American Dryer Corp. Phase 7 OPL with S.A.F.E. Gas DSI AD-78 IV manual

AD-78 IV (Phase 7 OPL with S.A.F.E. Gas DSI) Installation Manual For replacement parts, contact the reseller from which the dryer was purchased or American Dryer Corporation 88 Currant Road Fall River MA 02720-4781 USA T elephone: (508) 678-9000 / Fax: (508) 678-9447 e-mail: techsupport@amdry .com www .amdry .com W ARNING: For your safety the infor[...]

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 T O ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, OR TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health Administration) ST ANDARDS. W ARNING CHILDREN SHOULD NOT BE ALLOWED T O PLA Y O[...]

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

SECTION I IMPOR T ANT INFORMA TION ............................................................................... 3 A. Receiving and Handling ............................................................................................................... 3 B . Safety Precautions ......................................................................[...]

SECTION VII REVERSING TIMER SPIN/DWELL ADJUSTMENTS ..................................... 3 9 SECTION VIII DA T A LABEL INFORMA TION ............................................................................. 4 0 A. Data Label ..........................................................................................................................[...]

3 SECTION I IMPOR T ANT INFORMA TION A. RECEIVING AND HANDLING The dryer is shipped in a protective stretch wrap cover with protective cardboard corners and top cover (or optional box) as a means of preventing damage in transit. Upon delivery, the dryer and/or packaging, and wooden skid should be visually inspected for shipping damage. If any damag[...]

4 B. SAFETY PRECAUTIONS WARNING: 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. WARNING: The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJURY OR FIRE COULD RESUL[...]

5 7. A program should be established for the inspection and cleaning of lint in the burner area, exhaust ductwork, and area around the back of the dryer. The frequency of inspection and cleaning can best be determined from experience at each location. WARNING: The collection of lint in the burner area and exhaust ductwork can create a potential fir[...]

6 SECTION II SPECIFICA TIONS/COMPONENT IDENTIFICA TION A. SPECIFICA TIONS Gas Shaded areas are stated in metric equivalents * Motor specifications are for non-reversing models only. Please consult factory for reversing specifications. ** S.A.F.E. system must be supplied with a 40 psi +/- 20 psi (2.75 bar +/- 1.37 bar) water supply. NOTE: ADC reserv[...]

7 Specifications AD-78 NOTE: ADC reserves the right to make changes in specifications at any time without notice or obligation.[...]

8 B. COMPONENT IDENTIFICA TION 1. Dryer Front View Illus. No. Description 1 Controls 2 Control (top access) Door Assembly 3 Main Door Assembly 4 Lint Compartment Area (lint screen located behind door) 5 Data Label and Installation Label (affixed to the left side panel area behind the top control [access] door)[...]

9 2. Dryer Rear View Illus. No. Description 1 Heating Unit 2 Electric Service Relay Box 3 Electric Service Connections made here. 4 Basket (tumbler) Bearing Mount Assembly 5 Idler Bearing Mount Assembly 6 Basket (tumbler) (drive) Motor Assembly (for reversing models ONLY) 7 Leveling Leg (rear) 8 Blower Motor Assembly 9 Dryer Exhaust[...]

10 SECTION III INST ALLA TION PROCEDURES 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 Standards: ANSI Z223.1- LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electri[...]

11 10. The dryer must be installed with provisions for adequate combustion and make-up air supply. CAUTION: This dryer produces combustible lint and must be exhausted to the outdoors. Every 6 months, inspect the exhaust ducting and remove any lint build up. IMPORTANT: Dryer must be installed in a location/environment, which the ambient temperature [...]

12 c. Remove the four (4) self-taping screws on the burner box that secure it to the top of the dryer shown in the illustration below . d. Remove the two (2) self-taping screws on the back electrical box and pull through ALL associated wires from the motor to this electrical box (refer to the illustration below ). e. Reverse procedure for installin[...]

13 C. DR YER ENCLOSURE REQUIREMENTS Bulkheads and partitions should be made of noncombustible materials and must be located a minimum of 12-inches (30.48 cm) (18-inches [45.72 cm] or more is recommended for ease of installation, maintenance, and service) above the dryer outer top, except along the front of the dryer which may be partially closed in[...]

14 D. FRESH AIR SUPPL Y REQUIREMENTS When the dryer is operating, it draws in room air, heats it, passes this air through the basket (tumbler), and exhausts it out of the building. Therefore, the room air must be continually replenished from the outdoors. If the make-up air is inadequate, drying time and drying efficiency will be adversely affected[...]

15 E. EXHAUST REQUIREMENTS 1. General Exhaust Ductwork Information Exhaust ductwork should be designed and installed by a qualified professional. Improperly sized ductwork will create excessive back pressure which results in slow drying, increased use of energy, overheating of the dryer, and shutdown of the burner by the airflow (sail) switches, bu[...]

16 NOTE: As per the National Fuel Gas Code, “Exhaust ducts for Type 2 clothes dryers shall be constructed of sheet metal or other noncombustible material. Such ducts shall be equivalent in strength and corrosion resistance to ducts made of galvanized sheet steel not less than 0.0195-inches (26 gauge [0.05 mm]) thick.” IMPORTANT: Exhaust back pr[...]

17 IMPORTANT: Exhaust back pressure measured by a manometer in the exhaust duct must be no less than 0 and must not exceed 0.3 inches (0.74 mb) of water column (W.C.). IMPORTANT: Minimum duct size for a dryer that is vented vertically is 12-inches (30.48 cm) for a round duct or an equivalent of 80 square inches (516.1 square centimeters). THE DUCT [...]

18 F . ELECTRICAL INFORMA TION 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, materials,[...]

19 2. Electrical Service Specifications IMPORTANT: The dryer must be connected to the electric supply shown on the data label that is affixed to the left side panel area behind the top control (access) door. In the case of 208 VAC or 240 VAC, the supply voltage must match the electric service specifications of the data label exactly . IMPORTANT: Th[...]

20 3. Grounding A ground (earth) connection must be provided and installed in accordance with state and local codes. In the absence of these codes, grounding must conform to applicable requirements of the National Electrical Code ANSI/NFPA NO. 70-LATEST EDITION, or in Canada, the installation must conform to applicable Canada Standards: Canadian El[...]

21 If local codes permit, power to the dryer can be made by the use of a flexible U.L. listed power cord/ pigtail (wire size must conform to rating of dryer), or the dryer can be hard wired directly to the service breaker panel. In both cases, a strain relief must be installed where the wiring enters the dryer. b. 3-Phase (3ø) Wiring Connections ([...]

22 1) G as M odels The only electrical input connections to the dryer are the 3-phase (3ø) power leads (L1, L2, L3, and sometimes neutral) and ground. Single-phase (1ø) power for the control circuit is done internally to the dryer. No single-phase (1ø) input connection is required on a 3-phase (3ø) dryer. For gas dryers manufactured for operati[...]

23 2) E lectrically H eated M odels O nly The only electrical input connections to the dryer are the 3-phase (3ø) power leads (L1, L2, L3, and sometimes neutral) and ground. Single-phase (1ø) power for the control circuit is done internally to the dryer. No single-phase (1ø) input connection is required on a 3-phase (3ø) dryer. CAUTION: The dry[...]

24 c. 3-Phase (3ø) Wiring Connections (Hookup) For Reversing Models Only The electrical connections on ALL 3-phase (3ø) gas model dryers are made into the rear service box located at the upper left area of the dryer. Electrical connections for electrically heated dryers are made in the electric oven area located at the upper rear of the dryer. NO[...]

25 G . GAS INFORMA TION It is your responsibility to have ALL plumbing connections made by a qualified professional to assure that the gas plumbing installation is adequate and conforms to local and state regulations or codes. In the absence of such codes, ALL plumbing connections, materials, and workmanship must conform to the applicable requireme[...]

26 2. Technical Gas Data a. Gas Specifications * Measured at gas valve pressure tap when the gas valve is on. b. Gas Connections Inlet connection --- 3/4” N.P.T. Inlet supply size --- 3/4” N.P.T. (minimum) Btu/hr input -------- 204,000 (51,408 kcal/hr) 1) Natural Gas Regulation is controlled by the dryer’s gas valve’s internal regulator. In[...]

27 3. Piping/Connections ALL components/materials must conform to National Fuel Gas Code Specifications ANSI Z223.1-LATEST EDITION, or in Canada, CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (Liquid Propane [L.P.] Gas) or LATEST EDITION (for General Installation and Gas Plumbing), as well as local codes and ordinances and must be done by [...]

28 Consistent gas pressure is essential at ALL gas connections. It is recommended that a 3/4-inch (19.05 mm) pipe gas loop be installed in the supply line servicing a bank of dryers. An in-line pressure regulator must be installed in the gas supply line (header) if the (natural) gas pressure exceeds 12.0 inches (29.9 mb) of water column (W.C.) pres[...]

29 H. PREP ARA TION FOR OPERA TION/ST AR T -UP The following items should be checked before attempting to operate the dryer: 1. Read ALL “ CAUTION ,” “ WARNING ,” and “ DIRECTION ” labels attached to the dryer. 2. Check incoming supply voltage to be sure that it is the same as indicated on the dryer data label affixed to the left side p[...]

30 I. PREOPERA TIONAL TESTS ALL dryers are thoroughly tested and inspected before leaving the factory. However, a preoperational test should be performed before the dryer is publicly used. It is possible that adjustments have changed in transit or due to marginal location (installation) conditions. 1. Turn on electric power to the dryer. a. Open AL[...]

31 NOTE: To check for proper sail switch operation, open the main door and while holding main door switch plunger in, start dryer. Dryer should start but heat circuit should not be activated (on). If the heat system is activated, the sail switch is improperly adjusted and must be adjusted by bending the actuator arm of the sail switch toward the bu[...]

32 8. Check to insure that ALL setscrews (i.e., basket [tumbler] drive, idler, etc.) are tight. J . PREOPERA TIONAL INSTRUCTIONS OPL MODELS 1. To start the dryer: a. Microprocessor Controller (Computer) Dryers... 1) Light emitting diode (L.E.D.) display will read “REAdY” (meaning no cycle in progress). 2) Press the letter on the keyboard (touch[...]

33 K. SHUTDOWN INSTRUCTIONS If the dryer is to be shutdown (taken out of service) for a period of time, the following must be performed: 1. Discontinue power to the dryer either at the external disconnect switch or the circuit breaker. 2. Discontinue the heat supply: a. GAS MODELS ...discontinue the gas supply . 1) SHUT OFF external gas supply shut[...]

34 SECTION IV SER VICE/P AR TS INFORMA TION A. SER VICE 1. Service must be performed by a qualified trained technician, service agency, or gas supplier. If service is required, contact the reseller from whom the ADC equipment was purchased. If the reseller cannot be contacted or is unknown, contact the ADC Service Department for a reseller in your [...]

35 SECTION V W ARRANTY INFORMA TION A. RETURNING WARRANTY CARDS 1. Before any dryer leaves the ADC factory test area, a warranty card is placed on the back side of the main door glass. These warranty cards are intended to serve the customer where we record the individual installation date and warranty information to better serve you should you file[...]

36 2. Each part must be tagged with the following information: a. Model number and serial number of the dryer from which part was removed. b. Nature of failure (be specific). c. Date of dryer installation. d. Date of part failure. e. Specify whether the part(s) being returned is for a replacement, a credit, or a refund. NOTE: If a part is marked fo[...]

37 SECTION VI 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 [...]

38 90 DAYS 1. Remove lint from around basket (tumbler), drive motors, and surrounding areas. 2. Remove lint from gas valve burner area with a dusting brush or vacuum cleaner attachment. 3. Clean any lint accumulation in and around both the blower and drive motor casing openings. EVERY 6 MONTHS Inspect and remove lint accumulation in customer furnis[...]

39 SECTION VII REVERSING TIMER SPIN/DWELL ADJUSTMENTS Timer models have an electronic reversing timer in the electrical service box, which is located in the upper left rear area of the dryer. Both the dwell (stop) time and the basket (tumbler) spin time are adjustable by mode selection switches located on the electronic timer (refer to the illustra[...]

40 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 insure proper service/parts information from ADC . This information is on the data label that is affixed to the left side panel area behind the top control (access) door. When c[...]

41 THE DATA LABEL 1. MODEL NUMBER The model number is an ADC number, which describes the size of the dryer and the type of heat (gas, electric, or steam). 2. SERIAL NUMBER The serial number allows ADC to gather information on your particular dryer. 3. MANUFACTURING CODE NUMBER The manufacturing code number is a number issued by ADC, which describes[...]

42 SECTION IX PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. Microprocessor Controller (Computer) Board a. Upon completing installation of the replacement microprocessor controller (computer) board, reestablish power to the dryer. b. Start the drying cycle by pressing any of the preset cycles in letters A-F. c. Verify that the applicab[...]

43 2. For Models With Johnson Controls Direct Spark Ignition (DSI) Module (G760) Theory Of Operation: Start the drying cycle. When the gas burner ignites within the chosen trial for ignition time (6-seconds), the flame sensor detects gas burner flame and signals the DSI module to keep the gas valve open...as long as there is a call for heat. The DS[...]

44 SECTION X SENSOR ACTIV A TED FIRE EXTINGUISHING ( S.A.F.E .) SYSTEM The exclusive Sensor Activated Fire Extinguishing (S.A.F.E.) System will extinguish fires that may start in the drying basket (tumbler). A series of sensors positioned throughout the basket (tumbler) and interfaced with the microprocessor will trigger the S.A.F.E. system water j[...]

45 BEFORE YOU START! CHECK LOCAL CODES AND PERMITS Call your local water company or the proper municipal authority for information regarding local codes. IMPORTANT: It is your responsibility to have ALL plumbing connections made by a qualified professional to assure that the plumbing installation is adequate and conforms to local, state, and federa[...]

46 2. Water Connections: The water connection is made to the 1/2” M.P.T. bushing of the electric water solenoid valve located at the rear upper left area of the dryer (see photo). The water solenoid valve has a 3/8” M.P.T. connection and a 1/2” bushing is supplied to provide the minimum 1/2” supply (feed) line. Flexible supply line/coupling[...]

47 OPTIONAL MANUAL BYPASS Provisions are made in the dryer Sensor Activated Fire Extinguishing (S.A.F.E.) system for the installation of an optional manual bypass. Depending on the model dryer, the connections for the manual bypass are made at the “T” or “four way” fitting located in the outlet supply side of the water solenoid valve. The u[...]

48 Sensor Activated Fire Extinguishing (S.A.F.E.) System Theory of Operation While the dryer is in an idle state or 20-seconds after the heat turns off, the Phase 7 control monitors the S.A.F.E. system probe located in the top of the basket (tumbler) chamber and records the minimum temperature. If the minimum recorded S.A.F.E. system probe temperat[...]

49 Sensor Activated Fire Extinguishing (S.A.F.E.) System Parts Break Down Replacement parts can be obtained from your reseller or the ADC factory. When ordering replacement parts from the factory, you can FAX your order to ADC at (508) 678-9447 or telephone your order directly to the ADC Parts Department at (508) 678-9000. Please specify the dryer [...]

50 Illus. No. Part No. Qty. Description 1 822752 1 S.A.F.E. System Temperature Probe Assembly (includes illus. nos. 1 through 5) 2 154007 2 Push On Fastener 3 390390 1 Sensor Bracket ONLY 4 150301 2 #8-18 x 7/16” Phillips Pan Head TEK Screw 5 122647 1 Connector O NL Y ( does not include terminals)[...]

ADC 113164 1 - 01/16/03-25 2 * 02/27/03-25 3 * 05/09/03-50[...]