ADC AD-410 manual

ADC Part No. 450414 011499DMG/abe 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 AD-410 Service Manual[...]

Retain This Manual In A Safe Place For Future Reference Replacement parts can be obtained from your distributor or the ADC factory . When ordering replacement parts from the factory , you can F AX your order to ADC at (508) 678-9447 or telephone your orders directly to the ADC Parts Department at (508) 678-9000. Please specify the dryer model numbe[...]

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 ALLOWED[...]

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 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 or[...]

Table of Contents AD-310 REFERENCE GUIDE T umbler Section ............................................................................................................................. 3 AD-310 REFERENCE GUIDE Base Section ................................................................................................................... ............[...]

SECTION VI TROUBLESHOOTING .................................................................................................................. 104 SECTION VII PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS .............................................................................................................................. 1 12[...]

3 AD-410 Reference Guide (Tumbler Section)[...]

4 AD-410 Reference Guide (Base Section)[...]

5 INTRODUCTION AD-410 MACHINE OPERA TIONAL SUMMAR Y The model AD-410 incorporates one (1) “ EMERGENCY STOP (E-Stop) BUTTON ” located centrally on the Right Front Control Door . This " RED " MUSHROOM PUSH-BUTT ON is “ PUSH TO STOP ” the machine and “ TURN TO RELEASE ” or “ PULL TO RELEASE ” type control device. This button [...]

6 EMERGENCY (E-S top) ST OP BUTT ON (Push T o Stop/T urn T o Release or Pull T o Release) This " red " mushroom push-button, located in the center of the Right Front Control Door almost directly under the Phase 5 Microprocessor Controller (computer) is a “Push T o Stop” and “T urn T o Release” type push- button. This button must b[...]

7 CONTROL POWER (Off) This " RED LIGHTED OPERA TOR ," located on the Right Front Control Door , is for disabling the dryer ’ s output control voltage. This push-button is mainly for use as a troubleshooting function. END OF CYCLE / HEA TER F AUL T INDICA T OR / AIR JET This amber colored indicator located on the front/top of the dryer h[...]

8 AD-410 MACHINE OPERA TION TROUBLESHOOTING INFORMA TION END OF CYCLE/HEA TER F AUL T INDICA T OR The “END OF CYCLE” light located on the top/front of the dryer , is triggered by the Air Jet Signal of the Phase 5 Microprocessor Controller (computer) to the input of the PLC (Programmable Logic Controller). If this signal is not sensed by the PLC[...]

9 2. Check to see that the Air Jet L.E.D. (light emitting diode) is on at the end of the drying cycle. If the L.E.D. is not on it may be an indication of a failed Phase 5 Microprocessor Controller (computer). 3. If Air Jet L.E.D. is on then check the wiring from the Phase 5 Microprocessor Controller (computer) to the air valve. 4. Bad air valve. LO[...]

10 2. Check that 80 PSI of compressed air is supplied to the machine and that the “Front Up” solenoid is being actuated by the PLC (Programmable Logic Controller). Refer to the PLC (Programmable Logic Controller) signal information included in the ladder diagrams and schematics supplied with the machine. DR Y This selection prepares the machine[...]

11 When a “HEA TER F AUL T” occurs after the first twenty-five (25) seconds of the drying cycle, a “CLEAR/ STOP” will be sent to the Phase 5 Microprocessor Controller (computer), a “FILL” message will be displayed on the Phase 5 Microprocessor Controller ’ s (computer ’ s) display , and both the “HEA TER F AUL T” reset push- but[...]

12 The L.P . (liquid propane) gas pressure measured at each gas valve pressure tap must be 1 1-inches water column (W .C.) pressure, when the flame is established in both burner boxes. There is no means to adjust this pressure supplied with the dryer so the downstream L.P . pressure regulator must be adjusted to provide the 1 1- inch water column ([...]

13 ONE (1) BURNER WILL NOT IGNITE A T THE BEGINNING OF A CYCLE This condition can be caused by the following: • DEFECTIVE DSI (Direct Spark Ignition) MODULE • DEFECTIVE SP ARK IGNITOR/FLAME-PROBE ASSEMBL Y • DEFECTIVE GAS V AL VE • INSUFFICIENT GAS PRESSURE • DEFECTIVE ELECTRICAL HEA T CIRCUIT Refer to the ladder diagram and the schematic[...]

14 The dryer system is divided into a number of “electrical” sections which are as follows: 1. Right Front Control Panel The RIGHT FRONT CONTROL P ANEL is located in the Right Front Control Cabinet of the dryer . This panel is the heart of the drying system, where ALL control signals interface to or from this panel. The signals that interface t[...]

15 4. Optional Sprinkler Circuit The OPTIONAL SPRINKLER CIRCUIT main control panel will be located in the left front electrical enclosure. If a SPRINKLER OPTION is included with the dryer , this panel will include an “AUTOMA TIC EMERGENCY STOP” feature. This feature requires that the Sprinkler Circuit be functional for the dryer to be powered. [...]

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

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

18 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 duct work system. The frequency of cleaning can best be determined from experience at each location. Maximum operating efficiency is dependent upon proper a[...]

19 MONTHL Y Empty the compressed air filter bowl. Clean any lint accumulation from the gas valve and burner area at the top of the dryer , the fan (impellor/ blower) motor , and the fan (impellor) bearings located in the dryer base. EVERY 6 MONTHS STEAM MODELS - clean the steam coil fins. W e suggest using compressed air and a vacuum cleaner with b[...]

20 B. LUBRICA TION MONTHL Y Check compressed air filter bowl for water . Empty by pressing the rubber petcock to the side. Additionally , check lubricator bowl for oil. If empty , remove the fill plug and add oil. ( Use petroleum based 10/150 SSU misting oil.) Replace the fill plug. NOTE : LUBRICA TOR SHOULD BE SET A T 1 DROP PER CYCLE . NOTE : REG[...]

21 EVERY 6 MONTHS Change gear oil in the tumbler shaft gear 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 equivalent. C. ADJUSTMENTS 7 DA YS AFTER[...]

22 SECTION III SPECIFICA TIONS and DIMENSIONS A. SPECIFICA TIONS (Gas and S team Models) NOTE : ADC reserves the right to make changes in specifications at any time, without notice or obligation. Gas* Steam* M AXIMUM C AP AC ITY ( DRY W EIGHT ) 410 l bs. 18 6 . 4 kg M IN IMUM C AP AC I TY ( DRY WEIGHT ) 250 l bs. 1 1 3. 65 k g B AS K ET ( TUM BLER [...]

NOTE : ADC reserves the right to make changes in specifications at any time, without notice or obligation. 23 B. DIMENSIONS[...]

24 NOTE : ADC reserves the right to make changes in specifications at any time, without notice or obligation. AD-410 with INLET AIR ADAPTER (G AS M ODEL )[...]

25 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, installation must conform to applicable AMERICAN NA TIONAL ST ANDARDS: National Fuel Gas Code ANSI Z223.1-LA TEST EDITION and/or National Electric Code ANSI/NFP A No. 70-LA TEST[...]

26 B. ELECTRICAL REQUIREMENTS 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 with local and state regulations or codes. In the absence of such codes, ALL electrical connections, material, and w[...]

27 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 . (liquid propane) 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 u[...]

28 a . The Direct Spark Ignition (DSI) Module is a 24 V AC 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 verification, etc.). Additionally , the DSI Module has [...]

29 e . The T umbler 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). 225º F Thermostat MAN3484 f . The gas valve used in the dryer is of the redundant type which means that the gas valve is actually two (2) gas valve[...]

30 h. ADC Direct Spark Ignition (DSI) Operation Flow Chart Power Applied to the DSI Module DSI Module "LOCK-OUT" Indicator lights "RED". Computer/Timer Calls For Heat DSI Module will immediately attempt to re-light burner. DSI Module Indicator lights "RED" for up to approximately 1.3 seconds (prepurge). DSI Module Indi[...]

31 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-410 Installation/Operator's Manual ( ADC Part No. 1 12249) included with the dr[...]

32 1. Direct Spark Ignition (DSI) T roubleshooting T erms (definitions) a . DSI (Direct Spark Ignition) MODULE " RED " L.E.D. (Light Emitting Diode) INDICA T OR LIGHT This " red " L.E.D. (light emitting diode) light is located in the upper right corner of the DSI (Direct Spark Ignition) module (refer to the top illustration on p[...]

33 If the dryer repeatedly has DSI (Direct Spark Ignition) module "LOCK-OUT" failures, the cause may be due to high voltage not getting into the DSI module ignitor probe assembly . (1) Check to insure that the red high voltage wire (between the ignitor spark electrode and the DSI [Direct Spark Ignition] module) is not wrapped around the s[...]

34 c . Three V isual Checks 1) Does the DSI ignitor/flame-probe assembly start sparking? If not, refer to the FIRST VISUAL CHECK on page 35 . 2) Does the main burner ignite? If not, refer to the SECOND VISUAL CHECK on page 36 . 3) Does the main burner remain lit after ignition has been established ("FLAME-OUT")? If not, refer to the THIRD[...]

35 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[...]

36 e . T roubleshooting Flow Chart - 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 Va[...]

37 f . T roubleshooting Flow Chart - 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 h[...]

38 3. T roubleshooting and System Detailed Diagnosis When the dryer calls for heat, 24 V AC from the step down transformer is applied to the "TH" and "GND" terminals of the DSI (Direct Spark Ignition) module. The DSI module L.E.D. (light emitting diode) indicator will light " red " (for up to approximately 1.5-seconds [...]

39 a ) Connect the water column test gauge (manometer) to the gas valve pressure tap (1/8" N.P .T .). Refer to the illustration above. b) Start the dryer ... with the burner on, the correct water column pressure (W .C.) reading in inches should be : Natural Gas .......................... 3.5 - 4 inches W .C. L.P . (liquid propane) Gas ....... [...]

40 ( a) T o check and/or set the 1/8" GAP , use a DSI Gap Feeler Gauge or similar device to determine GAP size. DO NOT USE FEELER T O SET THE GAP , use it only to 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" GAP with a feeler gauge. (b) The ALIGNMENT [...]

41 NOTE : T o reset the dryer when a "HEA TER F AUL T" occurs, press the ("amber") "HEA TER F AUL T" reset push-button. 3) Air T urbulence If there is sail switch flutter due to air turbulence, or improper impellor (fan/blower) rotation, or a restriction in the exhaust duct work, the DSI (Direct Spark Ignition) module [...]

42 5 ) W iring If the DSI (Direct Spark Ignition) module is in the "LOCK-OUT" mode (where the L.E.D. [light emitting diode] indicator will LIGHT " RED " CONTINUOUSL Y) , and the mechanical components have been checked (i.e., the ignitor/flame-probe assembly , the gas valve, etc.), then, there may be a problem somewhere in the DS[...]

43 C. NA TURAL GAS and L.P . (Liquid Propane) GAS CONVERSION INSTRUCTIONS IMPOR T ANT : CONVERSION MUST BE PERFORMED BY COMPETENT TECHNICIANS IN ACCORDANCE WITH LOCAL and ST A TE 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.[...]

44 1 1 . Reverse the procedure for reinstalling the gas valve/manifold assembly to the dryer . 12 . Open ALL gas shut-off valves (closed in Step #2 ). 13 . Reestablish electrical service to the dryer . a . T est ALL connections for leaks. IMPOR T ANT : T est ALL connections for leaks by brushing on a soapy water solution (liquid detergent works wel[...]

45 D. STEAM COIL SYSTEM OPERA TION General Overview The dryers' steam coil is constantly charged thereby eliminating repeated expansion and contraction and also provide instant heating to start the drying process. The steam damper , located on top of the steam coil, is the only temperature controlling device in this system. When the steam damp[...]

46 2. Steam Damper Actuator System The steam damper actuator system consists of a hinged damper plate, pneumatic piston, and a 24 volt solenoid valve with a needle valve to control the speed of the piston actuation. On a call for heat, a 24 volt signal is applied to the 3-way/2-position solenoid valve. This signal switches the valve so that compres[...]

47 3. Steam Damper Actuator System Service and Replacement a . Steam Damper Cylinder or Piston Replacement 1) Disconnect compressed air supply from the dryer . 2) Disconnect tubing from the piston. 3) Remove the spring clip from clevis pin then slide out the clevis pin. 4) Remove the steam damper cylinder (piston). 5) T o install new steam damper c[...]

48 d. Steam Coil Replacement 1) Discontinue electrical service to the dryer . 2) Disconnect compressed air supply from the dryer . 3) Shut off ALL steam supply lines and steam return valves that feed the steam coil. 4) W ait a sufficient amount of time until ALL of the steam lines and the steam coil is cool. 5) Open 1/2" plug on the return lin[...]

49 12 ) Remove the steam coil damper hinges from the old coil and install them on the new steam coil. 13 ) Hoist the new steam coil into place and bolt down. 14 ) Replace ALL of the panels removed in Step #10 . 15 ) Reinstall ALL of the piping removed from the old steam coil in Step #9 . NOTE : Thread sealant certified for steam piping must be appl[...]

50 E. SPRINKLER SYSTEM DESCRIPTION The sprinkler system is monitored by a microprocessor based temperature controller as a designated " F AIL- SAFE ." The microprocessor circuit must have power in order to engage main power to the dryer . When cycling the dryer , if the temperature at the Resistive T emperature Device (R TD) reaches 575º[...]

51 d) Sprinkler Digital T emperature Controller The sprinkler digital temperature controller is a programmable microprocessor used to monitor temperatures via a Resistive T emperature Device (R TD). MAN3488 NOTE : Operating parameters are preset at the factory and should not require any adjustment. Master Relay - The coil in this relay must be ener[...]

52 3. Sprinkler System Component Replacement a . Resistive T emperature Device (R TD) Replacement 1) T urn the water supply to the dryer off. 2) Discontinue electrical service to the dryer . 3) Remove the 1/4" compression fitting. 4) Remove the two (2) screws from the junction box cover . 5) Remove the wires of the R TD (Resistive T emperature[...]

53 b. Sprinkler V alve Replacement 1) T urn the water supply to the dryer off. 2) Discontinue electrical service to the dryer . 3) Disconnect compressed air supply from the dryer . 4) Loosen and remove the hose clamp. 5) Remove any residual water to the valve. 6) Remove 1/4" air tubing going to the valve. 7) Remove the two (2) U-bolts holding [...]

54 c . 3 HP Control Relay Replacement W ARNING : THE SPRINKLER CIRCUIT HAS A SEP ARA TE POWER SUPPL Y (then the power supply for the dryer). DISCONNECT and LOCK-OUT BOTH POWER SUPPLIES BEFORE SER VICING THE DR YER. 1) Mark and identify the wires that will be removed for proper reinstallation. 2) Press down on the control relay and lift the bottom o[...]

55 MAN3169[...]

56 The tilting system in the dryer , whether it be 1-way tilt or 2-way tilt, is controlled by the Micro-1 Programmable Logic Controller (PLC). The PLC (Programmable Logic Controller) will determine if the dryer is safe to tilt based on inputs from several sources. If ALL conditions are met, the PLC will send a signal to the tilt relays which energi[...]

57 1. Speed Adjustment The speed of the tilting action can be regulated by adjusting the set of flow control valves located on the pneumatic panel. Each set of cylinders, both front and rear , will have two (2) flow control valves. One valve will be the extend (up) air line and the other valve will be retract (down) air line. The speed of the cylin[...]

58 3. T ilting Pistons The tilting piston is a double acting cylinder that has a 5-inch bore and an 15-inch stroke. When air is applied to the bottom port of the cylinder , the piston begins to extend and air is exhausted through the top port. Then, if air is applied to the top port, the bottom port will exhaust the air which will cause the piston [...]

59 b. Tilting Solenoid Replacement 1) Engage "EMERGENCY STOP" (E-Stop)... Discontinue electrical service to the dryer . 2) Remove panel covering the pneumatic controls. 3) Label the solenoid plugs as an aid when reconnecting. 4) Loosen screws from the solenoid plug. 5) Remove the solenoid plug (take notice of the gaskets). 6) Remove the E[...]

60 1 1 ) The left orifice (marked #12 on the tilting solenoid valve) now must be configured for external pilot. NOTE : For 1-W ay T ilt models proceed to S tep #23 . 12 ) Remove the two (2) Phillips head screws. 13) Car efully remove the end of the valve. NOTE : The pieces within the end of the valve are small. Handle car efully to avoid losing par[...]

61[...]

62 d. T ilting Piston Replacement 1) Disconnect compressed air supply from the dryer . 2) T ilt, then level the dryer to exhaust as much air as possible. 3) Disengage "EMERGENCY STOP" (E-Stop)... Discontinue electric service to the dryer . 4) Remove the six (6) screws holding the piston cover plate. 5 ) Label the air lines as an aid when [...]

63 G . 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 thirty (30) seconds, to remove lint which may have accumulated on the blower (impellor) fan blades. This function will be interrupted if the main door or lint [...]

64 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) T o install new air jet assembly , reverse above procedure. b. Pneumatic V alve Muffler Replacement 1) Disconnect compressed air supply from the dryer . 2) Remove damaged or nonfunction[...]

65 H. BLOWER (Squirrel Cage Fan) MOT OR ASSEMBL Y 1. Blower (Squirrel Cage) Motor Description The AD-410 uses an 22-1/4 inch diameter , blower (squirrel cage fan) wheel. It spins (turns) in a counterclock- wise (CCW) direction when looking at the back of the blower housing. The blower (squirrel cage fan) shaft is mounted in two (2) 1-3/4" diam[...]

66 2. Blower (squirrel cage fan) and Fan Motor Component Replacement a ) Blower (squirrel cage fan) Motor Replacement 1) Discontinue electrical service 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[...]

67 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 ) T ighten 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 u[...]

68 (d) Loosen the set screws on the bushing. ( e) Remove the bushing and the pulley . 1 1 ) Remove the shrouded pillow block bearing by removing the set screw . 12 ) Replace the shrouded pillow block bearing on to the fan shaft ... ( a) Secure the fan (blower) shaft bearing mount assembly . (b) Tighten and secure the set screws in the shrouded pill[...]

69 7) Remove the key on the blower (squirrel cage fan) shaft. ( a) Slide the blower (squirrel cage fan) off of the shaft. NOTE : Install this key on to the fan shaft before installing the new blower (squirrel cage fan) . 8) T o install blower (new squirrel cage fan) , reverse above procedure. d) V-Belt Replacement 1) Discontinue electrical power to[...]

70 ( a) Thermal Magnetic Starter (TMS) Replacement (1) Discontinue electrical service to the dryer . (2) Mark L1, L2, L3, and T1, T2, T3 on the wires to the to the TMS for correct replacement. (3) Set the amp rating on the TMS according to the manufacturers electrical schematic on the new thermal magnetic starter . (4) T o remove the thermal magnet[...]

71 2) Auxiliary Contact Block The Auxiliary Contact Block is mounted on the side of the overload. Its' function is to sense an over- load trip, thereby triggering a safety fault which will disable the drying cycle. A "DOOR" message will appear on the L.E.D. (light emitting diode) display on the Phase 5 microprocessor controller (comp[...]

72 FILTER / REGULATOR 1. Filter Maintenance a . T o remove filter element ... T wist the filter bowl 1/8 turn clockwise (CW). Then pull the bowl down to expose the filter element. T o remove the filter element, unscrew the baffle (this will allow element removal). b. T o clean filter element ... spring and transmits force from the adjustment screw [...]

73 J. DOOR SYSTEMS The dryer utilizes two (2) styles of doors, which are Manual Doors and Pneumatic Automatic Doors. 1. Manual Door Description The Manual Doors run on a single aluminum track with a wheel assembly mounted above the doors and a channel with teflon strips mounted on the bottom of the doors ... a . For dryers manufactured as of Novemb[...]

74 3. Door Component Replacement and Removal a . Manual Door Replacement or Removal 1) Discontinue electrical service 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. a ) For dryers manufactured as of November 1, 1995, loosen the jam nut and screw down the trolley adjustment[...]

75[...]

76 b. Pneumatic Automatic Door Replacement or Removal 1) Discontinue electrical service 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) Remove the three (3) 1/4-20 x 3/4" bolts from the bottom guard. Remove the bottom guard. 4) Remove the two (2) 8-32 x 3/4" scr[...]

77 1) Discontinue electrical service to the dryer . 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard. (Refer to the illustration on page 74 .) 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[...]

78 d. Proximity Switch Replacement 1) Discontinue electrical service 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. T ake notice of the depth of the proximity switch. 4 ) Unscrew and remove the nut tha[...]

79 f . 4-W ay V alve, and 3-W ay V alve and Supply Air Disable V alve Replacement 1) Discontinue electrical service 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 c[...]

80 K. Control and Electrical System Ladder Diagram[...]

81[...]

82 CAUTION: When servicing the HIGH V OL T AGE section of the dryer , the ELECTRIC SER VICE MUST BE DISABLED. THE " EMERGENCY ST OP" ( E-S top) BUTT ON DOES NOT DISABLE THE HIGH V OL T AGE T O THE DR YER. 1. Control/Electrical System Description a . 3-Phase (3ø) Electrical Power The 3-phase (3ø) electrical power for the dryer enters the[...]

83 3) 24 V AC Transformer The 24 V AC transformer consists of fuse 1 (F1) and fuse 2 (F2) which is the primary fusing for the transformer . For the proper rating of these fuses 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 st[...]

84 c ) Front Doors Closed circuit branch. There are two (2) magnetic proximity switches mounted in the door closed position and a magnet mounted on top of the doors. When this magnet aligns with the proximity switch, the contacts in the proximity switch close. When both doors are closed, the front doors closed relay (CR2) turns on. (1) There are tw[...]

85 2) The Rotational Sensor is a magnetic proximity switch that is mounted on the side of the right hand 1 1-inch drive wheels. There is a magnet mounted to the side of the wheel hub. After each rotation of the wheel, the magnet passes by the proximity switch causing the contacts to close and pulse the Phase 5 microprocessor controller (computer). [...]

86 b. PLC (Programmable Logic Controller) 1) The PLC (Programmable Logic Controller) can consist of one (1) or two (2) modules; a main module and in some cases an expansion module is used for additional inputs and outputs. NOTE : The information listed below is generic in nature, refer to blueprints for specific details. a ) The main PLC (Programma[...]

87 b) The expansion PLC (Programmable Logic Controller) module has eight (8) inputs which are labeled #10 through #17 and an six (6) output relays labeled #210 through #215. (1) Input Relays A fan on or off signal (input #10) determines if the dryer is operating. If the dryer is operating, the door function and tilt function shut down. Input #1 1 &[...]

88[...]

89[...]

90 2. Electrical Component Replacement a . Control V oltage T ransformer (refer to the illustration on page 91 ) Replacement 1) Discontinue electrical service 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) V erify the voltage of the new transformer [...]

91 b. PLC (Programmable Logic Controller) Replacement 1) Discontinue electrical service to the dryer . If there is an expansion module along side the main module carefully disconnect the ribbon cable connecting the two (2) units together . 2) Mark and identify the wires that will be removed for proper reinstallation. 3) T o remove the Programmable [...]

92 e . Keypad (touchpad) Replacement 1) Discontinue electrical service to the dryer . 2) Peel existing keypad (touchpad) from the door . 3) Remove as much of the remaining adhesive (from the removed keypad [touchpad] as possible. 4) Install and adhere new keypad (touchpad). 5) Reestablish electrical service to the dryer . f . Switch Replacement 1) [...]

93 i . T ilt Switch Replacement 1) Discontinue electrical service to the dryer . 2) Remove the base panel from the left hand side of the dryer . CAUTION: DO NOT PLACE HANDS BETWEEN THE DR YER BASE AND THE TUMBLER (Basket/Drum) SECTION. SERIOUS INJUR Y CAN RESUL T . 3) Unscrew tilt switch. 4) Loosen and remove the two (2) screws securing the junctio[...]

94 10 ) Holding the tilt arm, tighten up (snug up) on the nut. 1 1 ) Hold pivot point with a screwdriver and tighten the nut. 12 ) Replace base panel. 13 ) Reestablish power to the dryer . j . T ilt Switch Adjustment 1) Discontinue electrical service to the dryer . 2) Remove the base panel from the left hand side of the dryer . CAUTION: DO NOT PLAC[...]

95 L. TUMBLER (Basket) SYSTEM 1. T umbler Drive System The tumbler (basket) is supported and driven by four (4) 1 1-inch diameter drive wheel assemblies. T wo (2) of these wheels are attached to a 2-inch diameter idler shaft, while the other four (4) are attached to a 2- inch diameter drive shaft. Each of the wheels is fastened to the shafts by a w[...]

96 W ARNING : T O ENSURE THA T THE DRIVE IS NOT UNEXPECTEDL Y ST AR TED, TURN OFF and LOCK OUT and/or T AG POWER SOURCE BEFORE PROCEEDING . F AILURE TO OBSERVE THESE PRECAUTIONS COULD RESUL T IN PERSONAL INJUR Y . W ARNING : Drive shaft assembly is heavy . IMPROPER HANDLING CAN CAUSE PERSONAL INJUR Y . 2. Drive Motor Components a ) Drive Motor Repl[...]

97 3) Install new V-belts. NOTE : Replace V-belts in matched sets (both belts). 4) T ighten turnbuckle. IMPOR T ANT : DO NOT OVER TIGHTEN TURNBUCKLE. 5) Reestablish electrical service to the dryer . 3) T aper Bushing Assembly and Drive Motor Pulley Assembly Components a ) T aper Bushing and Drive Motor Pulley Replacement 1) Discontinue electrical s[...]

98 12 ) For Gear Reducer removal refer to Section d on page 99 and page 100 . 14 ) Reestablish electrical service to the dryer . 13 ) T o install new drive shaft, reverse above procedure. b) Drive Wheel Replacement 1) Discontinue electrical service to the dryer . 2) Follow Step #2 through Step #7 in the Drive Shaft Replacement instructions in the p[...]

99 c ) Pillow Block Bearing(s) Replacement 1) Discontinue electrical service to the dryer . 2) Follow S tep #2 through S tep #1 1 in the instructions on page 97 and page 98 . 3) T o install the new pillow block bearing(s), reverse S tep #1 1 through S tep #2 in the instructions on page 97 and page 96 . 4) Reestablish electrical service to the dryer[...]

100 1 1 ) Install the new gear (speed) reducer on the drive shaft long with the taper bushing, the pillow block bearing (set screws in the pillow block bearing face the end of the drive shaft), the trantorque, and the drive wheels. 12 ) Reinstall the drive shaft into the dryer . 13 ) Secure the gear reducer to the drive shaft by reinstalling the th[...]

101 NOTE : The guard panel must be removed from the dryer to access the rear bottom panel. 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 service to the dryer . 2) Remove the four (4) Phillips pan head screws to remove the cover . 3) Remove the [...]

102 CAUTION: USE EXTREME CARE WHEN SETTING RET AINING WHEEL TENSION. PERSONAL INJUR Y MA Y RESUL T . NOTE : Proper retaining wheel tension has been achieved when the wheel spins and stops when slight pressure is applied (to the retaining wheel itself). 6. T umbler/Basket Electrical Components a ) T umbler (Basket) Thermal Magnetic S tarter and Auxi[...]

103 1 1 ) Replace ALL the wires removed in Step #5 (refer to previous page [ page 91 ]). 12 ) Mount the top of the thermal magnetic starter to the top of the din rail and press down and in. Inspect ALL of the work performed. 13) Set the control of the thermal magnetic starter to the "start" position. 14 ) Reestablish electrical power to t[...]

104 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 TO ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) ST ANDARDS[...]

105 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 fuses or overloads. 2. Failed drive motor contactor . 3. Failed drive motor . * Microprocessor controller (computer) relay output indicator (neith[...]

106 2. Failed overload protector . E . Impellor (fan) motor is not operating (does not start)... * Microprocessor controller (computer) “MTR” relay output indicator is on. 1. Blown blower (impellor and fan) motor fuses or overloads. 2. Failed blower (impellor and fan) motor contactor (relay). 3. Failed blower (fan and impellor) motor . 4. Sail [...]

107 H . Both drive motor and blower (fan and impellor) motor are not operating...microprocessor controller (computer) L.E.D. (light emitting diode) motor indicator dots and the “door” L.E.D. indicator are on but the relay output L.E.D. indicators are off (microprocessor controller [computer] L.E.D. display does not read “door”). 1. Failed m[...]

108 K . Microprocessor controller (computer) L.E.D. display reads “door” and the microprocessor controller (computer) “DOOR” L.E.D. (light emitting diode) indicator is on... 1. Failed microprocessor controller (computer). L . Microprocessor controller (computer) will not accept any keyboard [touchpad] entries, (i.e., L.E.D. [light emitting [...]

109 Q. Microprocessor controller (computer) L.E.D. (light emitting diode) display reads “SEFL”... 1. Rotational sensor circuit failure... fault somewhere in the tumbler (basket) rotation or circuit ... a . T umbler (basket) not rotating ... 1) Broken tumbler (basket) drive belts. 2) Failure in drive motor circuit. b. Bad rotation sensor . c . B[...]

110 6. Lint drawer or screen is not being cleaned on a regular basis or often enough. 7. Extractors (washer) not performing properly . 8. Sail switch is fluttering...restriction in exhaust (for GAS MODELS ONLY) . 9. Failed microprocessor controller (computer)...temperature calibration is inaccurate. 10 . Failed microprocessor temperature sensor ...[...]

111 W . Dryer will not level from a tilt position... 1. Lint drawer is open. 2. Defective lint drawer switch. 3. Broken connection between the lint drawer switch and the lint drawer closed relay . 4. Defective pneumatic valve.[...]

112 SECTION VII PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. Microprocessor (computer) Board a . Upon completing installation of the replacement microprocessor (computer) board, reestablish power to the dryer . b. Start the drying cycle. c. V erify that the motor and the heat indicator dots, in the microprocessor (computer) L.E.D. di[...]

113 2. Direct Spark Ignition (DSI) System a . Upon completing installation of the replacement Direct Spark Ignition (DSI) module, reestablish power to the dryer . b. Start the drying cycle. c . The ignition (DSI) module's L.E.D. indicator will light " red " for up to approximately 1.5 seconds (prepurge time). d . The module's in[...]

ADC 450414 1 - 05/27/99-25[...]