ADC 450428 manual

121099DMG/tcosta ADC Part No. 450428 ML-130 Service Manual Phase 6 Microprocessor Timer Controls American Dryer Corporation 88 Currant Road Fall River , MA 02720-4781 T elephone: (508) 678-9000 / Fax: (508) 678-9447 e-mail: techsupport@amdry .com[...]

Retain This Manual In A Safe Place For Futur e 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 or THE STEAM SUPPL Y BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING , ADJUST - ING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) ST ANDARDS. CHILDREN SHOULD NOT BE ALLOW[...]

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 and operator's manual included with the dryer . Dryers must not be installed o[...]

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

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

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

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

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

6 NOTE: T o prevent damage, avoid cleaning, and/or touching ignitor and flame-probe assembly . Remove lint accumulation from inside control box and at rear area behind control box. EVERY 6 MONTHS Inspect and remove lint accumulation in customer furnished exhaust duct work system and from dryer ’ s internal exhaust ducting. WARNING: THE ACCUMULA T[...]

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

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

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

10 SECTION IV DESCRIPTION OF PAR TS A. CONTROL BOX Lifting the control door and opening the computer panel will reveal the control box. Inside the control box are ALL the electronic control components. Located on the back of the control panel is the computer . Included in the control box are the 30-position block, fuse block, and transformer . B. D[...]

11 D. GAS BURNER ASSEMBL Y Gas heated dryers are equipped with a gas burner assembly consisting of three (3) burner tubes, gas valve, glo bar , flame sensor , sail switch, and hi-limit thermostat. The inlet piping enters through the rear of the dryer on the left hand side (viewing from the front) and runs to the front of the dryer where the gas val[...]

12 G . TUMBLER (BASKET) BEARING and PULLEY ARRANGEMENT The tumbler (basket) bearing and pulley arrangement is located (viewing from the rear of the dryer) approximately at the upper center of the dryer . The arrangement consists of a pulley and two (2) bearings which serve to drive, adjust, and support the tumbler (basket). H. TUMBLER (BASKET) The [...]

13 J. SAIL SWITCH (Gas and Electric Models Only) The sail switch is located on the front of the burner box for gas dryers on the right side of the oven assembly for electric dryers. A sail switch consists of a round damper plate on a lever arm which is in contact with an electric switch. When the air blower comes on, it draws air through the gas or[...]

14 M. LINT DRA WER The lint drawer is a pull-out type and is located at the bottom of the dryer in the lint compartment. Simply grab the lint drawer handle, slide out the drawer , brush off the lint, and slide the drawer back in. The lint screen must be kept clean in order for the dryer to operate properly and efficiently . N. LINT DRA WER SWITCH T[...]

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

16 T o Replace Computer 1. Disconnect electrical power to the dryer . 2. Disconnect main power harness from rear of computer by squeezing locking tab and pulling connector straight back. 3. Disconnect the “green” ground wire from the computer . 4. Disconnect keyboard (touchpad) ribbon from computer . 5. Remove the two (2) hex nuts securing the [...]

17 b. Loosen the two (2) Phillips head screws securing bracket assembly to dryer and remove bracket from dryer . NOTE: DO NOT remove screws. 4 . Disassemble sensor probe from bracket assembly by removing the top push-on fastener securing the probe to the bracket. Use a small screwdriver to slowly pry the fastener off. 5. Disconnect the two (2) “o[...]

18 NOTE: Before reestablishing electrical power to the dryer visually check the following (refer to illustration above). 5. Reestablish procedure for installation of new ignitor . T o Remove Flame Sensor Probe 1. Discontinue electrical power to the dryer . 2. Disconnect the “red” wire from the flame sensor probe which goes to S2 on the HSI (Hot[...]

19 NOTE: Identify location of each wire for correct reinstallation. 4. Break union connection before gas valve. 5. Loosen and remove four (4) screws securing pipe brackets to burner . 6. Remove gas valve and manifold assembly from dryer . 7. Remove valve mounting bracket, manifold, and piping from gas valve. 8. Reverse procedure for installing new [...]

20 2. T o Adjust W ater Column Pressure (natural gas only , L.P . gas must be regulated at source): a . Remove the slotted vent cap on the top of the valve. b. T urn the slotted adjustment screw located on top of the valve next to the terminals. T urn clockwise (CW) to increase manifold pressure and counterclockwise (CCW) to decrease. NOTE: If corr[...]

21 T o Replace Burner T ubes 1. Refer to “T o Replace Gas V alve” and follow S tep #1 through S tep #6 . 2. Remove four (4) screws securing manifold rest and remove rest. 3. Remove the screws securing the front flanges of the burner tubes to the burner tube rest. 4. Remove the screws securing the burner tube rest to the oven and remove this res[...]

22 NOTE: Models manufactured as of 1998 are equipped with a manual reset hi-limit thermostat. 1. Discontinue electrical power to the dryer . 2. Disconnect wires from hi-limit thermostat. 3 . Remove the two (2) screws, washers, and nuts securing thermostat to the bracket. Remove thermostat. 4. Reversing procedure for installing new thermostat. 5. Re[...]

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

24 6. Reverse this procedure for installing new door switch assembly . 7. Reestablish electrical power to the dryer . IMPOR T ANT : UNDER NO CIRCUMST ANCES should the door switch be disabled. T o Replace Main Door Assembly 1. Open main door . 2. Holding the door upward remove the two (2) screws from the top hinge block. 3. Lift the door up to remov[...]

25 4. Remove glass and clean ALL old sealant off main door . This area must be clean for correct bonding. 5. Place a bead of silicone ( ADC P/N 170730) around the edge door and lightly press glass into place. 6. Reinstall the four (4) #10-32 acorn nuts that were removed in S tep #3 . IMPOR T ANT : DO NOT press hard or the silicone thickness between[...]

26 F . PULLEYS T o Replace T umbler (Basket) Pulley 1. Loosen V -belts. Rotate pulley and roll V -belts out of grooves. 2. Remove cap screws from the bushing. 3. Insert cap screws in tapped removal holes and tighten evenly until bushing becomes loose on shaft. Refer to figure “A.” 4. Remove bushing, pulley , and key . 5. Assemble bushing and sh[...]

27 7. Tighten cap screws progressively . There should remain a gap between the sheave hub and the flange of the bushing. IMPOR T ANT : Tighten screws evenly and progressively . Never allow the sheave to be drawn in contact with the flange of the bushing. This gap should measure from 1/8” to 1/4”. Proper cap screw torque is 6 ft-lbs. (8 Nm), if [...]

28 5. Assemble bushing and sheave as shown in figure “B” on page 26 . When cap screws are loosely inserted, bushing remains fully expanded to provide a sliding fit on the shaft. 6. Insert key on the shaft, then slide sheave to desired position with cap screw heads to the outside. 7. Tighten cap screws progressively . There should remain a gap b[...]

29 T umbler (Basket) Alignment (Lateral) (Side to Side Adjustment) 1. Discontinue electrical power to the dryer . 2. Remove back guard. 3. Loosen rear pillow block bearing bolts (C). 4. Back off jam nuts on the two (2) lateral adjustment bolts (A) and (B). 5. Simultaneously loosen one bolt and tighten the other . This will move the rear pillow bloc[...]

30 8. Remove tumbler (basket) from tumbler (basket) support. a . Remove the bolt in the center of the tumbler (basket) back wall. b. Loosen and remove the eight (8) sets of nuts and washers from tumbler (basket) tie rods. Remove the eight (8) tie rods. c . Replace either tumbler (basket) or tumbler (basket) support by reversing procedure. NOTE: Shi[...]

31 4. Remove the two (2) retaining rings from the tumbler (basket) shaft. 5. Remove the two (2) bolts holding the front tumbler (basket) support pillow block bearing to the dryer . 6. Loosen bearing collar set screws (2) and as the end of the tumbler (basket) shaft is lifted up slightly , slide the bearing off the shaft. 7. Prop a block of wood bet[...]

32 I. V -BEL TS V -belts should have proper tension. If too loose, they will slip, if too tight, excessive wear on the bearings will result. If the pulleys are not properly aligned, excessive belt wear will result. Proper belt tension will allow 1/2” displacement under normal thumb pressure at mid span of belt. NOTE: Belts must always be replaced[...]

33 NOTE: Always replace belts in matched sets (2 belts). J. MOTORS T o Replace Drive Motor 1. Discontinue electrical power to the dryer . 2. Remove drive belts. 3. Disconnect wiring harness from motor . 4. Remove bolts holding motor to mount and replace with new motor . DO NOT tighten bolts. 5. Remove pulley from old motor and install on new motor [...]

34 K. IMPELLOR 1. Discontinue electrical power to the dryer . 2. Remove the left side panel to access the fan shaft mount assembly . 3. Remove the two (2) left handed jam nuts that hold the impellor to the fan shaft. 4. Remove the impellor , washers, and the key . 5. Replace the impellor , key , washers, left handed jam nuts, and the side panel. 6.[...]

35 SECTION VI TROUBLESHOOTING 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[...]

36 C . Dryer will not start, but computer display indicators are on... 1. Failed contactors. 2. Failed arc suppressor (A.S.) board. 3. Failed microprocessor controller (computer). 4. Failed motors. D . Drive motor runs, burner is on, but tumbler (basket) will not turn... 1. Broken, damaged, or loose V -belt. 2. Belts contaminated (oil, grease, etc.[...]

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

38 I. Display reads “T emp Sensor Failure Check T emp Sensor Fuse.” Dryer Sensor Circuit Failure... 1. Check 1/8-amp fuse on microprocessor controller (computer). 2. Faulty microprocessor controller (computer) temperature sensor probe. 3. Open circuit in either one (1) of two (2) wires leading from the sensor probe to the computer ... a . Conne[...]

39 SECTION VII PHASE 6 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 T O ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administra[...]

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

41 11 . ROT A TE SENSOR F AIL- Indicates a rotational sensor circuit failure meaning that there is a fault somewhere in the tumbler (basket) rotating circuit, or the Phase 6 OPL microprocessor controller (computer) program related to this circuit (program location 2) is set incorrectly . In the active mode it should be (ROT A TE SENSOR ACTIVE), if [...]

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

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

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

45 12. “FLAME” (bURNER CONTROL F AIL) Input L.E.D. Indicator a . This routine monitors the ignition control’ s gas valve output response. If the valve output signal is not present from the ignition control within the valve time limits the microprocessor determines the ignition control has failed. If this occurs when the cycle is active the ?[...]

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

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

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

49[...]

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

51 If there is voltage, replace the coil or the complete contactor . If there is no voltage, check for voltage across the two (2) BS3 terminals on the arc suppressor (A.S.) board. If there is voltage across the two (2) BS3 terminals and no voltage across the coil of the reversing contactor (A1 and A2), the problem is faulty wires or terminations be[...]

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

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

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

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

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

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

ADC 450428 1 - 02/22/00-25[...]