ADC AD-200 manual

AD-200 Phase 7 Non-Tilt Service Manual 050801DMG/calbert ADC Part No. 450034 American Dryer Corporation 88 Currant Road Fall River, MA 02720-4781 Telephone: (508) 678-9000 / Fax: (508) 678-9447 E-mail: techsupport@amdry.com www.amdry.com[...]

Retain This Manual In A Safe Place For Future Reference 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. OBSERVE ALL SAFETY PRECA[...]

IMPORTANT YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLY AND THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANY COVERS OR GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, OR TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health Administration) STANDARDS. DO NOT STORE OR USE GASOLINE OR OTHER FLA[...]

IMPORTANT PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and specified in the installation manual included with the dryer. WARNING DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER OR SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. The wiring diagram for the dryer is located in the front electrical control [...]

Table of Contents AD-200 REFERENCE GUIDE (Basket [Tumbler] Section) .............................. 3 AD-200 REFERENCE GUIDE (Base Section) ................................................... 4 SECTION I SAFETY PRECAUTIONS ................................................................................... 5 SECTION II ROUTINE MAINTENANCE ...........[...]

SECTION VI PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS ........................................................... 86 SECTION VII PHASE 7 OPL SYSTEM DIAGNOSTICS ....................................................... 88 A. Diagnostic (L.E.D. Display) Fault Messages .......................................................................[...]

3 AD-200 Reference Guide (Basket [Tumbler] Section)[...]

4 AD-200 Reference Guide (Base Section)[...]

5 SECTION I SAFETY PRECAUTIONS CAUTION: The dryer should never be left unattended while in operation. 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 guar[...]

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

7 SECTION II ROUTINE MAINTENANCE A. CLEANING A 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 upon proper air [...]

8 WARNING: TO AVOID THE HAZARD OF ELECTRICAL SHOCK, DISCONTINUE ELECTRICAL SUPPLY TO THE DRYER. MONTHLY Empty the compressed air filter bowl. NOTE: REGULATOR PRESSURE IS TO BE SET AT 80 PSI (5.51 BARS). Clean any lint accumulation from the gas valve and burner area at the top of the dryer, the fan (squirrel cage fan) motor, and the fan (squirrel ca[...]

9 B. LUBRICA TION MONTHL Y The two (2) bearings that support the squirrel cage fan shaft must be lubricated. Use Shell Alvania #2 grease or its equivalent . Generically, this grease would be described as an NLGI Grade 2 multipurpose industrial grease with a lithium thickener and mineral base oil. EVERY 3 MONTHS The four (4) bearings that support th[...]

10 EVERY 6 MONTHS Change gear oil in basket (tumbler) shaft gear (speed) reducer. 1. Remove the drain plug (located at the bottom rear of the reducer). 2. After oil is completely drained, replace the drain plug. 3. Remove the vent plug and pour in 1.4 liters of Mobil Oil DTE HH5G ( I.S.O. viscosity grade 460 ), SAE 90 , or its equivalent . C. ADJUS[...]

11 SECTION III SPECIFICA TIONS AND DIMENSIONS A. SPECIFICA TIONS (GAS AND STEAM MODELS) * Dryer must be provided with a clean, dry, regulated 80 PSI +/- 10 PSI (5.51 bars +/- 0.68 bars) air supply (equivalent volume = 9 cfh [0.26 cmh]). NOTE: ADC reserves the right to make changes in specifications at any time without notice or obligation. Gas* Ste[...]

12 NOTE: ADC reserves the right to make changes in specifications at any time without notice or obligation. B. DIMENSIONS[...]

13 SECTION IV 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 Standards: ANSI Z223.1- LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electr[...]

14 B. ELECTRICAL AND GAS 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, and workmanship mus[...]

15 SECTION V COMPONENT DESCRIPTION/REPLACEMENT A. HEA T SECTION The dryer uses three (3) types of heat sources: natural gas, liquid propane (L.P.) gas, and steam. Natural gas and L.P. gas are not directly replaceable. The gas valves need to be modified to use other than the type of heat specified on the nameplate. 1. Gas dryers utilize a Direct Spa[...]

16 330º F (166º C) Thermostat MAN3484 Sail Switch Assembly a. The Direct Spark Ignition (DSI) Module is a 24 VAC device designed to be the “controller” of the DSI system. When activated by the dryer controls, this module constantly monitors and controls the functions of the DSI system (i.e., spark activation, gas valve off and on, flame verif[...]

17 e. The Manual Reset Basket (Tumbler) Hi-Limit Switch is a thermostat type switch located above the Lint Basket. Its function is to discontinue heat (flame) in the event of an over temperature situation (above 225º F [107º C]). f. The gas valve used in the ADG-200 is of the redundant type which means that the gas valve is actually two (2) gas v[...]

18 Is 24 VAC available at transformer? Is 24 VAC present from terminal THS2 to ground? Is power available to primary? Are thermostat contacts and limit control contacts closed? Close Contacts. Check continuity of wiring to determine why voltage does not exist at THS2. Is jumper installed from terminal 5 to ground? Install Jumper. Replace Transforme[...]

19 i. Troubleshooting Flowchart - Quick Reference... Second Visual Check Spark Present But Main Burner Does Not Come On Is main valve wiring securely attached to terminal M.V.3 and ground? No Yes Is 24 VAC present between terminals M.V.3 and ground ? No Yes Check for continuity in wiring from M.V.3 to gas valve, and gas valve to GR. No Yes Is inlet[...]

20 j. Troubleshooting Flowchart - Quick Reference... Third Visual Check Main Burner Lights But Will Not Stay On Is flame sensor cable securely attached to terminal 4? No Yes Does continuity exist from control to flame sensor? No Yes Is flame sensor corroded or is ceramic cracked? No Yes Does continuity exist in ground path from burner to control? N[...]

21 B. TROUBLESHOOTING THE DIRECT SP ARK IGNITION (DSI) SYSTEM NOTE: The troubleshooting information provided in this manual is intended for use by qualified service technicians only. OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the AD-200 Phase 7 Non-Tilting Installation/Operator’s Manual ( ADC Part No. 112142) includ[...]

22 1. Direct Spark Ignition (DSI) Troubleshooting Terms (definitions) ADC (DSI) Control Module P/N 128973 a. DSI MODULE “RED” L.E.D. INDICATOR LIGHT - This “red” light emitting diode (L.E.D.) light is located in the upper right corner of the DSI module (refer to the top illustration on page 16 ). This is a diagnostic indicator that simplifi[...]

23 If the dryer repeatedly has Direct Spark Ignition (DSI) module “LOCKOUT” failures, the cause may be due to high voltage (HV) not getting into the DSI module ignitor probe assembly. 5) Check to insure that the red high voltage wire (between the ignitor spark electrode and the DSI module) is not wrapped around the sensor probe wire (the wire b[...]

24 c. Three (3) Visual Checks 1) Does the Direct Spark Ignition (DSI) Ignitor/Flame-Probe Assembly start sparking? If not, refer to the FIRST VISUAL CHECK on page 25 . 2) Does the main burner ignite? If not, refer to the SECOND VISUAL CHECK on page 26 . 3) Does the main burner remain lit after ignition has been established (“FLAMEOUT”)? If not,[...]

25 First Visual Check (Does Ignitor Spark?) I s spark evident (on) at Ignitor Assembly? Is 24 Volts present across DSI Module terminals TH and COM? Check High Voltage (HV) Lead for nicks or cracking, where sparking to ground may occur. Is this wire damaged? Go To Chart 2 Open circuit to DSI System. Check the 24 VAC power source Sail Switch and Hi-L[...]

26 e. Troubleshooting Flowchart - Quick Reference... Second Visual Check (Does Main Burner Ignite?) Does main burner light? Is manual knob on the Gas Valve in the “ON” position? Is dryer Internal Gas Shut-Off Valve and ALL External Gas Shut-Off Valves in the open position? Go To Third Visual Check Yes Yes Turn manual knob on the Gas Valve to th[...]

27 f. Troubleshooting Flowchart - Quick Reference... Third Visual Check (Does Main Burner Ignite?) Does main burner remain lit? Does the Flame Probe have carbon or dust build up? Reposition Flame Sensor Probe to achieve a 2µa or greater sensor current or, if unattainable, replace the Sensor Probe Assembly. Correct ground wiring Control's heat[...]

28 3. Troubleshooting and System Detailed Diagnosis For Johnson Direct Spark Ignition (DSI) Module P/N 128935 When the dryer calls for heat, 24 VAC from the step down transformer is applied to the “TH” and “GND” terminals of the DSI module. The DSI module light emitting diode (L.E.D.) indicator will LIGHT “GREEN .” The gas valve will be[...]

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

30 (a) To check and/or set the 1/8” (3.175 mm) GAP, use a Direct Spark Ignition (DSI) Gap Feeler Gauge or similar device to determine GAP size. DO NOT USE FEELER TO SET THE GAP , USE IT ONL Y T O DETERMINE THE SIZE OF THE GAP . If an adjustment is necessary, bend the ground rod to achieve the correct GAP, then recheck the 1/8” (3.175 mm) GAP wi[...]

31 3) Air Turbulence If there is sail switch flutter due to air turbulence or improper blower (squirrel cage fan) rotation or a restriction in the exhaust ductwork, the Direct Spark Ignition (DSI) module will cycle erratically. This in turn might cause the DSI module to “LOCKOUT” (where the light emitting diode [L.E.D.] indicator will BLINK “[...]

32 CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THE BURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORT OUT. 6) Direct Spark Ignition (DSI) 24 VAC Transformer The DSI transformer is designed to step down the operating voltage of the dryer to 24 VAC. This operates the DSI module. This transformer, like ALL transformers is two (2) si[...]

33 4. Troubleshooting and System Detailed Diagnosis For ADC Direct Spark Ignition (DSI) Module P/N 128973 When the dryer calls for heat, 24 VAC from the step down transformer is applied to the “TH” and “GND” terminals of the DSI module. The DSI module light emitting diode (L.E.D.) indicator will LIGHT “RED ” (for up to approximately 1.5[...]

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

35 (a) To check and/or set the 1/8” (3.175 mm) GAP, use a Direct Spark Ignition (DSI) Gap Feeler Gauge or similar device to determine GAP size. DO NOT USE FEELER TO SET THE GAP , USE IT ONL Y T O DETERMINE THE SIZE OF THE GAP . If an adjustment is necessary, bend the ground rod to achieve the correct GAP, then recheck the 1/8” (3.175 mm) GAP wi[...]

36 3) Air Turbulence If there is sail switch flutter due to air turbulence or improper blower (squirrel cage fan) rotation or a restriction in the exhaust ductwork, the Direct Spark Ignition (DSI) module will cycle erratically. This in turn might cause the DSI module to “LOCKOUT” (where the light emitting diode [L.E.D.] indicator will LIGHT “[...]

37 CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THE BURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORT OUT. 6) Direct Spark Ignition (DSI) 24 VAC Transformer The DSI transformer is designed to step down the operating voltage of the dryer to 24 VAC. This operates the DSI module. This transformer, like ALL transformers is two (2) si[...]

38 C. NA TURAL GAS AND LIQUID PROP ANE (L.P .) GAS CONVERSION INSTRUCTIONS IMPORTANT: CONVERSION MUST BE PERFORMED BY COMPETENT TECHNICIANS IN ACCORDANCE WITH LOCAL AND STATE CODES. NOTE: Converting the dryer to L.P. gas disables the internal regulator of the gas valve, therefore, an external regulator must be provided at the source of the L.P. gas[...]

39 11. Reverse the procedure for reinstalling the gas valve/manifold assembly to the dryer. 12. Open ALL gas shutoff valves (closed in Step #2 ). 13. Reestablish electrical power to the dryer. a. Test ALL connections for leaks. IMPORTANT: T est ALL connections for leaks by brushing on a soapy water solution (liquid detergent works well). WARNING: N[...]

40 1. Steam Coil PH Level The normal PH level for copper type steam coils must be maintained between a value of 8.5 to 9.5. For steel type steam coils the PH level must be maintained between a value of 9.5 to 10.5. These limits are set to limit the acid attack of the steam coils. IMPORTANT : Coil failure due to improper PH level will VOID THE WARRA[...]

41 The steam damper plate should open and close slowly and smoothly. The speed can be modulated by adjusting the needle valve knob. Turning the knob clockwise (CW) restricts the compressed airflow and slows the steam damper movement. Counterclockwise (CCW) adjustment speeds up the steam damper motion. Upon completion of the adjustment, tighten the [...]

42 5) Remove the valve from the bracket. 6) Unscrew the valve from the outlet side. 7) To install new steam solenoid valve, reverse above procedure ( Step #6 thru Step #1 ). c. Needle Valve Replacement 1) Disconnect compressed air supply from the dryer. 2) Remove tubing from the valve. 3) Unscrew needle valve from the solenoid valve. 4) To install [...]

43 6) Remove steam coil damper cylinder (piston). 7) Remove the steam coil damper by unbolting from its hinges. 8) Disconnect steam supply lines and steam return lines at the unions. 9) Remove the remaining piping from the steam coil. 10) Remove ALL of the panels surrounding the steam coil. 11) Unbolt the steam coil and remove. WARNING: The steam c[...]

44 E. SPRINKLER SYSTEM DESCRIPTION The dryer’s sprinkler system is monitored by a microprocessor based temperature controller as a designated “FAIL-SAFE.” The microprocessor circuit must have power in order to engage main power to the dryer. When cycling the dryer, if temperature at the Resistive Temperature Device (RTD) reaches 575º F (301.[...]

45 MAN3488 d. Sprinkler Digital Temperature Controller The sprinkler digital temperature controller is a programmable microprocessor used to monitor temperatures via a Resistive Temperature Device (RTD). NOTE: Operating parameters are preset at the factory and should not require any adjustment. 2. Sprinkler System Operation NOTE: Refer to the ladde[...]

46 5) Remove the wires of the Resistive Temperature Device (RTD) from the terminal strip. NOTE: Identify the wires removed for proper reinstallation. 6) Loosen the cord grip cap. 7) Remove RTD. 8) To install new RTD, reverse above procedure ( Step #7 thru Step #1 ). b. Sprinkler Valve Replacement 1) Turn the water supply to the dryer off. 2) Discon[...]

47 c. 3 HP (2.24 kw) Control Relay Replacement WARNING: THE SPRINKLER CIRCUIT HAS A SEPARATE POWER SUPPLY (than the power supply for the dryer). DISCONNECT AND LOCKOUT BOTH POWER SUPPLIES BEFORE SERVICING THE DRYER. 1) Mark and identify the wires that will be removed for proper reinstallation. 2) Press down on the control relay and lift the bottom [...]

48 6) Mount the top of the control relay to the top of the din rail, then press down and snap the bottom into the rail. Set the overload to the setting specified on the dryer blueprints. 7) Inspect the work performed before reestablishing power (electrical power) to the dryer. 8) Reestablish electrical power to the dryer.[...]

49[...]

50 F . AIR JET ASSEMBL Y 1. Air Jet Assembly Description The air jet assembly is located in the left front base of the dryer. The air jet is designed to operate at the end of each cycle for 30-seconds, to remove lint which may have accumulated on the blower (squirrel cage fan) fan blades. This function will be interrupted if the main door or lint d[...]

51 5) Remove the valve support. 6) Remove the two (2) #6-32 x 1” hex head machine bolts by removing the two (2) #6 hex nuts and the two (2) #6 star washers. 7) To install new air jet assembly, reverse above procedure ( Step #6 thru Step #1 ). b. Pneumatic Valve Muffler Replacement 1) Disconnect compressed air supply from the dryer. 2) Remove dama[...]

52 G . BLOWER (SQUIRREL CAGE FAN) MOT OR ASSEMBL Y 1. Blower (Squirrel Cage Fan) Motor Description The dryer uses a 15-inch (38.1 cm) diameter, blower (squirrel cage fan) wheel. It spins (turns) in a counterclockwise (CCW) direction when looking at the back of the blower housing. The blower (squirrel cage fan) shaft is mounted in two (2) 1-3/8” ([...]

53 2. Blower (Squirrel Cage Fan) and Fan Motor Component Replacement a. Blower (Squirrel Cage Fan) Motor Replacement 1) Discontinue electrical power to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Loosen the bolts from the motor to the motor base... a) Slide the blower (squirrel cage fan) motor forwar[...]

54 18) Replace the V-belts... a) Adjust to proper tension by adjusting position of the new blower (squirrel cage fan) motor. b) Align the V-belts. 19) Tighten and secure the new motor to the motor base. 20) Rewire the new blower (squirrel cage fan) motor in the same order as the wiring from the motor that was removed. A wiring diagram is usually af[...]

55 c) Mark the inside of the motor shaft before removing the bushing. d) Loosen the setscrews on the bushing. e) Remove the bushing and the pulley. 11) Remove the pillow block bearing with shroud by removing the setscrew. 12) Replace the pillow block bearing with shroud on to the fan shaft... a) Secure the blower (squirrel cage fan) shaft bearing m[...]

56 7) Remove the 1/4” x 1/4” x 1-3/4” (6.35 mm x 6.35 mm x 4.45 cm) key on the blower (squirrel cage fan) motor shaft. a) Slide the blower (squirrel cage fan) motor off the shaft. NOTE : Install this 1/4” x 1/4” x 1-3/4” (6.35 mm x 6.35 mm x 4.45 cm) key to the fan shaft before installing the new blower (squirrel cage fan) . 8) To insta[...]

57 a) Thermal Magnetic Starter (TMS) Replacement (1) Discontinue electrical power to the dryer. (2) Mark L1, L2, L3, and T1, T2, T3 on the wires to the TMS for correct replacement. (3) Set the amp rating on the TMS according to the manufacturer’s electrical schematic on the new thermal magnetic starter. (4) To remove the TMS, pull the tab on the [...]

58 2) Auxiliary Contact Block The Auxiliary Contact Block is mounted on the side of the overload. Its function is to sense an overload trip, thereby triggering a safety fault, which will disable the drying cycle. An “Overload Fault” message will appear on the light emitting diode (L.E.D.) display on the Phase 7 microprocessor controller (comput[...]

59 H. FIL TER/REGULA T OR ASSEMBL Y The purpose of the filter is to remove bulk liquids and solid particles from the compressed air stream. The filter element provides mechanical separation of solids. Centrifugal force inside the filter bowl separates bulk liquids and larger solid particles. The filter consists of a louver, which causes a centrifug[...]

60 I. DOOR SYSTEMS The dryer utilizes one (1) style of doors, which is Pneumatic Automatic Doors. 1. Pneumatic Automatic Description/Operation a. Description The Pneumatic Automatic Doors run on a single aluminum track mounted above the doors and a split track mounted on the bottom of the doors. The doors are held on the track by four (4) stainless[...]

61 2. Door Component Replacement and/or Removal a. Pneumatic Automatic Door Replacement or Removal AUT OMA TIC DOORS 1) Discontinue electrical power to the dryer. 2) Remove the two (2) 1/4-20 x 1/2” bolts from each side of the middle guard and then remove the guard. 3) Remove the three (3) 1/4-20 x 3/4” bolts from the bottom guard. Remove the b[...]

62 b. Cable Cylinder Replacement and/or Removal 1) Discontinue electrical power to the dryer. 2) Remove the two (2) 1/4-20 x 1/2” bolts from each side of the middle guard. Remove the middle guard. 3) Disconnect the cables in the top of the electrical panel. 4) Remove the hardware from the top guard. Remove the top guard. 5) Remove the two (2) #8-[...]

63 c. Proximity Switch Replacement 1) Discontinue electrical power to the dryer. 2) Remove the two (2) 1/4-20 x 1/2” bolts from each side of the middle guard and then remove the guard. 3) Remove the three (3) 1/4-20 x 3/4” bolts from the bottom guard. Take notice of the depth of the proximity switch. 4) Unscrew and remove the nut that is on the[...]

64 e. 4-Way Valve, 3-Way Valve, and Supply Air Enable Valve Replacement 1) Discontinue electrical power to the dryer. 2) Disconnect compressed air supply from the dryer. 3) Remove the 1/4-20 self- tapping screws securing the pneumatic panel cover. 4) Remove the two (2) 1/4-20 screws securing the junction box cover. 5) Loosen the cord grip cap that [...]

65 J. CONTROL AND ELECTRICAL SYSTEM Ladder Diagram[...]

66[...]

67 CAUTION: WHEN SER VICING THE HIGH VOLTAGE (HV) SECTION OF THE DR YER, THE ELECTRICAL POWER MUST BE DISABLED. THE “EMERGENCY STOP” (E-Stop) BUTTON DOES NOT DISABLE THE HIGH VOLTAGE TO THE DRYER. 1. Control/Electrical System Description a. 3-Phase (3ø) Electrical Power The 3-phase (3ø) electrical power for the dryer enters the dryer through [...]

68 3) 24 VAC Transformer The 24 VAC transformer consists of CB5 (Circuit Breaker), which is the primary fusing for the transformer. For the proper rating of this circuit breaker, refer to the specific electric diagram. The transformer is located in the right hand electrical cabinet. Dryer models with an optional sprinkler system have an energizing [...]

69 c) Lint drawer closed circuit branch... The lint drawer closed switch is located in the front of the dryer. When the lint drawer is closed, it closes the switch contacts, powering the lint drawer closed relay. Then, the dry enable relay will close, supplying 24 VAC to the TSX 07 Programmable Logic Controller (PLC). When the lint drawer is closed[...]

70 Next reverse leads to temperature sensor black to black and red to white. At that point, you will measure approximately 1.8 amps, this is the turn on voltage of the device. If you hold the temperature sensor in your hands and warm it, the reading will decrease corresponding to a higher current flow (the decrease is very slight tenths of a volt).[...]

71 a) The Programmable Logic Controller (PLC) module has thirteen (13) input relays, which are labeled #0 through #13 and nine (9) output relays labeled #0 through #9. (1) Input Relays Input relays #0, #1, #2, and #3 are set up as user inputs to signal what specific function is to be performed (i.e., load, unload, tilt, and front identifier). These[...]

72 2. Electrical Component Replacement a. Control Voltage Transformer Replacement (refer to the illustration on page 74 ) 1) Discontinue electrical power to the dryer. 2) Locate the correct schematic for the specific change(s) required and verify the wiring of the transformer using the schematic. 3) Verify the voltage of the new transformer. 4) Loo[...]

73[...]

74 b. Programmable Logic Controller (PLC) Replacement 1) Discontinue electrical power to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) To remove the PLC from the mounting rail, using a screwdriver, very carefully pull out the mounting clip on the bottom of the PLC and lift the unit out of the rail. 4) [...]

75 5) To install new microprocessor controller (computer) input/output (I/O) board, reverse Step #4 thru Step #1 . 6) Reestablish electrical power to the dryer. e. Keyboard (Touch Pad) Replacement 1) Discontinue electrical power to the dryer. 2) Disconnect keyboard (touch pad) ribbon cable from the Phase 7 microprocessor controller (computer) displ[...]

76 5) With figer tip, gently push and turn the bulb to unlock. NOTE: A piece of tubing with an inside diameter the size of bulb may assist in bulb removal and replacment. 6) To install new bulb, reverse Step #5 thru Step #1. h. End of Cycle Light Replacement 1) Discontinue electrical power to the dryer. 2) Loosen and remove the cap screw on the top[...]

77[...]

78 WARNING: T O ENSURE THA T THE DRIVE IS NOT UNEXPECTEDL Y ST AR TED, TURN OFF AND LOCKOUT AND/OR T AG POWER SOURCE BEFORE PROCEEDING . F AILURE T O OBSER VE THESE PRECAUTIONS COULD RESUL T IN PERSONAL INJUR Y . WARNING: Drive shaft assembly is heavy . IMPROPER HANDLING CAN CAUSE PERSONAL INJURY. 2. Drive Motor Component(s) a. Drive Motor Replacem[...]

79 1) Discontinue electrical power to the dryer. 2) Loosen turnbuckle and remove V-belts. 3) Install new V-belts. NOTE: Replace V-belts in matched sets (both belts). 4) Tighten turnbuckle. IMPORTANT: DO NOT OVERTIGHTEN TURNBUCKLE . 5) Reestablish electrical power to the dryer. c. Taper Lock Bushing and Drive Motor Pulley Replacement 1) Discontinue [...]

80 3) Mark the position of the pillow block bearing on the mounting pad and loosen the setscrews. 4) Insert blocks of wood under the basket (tumbler) - access through the lint drawer - to take the weight off the drive wheels. 5) Loosen the turnbuckle and remove the V-belts. Remove bottom turnbuckle mounting bolt. 6) Remove the bolts from the pillow[...]

81 4) Verify proper position of drive shaft components prior to tightening onto shaft. 5) Reestablish electrical power to the dryer. f. Pillow Block Bearing(s) Replacement 1) Discontinue electrical power to the dryer. 2) Follow Step #2 thru Step #11 in the instructions on page 79 and page 80 . 3) Remove both drive wheels and taper lock bushings. 4)[...]

82 9) Reinstall the drive shaft into the dryer. 10) Secure the gear (speed) reducer to the drive shaft by reinstalling the three (3) bolts into the taper lock bushing and tighten evenly for proper mounting. 11) Repeat Step #12 to reinstall the other taper lock bushing. 12) Reinstall the bolt into the turnbuckle and mounting bracket. 13) Reinstall V[...]

83 4) Remove the bolts from the guard panel to gain access to the rear bottom retaining wheel. b. Retaining Wheel(s) Replacement 1) Discontinue electrical power to the dryer. 2) Remove the four (4) Phillips pan head screws to remove the cover. 3) Remove the hardware (i.e., bolt, lock washer, and flat washer) from the hex nut and weld nut on the whe[...]

84 4. Basket (Tumbler) Electrical Component(s) a. Basket (Tumbler) Thermal Magnetic Starter (TMS) and Auxiliary Contact Block Replacement 1) Discontinue electrical power to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Set the control of the TMS to the “stop” position. 4) Press down on the TMS and [...]

85 11) Replace ALL wires removed in Step #5 (refer to the previous page). 12) Mount the top of the thermal magnetic starter (TMS) to the top of the din rail and press down and in. Inspect ALL of the work performed. 13) Set the control of the TMS to the “start” position. 14) Reestablish electrical power to the dryer. 5 . Rotational Sensor Assemb[...]

86 SECTION VI PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. 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 k[...]

87 2. For Direct Spark Ignition (DSI) System Models Manufactured With ADC M odule Part No. 880815 a. Upon completing installation of the replacement DSI module, reestablish power to the dryer. b. Starting the drying cycle. c. The ignition DSI module’s light emitting diode (L.E.D.) indicator will light “red” for up to approximately 1.5-seconds[...]

88 SECTION VII PHASE 7 OPL SYSTEM DIAGNOSTICS IMPORTANT: YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLY AND THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANY COVERS OR GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, OR TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health Administration) STAND[...]

89 CALL FOR SERVICE - Indicates a board failure. FRONT DOOR NOT CLOSED - A front door is open when it should be closed. REAR DOOR NOT CLOSED - A rear door is open when it should be closed. CHECK CONTROL POWER - Indicates control power is off. EXHAUST HIGH TEMP FAULT - Indicates the temperature in the basket (tumbler) is above 225º F (107º C). LIN[...]

90 B. I/O BOARD INPUT AND OUTPUT L.E.D. INDICA T ORS[...]

91 Input/Output (I/O) Board Input Description (“Red” light emitting diode [L.E.D.]) 1. FDRC – (RED L.E.D.) This L.E.D. will indicate the status of the Front Doors. If the doors are closed, then the L.E.D. is ON. 2. FDRO – (RED L.E.D.) This L.E.D. will indicate the status of the Front Doors. If the doors are open, then the L.E.D. is ON. 3. T[...]

92 9. FAN – (RED L.E.D.) This L.E.D. will indicate the status of the Blower Fan. If the fan is on, then the L.E.D. is ON. 10. RBHL – (RED L.E.D.) This L.E.D. will indicate the status of the Rear Burner Hi-Limit Disk. If the disk is closed (Temperature below 330º F [166º C]), then the L.E.D. is ON. (N/A) 11. R_SS – (RED L.E.D.) This L.E.D. w[...]

93 Input/Output (I/O) Board Output Description (“Green” light emitting diode [L.E.D.]) 1. R_HEAT – (GREEN L.E.D.) This L.E.D. will indicate the status of the Rear Heat output. If the request to turn on the Rear Burner is made, then the L.E.D. is ON. (N/A) 2. ALERT – (GREEN L.E.D.) This L.E.D. will indicate the status of the Horn output. If [...]

94 16. OCL5 – (GREEN L.E.D.) This L.E.D. will indicate the status of the Open Collector #5 output. If the request to turn on the Open Collector #5 is made, then the L.E.D. is ON. (Programmable and Defaulted to Rear Down.) 17. OCL6 – (GREEN L.E.D.) This L.E.D. will indicate the status of the Open Collector #6 output. If the request to turn on th[...]

95 SECTION VIII TROUBLESHOOTING IMPORTANT: YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLY AND THE GAS SUPPLY OR THE STEAM SUPPL Y BEFORE ANY COVERS OR GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, OR TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health Administration) STANDARDS. The inf[...]

96 NOTE: SPRINKLER MUST HAVE POWER FOR THE DRYER TO OPERATE. B. Drive motor is not operating ( does not start)... * Microprocessor controller (computer) relay output indicator (either forward “FWD” or reverse “REV”) is on. 1. Blown drive motor contactor overloads. 2. Failed drive motor contactor. 3. Failed drive motor. 4. No 24 VAC present [...]

97 f. V-belts are too tight. g. Dryer has an oversized load. h. Voltage to the dryer is incorrect...check dryer data label for specified voltage. 2. Failed overload protector... a. Incorrect overload setting. E. Blower (squirrel cage fan) motor is not operating ( does not start)... * Microprocessor controller (computer) input/output (I/O) board “[...]

98 2. Failed overload protector... a. Incorrect overload setting. 3. Blown drive motor and blower (squirrel cage fan) motor fuses or overloads. 4. Failed motors (both blower [squirrel cage fan] motor and drive motor). 5. Failed microprocessor controller (computer). G. Microprocessor controller (computer) display board light emitting diode (L.E.D.) [...]

99 5. Front or rear doors are opened during cycle. 6. Failed microprocessor controller (computer) input/output (I/O) board. J. Microprocessor controller (computer) light emitting diode (L.E.D.) displays “Lint Drawer Open.” 1. Lint drawer is not closed ALL the way. 2. Lint drawer switch is out of proper adjustment. 3. Failed lint drawer switch. [...]

100 2) Failure in drive motor circuit. b. Faulty rotation sensor. c. Broken wire or connection between rotation sensor and microprocessor controller (computer) display board. d. Failure in rotational sensor circuit, magnet missing, or gap too large. e. Basket (tumbler) rotation below 12 RPMS. P. Microprocessor controller (computer) reads “Exhaust[...]

101 14. Undersized load, dryer requires a minimum load size of approximately 125 lbs (57 kg) for maximum drying efficiency. R. Excessive noise and vibration... 1. Dryer is not leveled properly. 2. Blower (squirrel cage fan) is out of balance... a. Excessive lint buildup on blower (squirrel cage fan)...check air jet. b. Failed blower (squirrel cage [...]

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