CMV SHARPER FINISH 3000 Maintenance, Additional Install, And Service Instructions

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1

TABLE OF CONTENTS

INTRODUCTION

IMPORTANT SAFETY INSTRUCTIONS ............................. 1

IMPORTANT INST ALLATION INSTRUCTIONS ....................... 4

MachineryClearances ........................................... 4

SafetyWarningsandDecals....................................... 4

SpecialToolsRequired........................................... 5

ReplacementParts.............................................. 5

Vocabulary.................................................... 5

StartupandShutdownProcedures................................. 8

GasHeatedModel............................................ 8

ElectricallyHeatedModel ...................................... 9

SteamHeatedModel.......................................... 9

SafetyControls................................................. 9

WiringDiagram................................................. 9

SECTION 1 MAINTENANCE

Introduction.................................................... 10

Lubrication .................................................... 10

PreventiveMaintenance.......................................... 10

Adjustments ................................................... 11

SECTION 2 TROUBLESHOOTING

MachineFailstoStart............................................ 12

FlatworkDoesNotIronProperly.................................... 13

MotorVibrates.................................................. 13

GasBurnerCutsOff............................................. 13

GasBurnerFailstoLight ......................................... 13

GasModelGeneratesExcessiveHeat............................... 14

GasModelFailstoHeatProperly................................... 14

Electric Model Fails to Heat Properly ................................ 15

Electric Model Generates Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SteamModelFailstoHeatProperly................................. 16

MeltedFlatworkonHeatedRoll.................................... 16

Built-inFolderDoesNotOperateProperly............................ 17

MonitoringSystemDoesNotFunction............................... 17

FeedRibbons;RubberCrownsare“Walking” ......................... 17

SECTION 3 SERVICE PROCEDURES

Feed and Conveyor Ribbon Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ReturnRibbonReplacement ...................................... 20

Compression Roll Cover/Padding Replacement . . . . . . . . . . . . . . . . . . . . . . . 20

V-BeltReplacement............................................. 24

CanopyBlowerReplacement...................................... 25

Finger Guard, Door Panel, Monitoring System Switch Replacement . . . . . . . . 25

VentilationSystem .............................................. 27

Rotary Pressure Joint/Steam Hose Replacement . . . . . . . . . . . . . . . . . . . . . . 28

HeaterElementReplacement ..................................... 29

FolderOperation ............................................... 30

Clutches ................................................... 31

ValveandAirAdjustments..................................... 32

Return Ribbon Drive Roll Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . 32

SystemControlOperation........................................ 33

Installation ................................................. 33

StartUpandCheckout........................................ 34

AutomaticValveCombinationGasControl........................... 38

Installation.................................................. 38

StartUpandCheckout........................................ 41

Service.................................................... 43

HighLimitSwitch............................................... 43

Thermostat/ContactShoeReplacement............................. 44

CompressionRollDriveBelt...................................... 45

GuideTapeReplacement........................................ 46

FeedBin/StackingSphereCleaning................................ 46

PressureSwitch............................................... 47

1

INTRODUCTION

CAUTION WARNING

DANGE R

These symbols alert reader to situations that could cause personal injury, and are shown

here in increasing levels of hazard seriousness.

WAR NING

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this

or any other appliance.

IMPORTANT: Purchaser must consult the local gas supplier for suggested instructions

to be followed if the ironer user smells gas. The gas utility instructions plus this warning

note must be posted in a prominent location near the ironer.

WHAT TO DO IF YOU SMELL GAS

1. Open windows.

2. Do not touch electric switches; do not use any phone in your building.

3. Extinguish any open flame.

4. Do not try to light any appliance.

5. Clear the room, buildi ng or area of all occupants.

6. Immediately call your gas supplier from a neighbor’s phone. Follow the gas

supplier’s instructions.

7. If you cannot reach your gas supplier, call the Fire Department.

A qualified installer, service agency or the gas supplier must perform installation and

service.

WAR NING

Failure to install, maintain, and/or operate this machine according to the manufacturers

instruction may r esult in conditions which can produce bodily injury and/or property

damage.

Do not repair or replace any part of the ironer or attempt any servicing unless specifically

recommended or published in these manuals that you understand and have the skills to

carry out.

W henever ground wires are removed during servicing, those gr ound wires must be

reconnected to ensure that the ironer is properly grounded and to reduce the risk of fire,

electrical shock, or personal injury.

NOTE: The WARNING and IMPORTANT instructions appearing in this manual are not

intended to cover all possible conditions and situations that m ay occur. It must be

understood that common sense, caution, and carefulness are factors that cannot be built

into these ironers. These f actors MUST BE supplied by the person(s) installing,

maintaining, or operating the ironer.

2

IMPORTANT: During the lifetime of the ironer, it will require service. The inf ormation

contained in the manuals is written and intended for use by qualified service technicians

who are familiar with the safety procedures required in the repair of your ironer, and who

are equipped with the proper tools and testing equipment.

Repairs that are made to your ironer by an unqualified person can result in hazards due

to improper assembly or adjustments subjecting you, or the inexperienced person

making such repairs, to the risk of injury or electrical shock which can be serious or even

fatal.

If you or an unqualified person perform service on your ironer, you must assume the

responsibility for any personal injury or property damage, which may result. The

manufacturer will not be responsible for any injur y or property damage arising from

improper service and/or service procedure.

To prevent possible equipment damage, please observe the following:

1. Car eless handling can damage pressure roll padding. Use care in removal of

protective paper wrap and wood positioning blocks.

2. Pr olonged heat build-up within the machine can shorten the life of ribbons, roll

pads, and other components. Use complete shutdown procedure even for brief

breaks and work stoppages.

3. Gaskets may be damaged by use and/or disassembly procedure, causing

breakage and failure if reused. Replace with new gaskets.

4. High temperatures generated by gas heated ironers impose severe stress on

mechanical components. Use only heat resistant grease for lubrication of

bearings.

5. This flatwork ironer is designed to process flatwork across its entire heated roll

and continued use of less than the full surface will allow hot spots to develop. To

avoid waste and damage, use as much of the heated roll as possible.

6. Lint or other debris entering the burner assembly of gas-heated ironers will clog

burner orifices and ports, which will impair or shut down operation.

7. The thermostat sensing element must be kept clean and in proper position and

operating condition to prevent damage to machine and work. An out-of-position or

lint-fouled thermostat contact shoe will result in overheating.

8. Always use flatwork wax to protect heated roll and thermostat contact shoe from

damage. Do not over wax machine. Under waxing will cause flatwork to stick to

roll and scorch. Over waxing will cause wax build-up on compression roll cover

and flatwork.

9. Do not sit or stand on any receiving tables, conveyors, or the canopy because

they are not designed to support your weight.

10. Check all set-scr ews on all spr ockets, and tighten if needed.

11. Make sure the ironer is vented properly. Consult the venting booklet, or the factory

directly.

4

Trained, qualified personnel must perform all operation, maintenance, and repair of the

flatwork ironer only. Adequate lighting, operating, and shutdown instructions must be

provided, and all operating and supervising personnel must be thoroughly instructed in

safe operating practices.

IMPORTANT INST ALLATION INSTRUCTIONS

1. The installation must conform with local codes or, in the absence of local codes, to

the National Fuel Gas Code, ANSI Z223.1-1988.

2. The ironer and its individual shutoff valve must be disconnected from the gas

supply piping system during any pressure testing of that system at test pressures

in excess of .5 psig, 14 water column inches (3.5 kPa).

3. The ironer must be isolated from the gas supply piping system by closing its individ-

ual manual shutoff valve during any pressure testing of the gas supply piping system

at test pressures equal to or less than .5 psig, 14 water column inches (3.5 kPa).

4. The ironer, when installed, must be electrically grounded in accordance with local

codes, or in the absence of local codes, with the National Electrical Code,

ANSI/NFPA 70-1990.

5. The ironer must not be installed or stored in an area where it will be exposed to

water and/or weather. In addition, LP G as heated ironers must not be installed or

operated in areas below ground level.

6. Items should not be stored near the ironer so those air openings into the combustion

chamber remains open.

CLEARANCES

The following m inimum clearances to construction and all combustible materials must be

maintained:

1. 18 inches to the rear of the ironer, measured from any portion of the ironer, if

possible.

2. 18 inches to either side of the unit as measured from the outside of the end frames,

if possible.

3. All flooring material must be noncombustible. No raised construction or combustible

materials are allowed beneath the ironer.

4. No combustible ceiling, or other construction materials are allowed on or above the

ironer.

SAFETY WARNINGS AND DECALS

Safety warnings and decals have been provided in key locations to remind you of

important precautions for the safe operation and maintenance of your ironer. Please take

time to review these warnings before proceeding with service work. All decals have been

designed and applied to withstand washing and cleaning. Decals should be checked

periodically to be sure they have not been damaged, removed, or painted. Replacement

warning labels are provided free of charge.

Compression Roll Pad or Pressure Roll Pad:

Compression Roll Cover or Pressure Roll Cover:

7

25) Frame:

The metal enclosures at each end of the ironer. The left frame contains most of the

electrical and utility components. The right frame contains the drive system.

26) Folding Conveyor:

The conveyor that oscillates to fold the flatwork.

27) Int ermediate Conveyor:

The conveyor or pinch rolls that suspend the flatwork above the folding conveyor so

that it may be folded.

28) Lower Conveyor:

The conveyor that takes the flatwork to either the front or rear of the ironer.

29) Guide Tape:

The half inch wide Nomex tape t hat prevents the flatwork from wrapping around the

compression roll. The guide tape is wrapped around the compression roll and one of

the tie rods.

30) Interlock Switch:

The micro switch located in each frame so t hat when the door panel is removed, the

ironer stops. The door panel must be replaced before the ironer will start.

31) System Control:

The electronic device that controls the gas system.

32) Monitoring System:

The electronic device that monitors the use of the ironer and turns off the heat when the

ironer is not used for twenty minutes. Other variations also shut the ironer completely

off when it has cooled. This device works in conjunction with a micro switch located

between the feed ribbons.

33) Door Panels:

The removable panels located on the outside of each end frame.

34) Stop Bar:

The red metal bar that runs the entire width of the feeding surface. If the operator

pushes or pulls this bar, t he ironer will stop.

35) Pull Cord:

The orange cord that runs the entire width of the feeding surface and along the back of

rear return of the ironer. The cord may be pushed or pulled in any direction to stop the

ironer. It must then be pulled again before the ironer can be started again.

36) Receiving Table:

The white metal tables located at the front of the ironer and at the back for rear return

models. These tables “receive” the flatwork after it has been ironed.

37) Feed Table:

The metal table that supports the feed ribbons near the heated r oll and guides or

“feeds” the flatwork into the ironer.

38) Pressure Differential Switch/Airflow Switch:

An electronic and mechanical switch that insures positive airflow of the canopy blower.

39) Igniter:

The electronic device that on gas heated ironers creates a spark to ignite the gas.

40) Flame Sensor:

The electronic device located at the far end of the gas burner that senses or “ proves”

ignition.

8

START UP AND SHUT DOWN PROCEDURES

These procedures should be used at all times to properly start and stop the ironer.

SHUT DOWN

To obtain long life and reliability from the flatwork ironer, use the following procedures

when shutting down the machine.

1. On gas or electric heated machines, set the thermostat dial to the off position. On

steam heated models, turn the Steam Inlet and Return valves t o the off position.

2. Allow ironer drive system to operate approximately 10 to 20 minutes for heat

dissipation.

3. Press the Stop Bar to shut off drive and canopy blower motor or pu

ll the Stop Cord.

IMPORTANT: Prolonged heat build-up withi

n the ironer can shorten the life of ribbons,

padding, and other components. Use complete shut down procedure even for brief breaks

and work stoppages.

START UP

GAS HEATED

Although the flatwork ironer has been designed for simplicity of operation, certain steps

must be taken to assure a smooth, efficient operation. Follow these steps to start the

ironer:

NOTE: Heat build-up can damage the unit if allowed to continue. Keep the ironer in

operation to avoid prolonged heat build up.

1. Check that the circuit breaker for the ironer is turned on; then press the start button

to energize the drive systems and vent system blower motor.

2. Check that the motor rotation is correct, moving feed ribbons into the rollers. Also

check that the c

anopy blower motor rot ation is correct, discharging air from the

top

of the ironer to the outside of the building.

3. Open the gas cock in the line delivering gas to the ironer.

4. Set the thermostat for the desired operating temperature.

5. Check that the burner is lit by looking through the hole in the left-hand door panel.

6. Warm up the ironer for approximately 10 minutes. The green light will illuminate

when the machine is ready to process flatwork.

WAR NING

If material is caught or jammed in an operating machine shut down the machine

immediately. Do not attempt to r em ove jammed material from an operating machine.

Disconnect power at the circuit box and wait until the machine is cool before attempting to

free jammed material from the machine.

9

ELECTRIC HEATED

1. Check that the circuit breaker for the ironer is tur ned on; then press the start button

to energize the drive system, vent system blower motor (if equipped), and the

electric heating elements.

NOTE: Heat build-up can shorten flatwork ironer life if allowed to continue. Keep machine

busy to avoid prolonged heat build-up.

2. Check that the drive motor rotation is correct, moving the feed ribbons into the

rollers.

3. Set the thermostat for the desired operat ing temperature.

4. Warm up ironer for approximately 10 minutes. The green light will indicate when the

ironer is ready to process flat

work. (NOTE: Machines ope

rating 380V or 415V will

take slightly longer to heat up).

A

AA

A W ARNING

If material is caught or jammed in an operating machine, shut down, and tag the machine

immediately. Do not attempt to remove jammed material from an operating machine.

Disconnect power at the circuit box and wait f or machine to cool before attempting to free

material from the machine.

STEAM HEATED

NOTE: Heat build-up can shorten the life of the ironer if allowed to continue. Keep the

ironer busy to avoid prolonged heat build-up.

1. Check that the circuit breaker for the ironer is tur ned on; then press the start button

to energize the ironer drive system motor and vent system motor (if equipped).

2. Check that the drive motor rotation is correct, moving the feed ribbons into the

rollers.

3. Open Steam Inlet and Return valves. Be sure Return valve is open before opening

Steam Inlet valve.

SAFETY CONTROLS

After completing any and all maintenance and/or service procedures, all safety systems

should be checked for proper op

eration. If any of the systems fail to operate properly, they

must be repaired before the ironer can be operated. Some, but not all of the safety

controls are listed below:

drauGraeR•raBpotS•

• Pull Cable (front and rear) • Heated Roll Guard

• Monitoring System • Manual Operating Device

• Ventilation Sail Switch/Pressure • High Limit Switch

Differential Switch • Gas Monitoring Switch

• Door Panel Switches

Are all Guards in place? Are all warning

and caution labels readable?

WIRING DIAGRAM

The wiring diagram is located on the inside of the left frame panel or on the electrical

control box cover.

WAR NING

If material is caught or jammed in an operating machine, shut down, and tag the machine

immediately. Do not attempt to remove jammed material from an operating machine.

Disconnect power at the circuit box and wait for machine to cool before attempting to free

material from the machine.

Feed Ribbons When New Should not be too tight. New feed ribbons

will shrink. Keep 1” play in feed ribbons.

Feed Ribbon Drive Roll adjustment

1 )Thereareadjustmentnutsoneachfeedribbondriverollbearing.Adjusteachnut

eq uallysothatther eis1”playinthefeedribbon.

2 )

ADJUSTMENTS

13

Table 2-2

Problem: Flatwork does not properly iron or dry.

1. Is heated cylinder temperature correct? Consult Operation Manual for suggested

operating temperatures.

2. Has flatwork excessive moisture? Increase extraction time or pre-dry flatwork. Is

flatwork too dry? Reduce dryer conditioning time because to properly iron flatwork

(just like hand ironing), heat, pressure, and moisture are required. The heat and

pressure (calendaring) are provided from the flatwork ironer. The moisture is provided

from the Washer/Extractor.

3. I s machine speed too fast? Reduce speed (if equipped with speed control).

4. Has compression roll padding and cover worn out? Replace.

5. Check if return ribbon drive roll cover is worn? Replace.

6. Check if return ribbons are worn or missing? Replace.

7. If wrinkles that are horizontal to the length of the ironer are observed, check the

following: 1) Lack of waxing.

2) Foreign mater deposited on the heated roll.

3) Worn return ribbons and/or worn return ribbon drive roll cover.

4) A frozen bearing on one of the conveyor rolls.

Any and all of the above conditions will cause the return ribbons not to t urn at there

proper speed thus preventing the calendaring effect that is essential for proper ironing.

Table 2-3

Problem: Motor vibrates excessively.

1. Check if V-belt is worn out. Replace.

2. Check if upper & lower pulleys are in line. Adjust pulley position.

Table 2-4

Problem: Burner ignites but automatically cuts off after a short period.

1. If venting is im proper, “back pressure” will shut the gas valve off.

2. If the flame reached the far end and hit flame sensor within 11 seconds of spark

generation, (Australian Gas Association Approved models within 5 seconds), check if

gas supply meets machine requirements. Also check if flame sensor rod is immersed

in the burner flame. Adjust and try again. Test with micro amp meter. See Section 3-12.

Natural gas pressure is 3.5” W.C. and liq uid propane pressure is 11.0” W.C.

3. Check if burner tips are clogged. Clean and try again. If that does not work replace

the module (system control) and try again.

Table 2-5

Problem: Gas Heated Model burner fails to light after thermostat is turned on.

1. If spark generator is not generating a spark, check if thermostat functions properly.

Turn on thermostat, check wire terminal by continuity test. If it fails, replace and try

machine again. If spark generator is generating a spark, check if wire connection from

system control (module) to valve is correct. Adjust and reset by turning thermostat to

off and on again. Also check if valve control knob is depressed and pointed to “On”

position. Adjust. Also check to be sure green pilot light is on. If not, activate monitoring

system feed table switch.

14

2. Check if wire connection from thermostat to system control (module) 25V is correct.

Check if 2A fuse of module is blown. Secure ignition cable.

3. Start machine and turn on thermostat. Check if spark is generated if not, replace

system control (module). Try again. Turn off thermostat and then turn it on and listen

to “Click” sound from valve. If no sound is heard, replace the valve.

4. Check sail switch or pressure differential switch to ensure positive airflow. Also

clean out any lint. If positive airflow is absent, venting will need to be shortened or

airflow will need to be assisted by another blower. Also, the pressure differential

switch requires static pressure to operate correctly, so if the unit is not vented, the

pressure switch will not close and the burner will not ignite.

Table 2-6

Problem: Machine generates excessive heat.

1. Check the vent and airflow situation. (See Table 2-4, No. 1).

2. Is heated cylinder clean without any f oreign materials? Clean and remove all foreign

materials.

3. Is heated c ylinder waxed at recommended periods? Wax machine following

recommended procedure.

4. Is thermostat contact s hoe fouled with lint? Clean.

5. Check if thermostat contact shoe and thermostat bulb is worn out. Replace either or

both.

6. Check if thermostat contact shoe is fully in contact with heated cylinder. Adjust

contact shoe bracket or replace.

7. Check if thermostat operates properly. Replace if necessary.

8. Is entire surface area of heated roll being used?

Table 2-7

Problem: Gas Heated Model fails to heat properly.

1. Is gas pressure adequate? Check if gas pressure meets the r equirements on

machine nameplate.

2. Has the space between primary air shutter and mixer body become clogged? Shut

off gas supply. Remove mixer head. Clean by removing the cap, locknut and air

shutter. Blow dirt out from mixer outlet. (See Fig. 2-1).

3. Is the gas orifice clogged with foreign materials? Shut off gas supply. Remove mixer

head. Clean orifice with a small brush.

4. Adjust primary air shutter until the base of the flame is blue and the tips of the flame

are slightly reddish or orange in color.

Recommended adjustments:

Yellow flame – Open the primary air shutter.

Red flame – T o o much air. Close primary air shutter.

15

A

AA

AWARNING

The gas used as f uel by ironers is extremely flammable. To reduce the risk of fire or explosion,

only an experienced and knowledgeable person is recommended to perform service. Make sure

all connections are tight and leak-proof. Use extreme care when operating ironer.

NOTE: When the gas flame is shut off by the module (m achine has reached heat set by

thermostat), the atmospheric pressure outside the burner pipe will be greater than the air inside

the pipe. Air will therefore be equalized between burner pipe and atmosphere by a sudden “blow

back” (making a popping noise). Keep hand and body clear from the mixer assembly after

adjustments have been made.

Figure 2-1

Table 2-8

Problem: Electrically Heated Model fails to heat properly.

1. If the heating elements are generating heat, check if thermostat functions properly.

Turn on thermostat, check wire terminal by continuity test. Replace thermostat and try

machine again.

2. If the heating elements are not generating heat, check if there is enough power

available at the site. (See ironer data plate).

3. Check if heater contactors inside electrical box are activated when thermostat is

turned on (listen for “Click” sound). Replace heater contactors if they are not functioning.

4. Check if position and adjustment of thermostat is correct. Measure the temperature

on the center of the roll with a pyrometer (with the correct probe) and compare to

temperature on dial.

5. Disconnect power and check wiring between heater contactors and heating elements

with continuity tester. Replace any defective wires.

A

AA

AWARNING

The gas used as fuel by ironers is extremely flammable. To reduce the risk of fire or explosion,

only an experienced and knowledgeable person is recommended to perform service. Make sure

all connections are tight and leak-proof. Use extreme care when operating ironer.

16

6. Check heating elements. Disconnect power and check each element with a c ontinuity

tester (no continuity indicates a bad element). Replace any defective element(s).

Table 2-9

Problem: Electrically Heated Model generates excessive heat.

1. Check the vent and airflow situation. Is t here something restricting the airflow? Is the

blower motor working properly? Is the exit CFM the same as the blower? Is machine

vented independently? (See Table 2-4, #1).

2. Is heated cylinder clean without any foreign material? Clean and remove all foreign

materials.

3. Is heated cylinder waxed at recommended periods? Wax machine following recommended

procedure.

4. Is thermostat contact s hoe fouled with lint? Clean.

5. Check if thermostat contact shoe and thermostat bulb is worn out. Replace either or

both.

6. Check if thermostat contact shoe is fully in contact with heated cylinder. Adjust contact

shoe bracket or replace.

7. Check if thermostat operates properly. Replac e t hermostat.

8. Are the contact fused or shorted in the heater contactor(s). Replace heater contactor(s).

Table 2-10

Problem: Steam Heated Model f ail s to heat properly.

1. Check if steam inlet and return valve is fully open.

2. Check if steam trap is properly operating.

3. Check if any leaks in steam line.

4. Remove rotary joint. Check if siphon pipe is properly installed.

Table 2-11

Problem: Melted flatwork or softener depositing on the heated roll.

Symptoms: Poor calendaring action of the ironer . The added friction caused by the deposition

prevents the return ribbons from operating at their proper speed.

1. Disconnect power to the ironer and lock out and tag the circuit breaker that repairs are in

progress.

WARNING

Electricity, heat, and pressure are present in potentially harmful quantities in an operating ironer.

Never attempt repairs on an ironer during operation.

2. Remove the drive chain(s).

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CMV SHARPER FINISH 3000, 1200, 2000, 3600, FINISH MASTER 1600, FINISH MASTER 2000, FINISH MASTER 2400, FINISH RITE, Glider, IMPRESS 950 Maintenance, Additional Install, And Service Instructions

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