. Temperature contact shoe • Check/correct alignment.

Temperature Sensor Not
not resting squarely on
Working Correctly
cylinder.
3. Temperature contact shoe • Replace. Refer to Temperature Sensor

is worn. Contact Shoe Replacement on page
7-33.
1. Burner tips are clogged or a • Refer to Burner Tip Maintenance on

burner tip has come out. page 7-32.
2. Gas supply to the burner is • Check the gas pressure when the main
too low when the main gas valve opens. Refer to Gas Connection
valve opens. Checkout on page 2-20.
3. Burner gas valve is leaking. • Inspect the burner gas valve and tighten
Flames Coming From Ends of
or replace, if necessary.
Ironing Cylinder
• Refer to Flame Does Not Travel Down
4. Flames come out briefly
the Entire Length of the Burner on
during ignition.
page 6-13.
5. If the flames come out for

• Refer to Gas Connection Checkout on
a longer period of time, the
page 2-20
gas pressure is wrong.
Excessive Wear on Tempera- 1. Chrome ironing cylinder • Refer to Waxing on page 3-7.
ture Sensor Contact Shoes needs waxing.
TOC INDEX 6-15

WARNING WARNING
6.5 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
4-11.
3. Exhaust blower sail switch • Check for lint build up on the sail switch
and/or wheel is dirty. and exhaust blower wheel. Refer to
Check and Clean Sail Switch and Ex-
haust Blower Wheel on page 4-11.
4. Sail switch is operating • With the unit running, check the circuit
incorrectly. for the sail switch by testing for 24 V
between terminal 11 and GND in the
Exhaust Poor or None main electrical panel. If 24 V is not pres-
ent, the sail switch is bad and must be
replaced.
5. Wire connections for the • Check the wire connections from the
exhaust blower motor are exhaust blower to the main electri-
loose or disconnected. cal panel. Refer to Sail Switch and
Exhaust Blower Motor Connection on
page 2-8.
6. 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.
7. Exhaust duct work in the • Clean out the exhaust duct work.
canopy is dirty or blocked.
6-16 TOC INDEX

Comet Executive Gas Repair
Chapter 7
REPAIR
Although designed for long service life, some individual consumable parts of the Comet Executive™
Gas eventually wear during normal use and must be cleaned, adjusted, or replaced. This chapter includes
the following sections:
7.1 Safety Considerations 7.5

Ironing Section
7.2 Parts Availability 7.6

Burner System
7.3 Feed Section 7.7

Return Section
7.4 Compression Roll
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.
• Clean the ironing cylinder when deposits or debris affect the finish of processed flatwork.
• Follow the 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 Comet Executive Gas
• Only work on the unit when it has been

7.1 Safety Considerations completely cooled down. For more
Before attempting any repair work, review information, refer to Shut-Down on
these safety steps and precautions to protect page 3-11.
yourself and the unit. • Make sure the TEMPERATURE control
• Safety should be the primary concern of dial is set to OFF.
anyone performing repair work on the • All maintenance procedures should
unit. be handled by at least two qualified
• Except where specifically directed, make persons. Using the “buddy system”
sure the power is turned OFF at the main facilitates a quicker procedure and
disconnect switch. decreases the risk of an accident.
• Always keep hands and clothing away
WARNING from the moving parts of the machine
Always use extreme caution when it must be running to make repairs
when performing any repair or adjustments.
procedure requiring the unit • Never bypass any of the unit’s safety
to be operating. features. Only operate the unit with
endframe doors and all guards in
Take every precaution place and all safety features operating
to keep hands and loose correctly.
clothing from coming into • Never stand, sit, or kneel on a receiving
contact with any of the shelf.
moving rolls or
• Your site should have lockout/tagout
other moving parts.
procedures in place that comply with
government standards for performing
maintenance and repair. Ask your
Whenever the unit is running, supervisor for specific information.
one person should be ready
at a red safety STOP button • The JOG REVERSE button remains
at all times to stop the unit powered even when one of the safety
interlock switches is open. This keeps it
if necessary.
available for emergency use. It is very
important that the unit is properly tagged
according 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
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

7.3 Feed Section

Flatwork is directed into the unit through the
feed section, which consists of the following
components (Figure 7-1):
• Feed Table (A)

• Feed Ribbon Drive Roll (B) D
A
• Feed Ribbons (C)
• Guide Tapes (D) B
Various of these components require periodic
adjustment, replacement, or occasional repair. C
These procedures include:
• Feed Ribbon Tension Adjustment
• Feed Ribbon Replacement
Figure 7-1: Feed section components.
• Feed Ribbon Drive Roll Friction
Material Replacement
• Guide Tape Replacement
• Feed Table Alignment and Positioning
7-4 TOC INDEX

Feed Ribbon Tension Adjustment 8. Run the unit briefly and make sure the rib-
bons track straight and do not rub on the
Adjust the tension of the feed ribbons when ribbon guides under the feed table.
they sag or track to one side of the ironing section.
Both conditions cause excessive wear on the 9. If tension on the ribbons is uneven, ribbons
ribbons and shorten their life. track toward the end of the drive roll where
the tension is highest.
Required Tools 10. Stop the unit and turn power OFF at the
Wrenches: main disconnect switch.
3/8”
9/16” 11. Either turn the adjusting bolt counter-
clockwise at the high tension end, or turn
Perform only when the unit is OFF the adjusting bolt clockwise at the low
with power disconnected and COOL. tension end.
1. Turn power OFF at the main disconnect 12. Repeat Steps 6 to 11 until the ribbons have
switch. the correct tension and track evenly.
2. Open both endframe doors. 13. Stop the unit and turn power OFF at the
3. Locate the feed ribbons drive roll tension
adjustment bolts (Figure 7-2, A). There is 14. While holding each adjustment bolt in
one on each side of the machine. place, secure its locknut.
4. While holding each adjustment bolt in 15. Close and secure both endframe doors.
place, loosen its locknut (Figure 7-2, B).
WARNING
CAUTION Never operate the unit unless
Do not over tension the all safety covers are in place
ribbons. Too much tension and all safety equipment is
can cause excessive motor working correctly.
amperage and premature
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 B
1/4” to 1/2” (6 to 13 mm).

switch.
7. Turn the SPEED knob to the slowest

speed.
A
Figure 7-2: Feed ribbon tension adjustment in the

left endframe.
TOC INDEX 7-5

Feed Ribbon Replacement 5. While holding each adjustment bolt in

place, loosen its locknut (Figure 7-2, B).
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.
NOTE: Read the FEED RIBBON WARNING

REPLACEMENT section on the Never start the unit while
Pink Operator Safety Reminder installing the feed ribbons.
in the front of this manual. It is dangerous
and unnecessary.
Replacing Worn Ribbons 7. Pull the worn ribbons around their tracks
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 front of the unit.
Required Tools NOTE: Make sure the rough

Pliers side of the ribbon faces down.
Wrenches:
3/8”
9/16” 8. Remove the connecting pin from an old
ribbon and attach a new ribbon to one end,
Perform only when the unit is OFF rough side down.
9. Pull the old ribbon through until the new
ribbon is in place.
1. Verify the replacement ribbons are the
correct size and there is sufficient quantity 10. Disconnect the old ribbon and connect the
to complete the procedure. See Rolls and ends of the new ribbon with a new pin.
Ribbons on page PL-6.
11. Repeat Steps 8 to 10 to replace additional
2. Turn power OFF at the main disconnect worn ribbons. Stagger the positions of the
switch. lacing clips to give the flatwork a smooth
flow.
12. Adjust ribbon tension; refer to Feed Rib-
bon Tension Adjustment on page 7-5.
adjustment bolts (Figure 7-2, A). There is
one on each side of the machine.
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.
Wrenches:
3/8”
9/16” 8. Position a replacement feed ribbon, rough
side down, on the feed table. Push the
Perform only when the unit is OFF ribbon under the red safety finger guard.
9. Using a long-shafted screwdriver or
1. Verify the replacement ribbons are the similar tool, push the leading edge of the
correct size and sufficient quantity for ribbon down the back edge of the feed
completing the procedure. See Rolls and table. Be careful not to scratch the ironing
Ribbons on page PL-6. cylinder.
2. Turn power OFF at the main disconnect 10. Reach under the feed table and pull the
switch. end of the ribbon toward the front of the
unit. Make sure the ribbon end is below the
3. Open both endframe doors. rod and between the feed ribbon guides.
Verify that the replacement ribbon follows
4. Locate the feed ribbons drive roll tension the path of the other ribbons.
one on each side of the machine. 11. Bring the ends of the ribbon together and
connect the ends with a new pin.
5. While holding each adjustment bolt in
place, loosen its locknut (Figure 7-2, B). 12. Repeat Steps 8 to 11 to replace additional
missing ribbons. Stagger the positions
6. Turn each bolt the same number of turns of the lacing clips to give the flatwork a
counterclockwise until the ribbons are smooth flow.
easily moved by hand.
7. Remove a ribbon from each end of the NOTE: If the remaining ribbons
unit and use one or both as replacement are being replaced, refer to
ribbons. These end ribbons can then be Replacing Worn Ribbons on
replaced by a pair of new ribbons. page 7-6.

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
one on each side of the machine.
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. Pull the feed ribbons around their tracks
is preferable to use three workers, until all the lacing clips are accessible and
each performing a single task. aligned at the front of the unit.
8. Remove all the connecting pins from the

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

1. Verify the correct replacement parts are

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

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

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

per, or another temporary protective cover- WARNING
ing over the ironing cylinder, compression Make sure there is adequate
roll, return ribbons, and receiving shelf. ventilation and wear
protective clothing before
11. Cut and remove the filament tape located
working with any solvent.
at each end of the drive roll.
Follow manufacturer’s
12. Pull or cut off the old feed ribbon drive directions for safe usage.
roll friction material.
13. Remove old cement from the drive roll 15. Wipe the entire surface of the compression
with a scraper, coarse sandpaper, or a roll with a solvent (low VOC). Make sure
steel brush. the roll’s surface is down to bare metal,
and that it is completely clean and dry.
14. Wipe away remaining residue with a clean
cloth.
CAUTION
You must be down to bare
metal before installing the
new cover or it may not
adhere properly.
NOTE: Spiral-wind the friction

material at a 45° angle (Figure 7-4,
Sprial Wound
A). To ensure this, the material
Friction Material (A)
edges must be aligned with no
gaps.
Filament Tape (B)
Figure 7-4: Friction material is secured with glass 16. Spiral wind the new cover over the roll
filament tape. without cement to make sure there is
enough material to cover the roll. Put it on
in the same spiral pattern as before.
17. Starting from the drive side of the ma-

chine, dry fit two or three full turns of the
material to establish the correct angle.
Make sure the material edges align with
no gaps. Secure with masking tape.
18. Use a paint brush to apply an even coat of

cement over a short section of the exposed
roll (about two turns worth), making sure
the entire surface is covered (Figure 7-5).
19. Carefully continue to turn the roll, making

sure the material goes on smoothly without
Figure 7-5: Apply an even coat of cement. any gaps.
TOC INDEX 7-9

20. Continue working down the length of the Guide Tape Replacement
roll applying the friction material quickly
after the cement is spread. The guide tapes (Figure 7-6) keep flatwork
from sticking to and wrapping around the
21. After the roll is covered, wrap the other compression roll. These tapes wear through at the
end of the roll with masking tape. staples or break over time, requiring replacement.
22. Go back to the drive side of the roll, remove
the masking tape and carefully unwind the NOTE: Replace any missing or
un-cemented portion of the material. broken guide tapes immediately.
23. Using the same technique, apply the ce-
ment and carefully rewind the material
onto the roll. Required Tools
24. Secure the end with masking tape. Masking tape
Stapler/staples
NOTE: If any cement gets onto Utility knife
the friction material surface, use a Wrenches: 9/16” (2)
piece of masking tape to lift if off.
RUNNING and COOL.
25. Wait about 10 minutes for the glue to hard- Use Extreme Caution.
en; then, trim the ends of the friction mate-
rial so it is even with the edges of the roll. 1. Make sure sufficient replacement guide
tape is available.
26. Carefully remove the masking tape.
27. Secure the friction material at each end of switch.
the drive roll with several wraps of glass
filament tape. Tape from the top while 3. Open both endframe doors.
turning the roll in its normal rotational
direction (Figure 7-4, B).
28. Remove the temporary protective covering

and clean up the area.
29. Reinstall the drive chain on its sprocket

and adjust its tension; refer to Drive Chain
30. Refasten the feed ribbons. Make sure the

ribbon end is below the rod and between
the feed ribbon guides. Stagger the posi-
tions of the lacing clips to give the flatwork
a smooth flow.
31. Allow the cement to harden for about 2

hours before operating the unit.
32. After the cement hardens, adjust ribbon

tension; refer to Feed Ribbon Tension Figure 7-6: Guide tapes help keep flatwork from
wrapping around the compression roll.
Adjustment on page 7-5.
7-10 TOC INDEX

CAUTION
Loosen just the bottom
locknut of compression roll
adjustment, this will ensure
you tighten to the same
pressure when finished.
4. Release tension from the compression roll

by loosening the bottom adjustment lock-
nuts of the tension spring in each endframe
all the way (Figure 7-7). Figure 7-7: Release tension on the compression
roll by loosening the bottom nut.
5. Remove the red safety finger guard:
a) Note the positioning of the spacers and/

or washers at the front left and right of
the guard.
b) In the each endframe, remove the finger

guard mounting bolt (Figure 7-8).
c) Carefully remove the guard. Make

sure to keep track of all spacers and
washers.
WARNING
Never start the unit while Figure 7-8: Red safety finger guard mounting bolt.
installing the guide tapes.
It is dangerous
Roll Pins
and unnecessary. Tie Rod
Guide Tape
Safety Guide
6. Cut a 26” (660 mm) length of guide tape Finger Tape Bar
Bar
for each guide tape to be installed.
7. Install the guide tapes following this path

(Figure 7-9): Compression
Roll
a) Over the front tie rod, between a pair Ironing
of roll pins to the guide tape bar. Cylinder
b) Around guide tape bar to the compres-

sion roll.
FRONT
c) Under the compression roll. BACK
d) Back up to the starting point. View From Right End Frame
Figure 7-9: Guide tape path.
TOC INDEX 7-11

CAUTION
The trailing edge of each
guide tape must be on top or
the tape edge can be caught
on the feed ribbons, causing
it to break.
8. Align and overlap the ends of the guide

tape 5 to 6” (120 to 150 mm). Be sure Trailing end
the trailing edge of the guide tape is on overlaps by 5-6”
top and the leading edge is on the bottom (125-150 mm)
(Figure 7-9).
9. Staple the ends together, placing a staple

near each end of the tape with one to three Staples
additional staples spaced evenly between
(Figure 7-10).
10. Repeat Steps 7 to 9 for the remaining

guide tapes.
11. Replace red safety finger guard by revers-

ing Step 5.
Figure 7-10: The trailing edge of the guide tape
12. Re-tension the compression roll by tight- must be on top, and the leading edge
ening the bottom adjustment locknuts. must be on the bottom.
WARNING
working correctly.
7-12 TOC INDEX

Feed Table Alignment and 2. Open both endframe doors.

Positioning
The feed table (Figure 7-1, A) is an important adjustment bolts (Figure 7-2, A). There is
component in the feed section and must be one on each side of the machine.
properly aligned and positioned.
If the feed table becomes bowed out of shape, place, loosen its locknut (Figure 7-2, B).
or is positioned too far from the ironing cylinder,
flatwork may not feed properly into the ironing 5. Turn each bolt the same number of turns
section. counterclockwise until the ribbons are
56” and 66” Machines 6. Pull the feed ribbons around their tracks
until all the lacing clips are accessible and
Required Tools aligned at the front of the unit.
Bar stock: 1/4” 7. Remove all the connecting pins from the
Wrenches: 9/16” (2)
feed ribbons. Position the feed ribbons
away from the drive roll.
with power disconnected and COOL. 8. Use a small piece of 1/4” bar stock to
check the spacing between the feed table
A feed table that is in poor alignment is usually and ironing cylinder at each end. There
due to heavy items being set on it, or people should be a snug fit.
standing on it, which may cause flatwork to feed
improperly. 9. If the feed table is:
When properly aligned and positioned, the a) Not properly positioned, go to the next
leading edge should be 1/4” (6 mm) from the step.
ironing cylinder (Figure 7-11, A).
b) Properly positioned, go to Step 14.
switch. 10. Starting at either end of the unit, loosen the
bolts in the slotted holes on the underside
of the feed table (Figure 7-11, B).
IRONING CYLINDER
1/4" (6mm) Gap (A) 1/4" (6mm) Gap (A)
FEED TABLE
Position Adjustment Bolts (B) Position Adjustment Bolts (B)

Figure 7-11: Proper positioning of the feed table is important for the flatwork to feed properly into the ironing
section.
TOC INDEX 7-13

11. Position the table 1/4” (6 mm) from the 80” Machines
ironing cylinder. Tighten the bolts to se-
cure the table in that position. Checking Alignment and Positioning
12. Repeat Steps 10 and 11 at the other end Improper handling of the unit during shipping
of the unit. can cause too much tension on the feed table,
making it bow upward excessively.
13. Make sure the spacing at each end of the
unit is 1/4” (6 mm) and the bolts in the A feed table that is in poor alignment is usually
slotted holes are securely tightened. due to heavy items being set on it, or people
standing on it.
14. Refasten the feed ribbons. Make sure the
ribbons are below the rod, and also below Over time, normal daily use also causes the
and between the feed ribbon guides. Stag- table to sag slightly. Any of these conditions may
ger the positions of the lacing clips to give cause flatwork to feed improperly.
the flatwork a smooth flow.
When properly aligned and positioned, the
15. Adjust ribbon tension; refer to Feed Rib- feed table will bow slightly upward in the middle.
bon Tension Adjustment on page 7-5. The leading edge should be 1/4” (6 mm) from the
ironing cylinder at either end and 3/8” (9 mm)
from the ironing cylinder in the middle (Figure
7-12).
IRONING CYLINDER
1/4" (6 mm) GAP 1/4" (6 mm) GAP

3/8" (9 mm) GAP
FEED TABLE
BOTTOM VIEW
Figure 7-12: Proper positioning of the feed table is important for the flatwork to feed properly into the ironing
section.
7-14 TOC INDEX

9. If the feed table is:

Required Tools
Bar stock: a) Not properly positioned, perform the
1/4” Adjusting Alignment and Position-
3/8” ing procedure next.
Perform only when the unit is OFF b) Properly positioned:

•
• Reconnect the feed ribbons. Make
1. Turn power OFF at the main disconnect sure the ribbons are below the ten-
switch. sion adjustment rod, and also below
and between the feed ribbon guides.
• Stagger the positions of the lacing
3. Locate the feed ribbons drive roll tension clips to give flatwork a smooth flow.
one on each side of the machine. • Perform Feed Ribbon Tension
place, loosen its locknut (Figure 7-2, B). Adjusting Alignment and Positioning
5. Turn each bolt the same number of turns

Required Tools
counterclockwise until the ribbons are
Bar stock:
1/4”
6. Pull the feed ribbons around their tracks 3/8”
Wrenches:
until all the lacing clips are accessible and
7/16” (2)
aligned at the front of the unit. 9/16” (2)
7. Remove all the connecting pins from the
feed ribbons. Position the feed ribbons Perform only when the unit is OFF
away from the drive roll. with power disconnected and COOL.
8. Use a small piece of 1/4” bar stock to 1. Starting at either end of the unit, loosen the
check the spacing between the feed table bolts in the slotted holes on the underside
and ironing cylinder at each end. There of the feed table (Figure 7-13, A).
should be a snug fit. Use a small piece of
3/8” bar stock to check the spacing at the 2. Position the table 1/4” (6 mm) from the
center of the unit. ironing cylinder. Tighten the bolts to se-
cure the table in that position.
FEED TABLE
Position Adjustment Bolts (A)
Tension Adjustment Rod (B)
Figure 7-13: The slotted holes and threaded adjusting rod are used to properly align and position the feed table.
TOC INDEX 7-15

3. Repeat Steps 1 and 2 at the other end of

the unit. 7.4 Compression Roll
The compression roll (Figure 7-14) improves
4. Make sure the spacing at each end of the
flatwork finish. Some of compression roll
unit is 1/4” (6 mm) and the bolts in the
components require periodic adjustment,
slotted holes are securely tightened.
replacement or occasional repair.
5. Check the spacing between the feed table
and the ironing cylinder at the center of the
unit. The correct spacing is 3/8”. • Compression Roll Pressure Check
• If the spacing is less than 3/8” • Compression Roll Pressure Adjustment

(9 mm), tighten the nuts equally on • Compression Roll Cover Replacement
each side of the tension adjustment
rod (Figure 7-13, B) until the middle
of the feed table is 3/8” from the iron-
ing cylinder.
• If the spacing is more than 3/8”

(9 mm), loosen the nuts equally on each
side of the tension adjustment rod (Fig-
ure 7-13, B) until the middle of the feed
table is 3/8” from the ironing cylinder.
6. Reconnect the feed ribbons. Make sure the

ribbons are below the tension adjustment
rod, and also below and between the feed
ribbon guides.
7. Stagger the positions of the lacing clips to

give flatwork a smooth flow.

Figure 7-14: The compression roll helps to move the
flatwork into the ironing section.
7-16 TOC INDEX

Compression Roll Pressure Check switch.
When flatwork does not feed smoothly into the 4. Press the green START button. Turn the
ironing section, the pressure of the compression SPEED knob to the slowest speed.
roll may need to be adjusted.
5. Feed the piece of paper under the com-
It is important that there is sufficient pressure pression roll (Figure 7-14) on the left side
and that pressure is even from side to side. Too about one-quarter of the distance from the
little pressure will cause poor ironing quality; too endframe. Immediately pull back gently
much pressure will cause premature wear of the on the paper.
compression roll covers and padding.
6. You should feel the compression roll
pulling the paper into the ironing section,
WARNING but be able to pull back the paper without
Specific procedures that tearing it. If there is uneven or no pres-
require the unit to be running sure placed on the paper, or if the paper
should be done with extreme tears, the compression roll pressure must
caution and attention be adjusted.
to detail. 7. Repeat Steps 5 and 6 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
middle may indicate too much
pressure at the ends.
RUNNING and COOL.
8. If pressure is uneven or nonexistent on the
paper, compression roll pressure must be
1. Make sure the unit is completely cool. For
adjusted; refer to Compression Roll Pres-
more information, refer to Shut-Down on
sure Adjustment on page 7-18.
page 3-11.
2. Cut a piece of brown packing paper ap-

proximately 9” wide and 4’ long (230 mm
x 1200 mm).
TOC INDEX 7-17

Compression Roll Pressure

Adjustment
Required Tools
Wrenches: 9/16” (2)
A

switch. C
B
3. Locate the adjustable springs attached to

their bracket slots each endframe (Figure Figure 7-15: A compression roll tensioning spring is
7-15, A). located in each endframe.
4. Loosen the locknut (Figure 7-15, B).
5. Turn the adjustment nut (Figure 7-15, C)

clockwise to increase the tension; coun-
terclockwise to decrease.
6. Tighten the locknut once the adjustment

has been made.
WARNING
working correctly.
8. Perform Compression Roll Pressure

Check on page 7-17.
9. Make further adjustments as necessary.
7-18 TOC INDEX

Compression Roll Cover Required Tools

Replacement Clean cloth
The cover on the compression roll must Gloves
Measuring tape
be replaced when the cover material is worn
Pen/pencil/marker
smooth or if flatwork does not move easily into Protective covering
the ironing section. Be sure the compression roll Protective covering
pressure has been adjusted correctly first. Ruler/straight edge
Scraper/sandpaper/steel brush
Solvent (low VOC)
NOTE: Read the REPLACING Utility knife/scissors
COMPRESSION ROLL PADS Wooden wedges
AND COVERS section on the Wrenches: 9/16” (2)
Pink Operator Safety Reminder
in the front of this manual. Perform only when the unit is OFF
with power disconnected.
1. Make sure the unit is completely cool. For

WARNING more information, refer to Shut-Down on
Do not attempt to replace page 3-11.
the compression roll
covers without experienced 2. Verify the replacement cover is the cor-
personnel. This procedure rect size. See Rolls and Ribbons on page
requires skill. PL-6.

switch.
NOTE: Take the time to read
through and understand the entire
procedure before replacing the 5. Release tension from the compression roll
compression roll cover. by loosening the bottom adjustment lock-
nuts of the tension spring in each endframe
all the way (Figure 7-16, A).
6. Remove the red safety finger guard:
a) Note the positioning of the spacers and/

or washers at the front left and right of
the guard.
B
b) In each endframe, remove the finger
guard mounting bolt (Figure 7-16, B).
c) Carefully remove the guard. Make

sure to keep track of all spacers and
A washers.
Figure 7-16: Release tension on the compression

roll by loosening the bottom nut.
TOC INDEX 7-19

7. Make sure the compression roll can be

turned by hand with some ease; wedges WARNING
may be useful to lift the roll. Make sure there is adequate
ventilation and wear
8. Place a tarp, plastic drop cloth, heavy protective clothing before
paper, or another temporary protective
working with any solvent.
covering over the feed ribbons, ironing
Follow manufacturer’s
cylinder, and return ribbons.
directions for safe usage.
9. Working at the front of the unit, remove
the old compression roll cover by loosen-
ing the corner at the right end of the ma- 12. Wipe the entire surface of the compression
chine and pulling the old cover off. roll with a solvent (low VOC). Make sure
the roll’s surface is down to bare metal,
10. Remove old cement/debris from the and that it is completely clean and dry.
compression roll with a scraper, coarse
sandpaper, or a steel brush.
CAUTION
11. Wipe away remaining residue with a clean You must be down to bare
cloth. metal (Figure 7-17) before
installing the new cover or it
will not adhere properly.
Figure 7-17: It is necessary to be at completely bare

metal before installing the new cover.
7-20 TOC INDEX

13. Remove the protective covering and clean

up the work area as necessary.
14. Prepare the new cover material for instal-

lation:
a) Place the cover material on a work

table and roll out a short section. The
end should be to your right.
b) Measure in 11” from the end and make

a mark on the bottom edge (Figure
7-18).
Figure 7-18: Make sure to trim to the specified
c) Use a straight edge to draw a line from
length.
the upper right corner to the mark
(Figure 7-19).
d) Use a sharp utility knife or strong scis-

sors to cut along the line (Figure 7-20).
15. Remove the backing from the trimmed

section plus a small additional length.
NOTE: When installing the

spiral-wind cover, the material
edges must be aligned with no
gaps.
Figure 7-20: Make sure to trim from the bottom to

16. Starting from the left side of the machine, the upper right corner.
carefully begin to spiral wind the cover
material onto the compression roll.
• Carefully align the trimmed edge with

the end of the roll.
• Turn the roll with its normal rotational

direction as you apply the material.
The spiral will “lean” toward the right.
• Make sure it goes on smoothly, and

completely covers the entire surface
of the roll with no gaps.
Figure 7-19: Use a straight edge to mark the line

for cutting.
TOC INDEX 7-21

17. When the entire roll is covered, trim the 19. Close and secure both endframe doors.
right end so that the cover material is even
with the edges of the roll (Figure 7-21).
WARNING
NOTE: The new padding will be all safety covers are in place
much thicker. It may be advisable and all safety equipment is
to follow the appropriate steps working correctly.
of Compression Roll Pressure
Adjustment on page 7-18
to accommodate this before 20. Turn power ON at the main disconnect
proceeding. switch.
21. Start the unit and test the red safety finger
18. Re-install the red safety finger guard by guard to make sure the unit comes to a
reversing Step 6. Make sure the spacers complete stop when the red safety finger
and washers are correctly positioned. guard is pushed.
22. Stop the unit.

switch.
24. Check and adjust compression roll pres-

sure following Compression Roll Pres-
sure Check on page 7-17 and Compres-
sion Roll Pressure Adjustment on page
7-18.
25. The ironing cylinder must be waxed before

resuming operation. For more information,
Refer to Waxing on page 3-7. Note this
step is not necessary for chrome ironing
Figure 7-21: Trim the material even with the end of cylinders.
the roll.
7-22 TOC INDEX

Drive Chain Tension Adjustment

7.5 Ironing Section
The drive chain in the right endframe powers
The following procedures should be used
the feed ribbon and return ribbon drive rolls as
to keep the ironing cylinder and other ironing
well as the ironing cylinder. The chain has an
section components operating properly:
adjustable tensioning arm.
• Drive Chain Tension Adjustment
Over time, the drive chain may stretch
• Ironing Cylinder Reconditioning slightly from the effects of heat and stress. If the
• Ironing Cylinder Hardened Ring unit becomes excessively noisy, or if the drive
Replacement mechanisms work unevenly because of chain
slippage, it will be necessary to adjust the tension
on the chain.
Required Tools
Wrenches:
11/16”
1-3/8” or Crescent


B switch.
2. Open the right endframe door.
3. Check the drive chain (Figure 7-22, A)

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 7-22, B).
When tension on the chain becomes loose,
Tension Idler Arm adjust the idler arm tensioner.
NOTE: A stretched chain that

Mounting Bolt 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

7-22, C) on the inside of the endframe.
6. Loosen the idler arm mounting bolt just

Endframe
enough to allow turning of the idler arm
base with a crescent wrench.
Figure 7-22: The drive chain is adjusted using the
tensioning idler arm.
TOC INDEX 7-23

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 7-22, 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
chrome surface will
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.
7-24 TOC INDEX

7. Remove the ribbon connecting pins.

Required Tools
Remove the ribbons from the idler rolls
on top and let the ribbons hang from the
Belt sander
Clean cloth
guide assembly onto the protective floor
Masking tape covering.
Pliers
Protective coverings
8. Place a tarp, plastic drop cloth, heavy
Sandpaper: 220-350 grit paper, or another temporary protective
Wire/string/guide tape covering over the return ribbons and guide
assembly.
with power disconnected and COOL. CAUTION
Avoid gouging or leaving any
1. Turn power OFF at the main disconnect flat spots on the cylinder.
switch.
The unit will work properly
2. Remove the protective backplate at the only if the fine polished
rear of the unit. This piece should be surface of the cylinder
handled by two maintenance personnel. is preserved.
Clean the cylinder using

WARNING
vertical motions, not a
This safety interlock switch
sideways motion, to preserve
is only to be defeated
the fine polished surface of
temporarily while performing
the cylinder.
this procedure.
Never operate the unit
unless all safety systems are 9. Clean the exposed part of the ironing cyl-
working correctly. inder. Use a belt sander with 220 to 350
Serious Injury Could Result. grit sandpaper. Use only light movements
of the sander, not heavy pressure.
3. The unit will not operate while a safety

interlock switch is open. As a temporary
measure during this work, defeat the pro-
tective backplate interlock switch by taping
down the switch inside the right endframe.
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 7-23).
5. Place a tarp, plastic drop cloth, heavy

paper, or another temporary protective
covering on the floor at the rear of the unit.
6. Pull the return ribbons around their tracks Figure 7-23: Use wire, string or guide tape to
until all the lacing clips are accessible and secure the return ribbon guide
aligned at the back of the unit. assembly in a high position.
TOC INDEX 7-25

10. Do not use any other tools as these will another portion of the cylinder. Do not
permanently damage the cylinder. Work use the JOG REVERSE button more than
across the entire length of the cylinder. 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 cover-
12. Now it is time to move on the next section. ing.
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. Verify the return ribbon tension spring
Take every precaution is functioning correctly; refer to Return
to keep hands and loose Ribbon Tension Spring Replacement
on page 7-37.
clothing from coming into
contact with any of the 21. Remove the tape holding down the protec-
moving rolls. tive backplate switch; then, replace and
Serious Injury Could Result. secure the protective backplate at the rear
of the unit. This piece should be handled
One person should be ready by two maintenance personnel.
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.
14. Use the JOG REVERSE button to access
7-26 TOC INDEX

Ironing Cylinder Hardened Ring Perform only when the unit is OFF
Replacement with power disconnected and COOL.
The left end of the ironing cylinder trunnion is

equipped with a case-hardened wear ring (Figure CAUTION
7-24, A). This ring is designed to prolong the life
Use extreme care when
of the ironing cylinder by protecting the trunnion.
removing the burner system.
The hardened ring rests on the two cam Make sure the weight of the
follower bearings and rotates against them. burner is properly supported.
After years of use, the case hardening may wear
through, developing a groove in the ring. When
a groove is visible, the hardened ring must be 1. Remove the burner system; refer to Burn-
replaced. er Removal/Replacement on page 7-29.
NOTE: This procedure involves WARNING

removal of the cam follower Use extreme care when
bearings. Carefully examine raising the ironing cylinder.
their condition and determine if It is extremely heavy and
replacement is appropriate. can cause serious personal
injury or damage to the unit
if dropped.
Required Tools
Cold chisel 2. Take the weight of the cylinder off the cam
Drill follower bearing by jacking up the ironing
Drill bit: 1/4” cylinder 1/8”.
Hardwood block
Jack 3. Install two wooden wedges between the
Machine oil cam follower bearings to support the iron-
Punch
ing cylinder.
Saw w/steel cutting blade
Scraper/coarse sandpaper
Sledgehammer/maul
Wooden block/wedges
Wrench: 1-1/16”
A C
Figure 7-24: The hardened ring helps prevent wear

to the ironing cylinder trunnion.
TOC INDEX 7-27

4. Remove the cam follower bearings (Figure

7-24, B) by unscrewing the nuts located CAUTION
on the inside of the left endframe (Figure Do not heat the hardened
7-25). Carefully examine their condition ring to make it easier
and determine if replacement is appropri- to install.
ate.
5. There are 3 or 4 1/4” roll pins located 9. Drive on the new hardened ring using a
around the body of the hardened ring block of hard wood as a cushion to pre-
(Figure 7-24, C). Use a punch to drive all vent damage. Do not strike the new ring
of these out. directly with a hammer. Drive on four
alternating points to avoid cocking or
jamming the ring.
CAUTION
Be careful not to damage the 10. Drill new holes for the roll pins through
surface of the trunnion when the holes in the hardened wear ring and
removing the old ring. into the trunnion.
11. Install new roll pins.

6. If possible, use a suitable punch to drive
off the old ring. Depending on the condi- 12. Re-install the cam follower bearings by
tion of the ring, it may have to be cut off reversing Step 4.
instead.
13. Slowly and carefully remove the wooden
7. If it is necessary to cut off the old ring, wedges. Use the jack to lower the ironing
use a saw with a steel cutting blade to cylinder onto the cam follower bearings.
cut a deep notch in the ring and then use
14. Re-install the burner system; refer to
a cold chisel to force the ring to expand
Burner Removal/Replacement on page
for removal.
7-29.
8. Use a scraper or coarse sandpaper to clean
any rust or scale from the surface of the
trunnion and lightly oil the trunnion.
Figure 7-25: Cam follower bearing nut inside the

left endframe.
7-28 TOC INDEX

Burner Removal/Replacement
7.6 Burner System
When the ironing cylinder does not heat up
Individual components of the burner system
properly, this may be caused by a lint buildup. The
may wear during normal use and may need
entire gas burner must be removed to completely
occasional repair, inspection, or adjustment.
clean the gas burner system.
If the burner is experiencing problems,
first inspect and clean the spark plug and pilot
NOTE: Before beginning this
assembly. For more information, refer to Check
procedure, refer to Heating
and Clean Pilot Assembly on page 4-18.
System on page 6-12, for other
If the spark plug does not appear to be the possible causes/solutions.
problem, the following procedures also may be
used to resolve the problem:
Make sure the unit is completely COOL before
• Burner Removal/Replacement beginning this procedure.
• Burner Tip Maintenance
• Temperature Sensor Contact Shoe NOTE: Ta k e t h e t i m e t o
Replacement read through and understand
the entire procedure before
• Temperature Control or High performing this work.
Temperature Limit Control Replacement
This procedure should be handled
by at least two qualified persons.
Using the “buddy system”
facilitates a quicker procedure
and decreases the risk of
an accident.
Required Tools
C-clamp: large
Clean cloth
Compressed air
Gloves
Pencil/marker
Pipe thread compound/Teflon
tape
Pipe wrench
Wrenches:
7/16”
9/16” (2)
TOC INDEX 7-29

Perform only when the unit is OFF 10. Then, loosen the union (Figure 7-27, B)
with power disconnected and COOL. between the gas valve and the burner.
Remove Burner NOTE: Three maintenance

people are required to remove
1. Turn power OFF at the main disconnect the burner assembly. Station one
switch. person at the right end of the unit
and the other two at the left end.
2. Turn OFF the gas supply to the unit.
3. Lockout and tagout both the electrical

and gas supplies following local work WARNING
rules and in compliance with government The burner assembly is
standards.
heavy and will rotate when it
4. Remove the protective backplate at the is removed.
rear of the unit. This piece should be
handled by two maintenance personnel. Make sure it is adequately
supported at both ends
5. Open both endframe doors. during removal and
6. In the left endframe, note the specific replacement and that there
connection point for the flame sensor wire are sufficient personnel/
(Figure 7-26, A) and the ignition electrode equipment to handle it to
wire (B) to the ignition control. prevent injury or damage.
7. Disconnect each wire.
11. Make sure a worker has a good hold on
8. Disconnect the pilot gas line from the gas the C-clamp and the burner assembly is
valve (Figure 7-27, A). supported.
9. Securely place a large C-clamp on the 12. Finish disconnecting the gas union (Figure
burner assembly and use it as a hand-hold 7-27, B).
to help balance and support the assembly.
A A B
Figure 7-26: Disconnect the flame sensor and Figure 7-27: Disconnect the pilot gas line at the gas
ignition electrode wires. valve.
7-30 TOC INDEX

13. Support the burner assembly while remov- Replace Burner

ing the bolts that hold the burner support
bracket in position (Figure 7-26, C). After all maintenance/repair is completed,
replacing the burner is generally a reversal of the
14. Remove the burner assembly slowly. When removal process with the following additional
the burner has been moved about 18” (450 guidelines:
mm), stop moving the assembly.
1. When the assembly has been pushed back
The tail pipe should be about ready to clear into the ironing cylinder, have a worker
the right endframe and will drop against help guide the tail pipe into place.
the bottom of the ironing cylinder if not
2. With two people at the left endframe push-
properly supported.
ing down slightly on the burner assembly,
15. The two people at the left end should push the third person reaches into the ironing
down slightly on the assembly, while the cylinder helps guide the tail pipe through
person at the right endframe reaches into the opening in the right endframe.
the ironing cylinder and supports the tail
3. Once the tail pipe is seated in the opening,
pipe.
slide it the rest of the way into position.
16. Begin slowly pulling the burner out an-
4. Make sure it is properly positioned in its
other few inches until the tail pipe is clear.
holding bracket.
Be careful to avoid letting the burner tail
pipe bang against the bottom of the iron- 5. Reinstall the burner support removed in
ing cylinder. Step 13 of Remove Burner on page 7-30.
17. Continue moving the burner assembly out 6. Make sure the burner is properly oriented
slowly. Keep downward pressure on it to and physically secured.
lift the tail pipe as it clears the cylinder
end and keep it from banging against the 7. Securely rejoin the gas line union for the
heat shield in the bottom of the cylinder, burner (Figure 7-27, B). Use pipe thread
which could cause damage. compound to assure a leakproof connec-
tion.
18. Continue sliding the burner assembly
slowly out of the ironing cylinder. When 8. Reconnect the pilot gas line (Figure 7-27,
the tail pipe reaches the left end, all three A). Use pipe thread compound or Teflon
people should lift the burner assembly so tape to assure a leakproof connection.
the tail pipe can clear the cylinder.
9. Reconnect the flame sensor and ignition
19. Place the burner assembly on a sturdy electrode wires as noted in 6 of Remove
worktable. Burner on page 7-30.
10. Reposition and secure the protective

backplate. This piece should be handled
11. Make sure the internal valve is in the fully

ON position.
TOC INDEX 7-31

12. Close and secure both endframe doors. Burner Tip Maintenance
An accumulation of lint and other debris can
WARNING clog burner tips. Cleaning may be necessary to
Never operate the unit unless obtain a proper flame and efficient use of gas.
and all safety equipment is This procedure is always performed with the
burner removed from the ironer and the starting
working correctly.
point assumes the burner is on a work table,
ready to go.
13. Start the unit to verify proper operation.
Required Tools
Compressed air
Gloves
Goggles
Muriatic acid: 50% dilute
Wrench: adjustable
1. Use an adjustable wrench to remove each

burner tip (Figure 7-28).
2. Blow out each tip with compressed air

from the top and bottom.
3. Use compressed air to blow out the burner

manifold.
WARNING
Acids can cause skin burns
or other reactions. Wear
gloves, goggles and other
protective clothing.
4. Put all of the tips into a dilute solution of

muriatic acid and water (50% each).
5. Allow the tips to soak for 8 hours.
6. Remove the tips from the solution.
7. Thoroughly rinse with water and blow dry

with compressed air.
8. Securely re-install each burner tip using

the adjustable wrench. Make sure the
hole at the bottom of each burner tip is
perpendicular to the burner manifold
Figure 7-28: The holes at the bottom of the burner
tips must be perpendicular to the
(Figure 7-28).
manifold.
7-32 TOC INDEX

Temperature Sensor Contact Shoe 1. Turn power OFF at the main disconnect
Replacement switch.
A contact shoe will eventually wear out 2. Locate the appropriate contact shoe as-
because it is constructed of softer material than sembly (Figure 7-29). The temperature
the ironing cylinder that it rides against. control sensor is located toward the center
of the ironing cylinder (A) while the high
When this occurs, the shoe must be replaced temperature limit sensor is located toward
immediately to ensure correct operation of the the left end of the cylinder (B).
ironer.
3. Remove the mounting screws which
secure the contact shoe brackets to its as-
CAUTION sembly (Figure 7-29, C).
Use only factory tested
replacement parts for 4. Loosen the screws which secure the con-
temperature sensors and tact shoe to its brackets (Figure 7-30, A/B).
contact shoes. Parts should 5. Carefully slide the capillary tube out of the
be order from your CHICAGO left end of the contact shoe (Figure 7-30,
authorized dealer or from C). Extreme care is required to accomplish
Chicago Dryer Company. this because the tube leading to the fluid
Overnight shipment of parts bulb breaks easily.
is available.
6. Finish loosening the screws so the contact
shoe can be removed from its brackets.
Note that the left screw (Figure 7-30, A) is
Required Tools noticeably longer than the right screw (B).
Pliers
Screwdriver 7. Install the new shoe in the brackets and
partially install the screws. Make sure the
Perform only when the unit is OFF longer screw goes into the left end of the
with power disconnected and COOL. bracket.
C C
B B
A
A
Figure 7-29: The two temperature sensors are Figure 7-30: Be careful when removing and
located under the feed ribbons. inserting the sensor tube.
TOC INDEX 7-33

8. Carefully insert the capillary tube into the Temperature Control or High
new contact shoe. Temperature Limit Control
Replacement
• Make sure it is fully seated (Figure
7-30, C). If the temperature or high temperature control
fails, replacement is a straightforward procedure.
• If any damage occurs, i.e. breaks or
leaks, the entire control/sensor tube
unit must be replaced along with the Required Tools
contact shoe. Pliers
Screwdriver
• Installation of a damaged capillary tube Wrench: 5/16”
will result in improper operation.
9. Tighten the contact shoe mounting screws with power disconnected and COOL.
until they just contact the bulb.
• Do not over-tighten the screws as they 1. Turn power OFF at the external discon-
can puncture the bulb. nect switch.
• If this happens or the capillary tube is 2. If replacing the temperature control, pull
damaged or leaking, the entire control/ off the TEMPERATURE control dial from
sensor tube unit must be replaced along the front of the left endframe.
with the contact shoe. 3. Open the left endframe door.
10. Reinstall the contact shoe brackets on its
assembly, reversing Step 3. NOTE: T h e c a p i l l a r y t u b e
(Figure 7-30, C) and sensor probe
are a part of the control.
switch and start the unit.
12. Visually check the positioning of the con-

tact shoe against the cylinder. Make sure
it is riding flat and making full contact.
13. If any adjustment is needed, stop the unit

and turn power OFF at the main discon-
nect switch.
14. Use a pair of pliers to carefully bend the

twisted springs.
15. Repeat Steps 11 to 14 until the contact

shoe is making correct contact against the
ironing cylinder.

17. Heat the unit and make sure it is operating

correctly.
7-34 TOC INDEX

4. Note where each of the two wires are 10. Use the hardware from Step 8 to secure
connected for the control being replaced the new control in position.
(Figure 7-31, A/B) and disconnect.
5. Locate the appropriate contact shoe as- CAUTION

sembly (Figure 7-29). The temperature Do not bend capillary tubing
control sensor is located toward the center sharply and no closer to
of the ironing cylinder (A) while the high switch or tube than 1/2”.
temperature limit sensor is located toward
the left end of the cylinder (B).
11. Carefully thread the capillary tube and sen-
6. Follow Steps 3 to 5 of Temperature sor through the hole in the left endframe
Sensor Contact Shoe Replacement on (Figure 7-30, B).
page 7-33.
12. Follow Steps 8 to 10 of Temperature
7. Carefully bring the capillary tube and Sensor Contact Shoe Replacement on
probe into the left endframe (Figure 7-30, page 7-33.
C).
13. Reconnect the control’s wires as noted
8. Remove the mounting hardware which in Step 4.
secures the control being replaced.
14. If replacing the temperature control, push
9. Remove the control and discard following the dial onto the control.
local codes.
15. Close and secure the left endframe door.
WARNING
A and all safety equipment is
working correctly.
C
17. Heat the unit and make sure it is operating

correctly.
B B
Figure 7-31: The TEMPERATURE control is

mounted inside the left endframe.
TOC INDEX 7-35

7.7 Return Section

Flatwork is directed around the ironing
cylinder by the return section (Figure 7-32),
which consists of the following components: D1
D1
• Return ribbons (A)
A
• Return ribbon guide assembly (B)
• Return ribbon drive roll (C)
• Idler rolls (D1, D2)
C B
The return ribbons hold the flatwork in proper
contact with the heated cylinder, ensuring quality
flatwork finish.
Various components of the return section

require periodic adjustment, replacement, or Figure 7-32: Return section components.
occasional repair.

• Return Ribbon Tension Spring
Replacement
• Return Ribbon Replacement
• Return Ribbon Drive Roll Friction
Material Replacement
7-36 TOC INDEX

Return Ribbon Tension Spring

Replacement
Tension on the return ribbons is held by the
weight of the return ribbon guide assembly. There
is no adjustment.
C
There is a spring (Figure 7-33, A) attached
to the return guide assembly bearing in each
endframe which prevents the assembly from
bouncing too much. These springs may wear and
need periodic replacement. A B
Required Tools
Pliers Figure 7-33: Return ribbon tension adjustment in
Wrenches: 7/16” (2) the left endframe.


switch.
3. Locate the tension spring (Figure 7-33, A).

There is one on each side of the machine.
4. Remove the bolt holding the lower part of

the spring in place (Figure 7-33, B).
5. Remove the spring from the upper bracket

(Figure 7-33, C) and replace with the new
one.
6. Repeat Steps 3 to 5 in the other endframe.
WARNING
working correctly.
8. Start the unit and make sure the return

ribbons track straight.
TOC INDEX 7-37

Return Ribbon Replacement

NOTE: HI-LYFE™ extended
Return ribbons stretch and flatwork moves wear ribbons are available. These
unevenly and improperly through the ironing ribbons provide superior quality
section. When tension on these ribbons can no flatwork finish. Specify HI-LYFE
longer be adjusted, the entire set must be replaced. extended wear ribbons when
reordering.
NOTE: R e a d t h e R E T U R N
RIBBON REPLACEMENT OR
ADJUSTMENT section on the
switch.
Pink Operator Safety Reminder
in the front of this manual. 3. Remove the protective backplate at the
handled by two maintenance personnel.
Replacing Worn Ribbons 4. Release tension on the return ribbons. Se-
Use this procedure to replace ribbons that are cure the return ribbon guide assembly in a
still in place, but are worn out. high position by tying off from above with
Required Tools
Allen wrench: 5/32” WARNING
Pliers Never start the unit while
Wire/string/guide tape installing the return ribbons.
It is dangerous
Perform only when the unit is OFF and unnecessary.
1. Verify the replacement ribbons are the 5. Pull the worn ribbons around their tracks
correct size and sufficient quantity for until all the lacing clips are accessible and
completing the procedure. See Rolls and aligned at the back of the unit.
NOTE: Whether using Nomex
or HI-LYFE ribbons, make sure
the darker side of the ribbon will
face the ironing cylinder.
6. Remove the connecting pin from an old

ribbon and attach a new ribbon to one end,
making sure the darker side will face the
ironing cylinder.
7. Pull the old ribbon through until the new

ribbon is in place.
Figure 7-34: Use wire, string or guide tape to 8. Disconnect the old ribbon and secure the
secure the return ribbon guide replacement ribbon with a new pin.
assembly in a high position.
7-38 TOC INDEX

9. Repeat Steps 6 to 8 to replace additional 2. Turn power OFF at the main disconnect
worn ribbons. Stagger the positions of the switch.
lacing clips to give the flatwork a smooth
flow. 3. Remove the protective backplate at the
10. Remove the wire/string/guide tape holding handled by two maintenance personnel.
the return ribbon guide assembly in the
high position. 4. Release tension on the return ribbons. Se-
11. Verify the return ribbon tension spring high position by tying off from above with
is functioning correctly; refer to Return wire or string or guide tape (Figure 7-34).
Ribbon Tension Spring Replacement
on page 7-37. 5. Remove a ribbon from both ends of the
unit and use one or both as replacement
12. Reinstall the protective backplate at the ribbons. These end ribbons can then be
rear of the unit. This piece should be replaced by a pair of new ribbons.
handled by two maintenance personnel.
WARNING
Replacing Broken or Missing Ribbons Never start the unit while
Ribbons that break should be replaced installing the return ribbons.
immediately. To avoid excessive stress on only It is dangerous
one new, slightly shorter ribbon, the entire set of and unnecessary.
ribbons should be replaced. At a minimum, it is
recommended that ribbons be replaced in pairs.
6. Move to the front of the unit at the posi-
tion where a ribbon is broken or missing.
Required Tools Fold the replacement ribbon in half. Do
Allen wrench: 5/32” not crease the ribbon.
Pliers
Wire/string/guide tape
NOTE: Whether using Nomex
Perform only when the unit is OFF or HI-LYFE ribbons, make sure
with power disconnected and COOL. the darker side of the ribbon will
face the ironing cylinder.
1. Verify the replacement ribbons are the
correct size and sufficient quantity for
completing the procedure. See Rolls and 7. Place one end of the replacement ribbon
Ribbons on page PL-6. over the return ribbon drive roll and one
end beneath, making sure the slightly
darker side will face the ironing cylinder.
NOTE: HI-LYFE™ extended
wear ribbons are available. These 8. Move to the back of the unit where both
ribbons provide superior quality ends of the ribbon are now exposed. Wrap
flatwork finish. Specify HI-LYFE the top end of the ribbon around the cyl-
extended wear ribbons when inder. Refer to Figure 7-32.
reordering.
9. Pass it under and around the top idler roll;
next, pass it over the second idler roll so
it is hanging down the back of the unit.
TOC INDEX 7-39

10. Pull the bottom end of the ribbon under Return Ribbon Drive Roll Friction
the return ribbon guide assembly. Bring it Material Replacement
up to meet the other end and connect the
ends of the ribbon with a new pin. If the friction material on the return ribbon
drive roll is worn smooth, or if the return ribbons
11. Repeat Steps 6 to 10 to replace additional slip in place when tension is adjusted properly,
ribbons. Stagger the positions of the lacing the friction material must be replaced.
clips to give the flatwork a smooth flow.
Required Tools
NOTE: If the remaining ribbons Allen wrench: 5/32”
are being replaced, refer to Caulk Gun
Replacing Worn Ribbons on Chain puller
page 7-38. Clean cloth
Hammer
Masking tape
Nail
12. Remove the wire/string/guide tape holding Pliers
the return ribbon guide assembly in the Protective covering
high position. Putty knife: serrated
Screwdriver
13. Verify the return ribbon tension spring Steel brush
is functioning correctly; refer to Return Utility knife
Ribbon Tension Spring Replacement Wire/string/guide tape
on page 7-37. Wooden wedges
Wrenches:
14. Reinstall the protective backplate at the 7-16”
rear of the unit. This piece should be 11/16”
handled by two maintenance personnel. 1-3/8” or Crescent

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

switch.
3. Release tension on the return ribbons. Se-

high position by tying off from above with
7-40 TOC INDEX

6. Pull the return ribbons around their tracks

WARNING until all the lacing clips are accessible and
The chain and power must aligned at the front of the unit. Remove
both remain disconnected the connecting pins and position the return
during this procedure. Do ribbon ends away from any contact with
not reconnect either of these the drive roll.
until the entire procedure
7. Place a tarp, plastic drop cloth, heavy pa-
is completed. per, or another temporary protective cov-
ering over the floor underneath the unit.
4. The friction material must be applied 8. Remove the screws at each end of the
while the return ribbon drive roll turns drive roll (Figure 7-36) that hold the fric-
freely: tion material in place. Set aside for re-use.
a) Open the right endframe door and lo- 9. Pull or cut off the old friction material. As
cate the drive chain (Figure 7-35, A). you do so, note the direction of the spiral
b) Release tension on the chain; refer to winding.
Drive Chain Tension Adjustment on 10. Remove the old cement from the drive
page 7-23. roll with a scraper, coarse sandpaper, or a
c) Locate the clips that secure the ends of steel brush. Wipe away remaining residue
the drive chain together. with a clean cloth. Make sure the roll’s
surface is down to bare metal, and that it
d) Use a chain puller to relieve tension at is completely clean and dry.
the site of the clips and remove them.
e) Remove the chain from the return rib- CAUTION

bon drive roll sprocket (B). You must be down to bare
metal before installing the
f) Close and secure the right endframe new cover or it may not
door. adhere properly.
5. Remove the front receiving shelf.
Screws
B A
Return Ribbon
Drive Roll
Friction Material
Figure 7-35: Remove the drive chain from the Figure 7-36: The friction material is secured to
return ribbon drive roll. each end of the drive roll by screws.
TOC INDEX 7-41

17. Remove the masking tape and then re-

NOTE: Spiral-wind the friction install the end screws (Figure 7-36).
material at a 45° angle. To ensure
this, the material edges must be 18. Remove the temporary protective covering
aligned with no gaps. and clean up the area.
19. Refasten the return ribbons. Stagger the

positions of the lacing clips to give the
11. Spiral wind the new cover over the roll
flatwork a smooth flow.
without cement to make sure there is
enough material to cover the roll. Put it on 20. Remove the wire/string/guide tape holding
in the same spiral pattern as before. the return ribbon guide assembly in the
high position.
12. Use a caulk gun to apply several beads of
cement across the length of the roll. 21. Reinstall the drive chain on the return
ribbon drive roll sprocket and adjust its
13. Use a serrated putty knife or other rough-
tension; refer to Drive Chain Tension
edged tool to spread the cement evenly
over the entire roll (Figure 7-37).
14. Starting either side of the machine:
• Spiral-wind two or three turns of the WARNING

material onto the roll and secure it with
masking tape so the material does not
unwind during installation.
• Carefully continue to spiral-wind the working correctly.
cover onto the roll, making sure it goes
on smoothly without any gaps.
23. Reinstall the front receiving shelf.
• This procedure is easier with two peo-
ple. One person turns the drive roll by 24. Allow the cement to harden for 5 to 6
hand while a second person holds the hours before operating the unit.
roll of material and guides the material
25. After the cement hardens, verify the return
onto the drive roll, pressing it firmly
ribbon tension spring is functioning cor-
into place.
rectly; refer to Return Ribbon Tension
• Continue working down the length of Spring Replacement on page 7-37.
the roll.
• After the roll is covered, wrap the other

end of the roll with masking tape. Feed Ribbons
Heated
15. Use a hammer to lightly tap the friction Cylinder
material at each end to break it off and

create an even edge or use a utility knife
to trim it. Cement applied to entire
drive roll surface
16. Use a nail to pierce the friction material Feed Ribbon

Drive Roll
Return Ribbon
Drive Roll
and expose the holes for the end screws.
Figure 7-37: Cement secures the friction material to
the return ribbon drive roll.
7-42 TOC INDEX

Comet Executive Gas 3031-005h
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).
Comet Executive Gas

Picture Parts List
Content
General Components
Front View .................................................................................................................................. PL-2
Rear View................................................................................................................................... PL-4
Rolls and Ribbons ...................................................................................................................... PL-6
Left Endframe Components

Left Endframe ............................................................................................................................ PL-8
Right Endframe Components

Right Endframe ........................................................................................................................ PL-10
Heating System Components

Burner Assembly ...................................................................................................................... PL-12
Contact Shoe Assembly ........................................................................................................... PL-13
TOC PL-TOC INDEX PL-1

3031-005h Comet Executive Gas
Front View
18
19
17 * *
20 21
22 23 24
26 9
14 15 16 25
11 12 13 10 27 28
10
9
29
8
30
7
31
6
32
5
33
4
3
3
34 35 36
37
2
1 40 39 38
38
39
40 * = Voltage Dependent
PL-2 TOC PL-TOC INDEX

Front View continued...
ID Part Number Qty Description

1 3000-050 1 CHICAGO FLATWORK IRONER NAMEPLATE
2 2001-995 1 LOCK, LIFT & TURN NON LOCKING
3 3004-316 2 BILINGUAL METAL PLATE ”DISCONNECT...”
4 2001-016 1 END FRAME DOOR PANEL COMET EXEC
5 3002-055 1 PLATE HEATING TEMPERATURE LEXAN/ALUM
6 3004-322 1 BILINGUAL METAL PLATE ”DO NOT ATTEMPT...”
7 4201-370 1 THERMOSTAT EA 3 W/DIAL
8 1416-550 1 INDICATOR LIGHT RED 24 VDC
9 3004-312 2 ”STOP / PARADA”
10 1411-560-01 2 SWITCH STOP 30 MM W/1 N/C CONTACT BLOCK
11 4801-035 1 CANOPY ONLY COMET 56”
14 2008-012 1 CONNECTING PIPE FRONT 1”x 64”
17 4803-426 1 BLOWER ASSY 870 CFM COMPRESSOR
18 4819-224 1 ADAPTER SHEET METAL REC TO 8
19 2217-641 1 SAIL SWITCH
20* 2801-150 1 MOTOR 1/3 HP 1/60/115/230 1725 RPM FR 56
21* 2801-240 1 MOTOR 1/3 HP 3/60/50/208-220/440
22 3210-520 1 SAFETY FINGER GUARD COMET 56”
25 3004-314 1 ARROW LABEL
26 3004-6372 1 WARNING LABEL ALUM. SET 1-6372
27 3002-050 1 PLATE LEXAN/ALUM ”START”
28 1411-600-01 1 SWITCH START GREEN W/BUL 3023-463
29 1402-550 1 SPEED CONTROL POT 5K
30 1414-510 1 KNOB FOR SPEED CONTROL SWITCH
31 1414-260-01 1 CONTACT BLOCK 1 N/O
32 1414-490-01 1 PUSHBUTTON YELLOW 22 MM
33 3004-304 1 ”JOG REVERSE”
34 3402-023 1 RECEIVING SHELF FOLKSTONE W/REINFORCEMEN
37 2809-200-01 1 GEARMOTOR 1/3 HP 72.89 :1 RATIO
38 2008-018 2 CONNECTING PIPE 1” x 88”
* = Voltage Dependent

Rear View
11 12
9 10 13
14 15 16 8
8 7
4 3 19 18 17
3
23 22 21 20
2
22 21 20

Rear View continued...

1 2001-579 1 HINGED DOOR PANEL BREEZE, COMET
2 1402-627 1 HANDLE, YELLOW/RED
3 3004-316 4 BILINGUAL METAL PLATE “DISCONNECT...
4 2001-995 1 LOCK, LIFT & TURN NON LOCKING
5 3004-322 1 BILINGUAL METAL PLATE “DO NOT ATTEMPT...
6 1411-560-01 2 SWITCH STOP 30 MM W/1 N/C CONTACT BLOCK
7 3004-312 2 “STOP / PARADA”
8 3004-313 2 “CAUTION-HOT”
9 2801-150 1 MOTOR 1/3 HP 1/60/115/230 1725 RPM FR 56
10 2801-240 1 MOTOR 1/3 HP 3/60/50/208-220/440
11 2217-641 1 SAIL SWITCH
12 4819-224 1 ADAPTER SHEET METAL REC TO 8
13 4803-426 1 BLOWER ASSY 870 CFM COMPRESSOR
14 4801-035 1 CANOPY ONLY COMET 56” or
15 4801-030 1 CANOPY ONLY COMET 66” or
17 3403-211 1 COVER REAR COMET 80” or
18 3403-025 1 COVER REAR 74” x 26” x 18 GA COMET 66” or
19 3403-056 1 COVER REAR 64” x 26” COMET 56”

Rolls and Ribbons
6 5 4
3 *
7
* 8
1
9
NOTES: Part numbers on BOM are for 66” machine.

Refer to chart for other machine lengths.
* = Quantities will vary depending on machine length

Rolls and Ribbons continued...

1 3202-020 1 DRIVE ROLL 3-1/2” OD x66-1/2”L W/FLEXTRA
2 3209-010 1 DRIVE ROLL 3-1/2” x 66-1/2” x 16 GA
3* 1003-204 1 POLYESTER RIBBON 3” x 24” W/PIN
4 1007-723 1 IMPREGNATED GUIDE TAPE 1/2” 36 YD ROLL
5 3207-010 1 COMP ROLL 3-1/2” x 66-1/2” x 16 GA
6 3203-010 2 IDLER ROLL 3-1/2” x 66-1/2” x 16 GA
7 3201-285 1 14” HEATED ROLL GAS 66-1/2” COMET 66”
8* 1002-510 1 HI-LYFE RIBBON 6” x 84+” W/PIN W/#25
9 3208-025 1 GUIDE ASSY RETURN RIBBON
* = Quantities Vary
Length Roll Number

1 2 5 6 11
80” 3202-001 3209-475 3207-073 3203-364 3208-179
66” 3202-020 3209-010 3207-010 3203-010 3208-025
56” 3202-019 3209-116 3207-011 3203-042 3208-050
COVERS
Length Roll Number
1 2 5
80” 1013-085 Flextra 1011-207 Red Cover 1004-800 Ribbon Felt - 30’
4004-000 CEMENT 4004-500 CEMENT 4004-250 CEMENT
Length POLYESTER FEED RIBBON #3 HI-LYFE RIBBON #10

1003-204 QTY. 1002-510 QTY.
80” 24 13
66” 20 11
56” 17 9
Length Heated Cylinder #7 Length GUIDE ASSY. RETURN RIBBON #11

Gas
80” 3201-289 80” 3208-179
66” 3201-285 66” 3208-025
56” 3201-052 56” 3208-050

Left Endframe
9 5
10
9
11
8
12
7
7
6
13
5
9
4
15
14
3
16
8
2
18 19 18 17

Left Endframe continued...

1 3603-150 1 SPRING 3/8” x 6”
2 2206-120-01 1 GAS VALVE 1/2” 24 V NATURAL GAS
3 5005-120 1 COUPLING 1/2”
4 5001-149 1 NIPPLE 1/2” x CLOSE
5 0402-788 2 BEARING 1” BORE PIVOT MOUNT COUNTERSUNK NEXT TO GF
or 0402-789 BEARING 1” BORE PIVOT MOUNT COUNTERSUNK OPPOSITE GF
6 2208-410 1 HANDLE 1/2” GAS COCK
7 0403-763 2 BEARING CAM FOLLOWER 1-3/4” BORE ASSY
8 5002-100 2 ELBOW 90 DEG 1/2”
9 0402-774 3 BEARING 1” BORE STAT MOUNT
10 0607-200 2 SPRING BRACKET
11 3603-200 1 SPRING 3/4” x 6”
12 0402-792 1 BEARING 1” BORE PIVOT MNT GF NEXT PIVOT
or 0402-793 BEARING 1” BORE PIVOT MNT GF OPPOSITE
13 3601-854 1 TENSION ROD 3/8” x 5”
14 4205-390 1 TEMP LIMIT SWITCH
15 0601-024 1 MAIN BURNER SUPPORT 7-3/4” x 2” x 7 GA
16 5001-153 2 NIPPLE 1/2” x 2-1/2”
17 2201-905 1 IGNITION CONTROL W/BUL 3023-158
18 5001-151 2 NIPPLE 1/2” x 1-1/2”
19 5019-100 1 1/2” 250LB BLK UNION
20* 2206-210 1 KIT CONVERSION TO LP GAS
* = Not Shown

Right Endframe
10 11 12 4 13 14
9 4
8 15
16
7
17
18
6
19
5
4 11
3 10
2 20
1
21
22
ELECTRICAL ENCLOSURE
ELECTRICAL COVER

Right Endframe continued...

1 1211-005 1 IDLER ARM FOR CHAIN RIDER
2 1211-006 1 CHAIN RIDER SET #40 CHAIN
3 1201-230 1 SPROCKET #40 16T 1” BORE KWAY 2 STSCRW
4 0402-774 3 BEARING 1” BORE STAT MOUNT
5 3601-854 1 TENSION ROD 3/8” x 5”
7 0402-792 1 BEARING 1” BORE PIVOT MNT GF NEXT PIVOT
or 0402-793 BEARING 1” BORE PIVOT MNT GF OPPOSITE
8 1206-325 1 BEARING SPROCKET #40 18T 5/8” BORE
9 3603-200 1 SPRING 3/4” x 6”
10 0607-200 2 SPRING BRACKET
11 0402-788 2 BEARING 1” BORE PIVOT MOUNT COUNTERSUNK NEXT TO GF
or 0402-789 BEARING 1” BORE PIVOT MOUNT COUNTERSUNK OPPOSITE GF
13 4003-600 1 GREASE EXTENSION PIECE 4”
14 4003-075 1 GREASE FITTING 1/4-28 90 DEG
15 1204-354 1 CHAIN #40 154 LINKS W/CONN LINK
16 1413-479 1 SWITCH
17 0402-665 1 BEARING STAT MOUNT 1-1/2” BORE
18 1201-395 1 SPROCKET #40 70T 1-1/2” BORE 2 STSCRW
19 0601-012 1 SUPPORT RIGHT FRAME BURNER 12-1/2” x 2”
20 3603-150 1 SPRING 3/8” x 6”
22 1201-254 1 SPROCKET #40 19T 3/4” BORE KWAY 2 STSCRW

Burner Assembly
8 9 10 7 1 2 3
11 15
4 14 13
5
6
16
12

1* 2203-226 42 BURNER TIP ATMOSPHERIC or
2* 2203-226 50 BURNER TIP ATMOSPHERIC or
3* 2203-226 62 BURNER TIP ATMOSPHERIC
4 2203-010 1 BURNER PIPE ASSY 1/2” x 61-1/2” COMET 66 or
5 2203-009 1 BURNER PIPE ASSY 1/2” x 51-1/2” COMET 56 or
6 2203-038 1 BURNER PIPE ASSY 1/2” x 75-1/2” COMET 80
7 2201-105 1 PILOT ASSY W/IGNITION ELECTRODE
8 2201-110 1 ORIFICE .023 NATURAL GAS
9 2201-120 1 ORIFICE .012 LP GAS
10 2211-115 1 SENSING PROBE
11 5002-100 2 ELBOW 90 DEG 1/2”
12** 5001-164 1 NIPPLE 1/2” x 8”
13 E19-435 1 FASTON INSULATED 0.250” 16-14AWG
14 2214-015 1 WIRE PROBE LEAD 24” LONG
15 5001-151 1 NIPPLE 1/2” x 1-1/2”
16 2215-020 1 PILOT TUBING 36” LONG
* Specify Natural Gas or LP

** Nipple Lengths May Vary

Contact Shoe Assembly
11 *
2
3 4
5
6
10
9
8
1 2 3 4 5 6 7
* = Quantity will vary depending on machine length
ID Part Number Description

1 4203-367 1 SHOE CONTACT BRASS 3/8” x 3/8” x12-5/8”
2 4215-600 2 BRACKET BRASS U-SHAPE
3 B05-205 4 10-24 x 1/4” SL RD HD M/S
4 3602-150 2 FLAT TWISTED SPRING CONTACT SHOE
5 B10-300 2 1/4-20 LK HEX NUT W/NYLON
6 4215-700 2 SPACER 1/4” x 1/2” FOR CONTACT SHOE
7 3603-075 1 COIL SPRING LH FOR CONTACT SHOE T 2 T 4
8 4215-900 1 BAR ROUND 1/4” x 10” FOR T-2
9 4215-400 1 BRACKET WELDED FOR T2/T4
10 3603-050 1 COIL SPRING RH FOR CONTACT SHOE T 2 T 4
11* 1001-085 20 CANVAS RIBBON 3” x 24” W/PIN

Cadet Gas/Comet Executive Gas/Breeze 3210-384H
NOTE: When ordering parts, please provide the serial number and a
complete description of the Cadet Gas/Comet Executive Gas/
Breeze, including any non-standard features.
Cadet/Comet Exec/Breeze Gas

Schematic Parts List
Content
Motor Circuits
Motor Circuit 115V 1 Phase....................................................................................................... SC-2
Motor Circuit 460V 3 Phase..................................................................................................... SC-10
Electrical Panels
Main Electrical Panel 115V 1 Phase........................................................................................ SC-12
TOC SC-TOC INDEX SC-1

Motor Circuit 115V 1 Phase
SC-2 TOC SC-TOC INDEX

Motor Circuit 115V 1 Phase (6220476)

Reference Part No. Description
BREC1 1710-250 BRIDGE RECTIFIER
CR1 1401-502 RELAY 24 VAC 2 POLE
CR1B 1401-503 SOCKET FOR 2 POLE RELAY
CR2 1401-275 RELAY 1 POLE 24VAC/DC
DISC1 1402-625 SWITCH, DISCONNECT 40 AMP
DISC1F 1402-626 FUSEHOLDER
DISC1H 1402-627 HANDLE, YELLOW/RED
DISC1S 1402-628 SHAFT, 200MM
FAN 1418-410 AXIAL FAN WITHOUT COVER 3-5/32” SQ
FS1 2217-641 SAIL SWITCH
FU1 1407-352 FUSE 15 A 600 V
FU4 1407-633 FUSE 30 AMP TYPE JLL 300 V
FU4H 1408-310 BLOCK FUSE DOUBLE 30 AMP
FU6 1407-200 FUSE CARTRIDGE 1 A 250 V
FU6H 1408-200 FUSE HOLDER SINGLE
GV1 2206-120-01 GAS VALVE 1/2” 24 V NATURAL GAS
HLT1 4205-390 TEMP LIMIT SWITCH
IGN1 2201-905 IGNITION CONTROL W/BUL 3023-158
INV1 1615-090 INVERTER 1/2 HP AC 110V W/BUL 3023-185
LS1 1413-479 SWITCH
LS3 1413-479 SWITCH
LT1 1416-550 INDICATOR LIGHT RED 24 VDC
MP1 1405-455 MOTOR PROTECTOR 6-10 AMP
MTR1 2801-150 MOTOR 1/3 HP 1/60/115/230 1725 RPM FR 56 (Breeze/Comet)
or 2801-040* MOTOR 1/4 HP 1/60/115/208-230 1725 RPM (Cadet)
or 2801-080* MOTOR 1/4 HP 3/60/208-230/460 1725 RPM (Cadet)
MTR2 2809-200-01 GEARMOTOR 1/3 HP 72.89 :1 RATIO
PB1 1411-560-01 SWITCH STOP 30 MM W/1 N/C CONTACT BLOCK
PB5 1411-600-01 SWITCH START GREEN W/BUL 3023-463
PB6 1414-490-01 PUSHBUTTON YELLOW 22 MM
PB6C 1414-260-01 CONTACT BLOCK 1 N/O
POT1 1402-550 SPEED CONTROL POT 5K
PROBE1 2201-105 PILOT ASSY W/IGNITION ELECTRODE
PROBE2 2211-115 SENSING PROBE
T1 1412-135 TRANSFORMER 120/208/240 TO 24VAC 50VA
TD1 1614-200 TIME DELAY RELAY 10 S 120 VAC
TSTAT1 4201-370 THERMOSTAT EA 3 W/DIAL
VM1 2604-400 SPEED INDICATOR



FU1 1407-975 FUSE 7.5 A CLASS CC 600 V
FU6 1407-195 FUSE 1/2 AMP 250 V
FU6H 1408-210 FUSE HOLDER DOUBLE
FU7 1407-195 FUSE 1/2 AMP 250 V
INV1 1615-100-01 INVERTER 1/2 HP AC 230V W/BUL 3023-211
LS1 1413-479 SWITCH
LS3 1413-479 SWITCH
MP1 1405-405 MOTOR PROTECTOR 2.5-4 AMP
MTR1 2801-150 MOTOR 1/3 HP 1/60/115/230 1725 RPM FR 56



FU6 1407-195 FUSE 1/2 AMP 250 V
FU7 1407-195 FUSE 1/2 AMP 250 V
LS1 1413-479 SWITCH
LS3 1413-479 SWITCH
MP1 1405-230 MOTOR PROTECTOR 1-1.6 AMP
MTR1 2801-240 MOTOR 1/3 HP 3/60/50/208-220/440 (Breeze/Comet)



FU1 1407-330 FUSE 3.2 A 600 V CLASS CC
FU6 1407-302 FUSE 1/4 A 600 VAC CLASS CC
FU6H 1408-260 FUSE HOLDER DOUBLE CLASS CC
LS1 1413-479 SWITCH
LS3 1413-479 SWITCH
MTR1 2801-240 MOTOR 1/3 HP 3/60/50/208-220/440
T1 1412-145 TRANSFORMER 208/277/480V TO 24VAC 50VA
T2 1412-850 TRANSFORMER 1 KVA LINE TO 120/240
VM1 2604-400 SPEED INDICATOR W/BULLETIN 3023-705



LS1 1413-479 SWITCH
LS3 1413-479 SWITCH
MTR1 2801-240 MOTOR 1/3 HP 3/60/50/208-220/440 (Breeze/Comet)
T2 1412-940 TRANSFORMER 500VA 240/480PRI 120/240 SEC

Main Electrical Panel 115V 1 Phase


(6280184)
FU1 1407-352 FUSE 15 A 600 V
FU6 1407-200 FUSE CARTRIDGE 1 A 250 V
FU6H 1408-200 FUSE HOLDER SINGLE
INV1 1615-090 INVERTER 1/2 HP AC 110V W/BUL 3023-185
MP1 1405-455 MOTOR PROTECTOR 6-10 AMP



(62801851)
FU6 1407-195 FUSE 1/2 AMP 250 V
FU7 1407-195 FUSE 1/2 AMP 250 V
MTR1 2801-150 MOTOR 1/3 HP 1/60/115/230 1725 RPM FR 56



(62801853)
FU6 1407-195 FUSE 1/2 AMP 250 V
FU7 1407-195 FUSE 1/2 AMP 250 V
MP1 1405-230 MOTOR PROTECTOR 1-1.6 AMP



(62801854)

TOC INDEX
TOC INDEX
TOC INDEX
Comet Exec-56-G TECHNICAL SPECIFICATIONS 07/08/09
Comet Exec-66-G 6500-038E App:GW
Production
Variable Speed Drive Output
Feet per Minute (m/min)
M inimum APPENDIX: Technical Specifications
12 (3. 7)
Ma x imum 36 (11)
Heating
Gas Model 56 Model 66
Maximum Gas Input per Hour , BTU* 76000 90000
Average Gas Input per Hour , BT U** 55-65% of max. 55-65% of max.
Operating Temperature Range , F (C) 200-400 (95-200) 200-400 (95-200)
Gas Supply Connection , inch (DN) 1/2 (DN 15) 1/2 (DN 15)
Motors
Total 0.66 (0.5)
D rive , H P ( k W ) 1 /3 (0. 25)
Exhaust Blower , HP (kW) 1/3 (0.25)
Electrical Frequency : All Models 50 / 60 Hz

Total Amps 4.0 3.5 2.1 1.8 1.5
T hre e P ha s e V olta ge 208 230 380 460 575
Total Amps 13.2 6.6

S ingle P ha s e V olta ge 115 230
Exhaust
Air Discharge Main
CFM , (l/min) max. at 1/4” S.P. 870 (24600)
Vent Diameter , inches (mm) 8 (205)
Rolls Model 56 Model 66

Number of Rolls 1 1
Roll Diameter , inch (mm) 14 (355) 14 (355)
Usable Length , inch (mm) 56 (1420) 66 (1680)
Approximate Shipping Weight Model 56 Model 66

Domestic , lb. (kg) 950 (430) 1100 (500)
Export , lb. (kg) 1100 (500) 1300 (590)
* Based on operation with natural gas at less than 1,500ft.(450m)alt itude. 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 subjec t to change withoutTOC

notice. INDEX
Comet Exec-80-G TECHNICAL SPECIFICATIONS 07/08/09
6500 A pp: G W
Production
Variable Speed Drive Output
Feet per Minute (m/min)
M inimum 12 (3. 7)
Ma x imum 36 (11)
Heating
Gas Model 80
Maximum Gas Input per Hour , BTU* 105000
Average Gas Input per Hour , BTU** 55-65% of max.
Operating Temperature Range , F ( C ) 200-400 (95-200)
Gas Supply Connection , inch (DN) 1/2 (DN 15)
Motors
Total 0.66 (0.5)
D rive , H P ( k W ) 1 /3 (0. 25)
Exhaust Blower , HP (kW) 1/3 (0.25)
Electrical Frequency : All Models 50 / 60 Hz

Total Amps 4.0 3.5 2.1 1.8 1.5
T hre e P ha s e V olta ge 208 230 380 460 575
Total Amps 13.2 6.6

S ingle P ha s e V olta ge 115 230
Exhaust
Air Discharge Main
CFM , (l/min) max. at 1/4” S.P. 870 (24600)
Vent Diameter , inches (mm) 8 (205)
Rolls Model 56
Number of Rolls 1 1
Roll Diameter , inch (mm) 14 (355)
Usable Length , inch (mm) 80 (2030)
Approximate Shipping Weight Model 80

Domestic , lb. (kg) 1250 (568)
Export , lb. (kg) 1450 (660)
* Based on operation with natural gas at less than 1,500ft.(450m)alt itude. 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 subjec t to change withoutTOC

notice. 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

3045-067: Honeywell Intermittent Pilot Modules (Flame Control)
3045-069: Honeywell Intermittent Pilot Combination Gas Controls
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
69-0463-1.fm Page 1 Wednesday, December 19, 2007 1:22 PM
S8600, S8610, S8660, S8670

3045067
Intermittent Pilot Module
INSTALLATION INSTRUCTIONS
APPLICATION
These ignition modules provide ignition sequence, flame ambient temperature rating is -40° F (-40° C). Maximum
monitoring, and safety shutoff for intermittent pilot central ambient rating is 175° F (79° C) for S8600, S8660 and
furnaces and heating appliances. S8600 and S8660 for S8610, S8670 used with 1.0A or less main valve.
models provide up to 1.0A pilot and 1.0A main valve Maximum ambient rating for S8610, S8670 used with 1.0
current rating. S8610 and S8670 models provide up to to 2.0A main valve is 165° F (74° C). See Table 1 for a
1.0A pilot and 2.0A main valve current rating. Minimum summary of other differences between models.
Table 1. Intermittent Pilot Ignition Modules.

Igniter 100
Sensor Type of Prepurge Percent Lockout
Model Type Gas Timing Shutoff Timing Ignition Sequencea
S8600A, Separate Natural None No No Spark on until pilot lightoff or manual
S8610A shutoff; pilot valve open until manual
S8600F, Combination shutdown.
S8610F
S8600B, Separate Natural None Yes at 15 or 90 Spark on until lightoff or lockout; pilot
S8610B or LP lockout sec. max., valve closes on lockout.
as ordered
S8600H, Combination Natural None Yes at 15 or 90 Spark on until lightoff or lockout; pilot
S8610H or LP lockout sec. max., valve closes on lockout.
as ordered
S8600M Combination Natural None Yes, at 90 No, Spark and pilot gas on until shutoff. After
or LP sec. max. continuous 5-min. minimum (6-min. nominal) delay,
retry ignition starts again. Ignition, wait, retry
repeats until pilot lights or system is
shutdown manually.
S8660D, Combination Natural 45 sec. Yes, at 90 15 or 90 Ignition trial follows prepurge; spark on
S8670D or LP sec. max. sec. max., until lightoff or lockout; pilot valve closes
as ordered on lockout.
a If established flame is lost, all models restart ignition trial.
BEFORE INSTALLATION
Intermittent pilot systems are used on a wide variety of in the environment. In these situations, special steps may
central heating equipment and on heating appliances be required to prevent nuisance shutdowns and
such as commercial cookers, agricultural equipment, premature control failure. These applications require
industrial heating equipment and pool heaters. Some of Honeywell Residential Division Engineering review;
these applications may make heavy demands on the contact your Honeywell Sales representative for
controls, either because of frequent cycling, or because assistance.
of moisture, corrosive chemicals, dust or excessive heat
69-0463—01
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S8600, S8610, S8660, S8670 INTERMITTENT PILOT MODULE
Frequency Cycling INSTALLATION

These controls are designed for use on space heating
appliances that typically cycle 3 to 4 times an hour during
the heating season and not at all during the cooling When Installing This Ignition System…
season. In an application with significantly greater cycling 1. Read these instructions carefully. Failure to follow
rates and closer to year-round use, we recommend them could damage the components or cause a
monthly checkout because the controls may wear out hazardous condition.
more quickly. 2. Check the ratings given in the instructions and on
the components to make sure they are suitable for
Water or Steam Cleaning your application.
Once a module or gas control has been wet, it may 3. Installer must be a trained, experienced service
operate unreliably and must be replaced. If the appliance technician.
is likely to be cleaned with water or steam, the controls 4. After installation is complete, check out component
and associated wiring should be covered so water or operation as provided in these instructions.
steam flow cannot reach them. The controls should be
high enough above the bottom of the cabinet so they will
not be subject to flooding or splashing during normal
cleaning procedures. If necessary, shield the controls to
WARNING
Fire or Explosion Hazard. Can cause severe
protect them from splashing water. A NEMA 4 enclosure injury, death or property damage.
is recommended for the ignition module; see the 1. The ignition module can malfunction if it gets wet,
Electronic Ignition Service Manual, form 70-6604. leading to accumulation of explosive gas.
• Never install where water can flood, drip, or
High Humidity or Dripping Water condense on module.
Over time, dripping water or high ambient humidity can • Never try to use a module that has been
create unwanted electrical paths on the module circuit wet-replace it.
board, causing the module to fail. Never install an 2. Liquefied petroleum (LP) gas is heavier than air and
appliance where water can drip on the controls. will not vent upward naturally.
• Do not light pilot or operate electric switches,
In addition, high ambient humidity can cause the gas lights or appliances until you are sure the
control to corrode, and finally to fail. appliance area is free of gas.
Where the appliance may be installed in a humid

atmosphere, make sure air circulation around the module
and gas control is adequate to prevent condensation. It is
CAUTION
Electrical Shock Hazard.
also important to regularly check out the system. A NEMA
Can cause severe injury, death or property
4 enclosure may be needed; see the Electronic Ignition
damage.
Service Manual, form 70-6604.
1. Disconnect power supply before beginning wiring to
prevent electrical shock or equipment damage.
Corrosive Chemicals 2. If a new gas control is to be installed, turn off gas
Corrosive chemicals can also attack the module and gas supply before starting installation. Conduct Gas
control and eventually cause a failure. Where chemicals Leak Test according to gas control manufacturer
may be used routinely for cleaning, make sure the instructions after the gas control is installed.
cleaning solution cannot reach the controls. Where 3. If module must be mounted near moisture or water,
chemicals are likely to be suspended in air, as in some provide suitable waterproof enclosure.
industrial and agricultural applications, protect the ignition
module from exposure with a NEMA 4 enclosure; see the
Electronic Ignition Service Manual, form 70-6604. Perform Preinstallation Safety Inspection
The preinstallation checks described in ANSI Standard
Z21.71 on page 19 must be done before the replacement
Dust or Grease Accumulation module is installed. If a condition which could result in
Heavy accumulation of dust or grease may cause the unsafe operation is detected, the appliance should be
controls to malfunction. Where dust or grease may be a shut off and the owner advised of the unsafe condition.
problem, provide covers for the module and the gas Any potentially unsafe condition must be corrected before
control that will limit environmental contamination. A proceeding with the installation.
NEMA 4 enclosure is recommended for the ignition
module; see the Electronic Ignition Service Manual, form
70-6604. Maintenance Requirements in Severe
Environments
Heat Regular preventive maintenance is important in any
The controls can be damaged by excessively high application, but especially in commercial cooking,
temperatures. Make sure the maximum ambient agricultural, and industrial applications, because:
temperature at the control locations will not exceed the 1. In many such applications, particularly commercial
rating of the control. If the appliance normally operates at cooking, the equipment operates 100,000-200,000
very high temperatures, insulation, shielding, and air cycles per year. Such heavy cycling can wear out
circulation may be necessary to protect the controls. the gas control in one to two years. A normal forced
Proper insulation or shielding should be provided by the air furnace, for which the controls were originally
appliance manufacturer; make sure adequate air intended, operates less than 20,000 cycles per
circulation is maintained when the appliance is installed. year.
69-0463—01 2
TOC MB-TOC INDEX

2. Exposure to water, dirt, chemicals, and heat can Wire the System
damage the module or the gas control and shut
down the control system. A NEMA 4 enclosure can
reduce exposure to environmental contaminants.
See Electronic Ignition Service Manual, form CAUTION
70-6604. Electrical Shock Hazard.
The maintenance program should include regular Can cause severe injury, death or property
checkout of the system as outlined under CHECKOUT, damage.
page 11. 1. Check the wiring diagram furnished by the
appliance manufacturer, if available, for circuits
differing from the wiring hookups shown in this
WARNING publication. Carefully follow any special instructions
affecting the general procedures outlined below.
Fire or Explosion Hazard. Can cause severe 2. Disconnect the power supply before making wiring
injury, death or property damage. connections to prevent electrical shock or
Do not attempt to take the module apart or to equipment damage.
clean it. Improper reassembly and cleaning may
cause unreliable operation. IMPORTANT
1. As shown in the wiring diagrams, a common
Maintenance frequency must be determined individually ground is required on:
for each application. Some considerations are: • The pilot burner mounting bracket, and the GND
• Cycling frequency. Appliances that may cycle more (BURNER) terminal on the ignition module.
than 20,000 times annually should be checked • Failure to use the GND (BURNER) terminal may
monthly. result in intermittent loss of spark and/or loss of
• Intermittent use. Appliances that are used seasonally flame current sensitivity.
should be checked before shutdown and again before 2. Make sure the transformer has adequate VA.
the next use. The ignition module requires at least 0.2A at 24
• Consequence of unexpected shutdown. Where the Vac. Add the current draws of all other devices in
cost of an unexpected shutdown would be high, the the control circuit, including the pilot and main
system should be checked more often. valves in the gas control, and multiply by 24 to
• Dusty, wet, or corrosive environment. Since these determine the total VA requirement of these
environments can cause the controls to deteriorate components. Add this total to 4.8 VA (for the
more rapidly, the system should be checked more ignition module). The result is the minimum
often. transformer VA rating. Use a Class II transformer
if replacement is required.
Any control should be replaced if it does not perform
properly on checkout or troubleshooting. In addition,
replace any module if it is wet or looks like it has ever
Connect Ignition Cable
been wet. Protective enclosures as outlined under Use Honeywell ignition cable or construct an ignition
"Planning the Installation" are recommended regardless cable that conforms to suitable national standards such as
of checkout frequency. Underwriters Laboratories Inc. (See Tables 2 and 3).
Table 2. Honeywell Preassembled Ignition Cables

Mount Ignition Module (UL Style 3257).
Select a location close enough to the burner to allow a Cable Part Module Igniter
short 3 ft. (0.9 m) max. direct cable route to the igniter. Number Length End End
Ambient temperature at the module must be within the
range listed under APPLICATION, page 1. The module 394800-30 30 in. 1/4 in. Rajah connector
must be protected from water, moisture, corrosive (762 mm) quick receptacle, 90 deg.
chemicals and excessive dust and grease. connect, rubber boot
insulated
We recommend mounting the module with the terminals 394801-30 30 in. 1/4 in. Rajah connector
down to protect them from dripping water and dust. It can (762 mm) quick receptacle, straight
also be mounted with the terminals on either side. DO connect, rubber boot
NOT MOUNT with the terminals pointing up. Fasten insulated
securely with four No. 6-32 machine or No. 8 sheetmetal
screws. Table 3. Recommended Ignition Cable for Field
Assembly.
Mount the System Controls Temperature
Mount any required controls, such as the gas control, Voltage Rating Rating
spark igniter, flame sensor, thermostat, limit and Cable Type (rms) C F
transformer according to manufacturer’s instructions. UL Style 3217 10,000 150 302
UL Style 3257 10,000 250 484
Cable must be no longer than 36 in. (0.9 m). To construct
a cable, fit one end of ignition cable with ¼ in. diameter
Rajah connector receptacle and the other with a ¼ in.
female quick connect. Protect both ends with insulated
boots.
3 69-0463—01
TOC MB-TOC INDEX

NOTE: The cable must not run in continuous contact 7. Adjust thermostat heat anticipator to match system
with a metal surface or spark voltage will be current draw. The current draw equals the total
greatly reduced. Use ceramic or plastic standoff current required for the ignition module (0.2A) plus
insulators as required. the gas control and any other auxiliary equipment in
the control circuit.
To Install:
1. Connect one end of the cable to the male quick Connect Gas Control
connect SPARK terminal on the ignition module. Use No. 18 gauge solid or stranded wire. Use 1/4 in.
2. Connect the other end of the cable to the igniter or female quick connects for module connections. Connect
igniter-sensor stud on the pilot burner/igniter- to gas control terminals as shown in wiring diagrams,
sensor. using terminals appropriate to the gas control.
Connect Vent Damper Ground Control System

The D80B Vent Damper can be used with all ignition The igniter, flame sensor and ignition module must share
modules, although the Molex plug provided on some a common ground with the main burner. Use
modules simplifies wiring connections when used with the thermoplastic insulated wire with a minimum rating of
D80D Plug-In Vent Damper. Once a module with vent 221° F (105° C) for the ground wire; asbestos insulation is
damper plug has powered a vent damper circuit, it cannot not acceptable. If necessary, use a shield to protect the
be used in a gas system without a vent damper. A wire from radiant heat generated by the burner. Connect
non-replaceable fuse in the module blows on initial the ground wire as follows:
power-up. Once this fuse has blown, the module will not
work unless the vent damper is connected. 1. Fit one end of the ground wire with a female ¼ in.
quick-connect terminal and connect it to the male
To connect the plug-in model to the D80D: quick-connect GND (BURNER) terminal on the
1. Remove the plug from the terminal strip on the ignition module.
ignition module case and discard. 2. Strip the other end of the wire and fasten it under
2. Using the wiring harness supplied, insert the the igniter bracket mounting screw. If necessary,
matching pin plug into receptacle on case and other use a shield to protect the ground wire from radiant
end to vent damper. heat.
3. To connect the D80B, follow the wiring diagrams 3. The burner serves as the common grounding area.
supplied with the vent damper or Refer to Fig. 7 for If there is not good metal-to-metal contact between
typical connections. the burner and ground, run a lead from the burner
to ground.
Connect Ignition Module NOTE: “Earth” ground is not required.
1. Connect remaining system components to the
ignition module terminals as shown in the
appropriate wiring diagram, Figures 1 through 10. Replacing Module with TH-R, TH-W Terminals
2. Fig. 1 is a basic circuit for a heating only atmo- On modules that do not have a vent damper plug, the
spheric burner with S8600F,H,M S8660D or thermostat must be connected between the transformer
S8670D. and the 24V terminal on the module. To change out a
3. Fig. 2 shows S8600F,H,M; S8610F,H with vent module with TH-R, TH-W terminals:
damper plug in a heating only atmospheric burner
system with D80D vent damper. Never use a vent 1. Remove the wires from the 25V(2) and TH-R
damper in an LP gas system or in a fan-assisted terminals on the old module. Connect these two
combustion system. wires with a solderless connector.
4. Figures 3 and 4 show S8600A,B; S8610A,B with 2. Tag and remove the remaining wires from the old
separate sensor and ignitor, with and without the module.
D80D vent damper. 3. Remove the old module and mount the new one in
5. Figures 5 through 10 show S8600F,H,M; S8610F,H; the same location.
S8660D; and S8670D in a variety of systems, with 4. Reconnect the remaining wires as shown in
alternate connections for modules with vent damper Table 4.
plug. Remember, however, that a vent damper 5. Increase the thermostat anticipator setting by 0.2A.
should not be used in an fan-assisted combustion
system or an LP gas system and that the vent Table 4. Terminal Cross Reference.
damper plug must not be removed except to con-
nect the module to a D80D with the plug-in cable. Terminal on Terminal on
S8600A,B; S8610A,B can be substituted in these Old Module: New Module
drawings by simply connecting the igniter and sen- 25V (1) 24V (GND)
sor as shown in Figures 3 and 4. TH-W 24V
6. Refer to heating appliance manufacturer’s
instructions for wiring auxiliary controls. MV MV
MV/PV MV/PV
PV PV
GND (Burner) GND (Burner)
69-0463—01 4
TOC MB-TOC INDEX

S8600F,H,M; S8610F,H; S8660D; S8670D

5 VENT
GND 24V TH-W DAMPER
MV MV/PV PV (BURNER) GND 24V (OPT) PLUG (OPT) SPARK
3
5
MAIN
PILOT COM VALVE
4
1ST 2ND
OPERATOR OPERATOR
2
THERMOSTAT
DUAL VALVE COMBINATION
GAS CONTROL
LIMIT
CONTROLLER
L1
L2
(HOT)
PILOT BURNER 1
Q345, Q346,
GROUND
Q348, Q362, Q381
PILOT BURNER/
IGNITER-SENSOR PILOT GAS
SUPPLY
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2 ALTERNATE LIMIT CONTROLLER LOCATION.
3 MAXIMUM CABLE LENGTH 3 ft [0.9 m].
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND

LEG TO TRANSFORMER.
5 FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG. M1175D
Fig. 1. S8600F,H,M; S8610F,H; S8660D; S8670D Connections in a Heating System with an Atmospheric Burner.
S8600F,H,M; S8610F,H; S8660D; S8670D

5 VENT
GND 24V TH-W DAMPER
3
5
MAIN
PILOT COM VALVE
4
1ST 2ND
OPERATOR OPERATOR
2
THERMOSTAT
GAS CONTROL
LIMIT
CONTROLLER
L1
L2
(HOT)
PILOT BURNER 1
Q345, Q346,
GROUND
Q348, Q362, Q381
PILOT BURNER/
SUPPLY
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND

LEG TO TRANSFORMER.
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG. M1175D
Fig. 2. S8600F,H,M; S8610F,H with a Vent Damper Plug in a Heating System with an Atmospheric Burner and a
D80D Vent Damper.
5 69-0463—01
TOC MB-TOC INDEX

S8600A,B; S8610A,B
5 VENT
GND 24V TH-W DAMPER
MV MV/PV PV (BURNER) GND 24V (OPT) PLUG (OPT) SENSE SPARK
5 3
MAIN
PILOT COM VALVE
1ST 2ND THERMOSTAT

OPERATOR OPERATOR
DUAL VALVE COMBINATION 2

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS GAS CONTROL
AND OVERLOAD PROTECTION AS REQUIRED.
SENSOR
1
3 MAXIMUM CABLE LENGTH 3 ft [0.9 m]. L2
4
L1
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN (HOT)
GROUND LEG TO TRANSFORMER. LIMIT
IGNITER GROUND CONTROLLER
5 FOR MODULE WITH TH-W TERMINAL AND VENT
DAMPER PLUG, CONNECT THERMOSTAT TO TH-W. PILOT GAS
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG. SUPPLY
M1186D
Fig. 3. S8600A,B; S8610A,B Connections in a Heating System with an Atmospheric Burner.
S8600A,B; S8610A,B
VENT
GND 24V DAMPER
MV MV/PV PV (BURNER) GND 24V TH-W PLUG 5 SENSE SPARK
3
PILOT COM MAIN
197516A
VALVE
WIRING
1ST 2ND HARNESS
OPERATOR OPERATOR
THERMOSTAT
DUAL VALVE COMBINATION 2
GAS CONTROL
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS SENSOR D80D VENT DAMPER

AND OVERLOAD PROTECTION AS REQUIRED.
2 1
ALTERNATE LIMIT CONTROLLER LOCATION.
L2
3 4
MAXIMUM CABLE LENGTH 3 FEET [0.9 METERS]. L1
(HOT)
4 LIMIT
CONTROLS IN 24V CIRCUIT MUST NOT BE IN IGNITER GROUND
GROUND LEG TO TRANSFORMER. CONTROLLER
5 PILOT GAS
REMOVE PLUG ONLY IF USING VENT DAMPER. SUPPLY
M1185E
Fig. 4. S8600A,B; S8610A,B with Vent Damper Plug in an Atmospheric Burner Heating System with a D80D Vent
Damper.
69-0463—01 6
TOC MB-TOC INDEX

S8600F,H,M; S8610F,H; S8660D; S8670D

5 VENT
GND 24V TH-W DAMPER
5 3
MAIN AIR THERMOSTAT

PILOT COM VALVE PROVING
SWITCH
1ST 2ND
OPERATOR OPERATOR
2
GAS CONTROL 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS
COMBUSTION AND OVERLOAD PROTECTION AS REQUIRED.
AIR BLOWER
RELAY 4 2 ALTERNATE LIMIT CONTROLLER LOCATION.

4
CONTROLS IN 24V CIRCUIT MUST NOT BE IN
GROUND LEG TO TRANSFORMER.
LIMIT
L1 CONTROLLER 5
L2 FOR MODULE WITH TH-W TERMINAL AND VENT
(HOT) COMBUSTION
PILOT 1 DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
AIR BLOWER LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
Q345, Q346, BURNER MOTOR L2 L1
Q348, Q362, Q381 GROUND
PILOT BURNER/ (HOT)
1
SUPPLY
M1177D
Fig. 5. S8600F,H,M; S8610F,H; S8660D; S8670D Connections in a Heating System with Power-Assisted
Combustion.
S8600F,H,M; S8610F,H; S8660D; S8670D

5 VENT
GND 24V TH-W DAMPER
5 3
MAIN VALVE AIR

MAIN STAGE 2 PROVING
VALVE SWITCH
THERMOSTAT
PILOT COM GROUND STAGE 1
R W2 W1
1ST 2ND
OPERATOR OPERATOR
2 Q345, Q346,
Q348, Q362,
TWO STAGE DUAL VALVE Q381PILOT
COMBINATION GAS CONTROL COMBUSTION PILOT
BURNER/
AIR BLOWER BURNER
IGNITER-
RELAY GROUND
SENSOR
PILOT GAS
SUPPLY
4
LIMIT
CONTROLLER
COMBUSTION
L1 L2
1 AIR BLOWER
(HOT) 1
L1 L2 MOTOR
(HOT) M1178D
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.
24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
Fig. 6. S8600F,H,M; S8610F,H; S8660D; S8670D Connections in a Heating System with a Two-Stage Gas Control
and Power-Assisted Combustion.
7 69-0463—01
TOC MB-TOC INDEX

S8600F,H,M; S8610F,H; S8660D; S8670D

5 VENT
GND 24V TH-W DAMPER
5 3
MAIN D80B
PILOT COM VALVE END SWITCH
N.O. N.C.
1ST 2ND
OPERATOR OPERATOR 1K2
DUAL VALVE COMBINATION 1K1

GAS CONTROL
MOTOR
R
1K3 1K
Q345, Q346,
Q348, Q362, Q381
PILOT BURNER/ 1 2 3 4 5
IGNITER-SENSOR PILOT
BURNER
BLACK
RED
BLUE
ORANGE
YELLOW
GROUND 6
PILOT GAS
SUPPLY 4
TRANSFORMER THERMOSTAT
L2 OR
CONTROLLER
L1
LIMIT
(HOT)
LIMIT 2 CONTROLLER
1 CONTROLLER
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN GROUND LEG TO TRANSFORMER.
5 FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
6 COLORS REFER TO WIRE HARNESS, IF USED.

M1180D
Fig. 7. S8600F,H,M; S8610F,H; S8660D; S8670D in a Heating System with an Atmospheric Burner and a D80D
Vent Damper.
69-0463—01 8
TOC MB-TOC INDEX

S8600F,H,M; S8610F,H; S8660D; S8670D

5 VENT
GND 24V TH-W DAMPER
5 3
MAIN
PILOT COM VALVE
1ST 2ND
OPERATOR OPERATOR

GAS CONTROL
Q345, Q346,
L1 L2
L2 L1 THERMOSTAT Q348, Q362, PILOT
(HOT) 1
(HOT) Q381PILOT BURNER
1 BURNER/ GROUND
R G IGNITER-
COMBUSTION SENSOR PILOT GAS
W Y
R8239 AIR BLOWER SUPPLY
FAN MOTOR
LIMIT
CON- CENTER
TROLLER COMBUSTION
R C AIR BLOWER
4
RELAY
W G Y
COIL 2 AIR PROVING 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS

SWITCH AND OVERLOAD PROTECTION AS REQUIRED.

COOLING PRESSURE
CONTROL CONTROLLER 3 MAXIMUM CABLE LENGTH 3 ft [0.9 m].
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN

FAN
MOTOR 5
FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER
FAN PLUG, CONNECT THERMOSTAT TO TH-W. LEAVE
L
CONTROL 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
C H
M1182D
Fig. 8. S8600F,H,M; S8610F,H; S8660D; S8670D Connections in a Heating-Cooling System with

Power-Assisted Combustion.
9 69-0463—01
TOC MB-TOC INDEX

S8600F,H,M; S8610F,H; S8660D; S8670D

4 VENT
GND 24V TH-W DAMPER
4 3
PILOT COM MAIN
VALVE
1ST 2ND
OPERATOR OPERATOR D80D
DUAL VALVE COMBINATION 1K
GAS CONTROL 1K1
D80 MOTOR Q345, Q346,

PILOT
Q348, Q362,
BURNER
Q381PILOT
GROUND
BURNER/
N.C. 1K2 IGNITER- PILOT GAS
C.
N.O. SENSOR SUPPLY
1K3
4 3 2 1
CABLE
2 BLUE
YELLOW
BLACK
ORANGE
G L8148J
L1 L1
(HOT)
1 TP B R 1K1
5
1K
1K3 Z W T AUTO
MANUAL
TV 1K2
SWITCH FAN
MOTOR
C1
B3 B2 B1 C2
L2 L2
THERMOSTAT
M1181D
2 CUT PLUG OFF MODULE END OF D80D WIRE HARNESS, CONNECT LEADWIRE COLORS AS SHOWN.
4 FOR MODULE WITH TH-W TERMINAL AND VENT DAMPER PLUG, CONNECT THERMOSTAT TO TH-W.
LEAVE 24V OPEN. DO NOT REMOVE VENT DAMPER PLUG.
5 LEAVE TP-Z AND Z-W JUMPERS IN PLACE.
Fig. 9. S8600F,H,M; S8610F,H; S8660D; S8670D Connections in a Hydronic Heating System with a D80D Vent
Damper.
69-0463—01 10
TOC MB-TOC INDEX

S8610U
4 VENT
GND 24V TH-W DAMPER
M MV/P PV (BURNER) GND 24 (OPT) PLUG SENSE SPARK
V V V
5 6
3
MAIN L8100
PILOT COM VALVE
2
1ST 2ND ECO
OPERATOR OPERATOR CONTROLLER

GAS CONTROL
4
1 POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS
1
REQUIRED.
2 ALTERNATE LIMIT CONTROLLER LOCATION. L1 L 2

(HOT)
4 CONTROLS IN 24V CIRCUIT MUST NOT BE IN

GROUND
PILOT GAS
5 DO NOT REMOVE VENT DAMPER PLUG. SUPPLY
6 REMOVE JUMPER AND CONNECT SENSE

TERMINAL ON TWO ROD APPLICATION ONLY. M1179B
Fig. 10. S8600F,H,M; S8610F,H; S8660D; S8670D Connections in a Commercial Water Heater Control System.
CHECKOUT
Check out the gas control system: STEP 3: Reset the Module.
• At initial installation of the appliance. • Turn the thermostat to its lowest setting.
• As part of regular maintenance procedures. • Wait one minute.
Maintenance intervals are determined by the
application. See PLANNING THE INSTALLATION, As you do Steps 4 and 5, watch for points where
page 1, for more information. operation deviates from normal. Refer to Troubleshooting
• As the first step in troubleshooting. Chart to correct problem.
• Any time work is done on the system.
STEP 4: Check Safety Shutoff Operation.
This step applies to lockout and continuous retry modules
WARNING only.
• Turn gas supply off.
Fire or Explosion Hazard. • Set thermostat or controller above room temperature
Can cause severe injury, death, or property to call for heat.
damage. • Watch for spark at pilot burner either immediately or
1. If you smell gas or suspect a gas leak, turn off following prepurge. See device label.
gas at manual service valve and evacuate the • Time spark from start to shutoff. See device label. On
building. Do not try to light any appliance, do S8600M, wait 6 min. nominal. Ignition sequence
not touch any electrical switch or telephone in should start again followed by shutoff after 90 sec.
the building until you are sure no spilled gas max.
remains. • Open manual gas cock and make sure no gas is
2. Gas leak test must be done as described in flowing to pilot or main burner.
Steps 1 and 5 below on initial installation and • Set thermostat below room temperature and wait one
any time work is done involving the gas piping. minute before continuing.
STEP 1: Perform Visual Inspection. STEP 5: Check Normal Operation.
• With power off, make sure all wiring connections are • Set thermostat or controller above room temperature
clean and tight. to call for heat.
• Turn on power to appliance and ignition module. • Make sure pilot lights smoothly when gas reaches the
• Open manual shutoff valves in the gas line to the pilot burner.
appliance. • Make sure main burner lights smoothly without
• Do gas leak test ahead of gas control if piping has flashback.
been disturbed. • Make sure burner operates smoothly without floating,
GAS LEAK TEST: Paint pipe joints with rich soap and lifting, or flame rollout to the furnace vestibule or heat
water solution. Bubbles indicate gas leak. Tighten joints to buildup in the vestibule.
stop leak. Recheck with soap and water.
If gas line has been disturbed, complete gas leak test.
STEP 2: Review Normal Operating Sequence and GAS LEAK TEST: Paint gas control gasket edges and all
Module Specifications. pipe connections downstream of gas control, including
• See OPERATION, page 12 and APPLICATION, pilot tubing connections, with rich soap and water
page 1.
11 69-0463—01
TOC MB-TOC INDEX

solution. Bubbles indicate gas leaks. Tighten joints and Figures 11 and 12 summarize the normal operating
screws or replace component to stop gas leak. Recheck sequences of the modules.
with soap and water.
• Turn thermostat or controller below room temperature. Prepurge (S8660, S8670 ONLY)
Make sure main burner and pilot flames go out. When the S8660 is used in a fan-assisted combustion
system, the combustion air blower starts on a call for heat.
On proof of airflow, the air proving switch closes and
OPERATION energizes the S8660, S8670. When the module is used in
an atmospheric system, the call for heat energizes the
module.
Module operation can be conveniently divided into two
phases for S8600, S8610 and three for S8660, S8670. In either case, the module first initiates a 45 sec. delay to
The phases are: allow system prepurge. After prepurge, the module starts
• Prepurge (S8660, S8670 only) the pilot ignition sequence.
• Trial for ignition (all models)
• Main burner operation (all models)
START 11
THERMOSTAT (CONTROLLER)
CALLS FOR HEAT
STAGE 1 2
SPARK GENERATOR POWERED
TRIAL FOR First valve (pilot) operator opens
IGNIITION
3
PILOT BURNER OPERATION
Pilot burner lights. Pilot burner does not light.
Module senses OR Module Response
flame current. S8600A,F Ignition spark continues, pilot
S8610A,F valve remains open until system
is reset
S8600B,H After 15 or 90 sec a system

S8610B,H locks out; must be
manually reset.
S8600M After 90 sec.a system shuts off;
after 5 minutes min. (6 minutes
nom.), module restarts trial for
ignition; ignition trial, shutoff, wait
sequence repeats until pilot lights
or call for heat ends.
a Shutoff/lockout timing is stamped on module
4 FLAME CURRENT SENSED

STAGE 2 • Spark generator off.
• Second valve operator (main)
MAIN BURNER
OPERATION opens.
POWER INTERRUPTION
System shuts off, restarts when power is
5 MAIN BURNER OPERATION restored.
Module monitors pilot flame
current. PILOT FLAME FAILURE
Main valve closes.
Module starts trial for ignition.
6 THERMOSTAT (CONTROLLER)
SATISFIED
Valves close, pilot and main
END burners are off.
M1172C
Fig. 11. S8600, S8610 Normal Operating Sequence.
Trial for Ignition

Pilot Ignition If the pilot does not light, or the pilot flame current is not at
Following prepurge timing (S8660, S8670), or on the call least 1.0 μA and steady, the module will not energize the
for heat (S8600, S8610), the module energizes the first second (main) valve and the main burner will not light.
main valve operator. The first main valve opens, which S8600A,F; S8610A,F will continue to spark as long as the
allows gas to flow to the pilot burner. At the same time, thermostat calls for heat, or until the pilot lights.
the electronic spark generator in the module produces
over 10,000 volt spark pulse output. The voltage Safety Lockout (S8600B,H; S8610B,H; S8660D;
generates a spark at the igniter (S8600A,B; S8610A,B) or
igniter-sensor (S8600F,H,M; S8610F,H; S8660; S8670)
S8670D)
that lights the pilot. These modules provide 100 percent shutoff and safety
lockout. A timer in these models starts timing the moment
the trial for ignition starts. Ignition spark continues only
until the timed trial for ignition period ends. Then the
module goes into safety lockout. Lockout de-energizes
the first main valve operator and closes the first main
(pilot) valve in the gas control, stopping pilot gas flow. The
69-0463—01 12
TOC MB-TOC INDEX

control system must be reset by setting the thermostat Main Burner Operation
below room temperature for one minute or by turning off When the pilot flame is established, a flame rectification
power to the module for one minute. circuit is completed between the sensor and burner
ground. The flame sensing circuit in the module detects
Safety Shutoff with Continuous Retry (S8600M) the flame current, shuts off the spark generator and
The S8600M provides 100 percent gas shutoff, followed energizes the second main valve operator. The second
by retry for ignition. Operation on ignition failure is the main valve opens and gas flows to the main burner,
same as lockout modules, except that a timer starts timing where it is ignited by the pilot burner. On lockout models,
immediately following shutoff. Six minutes nom. (five the flame current also holds the safety lockout timer in the
minutes min.) after shutoff, the module restarts the reset (normal) operating condition.
ignition sequence. The ignition trial, shutoff, wait
sequence continues until either the pilot lights or the When the call for heat ends, both valve operators are
thermostat is set below room temperature to end the call de-energized, and both valves in the gas control close.
for heat. The module can also be reset by setting down
the thermostat for one minute.
START 1
THERMOSTAT
CALLS FOR HEAT
STAGE 1 2
PREPURGE
PREPURGE
Combustion air blower starts.
3
SPARK GENERATOR POWERED
STAGE 2 First valve (pilot) operator opens.
TRIAL FOR IGNITION
4
PILOT BURNER OPERATION
Pilot burner lights. Pilot burner does not light.
S8660, S8670 senses flame OR After 15 or 90 seca , system
current. locks out; must be manually reset.
a Lockout timing is
stamped on module.
5 FLAME CURRENT SENSED

• Spark generator off.
• Second valve operator (main)
opens.
STAGE 3 POWER INTERRUPTION

MAIN BURNER System shuts off, restarts when power is
OPERATION 6 MAIN BURNER OPERATION restored.
Module monitors pilot flame
current. PILOT FLAME FAILURE
Main valve closes.
S8660, S8670 starts trial for ignition.
7 THERMOSTAT SATISFIED
Valves close, pilot and main
END burners are off.
M1171C
Fig. 12. S8660, S8670 Normal Operating Sequence.
TROUBLESHOOTING
IMPORTANT Perform the checkout on page 11 as the first step in
1. The following service procedures are provided troubleshooting. Then check the appropriate
as a general guideline. Follow appliance troubleshooting guide (Figures 14 or 15) and the
manufacturer service instructions, if available. schematic diagram (Figures 16 or 17) to pinpoint the
2. On lockout and retry models, meter readings cause of the problem. If troubleshooting indicates an
between gas control and ignition module must ignition problem, see Ignition System Checks below to
be taken within the trial for ignition period. Once isolate and correct the problem.
the ignition module shuts off, lockout models
must be reset by setting the thermostat down for Following troubleshooting, perform the checkout
at least one minute before continuing. On retry procedure again to be sure system is operating normally.
models, wait for retry or reset at the thermostat.
3. If any component does not function properly,
make sure it is correctly installed and wired Ignition System Checks
before replacing it. STEP 1: Check ignition cable.
4. The ignition module cannot be repaired. If it Make sure:
malfunctions, it must be replaced. 1. Ignition cable does not run in contact with any metal
5. Only trained, experienced service technicians surfaces.
should service intermittent pilot systems. 2. Ignition cable is no more than 36 in. (0.9 m) long.
13 69-0463—01
TOC MB-TOC INDEX

3. Connections to the ignition module and to the 3. If so, ensure adequate flame current as follows.
igniter or igniter-sensor are clean and tight. a. Turn off furnace at circuit breaker or fuse box.
4. Ignition cable provides good electrical continuity. b. Clean the flame rod with emery cloth.
c. Make sure electrical connections are clean and
STEP 2: Check ignition system grounding. Nuisance tight. Replace damaged wire with moisture-
shutdowns are often caused by a poor or erratic ground. resistant No. 18 wire rated for continuous duty
1. A common ground, usually supplied by the pilot up to 221° F (105° C).
burner bracket, is required for the module and the d. Check for cracked ceramic insulator, which can
pilot burner/igniter-sensor. cause short to ground, and replace igniter-
a. Check for good metal-to-metal contact between sensor if necessary.
the pilot burner bracket and the main burner. e. At the gas control, disconnect main valve wire
b. Check the ground lead from the from the TH or MV terminal.
GND(BURNER) terminal on the module to the f. Turn on power and set thermostat to call for
pilot burner. Make sure connections are clean heat. The pilot should light but the main burner
and tight. If the wire is damaged or deteriorated, will remain off because the main valve actuator
replace it with No. 14-18 gauge, moisture- is disconnected.
resistant, thermoplastic insulated wire with 221° g. Check the pilot flame. Make sure it is blue,
F (105° C) minimum rating. steady and envelops 3/8 to 1/2 in. (10 to 13
(1) Check the ceramic flame rod insulator for mm) of the flame rod. See Fig. 13 for possible
cracks or evidence of exposure to extreme flame problems and their causes.
heat, which can permit leakage to ground.
Replace pilot burner/igniter-sensor and pro-
vide shield if necessary.
APPEARANCE CAUSE
(2) If flame rod or bracket are bent out of posi- SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM:
tion, restore to correct position. • CLOGGED ORIFICE FILTER
• CLOGGED PILOT FILTER
STEP 3: Check spark ignition circuit. You will need a short • LOW GAS SUPPLY PRESSURE
jumper wire made from ignition cable or other heavily • PILOT ADJUSTMENT AT MINIMUM
insulated wire.
1. Close the manual gas valve.
2. Disconnect the ignition cable at the SPARK terminal LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM:
to the module. • DIRTY ORIFICE
• DIRTY LINT SCREEN, IF USED
WARNING
• DIRTY PRIMARY AIR OPENING,
IF THERE IS ONE
• PILOT ADJUSTMENT AT MINIMUM
Electrical Shock Hazard.
Can cause severe injury, death or property
damage. WAVING BLUE FLAME CHECK FOR:
When performing the following steps, do not touch • EXCESSIVE DRAFT AT PILOT
LOCATION
the stripped end of jumper or SPARK terminal.
• RECIRCULATING PRODUCTS
The ignition circuit generates over 10,000 volts OF COMBUSTION
and electrical shock can result.
3. Energize the module and immediately touch one

end of the jumper firmly to the GND terminal on the NOISY LIFTING CHECK FOR:
module. Move the free end of the jumper slowly BLOWING FLAME
• HIGH GAS PRESSURE
toward the SPARK terminal until a spark is estab-
lished.
4. Pull the jumper slowly away from the terminal and
note the length of the gap when sparking stops.
Check Table 5 below.
HARD SHARP FLAME THIS FLAME IS CHARACTERISTIC
Table 5. Checking Arc Length. OF MANUFACTURED GAS
CHECK FOR:
Arc Length Action
• HIGH GAS PRESSURE
No arc or arc less Check external fuse, if provided. • ORIFICE TOO SMALL
than 1/8 in. (3 mm) Verify power at module input
terminal. Replace module if fuse M3272A
and power okay.

Arc 1/8 in. (3 mm) or Voltage output is okay. Fig. 13. Examples of Unsatisfactory Pilot Flames.
longer.
h. If necessary, adjust pilot flame by turning the
STEP 4: Check pilot and main burner lightoff.
pilot adjustment screw on the gas control
1. Set the thermostat to call for heat.
clockwise to decrease or counterclockwise to
2. Watch the pilot burner during the ignition sequence.
increase pilot flame. Following adjustment,
See if.
always replace pilot adjustment cover screw
a. Ignition spark continues after the pilot is lit.
and tighten firmly to assure proper gas control
b. The pilot lights and the spark stops, but main
operation.
burner does not light.
i. Set thermostat below room temperature to end
c. S8600B,H,M; S8610B,H; S8660D; S8670D
call for heat.
only: The pilot lights, the spark stops and main
burner lights, but the system shuts down.
69-0463—01 14
TOC MB-TOC INDEX

4. Recheck ignition sequence as follows. e. If main burner doesn’t light or if main burner
a. Reconnect main valve wire. lights but system locks out, check module,
b. Set thermostat to call for heat. ground wire and gas control as described in
c. Watch ignition sequence at burner. appropriate troubleshooting chart, Figures
d. If spark still doesn’t stop after pilot lights, 14 or 15.
replace ignition module.
Before troubleshooting, familiarize yourself with the startup and checkout procedure.
START NOTE: Models with TH-W terminal (7) must have call for heat 24 Vac supply connected to the TH-W terminal.
Models with no TH-W terminal must have call for heat 24 Vac supply connected to 24V terminal (6).
TURN GAS SUPPLY OFF.
TURN THERMOSTAT
(CONTROLLER) TO CALL Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Also,
FOR HEAT NO check air proving switch on combustion air blower system (if used) and that vent damper (if used) is open and
end switch is made.
POWER TO MODULE?
(24V NOMINAL)
YES • On models with vent damper plug, make sure vent damper
Pull ignition lead and NO
check spark at module. has not been installed, then removed. Replace vent damper
if necessary.
NO • On other models, replace module.
SPARK ACROSS Spark okay?
IGNITER/SENSOR GAP?
(S8660, S8670, S8680
YES
HAVE 45 SECOND [NOMINAL]
PREPURGE BEFORE SPARK
STARTS.) • Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and
boot from excessive temperatures.
YES
TURN GAS SUPPLY ON

AND RECYCLE CALL NO • Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice
is not blocked.
FOR HEAT
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay, replace gas control; if not,
PILOT BURNER LIGHTS? replace module.
NOTE: It may be necessary to recycle the call for heat to clear the pilot supply tubes of air.
YES
NOTE: If S86XXB,H,D,J goes into lockout, reset system. For S86XXC,M,U,J,K, wait 6 min.
nom. for retry or reset system.
SPARK STOPS WHEN •
NO Check continuity of ignition cable and ground wire.
PILOT IS LIT? • Clean flame rod.
YES • Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
• Check that pilot flame covers flame rod and is steady and blue.
• Adjust pilot flame.
• If problem persists, replace module.
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.

MAIN BURNER LIGHTS? NO • Check electrical connections between module and gas control. If okay, replace gas control or gas control
operator.
YES
NOTE: If S86XXB,H,D,J goes into lockout, reset system. For S86XXC,M,U,J,K, wait 6 min.
SYSTEM RUNS UNTIL nom. for retry or reset system.
CALL FOR HEAT ENDS? NO
• Check continuity of ignition cable and ground wire.
YES NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at
the time of checkout.
• If checks are okay, replace module.
CALL FOR HEAT ENDS

NO • Check for proper thermostat (controller) operation.
SYSTEM SHUTS OFF? • Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas
control.
YES
TROUBLESHOOTING Repeat procedure until troublefree operation is obtained.

ENDS M1174G
Fig. 14. S8600, S8610 Troubleshooting Guide.
15 69-0463—01
TOC MB-TOC INDEX

START NOTE: Before troubleshooting, familiarize yourself with the startup and checkout procedure.
TURN GAS SUPPLY OFF.

TURN THERMOSTAT TO
CALL FOR HEAT Check line voltage power, low voltage transformer, limit controller, thermostat and wiring. Also, check air
NO proving switch on combustion air blower system and that vent damper (if used) is open and end switch is
POWER TO MODULE made.
(24V NOMINAL)
YES
45 SECOND
NO Replace S8670.
DELAY
YES
SPARK ACROSS
NO Pull ignition lead and check NO Replace module.
IGNITER/SENSOR GAP
spark at S8670.
YES
Spark okay?
YES
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and
boot from excessive temperatures.
TURN GAS SUPPLY ON

NO • Check that all manual gas cocks are open, supply tubing and pressures are good, and pilot burner orifice is
PILOT BURNER LIGHTS? not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module; If voltage is okay, replace gas control; if no
YES
voltage, replace module.
NOTE: If module goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.
SPARK STOPS WHEN • Clean flame rod.
PILOT IS LIT? NO
• Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
YES
• Adjust pilot flame.
• Check for 24 Vac (nominal) across MV-MV/PV terminals. if no voltage, replace module.
MAIN BURNER LIGHTS? NO • Check electrical connections between module and gas control. If okay, replace gas control.
YES
NOTE: If module goes into lockout, reset system.

SYSTEM RUNS UNTIL
NO • Check continuity of ignition cable and ground wire.
CALL FOR HEAT ENDS?
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the
YES time of checkout.
CALL FOR HEAT ENDS

NO • Check for proper thermostat (controller) operation.
SYSTEM SHUTS OFF? • Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas
control.
YES
TROUBLESHOOTING
Repeat procedure until troublefree operation is obtained.
ENDS M1173D
Fig. 15. S8660, S8670 Troubleshooting Guide.
69-0463—01 16
TOC MB-TOC INDEX

L1
LIMIT ON-OFF (HOT) L2
CONTROLLER SWITCH 1
THERMOSTAT OR
CONTROLLER 24V
2
TRANSFORMER
24V
24V
(GND)
ARC
GAP
2K1 SPARK
DRIVE
CIRCUIT
FLAME GND
DETECTOR SPARK (BUR-
CIRCUIT NER)
IGNITER
HYBRID CIRCUIT SENSOR
1K
BURNER
LOW GROUND
VOLTAGE 2K RELAY TIMING
POWER DRIVERS CIRCUITS
SUPPLY 3K
3
MAIN
1K1 1K2 3K2 VALVE
MV/
MV
PV
PILOT
2K2 3K1 VALVE
PV
3 3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY. ON NON-SHUTOFF MODELS, PV AND MV

WIRED AS FOLLOWS.
TO 24V TO 24V (GND)
MAIN INTERNAL WIRING

1K1 1K2 VALVE EXTERNAL WIRING
MV/
MV
PV
PILOT
2K2 VALVE
PV M1165D
Fig. 16. Representative Schematic for S8600F,H,M; S8610F,H: See Fig. 1 for Hookup. S8660 and S8670 are
Similar Except the Timing Circuit includes a Purge Timer. See Fig. 6 for Hookup.
17 69-0463—01
TOC MB-TOC INDEX

L1
(HOT) L2
LIMIT ON-OFF
CONTROLLER SWITCH 1
THERMOSTAT OR
CONTROLLER 24V
2
TRANSFORMER
24V
24V (GND)
ARC
GAP
2K1
SPARK
DRIVE
CIRCUIT SENSOR
SENSE
FLAME
DETECTOR GND
CIRCUIT SPARK (BUR-
IGNITER NER)
HYBRID CIRCUIT
1K
LOW BURNER
VOLTAGE 2K RELAY TIMING
GROUND
POWER DRIVERS CIRCUITS
3K
SUPPLY
3
MAIN
1K1 1K2 3K2 VALVE
MV/
MV
PV
PILOT
2K2 3K1 VALVE
PV
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

3K RELAY ON 100 PERCENT SHUTOFF MODELS ONLY. ON NON-SHUTOFF MODELS, PV AND
3 MV WIRED AS FOLLOWS.
TO 24V TO 24V (GND) INTERNAL WIRING

MAIN EXTERNAL WIRING
1K1 1K2 VALVE
MV/
MV
PV
PILOT
2K2 VALVE
PV M1166D
Fig. 17. Representative Schematic for S8600A,B; S8610A,B: See Fig. 3 for Hookup.
69-0463—01 18
TOC MB-TOC INDEX

ANSI STANDARDS
EXHIBIT A
RECOMMENDED PROCEDURE FOR SAFETY INSPECTION OF AN EXISTING APPLIANCE INSTALLATION AS A
PRELIMINARY STEP TO APPLYING AN AUTOMATIC INTERMITTENT PILOT SYSTEM
The following procedure is intended as a guide to aid in exhausts, so they will operate at maximum speed.
determining that an appliance is properly installed and is Do not operate a summer exhaust fan. Close
in a safe condition for continuing use. fireplace dampers. If, after completing steps 7
through 12, it is believed sufficient combustion air is
This procedure is predicated on central furnace and boiler not available, refer to 1.3.4 of the National Fuel Gas
installations equipped with an atmospheric gas burner(s) Code (Z223.1) for guidance.
and not of the direct vent type. It should be recognized 8. Place in operation the appliance being inspected.
that generalized test procedures cannot anticipate all Follow the lighting instructions. Adjust thermostat so
situations. Accordingly, in some cases, deviations from appliance will operate continuously.
this procedure may be necessary to determine safe 9. Determine that the pilot is burning properly and that
operation of the equipment. main burner ignition is satisfactory by interrupting
a. This procedure should be performed prior to and re-establishing the electrical supply to the
any attempt at modification of the appliance or appliance in any convenient manner.
the installation. a. Determine manifold pressure in order to match
b. If it is determined there is a condition that could input after the new control is installed.
result in unsafe operation, the appliance should 10. Visually determine that main burner gas is burning
be shut off and the owner advised of the unsafe properly; i.e., no floating, lifting or flashback. Adjust
condition. the primary air shutter(s) as required.
The following steps should be followed in making the a. If appliance is equipped with high and low flame
safety inspection: control or flame modulation, check for proper
1. Conduct a Gas Leakage Test of the appliance main burner operation at low flame.
piping and control system downstream of the 11. Test for spillage at the draft hood relief opening after
shutoff valve in the supply line to the appliance. five minutes of main burner operation. Use a draft
2. Visually inspect the venting system for proper size gauge, the flame of a match or candle, or smoke
and horizontal pitch and determine there is no from a cigarette, cigar, or pipe.
blockage or restrictions, leakage or corrosion or 12. Return doors, windows, exhaust fans, fireplace
other deficiencies that could cause an unsafe dampers and all other fuel-burning appliances to
condition. their previous conditions of use.
3. Shut off all gas to the appliance and shut off any 13. Applicable only to warm air heating appliances.
other fuel-burning appliances within the same room. Check both limit controller and fan controller for
Use the shutoff valve in the supply line to each proper operation. Limit controller operation can be
appliance. checked by temporarily disconnecting the electrical
4. Inspect burners and crossovers for blockage and supply to the blower motor and determining that the
corrosion. limit control acts to shut off the main burner gas.
5. Applicable only to warm air heating appliances. 14. Applicable only to boilers:
Inspect heat exchangers for cracks, openings or a. Determine that the circulating water pumps are
excessive corrosion. in operating condition.
6. Applicable only to boilers. Inspect for evidence of b. Test low water cutoffs, automatic feed controls,
water or combustion product leaks. pressure and temperature limit controls and
7. Insofar as is practical, close all building doors and relief valves in accordance with the
windows and all doors between the space in which manufacturer recommendations and
the appliance is located and other spaces of the instructions to determine they are in operating
building. Turn on clothes dryers. Turn on any condition.
exhaust fans, such as range hoods and bathroom
EXHIBIT A OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR
FIELD INSTALLATION
19 69-0463—01
TOC MB-TOC INDEX

EXHIBIT B
PROCEDURE FOR INSTALLING AUTOMATIC INTERMITTENT PILOT SYSTEMS
Prior to beginning this procedure, a preliminary 6. Check the heat anticipator in the comfort
examination of the appliance and the automatic thermostat to determine if it is properly adjusted to
intermittent pilot system should be made to determine the current draw of the control system. Follow the
that the automatic intermittent pilot system can be thermostat manufacturer’s instructions.
properly applied to the appliance. 7. Make certain wiring connections are tight and wires
are positioned and secured so they will not be able
This procedure is intended as a guide to aid in safely to contact high temperature locations.
installing a listed automatic intermittent pilot system on 8. Conduct a Gas Leakage Test of the appliance
an existing listed appliance equipped with an piping and control system downstream of the
atmospheric gas burner(s) and not of the direct vent type. shutoff valve in the supply line to the appliance.
9. Adjust the thermostat to its highest temperature
This procedure is based on the assumption that the setting, and test manifold pressure and adjust the
history of the specific installation has been one of safe pressure regulator to match original input as
and satisfactory operation. required (refer to Exhibit A, Step 9b).
a. Visually determine that main burner is burning
This procedure is predicated on central furnace and properly; i.e., no floating, lifting, or flashback.
boiler installations, and it should be recognized that Adjust the primary air shutters as required.
generalized procedures cannot anticipate all situations. 10. If the appliance is equipped with high and low
Accordingly, in some cases, deviation from this flame control or flame modulation, check for proper
procedure may be necessary to determine safe operation main burner operation at both high and low flame.
of the equipment. 11. Determine that the pilot is igniting and burning
properly and that main burner ignition is
The following steps should be followed in making the satisfactory by interrupting and re-establishing the
modifications: electrical supply to the appliance in any convenient
1. Perform a safety inspection of the existing manner. Make this determination with the
appliance installation. See Exhibit A for a appliance burner both cold and hot. Perform this
recommended procedure for such a safety step as many times as is necessary to satisfy
inspection. yourself that the automatic intermittent pilot system
2. Shut off all gas and electricity to the appliance. To is operating properly.
shut off gas, use the shutoff valve in the supply line 12. Test the pilot safety device (1) to determine if it is
to the appliance. Do not use the shutoff valve that operating properly, and (2) for turndown
is provided as part of a combination control. characteristics according to the manufacturer’s
3. Install the automatic intermittent pilot system in installation instructions. No adjustment should be
strict accordance with the manufacturer’s made other than those recommended by the
installation instructions. system manufacturer.
4. Turn on all gas and electricity to the appliance. 13. Sequence the appliance through at least three
5. Determine that the appliance transformer has operating cycles.
adequate capacity by following the steps outlined 14. Applicable only to furnaces. Check both the limit
below: controller and the fan controller for proper
a. Compute the approximate current draw by operation. Limit control operation can be checked
adding the current draw of the automatic by blocking the circulating air inlet or temporarily
intermittent pilot system to (1) the current draw disconnecting the electrical supply to the blower
of the associated valving, and (2) the current motor and determining that the limit controller acts
draw of any relays or other devices operated to shut off the main burner gas.
by the transformer. 15. Applicable only to boilers:
b. Multiply the total current draw as computed a. Determine that the circulating water pumps are
above by 24V to determine the total VA in operating condition.
(volt-ampere) required. b. Test low water cutoffs, automatic feed water
c. The total VA (volt-ampere) required should be controls, pressure and temperature limit
equal to or less than the VA rating of the controllers and relief valves in accordance with
transformer. the manufacturer’s recommendations to
d. If the total VA (volt-ampere) required is greater determine they are in operating condition.
than the VA rating of the transformer, the 16. Add the labels (see 1.6.1-n and -o) on the
transformer must be replaced with a Class 2 appliance.
transformer of adequate rating.
EXHIBIT B OF ANSI STANDARD Z21.71 FOR AUTOMATIC INTERMITTENT PILOT IGNITION SYSTEMS FOR
FIELD INSTALLATION
Automation and Control Solutions

Honeywell International Inc. Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9
customer.honeywell.com
® U.S. Registered Trademark
© 2007 Honeywell International Inc.
69-0463—01 J.I. Rev. 12-07
TOC MB-TOC INDEX

3045069
TOC MB-TOC INDEX

TOC MB-TOC INDEX
TOC MB-TOC INDEX
TOC MB-TOC INDEX
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TOC MB-TOC INDEX

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TOC MB-TOC INDEX

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TOC MB-TOC INDEX

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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
1 BURNER IRONER
Model: Serial #: Date: / / Approved by:
APPENDIX: Operating Standard form
FLATWORK / FABRIC CONTENT TEMPERATURE SETTING 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.
3010900
TOC INDEX
Comet Executive Gas Index
INDEX
A Clean Behind Service Panels 4-6
Clearing a Jam Safely 3-10
Alignment and Positioning, Feed Table 7-13 Compression Roll 7-16
Annual PM (2000 Hours) 4-17 Check Pressure and Padding Condition 4-15
Check and Clean Pilot Assembly 4-18 Cover Replacement 7-19
Pressure
B
Adjustment 7-18
Bearings, Greasing Check 7-17
Monthly 4-14 Unit Settings 3-14
Weekly 4-8 Conditioning Flatwork Before Ironing 3-12
Broken or Missing Ribbon Replacement Final Rinse 3-13
Feed 7-7 Moisture Retention 3-13
Return 7-39 Timing Between Washing and Ironing 3-13
Burner System 7-29. See also Heating System Wash Load 3-12
Burner Removal/Replacement 7-29 Control Function Check 2-19
Burner Tip Maintenance 7-32 Controls, Operating. See Operating Controls
Components 5-9 Cover Replacement
Temperature Control Compression Roll 7-19
About 5-10 Feed Ribbon Drive Roll Friction Material 7-8
Replacement 7-34 Return Ribbon Drive Roll Friction Material 7-40
Temperature Sensor Contact Shoes
About 5-10 D
Check and Clean 4-4 Daily Operating Procedures. See Standard Operat-
Replacement 7-33 ing Procedures
High Temperature Limit Control Replacement Daily Operation Safety 1-3
7-34 Daily PM (8 Hours) 4-3
Ignition, Heating System Troubleshooting 6-13 Check
Operation, Heating System Troubleshooting 6-14 Guide Tapes 4-4
Operation Stage, Sequence of Operation 5-12 Safety Equipment 4-5
Pilot Assembly, Check and Clean 4-18 Check and Clean Temperature Sensor Contact
Shoes 4-4
C
General Cleanliness 4-3
Check Watch and Listen for Anything Abnormal 4-3
Compression Roll Pressure and Padding Condition Wax Ironing Cylinder 4-5
4-15 Disconnect Switch and Fuses 5-3
Gas Pressure 4-16 Drive Chain
Guide Tapes 4-4 Oil 4-14
Ironing Cylinder 4-7 Tension Adjustment 7-23
Mechanical and Electrical Connections 4-16 Drive Roll Friction Material Replacement
Ribbon Condition and Tension 4-12 Feed Ribbon 7-8
Safety Equipment 4-5 Return Ribbon 7-40
Setscrews 4-13 Drive System 5-5
Check and Clean Ductwork 2-5
Inverter 4-7
Motors 4-11
Pilot Assembly 4-18
Sail Switch and Exhaust Blower Wheel 4-11
Temperature Sensor Contact Shoes 4-4
TOC INDEX I-1

Index Comet Executive Gas
E G
Electrical Gas Burner Removal/Replacement 7-29
Check Mechanical and Electrical Connections Gas Connection
4-16 Checkout 2-20
Checkout Exhaust Blower Motor Rotation Check- Gas Supply 2-20
out 2-17 Ignition Test 2-23
Connection 2-8 Inspect Gas Piping 2-22
Main Power 2-10 Overview 2-12
Sail Switch and Exhaust Blower Motor 2-8 Shut-Off Valve Installation 2-13
Electrical System Gas Pressure Check 4-16
About 5-2 Gas Supply Checkout 2-20
Disconnect Switch and Fuses 5-3 General Cleanliness 4-3
Electrical Panel 5-4 Grease
Step-Down Transformer 5-3 Monthly Bearings 4-14
Troubleshooting 6-4 Weekly Bearings 4-8
Endframe Controls. See Operating Controls Guide Tape
Exhaust Blower Check 4-4
About 5-7 Replacement 7-10
Installation 2-5
Ductwork 2-5 H
Electrical Connection 2-8 Hardened Ring Replacement, Ironing Cylinder 7-27
Installing the Exhaust Blower 2-6 Heating System 5-7. See also Burner System
Locating the Exhaust Blower 2-6 Burner System Components 5-9
Ventilating the Work Area 2-7 Temperature Control 5-10
Motor Rotation Checkout 2-17 Temperature Sensor Contact Shoes 5-10
Exhaust System 5-7 Troubleshooting 6-12
Exhaust Blower, About 5-7 Burner Ignition 6-13
Sail Switch, About 5-7 Burner Operation 6-14
Troubleshooting 6-16 High Temperature Limit Control
F Replacement 7-34
Feed Section 7-4 I

Drive Roll Friction Material Replacement 7-8 Ignition Test, Installation 2-23
Feed Table Alignment and Positioning 7-13 Inspect
Guide Tape Replacement 7-10 Gas Piping 2-22
Ribbon Installation 2-3
Replacement 7-6 Installation Procedures 2-3
Tension Adjustment 7-5 Electrical Connection 2-8
Final Protective Wrapper Removal 2-15 Exhaust Blower Installation 2-5
Final Rinse, Conditioning Flatwork Before Ironing Final Protective Wrapper Removal 2-15
3-13 Gas Connection 2-12
Flatwork Handling 3-9 Inspection 2-3
Ironing Cylinder 3-10 Receiving Shelf Set-Up 2-14
Maximum Efficiency 3-9 Uncrating and Positioning 2-4
Safety 3-9 Installing the Exhaust Blower 2-6
Friction Material Replacement Ironing Cylinder
Feed Ribbon Drive Roll 7-8 Check 4-7
Return Ribbon Drive Roll 7-40 Flatwork Handling 3-10
Hardened Ring Replacement 7-27
I-2 TOC INDEX

Paper Removal 2-19 Roll Bearing Pivots 4-10

Reconditioning 7-24 Operating Controls 3-4
Temperature, Unit Settings 3-14 Left Endframe Controls 3-5
Waxing 4-5 Right Endframe Controls 3-4
Ironing Quality Troubleshooting 6-9 Operating Techniques 3-12
Ironing Section 7-23 Conditioning Flatwork Before Ironing 3-12
Drive Chain Tension Adjustment 7-23 Maximum Productivity 3-15
Ironing Cylinder Hardened Ring Replacement Processing Standards 3-15
7-27 Unit Settings 3-14
Ironing Cylinder Reconditioning 7-24
Ironing Speed, Unit Settings 3-14 P
J Parts Availability, Repair 7-3

Pilot Assembly
Jams, Clearing Safely 3-10 Check and Clean 4-18
JOG REVERSE Operation Stage, Sequence of PM Task Tables
Operation 5-11 Daily, Weekly Tasks 4-1
Monthly, Semi-Annual Tasks 4-2
L Positioning the Unit 2-4
Left Endframe Controls 3-5 Pre-Operational Checkout 2-15
Locating the Exhaust Blower 2-6 Checkout Completion 2-25
Cleaning the Unit 2-25
M Exhaust Blower Motor Rotation Checkout 2-17
Gas Connection Checkout 2-20
Main Disconnect Switch 1-4, 3-2 Ironing Cylinder Paper Removal 2-19
Main Power Connection 2-10 Safety Device and Control Function Checkout
Maintenance and Repair Safety 1-3 2-18
Manual Scope 1-2 Security of Hardware 2-16
Maximum Efficiency, Flatwork Handling 3-9 Pressure Adjustment, Compression Roll 7-18
Maximum Productivity 3-15 Pressure Check, Compression Roll 7-17
Mechanical Start-Up Stage, Sequence of Operation Preventive Maintenance
5-12 Annual PM (2000 Hours) 4-17
Mechanical System Daily PM (8 Hours) 4-3
About 5-5 Monthly PM (200 Hours) 4-13
Drive System 5-5 Semi-Annual PM (1000 Hours) 4-15
Ribbon Sets 5-6 Task Tables
Troubleshooting 6-6 Daily, Weekly Tasks 4-1
Missing or Broken Ribbon Replacement Monthly, Semi-Annual Tasks 4-2
Feed 7-7 Weekly PM (50 Hours) 4-6
Return 7-39 Processing Standards 3-15
Moisture Retention, Conditioning Flatwork Before
Ironing 3-13 R
Monthly PM (200 Hours) 4-13
Check Receiving Shelf Set-Up 2-14
Compression Roll Pressure and Padding Condi- Reconditioning, Ironing Cylinder 7-24
tion 4-15 Repair
Setscrews 4-13 Parts Availability 7-3
Grease Bearings 4-14 Safety Considerations 7-2
Oil Drive Chains and Tension Springs 4-14 Return Section 7-36
Drive Roll Friction Material Replacement 7-40
O Ribbon
Replacement 7-38
Oil
Drive Chains and Tension Springs 4-14
TOC INDEX I-3

Index Comet Executive Gas
Tension Spring Replacement 7-37 Stand-By Stage 5-11

Ribbon Setscrews, Check 4-13
Condition and Tension Check 4-12 Shut-Down 3-11
Replacement Temporary Shut-Down 3-11
Feed 7-6 Site and Utility Requirements 2-2
Return 7-38 Spring
Sets 5-6 Oil Tension 4-14
Tension Adjustment Replace Return Ribbon Tension 7-37
Feed 7-5 Standard Operating Procedures 3-6
Return 7-37 Clearing a Jam Safely 3-10
Right Endframe Controls 3-4 Flatwork Handling 3-9
Shut-Down 3-11
S Start-Up 3-6
Safety 1-3, 5-2 Waxing 3-7
Flatwork Handling 3-9 Stand-By Stage, Sequence of Operation 5-11
Repair Safety Considerations 7-2 Start-Up 3-6
Safety Features 1-4 Step-Down Transformer 5-3
Safe Work Habits 1-3 T
Safety Considerations, Repair 7-2
Safety Device and Control Function Checkout 2-18 Task Tables, PM
Control Function Check 2-19 Daily, Weekly Tasks 4-1
Safety Device Check 2-18 Monthly, Semi-Annual Tasks 4-2
Safety Features 1-4, 3-2 Temperature Control
Main Disconnect Switch 1-4, 3-2 About 5-10
Safety Guards 1-5, 3-2 Replacement 7-34
Safety Interlock Switches 1-5, 3-3 Temperature Sensor Contact Shoes
Safety Labels 1-5, 3-3 About 5-10
Safety Messages in this Manual 1-6 Check and Clean 4-4
Safety Stop Buttons 1-4, 3-2 Replacement 7-33
Safety Guards 1-5, 3-2 Temporary Shut-Down 3-11
Safety Interlock Switches 1-5, 3-3 Tension Adjustment
Safety Labels 1-5, 3-3 Drive Chain 7-23
Safety Messages in this Manual 1-6 Feed Ribbon 7-5
Safety Stop Buttons 1-4, 3-2 Return Ribbon 7-37
Safe Work Habits 1-3 Tension Spring, Oil 4-14
During Daily Operation 1-3 Timing Between Washing and Ironing, Conditioning
Maintenance and Repair 1-3 Flatwork Before Ironing 3-13
Sail Switch Tip Maintenance, Burner 7-32
About 5-7 Troubleshooting
Sail Switch and Exhaust Blower Motor Electrical Electrical 6-4
Connection 2-8 Exhaust System 6-16
Sail Switch and Exhaust Blower Wheel Check and Heating System 6-12
Clean 4-11 Ironing Quality 6-9
Scope of the Manual 1-2 Mechanical System 6-6
Security of Hardware 2-16 Symptoms 6-2
Semi-Annual PM (1000 Hours) 4-15
Check U
Gas Pressure 4-16 Uncrating and Positioning 2-4
Mechanical and Electrical Connections 4-16 Unit Settings 3-14
Sequence of Operation 5-11
Burner Operation Stage 5-12
JOG REVERSE Operation Stage 5-11
Mechanical Start-Up Stage 5-12
I-4 TOC INDEX

Compression Roll Pressure 3-14

Ironing Cylinder Temperature 3-14
Ironing Speed 3-14
V
Ventilating the Work Area 2-7
W
Warranty 1-2
Wash Load, Conditioning Flatwork Before Ironing
3-12
Watch and Listen for Anything Abnormal 4-3
Waxing 3-7
Wax Ironing Cylinder 4-5
Weekly PM (50 Hours) 4-6
Check
Ironing Cylinder 4-7
Ribbon Condition and Tension 4-12
Check and Clean
Inverter 4-7
Motors 4-11
Sail Switch and Exhaust Blower Wheel 4-11
Clean Behind Service Panels 4-6
Grease Weekly Bearings 4-8
Oil Roll Bearing Pivots 4-10
Worn Ribbon Replacement
Feed 7-6
Return 7-38
TOC INDEX I-5

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INSTRUCTION MANUAL

Chapter 3 - Operating Guidelines

Chapter 4 - Preventive Maintenance

Chapter 5 - Operating Principles

PICTURE PARTS LIST

SCHEMATIC 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...................................................................... 2-15

TOC INDEX iii

CHAPTER 3 OPERATING GUIDELINES

3.2 Operating Controls................................................................................... 3-4

3.3 Standard Operating Procedures.............................................................. 3-6

3.4 Operating Techniques............................................................................ 3-12

CHAPTER 4 PREVENTIVE MAINTENANCE

4.1 Daily PM (8 Hours)................................................................................... 4-3

4.2 Weekly PM (50 Hours)............................................................................. 4-6

4.3 Monthly PM (200 Hours)........................................................................ 4-13

4.4 Semi-Annual PM (1000 Hours).............................................................. 4-15

4.5 Annual PM (2000 Hours)........................................................................ 4-17

CHAPTER 5 OPERATING PRINCIPLES

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

5.2 Mechanical System.................................................................................. 5-5

5.3 Exhaust System....................................................................................... 5-7

5.4 Heating System........................................................................................ 5-7

5.5 Sequence of Operation...........................................................................5-11

6.1 Electrical................................................................................................... 6-4

6.2 Mechanical System.................................................................................. 6-6

6.3 Ironing Quality.......................................................................................... 6-9

6.4 Heating System...................................................................................... 6-12

6.5 Exhaust System..................................................................................... 6-16

TOC INDEX vii

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

7.3 Feed Section............................................................................................ 7-4

7.4 Compression Roll................................................................................... 7-16

7.5 Ironing Section....................................................................................... 7-23

7.6 Burner System....................................................................................... 7-29

7.7 Return Section....................................................................................... 7-36

viii TOC INDEX

1.2 Scope of the Manual

 Chicago Dryer Company  (773) 235-4430

TOC INDEX 1-1

Chapter 4 - Preventive Maintenance

Chapter 1 - Introduction Parts List

Chapter 2 - Installation Schematics

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

Unless otherwise indicated, turn the main

The preferred method of stopping the operation

Pressing any of these buttons immediately

1-4 TOC INDEX

Safety Guards Safety Labels

A safety interlock switch is located behind NOTE: Do not remove safety

TOC INDEX 1-5

Safety Messages in this Manual

WARNING and CAUTION messages appear

WARNING messages alert personnel that

BLACK BOX WARNING messages alert

Perform only when the unit is OFF