American Dryer Corp. D120 manual

D120 Installa tion Manual Phase 7 / OPL Sensor Activated Fire Extinguishing System 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 death. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this[...]

D120 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 SAF[...]

IMPOR T ANT YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPL Y AND THE GAS SUPPL Y OR THE STEAM 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 B[...]

W ARNING The dryer must never be operated with any of the back guards, outer tops, or service panels removed. 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 manual included with the dryer . W ARNING DR YER MUST NEVER BE OPERA TED WITHOUT THE [...]

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

SECTION VI ROUTINE MAINTENANCE .................................................................................. 3 9 A. Cleaning ................................................................................................................................... 39 B. Adjustments ......................................................................[...]

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 dama[...]

4 B. 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 removed. PERSONAL INJUR Y OR FIRE COULD [...]

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. W ARNING: The collection of lint in the burner area and exhaust ductwork can create a potential f[...]

6 MA X I MUM C APA C I TY (D RY WE I GHT) 1 2 0 l b 54. 43 kg T U M B L E R DI A M E T E R 44-1/ 8” 1 12.09 cm TUMBL E R D EP TH 4 0 - 9 / 1 6 ” 103.0 2 cm TUMBL E R V OLUME 3 5 . 9 0 c u f t 1,0 16.57 L TUMBL E R/D RI V E MOTOR 1 h p 0.75 kW BLO WER/ F AN M OT OR 3 hp 2. 24 kW D OOR OPE NI NG (DI A ME TER) 3 1 - 3 / 8 ” 79.7 1 cm DO OR SI LL[...]

7 NOTE: ADC reserves the right to make changes in specifications at any time without notice or obligation. Specifications D120[...]

8 B. COMPONENT IDENTIFICA TION 1. Dryer Front V iew Illus. No. Description 1 Microprocessor Control/Keyboard (touch pad) Panel Assembly (controls) 2 Control (top access) Door Assembly 3 Main Door Assembly 4 Lint Panel Assembly 5 Lint Door 6 W ire Diagram (located behind control door) 7 T op Console (module) Assembly[...]

9 2. Dryer Rear V iew Illus. No. Description 1 Electrical Service Connections 2 T op Console 3 Heating Unit 4 Relay/W iring Box 5 Data Label and Installation Label 6 Air Connection 7 Exhaust T ransition Piece[...]

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- LA TEST EDITION (National Fuel Gas Code) or ANSI/NFP A NO. 70-LA TEST EDITION (National Elec[...]

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. IMPOR T ANT : Dryer must be installed in a location/environment, which the ambient tempera[...]

12 2. If more headroom is needed when moving the dryer into position, the top console (module) may be removed. a . T o Remove T op Console (module)... 1) Disconnect the ground wire (A in the illustration below ) located at the rear upper left corner of the dryer . 2) Remove the six (6) sets of nuts and washers (B in the illustration below ) holding[...]

13 C. DR YER ENCLOSURE REQUIREMENTS Even though a 12-inch (30.48 cm) clearance is acceptable, it is recommended that the rear of the dryer be positioned approximately 24-inches (60.96 cm) from the nearest obstruction (i.e., wall) for ease of installation, maintenance, and service. Bulkheads and partitions should be made from noncombustible material[...]

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 affecte[...]

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, [...]

16 a . Outside Ductwork Protection 1) T o protect the outside end of the horizontal ductwork from the weather , a 90° elbow bent downward should be installed where the exhaust exits the building. If the ductwork travels vertically up through the roof, it should be protected from the weather by using a 180° turn to point the opening downward. In e[...]

17 It is suggested that the ductwork from each dryer not exceed 20 feet (6.09 meters) with no more than two (2) elbows (excluding dryer connections). If the ductwork exceeds 20 feet (6.09 meters) or has numerous elbows, the cross-sectional area of the ductwork must be increased in proportion to the length and number of elbows in it. In calculating [...]

18 IMPOR T ANT : For extended ductwork runs, the cross section area of the ductwork can only be increased to an extent. Maximum proportional ductwork runs cannot exceed 20 feet (6.09 meters) more than the original limitations of 20 feet (6.09 meters) with two (2) elbows. When the ductwork approaches the maximum limits as noted in this manual, a pro[...]

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20 IMPOR T ANT : For extended ductwork runs, the cross section area of the ductwork can only be increased to an extent. Maximum proportional ductwork runs cannot exceed 20 feet (6.09 meters) more than the original limitations of 20 feet (6.09 meters) with two (2) elbows. When the ductwork approaches the maximum limits as noted in this manual, a pro[...]

21 2. Electrical Service Specifications IMPOR T ANT : The dryer must be connected to the electric supply shown on the data label that is affixed to the left side panel/wall area behind the control door . In the case of 208 V AC OR 230/240 V AC, the supply voltage must match the electric service specifications of the data label exactly . W ARNING: 2[...]

22 3. Electrical Connections NOTE: A wire diagram is included with each dryer and is affixed to the back side of the top control (access) door . The only electrical input connections to the dryer are the 3-phase (3ø) power leads (L1, L2, and L3), GROUND, and in the case of 4 wire service, the NEUTRAL. These electrical connections are made at the t[...]

23 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[...]

24 2. T echnical Data a . Gas Specifications * Measured at the gas valve pressure tap when the gas valve is on. b. Gas Connections: Inlet connection ---- 1-1/4” F .P .T . Inlet supply size ---- 1-1/4” N.P .T . (minimum) Btu/hr input --------- 415,000 (104,580 kcal/hr) 1) Natural Gas Regulation is controlled by the dryer ’ s gas valve’ s int[...]

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

26 IMPOR T ANT : The dryer and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa). NOTE: The dryer must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure test of[...]

27 H. STEAM 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. IMPOR T ANT : Failure to comply with the requirements stipulated in this manual can result in component failure, which wil[...]

28 a . The pressure of the condensate in the steam supply line will cause water hammer and subsequent heat exchanger (steam coil) failure. The steam supply connection into the main supply line must be made with a minimum 12-inch (30.48 cm) riser . This will prevent any condensate from draining towards the dryer . b. The steam supply line to the dry[...]

29 4. S team Damper Air System Connections The dryer is manufactured with a pneumatic (piston) damper system, which requires an external supply of compressed air . The air connection is made to the steam damper solenoid valve, which is located at the rear of the top console. a . Air Requirements b. Air Connection Air connection to system --- 1/8”[...]

30 6. S team Damper Air Piston (Flow Control) Operation Adjustment Although the steam damper operation was tested and adjusted prior to shipping at 80 PSI (5.51 bar), steam damper operation must be checked before the dryer is put into operation. Refer to page 33 for instructions to check steam damper operation. If steam damper adjustment is necessa[...]

31 I. 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 ,” “ W ARNING ,” 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 that is affixed to the l[...]

32 J. 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. T urn on electric power to the dryer . 2. Mak[...]

33 b. Steam Models 1) Check to insure that the steam damper is functioning properly . a ) The steam damper should not “slam” (open or closed) when it reaches the end of (piston) travel. Additionally , the steam damper should not bind and/or stop during travel. If either of these conditions occur , the flow control must be adjusted. Refer to the[...]

34 K. COMPRESSED AIR REQUIREMENTS The dryer requires an external supply of compressed air (2.5 cfh at 80 PSI [0.07 cmh at 5.51 bar] for gas models and 3.25 cfh at 80 PSI [0.09 cmh at 5.51 bar] for steam models). For steam models, compressed air is necessary for the air operated steam damper . On both the steam models as well as the gas models, comp[...]

35 L. 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[...]

36 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 you[...]

37 SECTION V WARRANTY INFORMA TION A. RETURNING W ARRANTY 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[...]

38 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 [...]

39 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[...]

40 STEAM DRYERS Clean the steam coil fins. Compressed air and a vacuum cleaner with brush attachment are suggested. NOTE: When cleaning steam coil fins, be careful not to bend the fins. If fins are bent, straighten by using a fin comb, which is available from any local air conditioning supply house. 90 DA YS Remove lint from around basket (tumbler)[...]

41 B. ADJUSTMENTS 7 DA YS AFTER INST ALLA TION AND EVER Y 6 MONTHS THEREAFTER Inspect bolts, nuts, screws, (bearing setscrews), grounding connections, and nonpermanent gas connections (i.e., unions, shutoff valves, and orifices). Motor and drive belts should be examined. Cracked or seriously frayed belts should be replaced. T ighten loose V -belts [...]

42 SECTION VII MANUAL RESET BURNER HI-LIMIT INSTRUCTIONS A. PHASE 7 This dryer was manufactured with a manual reset burner hi-limit thermostat, which is monitored by the Phase 7 computer . If the burner hi-limit is open prior to the start of the drying cycle, the dryer will start momentarily and then shut down, the Phase 7 computer will display “[...]

43 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 af fixed to the left side panel/wall area behind the control door . When contacting ADC , please have the model number and serial number available. SECTION VIII DA T A LA[...]

44 SECTION IX PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. For Heat Control Module Ignition Circuit a . For Models with Direct Spark Ignition (DSI) Module (T ype I) 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 [...]

45 SECTION X PHASE 7 OPL SYSTEM DIAGNOSTICS IMPOR T ANT : YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPL Y AND THE GAS SUPPL Y OR THE STEAM 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 Administratio[...]

46 Input/Output (I/O) Board Output Description (“Green” light emitting diode [L.E.D.]) 1. F AN – (GREEN L.E.D.) This L.E.D. will indicate the status of the Fan output. If the request to turn on the Fan (blower) is made, then the L.E.D. is ON. 2. FWD – (GREEN L.E.D.) This L.E.D. will indicate the status of the Basket (T umbler) Forward direc[...]

47 S.A.F.E. System In Action 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 jet(s) to quickly extinguish the flames. [...]

48 BEFORE YOU ST ART! CHECK LOCAL CODES AND PERMITS Call your local water company or the proper municipal authority for information regarding local codes. IMPOR T ANT : 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 fe[...]

49 2. W ater 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-inch supply (feed) line. Flexible supply line/c[...]

50 OPTIONAL MANUAL BYP ASS 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. Th[...]

51 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 temper[...]

ADC Part No. 1 13179 3 - 09/1 1/08 - 5[...]