American Dryer Corp. AD-540 manual

AD-540 Mechanical/Electrical Service Procedure 090603SRS/tcosta ADC Part No. 450246 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 www .amdry .com[...]

Retain This Manual In A Safe Place For Futur e Refer ence American Dryer Corporation products embody advanced concepts in engineering, design, and safety . If this product is properly maintained, it will provide many years of safe, efficient, and trouble free operation. ONLY qualified technicians should service this equipment. OBSER VE ALL SAFETY P[...]

IMPOR T ANT YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPL Y AND 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. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE V AP[...]

IMPOR T ANT PLEASE OBSER VE ALL SAFETY PRECAUTIONS displayed on the equipment and specified in the installation manual included with the dryer . W ARNING DR YER MUST NEVER BE OPERA TED WITHOUT THE LINT FIL TER OR SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. The wiring diagram for the dryer is located behind the left front co[...]

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

SECTION VI BCD-1 TYPE MODULE .......................................................................................... 2 9 A. Introduction .............................................................................................................................. 29 B. General System Information ..................................................[...]

3 SECTION I IMPOR T ANT INFORMA TION A. SAFETY PRECAUTIONS 1. DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. 2. Purchaser and/or user should consult the local gas supplier for proper instructions to be followed in the event the user smells gas. The instructions should be posted in [...]

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

5 AS REQUIRED: In cleaning and care of the cabinet, avoid using harsh abrasives. A product intended for the cleaning of appliances is recommended. B. ADJUSTMENTS S UGGESTED INTER V AL 6 MONTHS Drive belts should be examined. Cracked or seriously frayed belts should be replaced. T ighten loose drive belts when necessary , and check belt alignment. C[...]

6 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 National S tandards: ANSI Z223.1- LA TEST EDITION (National Fuel Gas Code) or ANSI/NFP A NO. 70-LA TEST EDITION (National El[...]

7 B. ELECTRICAL AND GAS REQUIREMENTS 1. Electrical Requirements It is your responsibility to have ALL electrical connections made by a properly licensed and competent electrician to assure that the electrical installation is adequate and conforms to local and state regulations or codes. In the absence of such codes, ALL electrical connections, mate[...]

8 The dryer must be connected to the type of gas (natural or liquid propane [L.P .]) indicated on the dryer data label. If this information does not agree with the type of gas available, contact the reseller who sold the dryer or contact the ADC factory . The gas input ratings shown on the dryer data label are for elevations up to 2,000 feet (609.6[...]

9 SECTION IV DESCRIPTION OF P AR TS A. CONTROL PANEL The coin panel assembly consists of the coin operator , a display board, and the keyboard (touch pad) label. The coin acceptor is used to acknowledge that the proper coin has been put through the acceptor . The display board will just display the time and temperature in a readable number of lette[...]

10 D. DOOR SWITCH (HINGE BLOCK) The main door switch is located behind the main door on the right hand side. When the main door is opened, the switch will also open, preventing the dryer from operating. The main door switch is a safety device and should never be disabled. G . BASKET (TUMB LER) AND DRIVE MOT OR ASSEMBL Y ARRANGEMENT The basket (tumb[...]

11 H. IDLER ARM AND IMPELLOR MOUNT ASSEMBL Y The idler assembly is located in the back of the dryer , which is attached to the drive motor assembly . The main purpose of the idler assembly is to reduce the speed of the motor , in turn increasing the torque of the basket (tumbler) pulley . I. DRIVE MOT OR AND IDLER PULLEY ARRANGEMENT The dryer has a[...]

12 K. GAS BURNER The gas burner assembly consists of two (2) burner tube orifices (the orifice has a hole in it to allow gas to flow through). The hole size varies with different elevation Btus, gas valve (which can be up for natural or liquid propane [L.P .]), and a flame-probe assembly . M. HI-LIMIT THERMOST A T The burner hi-limit thermostat is [...]

13 N. LINT DRA WER SWITCH The lint drawer switch is located under the basket (tumbler) on the right side. It is another added safety device that stops the operation of the dryer , when the lint drawer is opened. This device and the door switch are the two (2) safety switches designed to halt the basket (tumbler). P . FRONT THRUSTER WHEEL BRACKET AS[...]

14 Q. REAR BASKET (TUMBLER) DRIVE WHEELS There is a left and right basket (tumbler) drive wheel bracket assembly . This allows the basket (tumbler) to spin freely without bearings or basket (tumbler) support shaft. R. ROT A TIONAL SENSOR ASSEMBL Y The Rotational Sensor Assembly is located in the rear of the dryer . It consists of a magnet and a rot[...]

15 SECTION V SER VICE A. INTRODUCTION ALL electrical or mechanical service or repairs should be made with the electrical power to the dryer disconnected (power off). W ARNING: PERSONAL INJURY 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 sh[...]

16 5. Disconnect the keyboard (touch pad) connector from the computer board keyboard (touch pad) harness (simply pull straight out). 6. Disconnect the 9-pin main computer harness from the computer (squeeze the one [1] tab on the connector and pull straight back). 7. Disconnect the green ground wire from the computer board. 8. Remove the two (2) Phi[...]

17 TO REMOVE OPTIC SWITCH 1. Disconnect power to the dryer . 2. Remove top or bottom coin panel. 3. Remove optic switch from the coin acceptor (one [1] screw). 4. Unplug optic switch connector . 5. Remove optic switch from the dryer . 6. Reverse procedure for installing new optic switch. T O REPLACE MOT OR CONT ACT OR 2-POLE, 24 V AC 1. Discontinue[...]

18 REPLACE BURNER TUBE ASSEMBL Y (Refer to the illustration below ) 1. Discontinue power to the dryer . 2. Remove the four (4) hex nuts that hold the burner hood bracket to the burner box. 3. Remove the two (2) hex nuts that hold the burner tube to the burner box. 4. Pull down on the burner tube to remove it. 5. Reassemble new burner tube ( ADC PN:[...]

19 C. BURNER CONTROLS (GAS) The illustration below shows you the gas valve assembly and the gas chamber . TO REPLACE MAIN BURNER ORIFICE 1. Discontinue power to the dryer . 2 . Remove back guard. 3. Remove screws securing gas valve bracket to the burner box, and remove the two (2) screws securing pipe bracket. 4. Move the manifold assembly to the l[...]

20 T O TEST AND ADJUST GAS (W A TER COLUMN [W .C.]) PRESSURE There are two (2) types of devices commonly used to measure water column pressure. They are spring/ mechanical type gauges and manometers. The spring/mechanical type gauge is not recommended because it is easily damaged and not always accurate. One (1) form of a manometer is a hydro-gauge[...]

21 T O CONVER T FROM NA TURAL T O LIQUID PROP ANE (L.P .) GAS 1. Disconnect electrical power to the dryer . 2. Close ALL shutoff valves in dryer gas supply line. 3. Disconnect gas valve wiring. NOTE: Identify location of each wire for correct reinstallation. 4. Break union connection (nut) between union shutoff and gas valve. 5. Loosen and remove f[...]

22 T O REPLACE D IRECT SP ARK IGNITION ( DSI) MODULE 1. Discontinue power to the dryer . 2. Remove the back guard. 3. Remove the wires connected to the terminal strip at the bottom of the module. 4. Remove the four (4) nuts securing the module to the mounting bracket. 5. Replace module by reversing process. NOTE: T ake note of where wires are for i[...]

23 T O REMOVE THE TEMPER A TURE SENSOR OR HIGH HEA T PROTECT OR 1. High Heat Protector a . Discontinue power to dryer . b. Remove the lint drawer from the dryer . c . Remove the two (2) free spin wash nuts that is securing the temperature sensor bracket to the dryer . d. Disconnect the 4-pin connector on the temperature sensor bracket. NOTE: Be car[...]

24 E. SAIL SWITCH ASSEMBL Y The sail switch is a heat circuit safety device, which controls the heat 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 . If an improper airflow occurs, the sail swi[...]

25 F . FRONT P ANEL AND MAIN DOOR ASSEMBLIES TO REPLACE MAIN DOOR SWITCH 1. Discontinue power to the dryer . 2. Open main door . 3. Remove the two (2) Phillips head screws holding the main door switch in place. 4. Disassemble door switch bracket by removing the two (2) nuts holding the door switch to the housing, and remove the door switch. 5. Reve[...]

26 T O REPLACE FRONT P ANEL 1. Discontinue power to the dryer . 2. Remove the computer panels. 3. Remove the kick trim plate. 4. Remove lint screen drawers from the dryer . 5. Remove the screws securing the front panel to the dryer . 6. Disconnect the 4-pin door switch harness connector from the lint drawer switch box, top and bottom. 7. Remove the[...]

27 TO REPLACE ROT A TIONAL SENSOR SWITCH 1. Discontinue electrical power to the dryer . 2. Remove the magnetic rotational sensor switch from the bracket by loosening the nuts. 3. Depress the tabs on the rotational sensor harness plug and pull apart, then remove the sensor switch. 4. T o install a new sensor switch, connect the plug of the new senso[...]

28 BASKET (TUMBLER) REMOV AL 1. Disconnect power to the dryer . 2. Remove the control panels and kick trim plate. 3. Remove the front panel, and disconnect the door switches. 4. Now remove the motor separator panel if removing the top basket (tumbler). 5. Loosen the two (2) nuts on the idler tension arm. 6. Move to the rear of the dryer . Remove th[...]

29 SECTION VI BCD-1 TYPE MODULE A. INTRODUCTION The Direct Spark Ignition (DSI) system operates at 24 V AC and is a discrete component based gas ignition control (DSI module) system, which utilizes a line frequency spark as an ignition source. Safe proof of flame is accomplished through flame rectification. The DSI module has a diagnostic light emi[...]

30 The module also provides for safe proof of ignition. If a flame is not sensed by the flame-probe electrode (of the ignitor/flame-probe assembly) within a specified time frame, the module will de-energize the gas valve and the ignitor/flame-probe assembly , and go into the LOCKOUT mode. If a flame is established (sensed) but then lost (flame out [...]

31 IMPOR T ANT : THE GAP SETTING ON THE IGNIT OR/FLAME-PROBE ASSEMBL Y IS CRITICAL. d. The Direct Spark Ignition (DSI) 24 V AC gas valve(s) used are of the redundant type, which means the gas valve is actually two (2) gas valves in one (1); one (1) in series with the other . This is a safety feature, which provides protection against gas flow in th[...]

32 C. G-760 DIRECT SP ARK IGNITION (DSI) FLOWCHAR T 1. Normal Operation (Summary) On a call for heat by the dryers’ controls, 24 V AC is applied to the DSI module at which time the modules’ light emitting diode (L.E.D.) indicator will light “GREEN” indicating that power has been established to the module. Almost immediately (up to approxima[...]

33 D. TROUBLESHOOTING The troubleshooting information provided in this manual is intended for use only by qualified service technician. Observe ALL safety precautions displayed on the equipment or specified in the installation/operator ’ s manual included with the dryer . IMPOR T ANT : UNDER NO CIRCUMST ANCES SHOULD ANY SAFETY OR HEA T CIRCUIT DE[...]

34 1. Direct Spark Ignition (DSI) T roubleshooting T erms (Definitions) a. LOCKOUT Mode - DSI module “GREEN” light emitting diode (L.E.D.) indicator light blinks continuously . This indicates there is a system fault and most likely the fault is that the DSI module was not able to ignite the gas. b. FLAMEOUT - Burner flame shutdown by the DSI mo[...]

35 2) Direct Spark Ignition (DSI) module light emitting diode (L.E.D.) indicator lights “GREEN” for up to approximately 1.5-seconds (prepurge). This indicates that ALL the controls (including ALL the safety circuits) are functioning and power is being supplied to the DSI module. a ) DSI module L.E.D. indicator lights “GREEN.” This indicates[...]

36 1) T o ef fectively use this information or the flowcharts (on page 37 , page 38 , and page 39 ), each step must be completed in sequence, performing whatever tests are suggested. After the completion of each test, the guide will direct the service technician to the next logical step in the troubleshooting sequence based on the outcome of the pr[...]

37 d. T roubleshooting Flowchart - Quick Reference... First V isual Check NO SP ARK AND SYSTEM DOES NOT WORK Repl ace transforme r. Determine why volt age is not present. Is pow er availabl e at primary? NO YES Are the rmostats con tacts and limi t cont rol contac ts closed ? NO YES Close con tacts. Is 24 VA C present fr om termina l THS2 to ground[...]

38 e . T roubleshooting Flowchart - Quick Reference... Second V isual Check SP ARK PRESENT BUT MAIN BURNER DOES NOT COME ON Is ma in valv e wirin g secu rely attach ed to te rminal M.V . 3 and ground? NO YES Is 24 VAC present between terminals M. V.3 and ground? NO YES Corr ect Replace Johnson Control module G760/761 Check for conti nuity in wiring[...]

39 f . T roubleshooting Flowchart - Quick Reference... Third V isual Check MAIN BURNER LIGHTS BUT DOES NOT ST A Y ON Is fl ame sensor cable securely att ached to ter minal 4 ? NO YES Does continui ty exist from control to fl ame sensor? NO YES Is f lame sensor corroded or is ceramic cracked? NO YES Does continui ty exist i n ground path f rom burne[...]

40 3. T roubleshooting/System Detailed Diagnosis When the dryer calls for heat, 24 V AC from the step down transformer is applied to the “THS” and “GND” (ground) terminals of the Direct Spark Ignition (DSI) module. The DSI module light emitting diode (L.E.D.) indicator will light “GREEN.” The gas valve will be energized, and the spark b[...]

41 a ) Connect water column (W .C.) test gauge (manometer) to the gas valve pressure tap (1/8” N.P .T .). b) Start the dryer ...with the burner on, the correct water column reading in inches should be: Natural Gas .................................. 3.5 inches (8.7 mb) water column. Liquid Propane (L.P .) Gas ............ 10.5 inches (27.4 mb) wat[...]

42 NOTE: T o reset the Direct Spark Ignition (DSI) module if it is in the LOCKOUT mode, open and close the main door , then restart the dryer . (a ) T o check and/or set the 1/8” gap, use a DSI Ignitor gap feeler gauge (refer to the illustration on page 41 ) or similar type device to determine the gap size. DO NOT USE FEELER GAUGE T O SET GAP , u[...]

43 NOTE: T o reset the Direct Spark Ignition (DSI) module if it is in the LOCKOUT mode, open and close the main door , then restart the dryer . 4) DSI Module If there is some sort of operational interference in the DSI system, the DSI module (acting as the “controller” for the system) will go into a LOCKOUT mode (where the light emitting diode [...]

44 a ) Primary Side This is the incoming voltage side -120 V AC, 208 V AC, 230/240 V AC - of the transformer . b) Secondary Side This is the step down side - 24 V AC - of the transformer . W ARNING: 208 V AC and 230/240 V AC ARE NOT THE SAME . ALL voltage connections should be checked and confirmed according to the wiring diagram provided with the [...]

45 (e ) One (1) YELLOW or ORANGE wire supplies the 24 V AC signal for the control and/ or DSI circuit. (Refer to specific wiring diagram with the dryer for connection point.) 7) Direct Spark Ignition (DSI) 24 V AC Redundant Gas V alve There are three (3) DSI 24 V AC Redundant Gas V alves in use (refer to the illustration below and on the next page [...]

46 DIRECT SP ARK IGNITION (DSI) SYSTEM COMPONENTS 24 V AC DIRECT SP ARK IGNITION (DSI) TRANSFORMER ADC PN 141403 G760 DIRECT SP ARK MODULE ADC PN 128935[...]

47 SECTION VII TROUBLESHOOTING The information provided will help isolate the most probable components associated with the difficulty described. The experienced technician realizes that a loose connection or broken or shorted wire may be at fault where electrical components are concerned, however , not necessarily the suspected component itself. El[...]

48 IMPOR T ANT : The Phase 5 coin microprocessor controller (computer) has its own internal heat sensing circuit fuse protection, located on the back side of the controller . If a “ dSFL ” condition occurs, check to see if this fuse has blown. If it has, DO NOT replace the entire microprocessor controller (computer); replace the fuse and do so [...]

49 NOTE: If the dryer is started (the light emitting diode [L.E.D.] display indicator dots are on) and there are no outputs (heat and/or motor output L.E.D.s are off) and the “ dOOr ” input L.E.D. is on, the fault is in the Phase 5 microprocessor controller (computer) itself. If the L.E.D. display indicators are on and the door L.E.D. input and[...]

50 B. NO HEA T CONDITION (BLOWER IS ON) The following procedure must be performed with the microprocessor controller (computer) display in the normal operating mode, the heat indicator dot on, and the light emitting diode (L.E.D.) output light is on. V oltage is 24 V AC unless otherwise specified.[...]

51 1. With the heat indicator on check for voltage at J1 connector 9-pin connector pin #8 (orange wire to ground) if 24 volt is present. 2. If no voltage (24 V AC) check for loose connection at 9-pin connector or problem may be faulty microprocessor . 3. Check for voltage (24 V AC) at J11 connector pin #3 orange wire. If no voltage, check for loose[...]

52 C. NO ST AR T CONDITION Follow this test procedure, providing that the microprocessor controller (computer) is functioning where the display is in the normal operating mode and the motor indicator dot is on, and the light emitting diode (L.E.D.) motor output light is on. The voltage you should be reading is 24 V AC unless otherwise specified. 1.[...]

53 D. NO DISPLA Y CONDITION NOTE: Regardless of the voltage (120-240 V AC) make sure the voltage selector switch is set to 1 15 V AC. 1. Check power supply . (Dryer voltage 1 10v , 208v , 220v) (Circuit breaker box or fuse panel) 2. Check fuse 2 (3/4-amp Slo-Blo) if blown, replace it. 3. Check for voltage at the (J5) 6-pin connector (120 V AC) pin [...]

54 E. “dSFL” DISPLA Y CONDITION When the display reads “ dSFL ” this condition indicates a fault in the microprocessor controller (computer) heat circuit. This circuit includes the microprocessor controller (computer), microprocessor temperature sensor (located in lint compartment) and wires to and from these two (2) points. 1. Check the 1/[...]

55 F . “dOOr” DISPLA Y CONDITION When the display reads “ dOOr ,” this indicates that there is a fault (open circuit) somewhere in the microprocessor controller ’ s (computer ’ s) door switch circuit. Include the door switch, microprocessor controller (computer) and the wires to end from these two (2) points. Before following this test [...]

56 SECTION VIII DA T A LABEL INFORMA TION A. DA T A LABEL Contact American Dryer Corporation When contacting American Dryer Corporation , certain information is required to ensure proper service or parts information from ADC . This information is on the data label, which is af fixed to the left side panel/wall area behind the bottom control panel. [...]

57 4. TYPE OF HEA T This describes the type of heat for your particular dryer: gas (either natural gas or liquid propane [L.P .] gas), electric, or steam. 5. HEA T INPUT (for GAS DR YERS) This describes the heat input in British Thermal Units per Hour (Btu/hr). 6. ORIFICE SIZE (for GAS DR YERS) Gives the number drill size used. 7. ELECTRIC SER VICE[...]

58 C. LIGHT EMITTING DIODE (L.E.D.) DISPLAY CODES A Automatic Cycle (Slope Program Factor) ACOn Accumulative Coin Adrt Maximum Auto Dryness T ime AF A t Amount For Additional T ime AGt Active Anti-W rinkle Guard Time AtIn Accumulative T ime AtSt Amount Start AUtO Automatic Mode (Patent No. 4,827,627 ) b Automatic Cycle (Heat loss [offset] Factor) b[...]

59 The revision number is located on the top right hand corner of the diagram. It is a six (6) digit number followed by a letter to distinguish the version dates (refer to the illustration ). Y our particular model will be different depending on the date of manufacturing and options available. The correct wiring diagram for your dryer is folded and[...]

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ADC 450246 1- 09/08/03-0[...]