ADC ML-96 manual

080699DMG/tcosta ADC Part No. 450406 ML-96 Service Manual American Dryer Corporation 88 Currant Road Fall River , MA 02720-4781 T elephone: (508) 678-9000 / Fax: (508) 678-9447 e-mail: techsupport@amdry .com[...]

Retain This Manual In A Safe Place For Futur e Reference Replacement parts can be obtained from your distributor or the ADC factory . When ordering replacement parts from the factory , you can F AX your order to ADC at (508) 678-9447 or telephone your orders directly to the ADC Parts Department at (508) 678-9000. Please specify the dryer model numb[...]

IMPOR T ANT YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPL Y and THE GAS SUPPL Y SUPPL Y BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE T O ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) ST ANDARDS. CHILDREN SHOULD NOT BE ALLOWED TO PLA Y ON [...]

W ARNING The dryer must never be operated with any of the back guards, outer tops, or service panels r emoved. PERSONAL INJURY or FIRE COULD RESUL T . IMPOR T ANT PLEASE OBSER VE ALL SAFETY PRECAUTIONS displayed on the equipment and/or specified in the installation and operator's manual included with the dryer . Dryers must not be installed or[...]

Table of Contents SECTION I IMPOR T ANT INFORMA TION ............................................................................... 3 A. Safety Precautions ..................................................................................................................... 3 SECTION II ROUTINE MAINTENANCE ..........................................[...]

SECTION V SER VICING .............................................................................................................. 1 5 A. Computer Controls ................................................................................................................. 15 B. Ignition Controls .......................................................[...]

3 SECTION I IMPOR T ANT INFORMA TION A. SAFETY PRECAUTIONS W ARNING: For your safety , the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury , or loss of life. W ARNING: The dryer must never be operated with any of the back guards, outer tops, or service panels remov[...]

4 W ARNING: DO NOT dry mop heads. Contamination by wax or flammable solvents will create a fire hazard. W ARNING: DO NOT use heat for drying articles that contain plastic, foam, sponge rubber , or similarly textured rubber materials. Drying in a heated tumbler (basket) may damage plastics or rubber and also may be a fire hazard. 7. A program should[...]

5 SECTION II ROUTINE MAINTENANCE A. CLEANING A program and schedule should be established for periodic inspection, cleaning, and removal of lint from various areas of the dryer , as well as throughout the duct work system. The frequency of cleaning can best be determined from experience at each location. Maximum operating efficiency is dependent up[...]

6 EVERY 6 MONTHS Inspect and remove lint accumulation in customer furnished exhaust duct work system and from dryer  s internal exhaust ducting. WARNING: THE ACCUMULA TION OF LINT IN THE EXHAUST DUCT WORK CAN CREA TE A POTENTIAL FIRE HAZARD . WARNING: DO NOT OBSTRUCT THE FLOW OF COMBUSTION and VENTILA TION AIR. CHECK CUSTOMER FURNISHED BACK DRAF[...]

7 SECTION III INST ALLA TION REQUIREMENTS Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, the installation must conform to applicable AMERICAN NA TIONAL ST ANDARDS: National Fuel Gas Code ANSI.Z223.1-LA TEST EDITION or National Electrical Code ANSI/NFP A No. 70- LA T[...]

8 IMPOR T ANT : Failure to comply with these codes or ordinances and the requirements stipulated in this manual can result in personal injury or component failure. The dryer installation must meet the American National S tandard, National Fuel Gas Code ANSI Z223.1- LA TEST EDITION, or in Canada, the Canadian Electrical Codes Parts 1 & 2 CSA C22[...]

9 NOTE: W ater column pressure requirements (measured at the pressure tap on the gas valve body): Natural Gas - 3.5 inches water column (W .C.) - 8.7 mb. L.P . Gas - 10.5 inches water column (W .C.) - 26.1 mb. 6. If computer program changes are required, refer to the Phase 6 OPL Operator  s Manual ( ADC Part No. 1 13022) for details. 7. The drye[...]

10 SECTION IV DESCRIPTION OF PAR TS A. COMPUTER PANEL (MICROPROCESSOR) Lifting the control door will reveal the control panel assembly . Opening the control panel will allow access to the major components which include the computer board and keypad (touchpad). The keypad (touchpad) inputs to the computer what temperature and program has been select[...]

11 C. HSI (HOT SURF ACE IGNITION) MODULE (Gas Models Only) The HSI (Hot Surface Ignition) system consists of a microprocessor based control module, along with a hot surface ignitor probe and a flame probe assembly . The hot surface ignitor is a silicon carbide ignitor that upon application of 24 V AC will glow bright orange for the inter-purge time[...]

12 F . DRIVE SHAFT ASSEMBL Y (V iewing from the front of the dryer .) Behind front panel on the left side of the dryer , you can view the drive shaft assembly which consists of a 9-inch (22.86 cm) drive pulley , two (2) 6-inch (15.24 cm) wheels, one (1) taper lock bearings, and one (1) 1- inch (2.54 cm) pillow block bearings. G . IDLER SHAFT ASSEMB[...]

13 I. MAIN DOOR SWITCH The main door switch is mounted to the front panel behind the main door . When the main door opens, the switch will also open, preventing the dryer from operating. The main door switch is a safety device and should never be disabled. J. SAIL SWITCH (Gas Models Only) The sail switch is located on the front of the burner box. A[...]

14 L. MANUAL RESET THERMOST A T This is located inside the dryer in the lint compartment above the lint screen. This thermostat senses the heated air after it passes through the tumbler (basket). If the air temperature gets too hot, the thermostat will shut off the burner . The dryer will not run until the air temperature cools down. At this time, [...]

15 SECTION V SER VICING INTRODUCTION ALL electrical and mechanical service or repairs should be made with the electrical power to the dryer disconnected (power off). W ARNING: PERSONAL INJUR Y COULD RESUL T . The information provided in this section should not be misconstrued as a device for use by an untrained person making repairs. Service work s[...]

16 4. Remove the two (2) screws securing the computer to the computer panel. Remove the computer by pulling the other two (2) corners off the clinch studs. 5. Install new computer by reversing this procedure. Keyboard (T ouchpad) Label Assembly Replacement 1. Discontinue electrical power to the dryer . 2. Unplug keyboard (touchpad) ribbon from rear[...]

17 B. IGNITION CONTROLS Hot Surface Ignition Module Replacement (refer to burner illustration on page 1 1 ) 1. Discontinue electrical power to the dryer . 2. Disconnect wire from S1 and GND on the HSI (Hot Surface Ignition) module. 3. Disassemble ignitor from burner by removing the one (1) self tapping screw . 4. Reverse procedure for installation [...]

18 NOTE: DO NOT WRAP THE HOT SURF ACE IGNITOR WIRES AND THE FLAME ELECTRODE WIRE T OGETHER. IMPROPER OPERA TION MA Y RESULT . THEY MA Y RUN ALONGSIDE EACH OTHER. 5. Reestablish procedure for installation of new ignitor . Gas V alve Replacement (Refer to burner illustration on page 1 1 ) 1. Discontinue electrical power to the dryer . 2. Close shut-o[...]

19 T o T est and Adjust Gas (W ater Column) Pressure There are two (2) types of devices commonly used to measure column pressure. They are spring and mechanical- type gauges and manometers. The spring and mechanical-type gauge is not recommended, because it is easily damaged and not always accurate. A manometer is simply a glass or transparent plas[...]

20 3. Reverse the procedure for reinstalling valve assembly to the dryer . WARNING: T est ALL connections for leaks by brushing on a soapy water solution. W ARNING: NEVER TEST FOR LEAKS WITH A FLAME!!! NOTE: There is no regulator provided in an L.P . dryer . The column pressure must be regulated at the source (L.P . tank) or an external regulator m[...]

21 C. MANUAL RESET BURNER HI-LIMIT (330º F [166º C]) THERMOST A T REPLACEMENT (Gas Models Only) 1. This thermostat is an important safety device as an added protection against failure of the airflow (sail switch) to open in the event of motor failure or reduced airflow conditions. IMPOR T ANT : UNDER NO CIRCUMST ANCES should heat circuit safety d[...]

22 D. SAIL SWITCH ASSEMBL Y (Gas Models Only) The sail switch is a heat circuit safety device which controls the burner circuit only . When the dryer is operating and there is proper airflow , the sail switch damper pulls in and closes the sail switch. Providing ALL the other heat-related circuits are functioning properly , ignition should now be e[...]

23 IMPOR T ANT : UNDER NO CIRCUMST ANCES should the door switch be disabled. Main Door Assembly Replacement 1. Open main door . 2. Holding the door upward remove the two (2) screws from the top hinge block. 3. Lift the door up to remove. 4. Reverse this procedure for reinstalling new main door assembly . T o Install New Main Door Glass 1. Remove ma[...]

24 Front Panel Replacement 1. Discontinue electrical power to the dryer . 2. Remove bottom lint drawer assembly . 3. Remove the screws securing the front panel to the dryer . 4. Disconnect the two (2) door switch wires located behind the front panel. 5. Remove the front panel. IMPOR T ANT : When pulling the front panel off, the door switch harness [...]

25 F . DRIVE SHAFT PULLEY REPLACEMENT 1. Discontinue electrical power to the dryer . 2 . Remove front panel from dryer (Follow front panel replacement directions on page 24 .) 3. Loosen V -belts. Rotate pulley and roll V -belts out of grooves. 4. Remove set screw from the 9 (22.86 cm) pulley . 5. Remove pulley and key . NOTE: A gear puller may b[...]

26 5. Loosen V -belts. Rotate pulley and V -belts out of the groove. 6. Block the tumbler (basket) assembly in position. 7. Mark the position of pillow block bearing then remove the bolts from the pillow block bearings. 8. Remove the drive shaft assembly through the front of the machine. 9. Remove the set screw from the 9 (22.86 cm) pulley . 10 [...]

27 3. Remove the ten (10) 1/4-20 x 1/4 socket button head screws from the perforated basket side. 4. Remove the wrapper assembly . 5. Block the tumbler (basket) assembly in position. 6. Mark the position of the pillow block bearings. Then remove the bolts from the pillow block bearing. 7. Remove the idler shaft assembly through the front of the [...]

28 3. Depress the tabs on the rotational sensor harness plug and pull apart. 4. Remove the retaining ring from the tumbler shaft. 5. Remove the four (4) bolts, lock washers and flat washers securing the flange bearing to the dryer cabinet. 6. Loosen the set screws from the flange bearing. 7. Remove the flange bearing from the tumbler shaft. 8. T o [...]

29 L. IDLER SHAFT PILLOW BLOCK BEARING REPLACEMENT 1. Refer to tumbler wheel replacement on idler assembly page 26. 2. Complete S tep #1 through S tep #1 1 . 3. Remove both set screws from each pillow block bearing. 4. Remove pillow block bearing from shaft. 5. Reverse this procedure for replacement. NOTE: Once the shaft assembly has been installed[...]

30 8. Retighten motor mount bolts and jam nuts. 9. Assemble front panel lint door assemblies back to dryer . 10 . Reestablish electrical power to the dryer . Drive Motor V -Belts Replacement 1. Discontinue electrical power to the dryer . 2. Remove the belt guard cover from the rear of the dryer . 3. Loosen tension on V -belt so that it can easily b[...]

31 P . MOTORIZED IMPELLOR (BLOWER) REPLACEMENT 1. Discontinue electrical power to the dryer . 2. Remove lint draw . 3. Remove the perforated panel inside the tumbler (basket). 4. Remove the bolts securing the inlet cone. 5. Remove the inlet cone. 6. Remove the bolts securing the motor plate to the dryer cabinet. 7 . Remove the motorized impellor al[...]

32 SECTION VI TROUBLESHOOTING IMPOR T ANT : YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPL Y a nd THE GAS SUPPL Y BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) ST ANDARDS. The information pro[...]

33 C . Dryer will not start, but computer L.E.D. (light emitting diode) indicators are on... 1. Failed contactors. 2. Failed arc suppressor (A.S.) board. 3. Failed microprocessor controller (computer). 4. Failed motors. D . Drive motor runs, burner is on, but tumbler (basket) will not turn... 1. Broken, damaged or loose V -belt. 2. Belts contaminat[...]

34 F . Thermal overload for drive motor is tripping... 1. Either an exceptionally low or high voltage supply . 2. Motor bearing failure. 3. Motor vents are blocked with lint. 4. Failed motor . 5. Failed overload. 6. Out of balance impellor (fan). 7. Insuf ficient make-up air . G . Overload for impellor (fan) motor is tripping... 1. Either an except[...]

35 I. L.E.D. (light emitting diode) display reads T emp Sensor Failur e Check T emp Sensor Fuse. Dryer Sensor Circuit Failure... 1. Check 1/8-amp fuse on microprocessor controller (computer). 2. Faulty microprocessor temperature sensor probe. 3. Open circuit in either one of two (2) wires leading from the sensor probe to the computer ... a . [...]

36 SECTION VII PHASE 6 OPL SYSTEM DIAGNOSTICS IMPOR T ANT : YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPL Y a nd THE GAS SUPPL Y BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) S T ANDARDS. AL[...]

37 6. bURNER CONTROL F AIL- This routine monitors the ignition control s gas valve output response. If the valve output signal is not present from the ignition control within the valve time limits the Phase 6 microprocessor controller (computer) determines the ignition control has failed. If this occurs when the cycle is active the machine will [...]

38 11 . ROT A TE SENSOR F AIL- Indicates a rotational sensor circuit failure meaning that there is a fault somewhere in the tumbler (basket) rotating circuit, or the Phase 6 OPL microprocessor controller (computer) program related to this circuit (program location 2) is set incorrectly . In the active mode it should be (ROT A TE SENSOR ACTIVE), if [...]

39 4. L.E.D. DISPLA Y INDICA TOR NUMBER 4 a . On Indicator: 1) This indicator dot is on whenever a cycle is in progress. Additionally , when the Anti-W rinkle program is active, the indicator dot will be on whenever the Phase 6 OPL microprocessor controller (computer) is in the Guard On T ime program. 5. L.E.D. DISPLA Y INDICA TOR NUMBER 5 a . Air [...]

40 1. F AN (BLOWER) Output L.E.D. (light emitting diode) Indicator a . If the dryer is started and the blower motor is not operating, yet the Phase 6 OPL microprocessor controller (computer) display fan indicator dot and power supply input L.E.D. (light emitting diode) are on, but the fan output L.E.D. is off, then the fault is the Phase 6 OP[...]

41 6. FUSE (MAIN FUSE) Input L.E.D. (light emitting diode) Indicator a. Should be on ALL the time (even if the dryer is not running). If the L.E.D. (light emitting diode) is not on; then the display will read CHECK MAIN FUSE. If the main fuse is good then the fault is on the Phase 6 microprocessor controller (computer). 7. LINT (L[...]

42 12. FLAME (bURNER CONTROL F AIL) Input L.E.D. (light emitting diode) Indicator a . This routine monitors the ignition control s gas valve output response. If the valve output signal is not present from the ignition control within the valve time limits the microprocessor determines the ignition control has failed. If this occurs when the[...]

43 D. L.E.D. CODES 1. Display Codes A ALL REV ANTI WRINKL dELA Y TIME ANTI WRINKL GUARd ACTIVE ANTI WRINKL GUARd ON TIME AUTO CYCLE b bURNER CONTROL F AIL bURNER FLAME F AIL bURNER SAFETY F AIL bUZZ bUZZ TIME CEL CHECK MAIN FUSE CLEAN LINT COOL COOL TIME_M COOL TEMP_ CYCLEA CYCLEb CYCLEC CYCLED CYCLEE CYCLEF dONE dR YING dR Y LEVEL_ dR Y TEMP F_ dR[...]

44 2. Fault Codes bURNER CONTROL F AIL - GAS MODELS ONL Y POWER (24 V AC) IS NOT EVIDENT A T GAS V AL VE bURNER FLAME F AIL - The Phase 6 Microprocessor Controller (Computer) DOES NOT SENSE FLAME VERIFICA TION (GAS MODEL ONL Y) bURNER SAFETY F AIL - GAS/ELECTRIC ONL Y BURNER/OVEN OPEN HI-LIMIT CIRCUIT dRUM SAFETY F AIL - Fault in the TUMBLER HI-LIM[...]

45 E. COMPUTER LOGIC and WIRING DIAGRAM 1. Operator enters desired selections. 2. Information entered is sent to the microprocessor via the keyboard (touchpad). 3. The input information is sorted, processed and executed by the microcomputer chip. 4. The microcomputer output signal activates the contactors and HSI (Hot Surface Ignition) module which[...]

46[...]

47 1. No Display Condition a . Check position of EMERGENCY STOP (E-Stop) to verify it is in operating position (pull or twist for operating position). b. Check fuse one or two and if either are blown, replace. c . T ake voltage reading across the microprocessor (J7) 9-pin connector pins 1 and 2. If no voltage is present at pins 1 and 2, doubl[...]

48 If there is voltage, replace the coil or the complete contactor . If there is no voltage, check for voltage across the two BS3 terminals on the arc suppressor (A.S.) board. If there is voltage across the two BS3 terminals and no voltage across the coil of the reversing contactor (A1 and A2), the problem is faulty wires or terminations between BS[...]

49 c . If no voltage is present at J7 9-pin connector no. 4 to ground, but voltage is present at no. 3 to ground. The problem is a faulty switch, wires or termination between J7 to J8 and J8 to the lint switch no. 20 and 21. d. If no voltage is present at J7 9-pin connector no. 3 to ground, then voltage should not be present at no. 5 to ground. Rep[...]

50 IMPORT ANT MANUAL RESET HI-LIMIT INSTRUCTIONS FOR PHASE 6 MODELS This dryer was manufactured with a manual reset burner hi-limit and tumbler/lint chamber hi-limit thermostat which is monitored by the Phase 6 computer . If either manual reset thermostat is open prior to start of the drying cycle, the dryer will start momentarily and then shut dow[...]

51 SECTION VIII TECHNICAL INFORMA TION The following section contains various technical information important to the service person in servicing and maintaining the dryer . A. MOT OR PLA TE (HIGH and LOW VOL T AGE) The motor plate is located on the side of the drive motor (refer to illustration) and contains a graphical representation of the motor [...]

52 B. DA T A LABEL Contacting American Dryer Corporation (ADC) When contacting ADC , certain information is required to ensure proper service and parts information. This information is on the data label, located on the top right corner of the dryer , viewed from the rear (refer to illustration). When contacting ADC , please have the model number an[...]

53 C. HOW T O USE A MANOMETER 1. W ith dryer in nonoperating mode, remove plug on the gas valve pressure tap. 2. Attach plastic tubing to pressure tap. Fitting is supplied with manometer (see illustration). 3. Attach manometer to dryer using magnet. NOTE: Place manometer in a position so that readings can be taken at eye level. 4. Fill manometer wi[...]

54 D. ML-96 T OOL LIST Straight Head Screwdriver Phillips Head Screwdriver Sensor Pin and Socket T ool (P/N 122801) Pliers 1/4 Nut Driver 3/8 Open End W rench 5/8 Open End W rench 3/8 Socket W rench 1/2 Socket or Open End W rench 1/4 Open End W rench 5/16 Socket or Open W rench 1/2 Socket W rench 7/16 Socket or Open End W[...]

ADC 450406 1 - 02/09/00-25[...]