American Dryer Corp. AD-464 manual

AD-464 / ML-460 Phase 7 Ser vice Manual 031504SCOST A/gbennett ADC Part No. 450260 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 ww w .amdry .com[...]

R etain T his Man ual In A Saf e Place F or Futur e R ef er 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. Observe all sa[...]

Impor tant Y ou 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. Please observe all safety precautions d[...]

2 American Dryer Corp. 450260-1 R efe r ence Guide (Front)[...]

450260-1 www .amdry .com 3 R efe r ence Guide (Left Side)[...]

4 American Dryer Corp. 450260-1 R efe r ence Guide (Right Side)[...]

450260-1 www .amdry .com 5 R efe r ence Guide (Right Side)[...]

6 American Dryer Corp. 450260-1 S AFETY P RECA UTIONS __________ 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. The dryer must never be operated with any of the back guards, outer tops, or service panels removed. Pe[...]

450260-1 www .amdry .com 7 R OUTINE M AINTENANCE _________ 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. Max[...]

8 American Dryer Corp. 450260-1 I NST ALLA TION R EQUIREMENTS ____ 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 S tandards: ANSI Z223.1-LA TEST EDITION (National Fuel Gas Code) or ANSI/NFP A NO. 70-LA T[...]

450260-1 www .amdry .com 9 C OMPONENT D ESCRIPTION / R EPLACEMENT _________________ Gas Bur ner and Ignition System ____ The dryer's gas burner system operates on an On or Off gas rate sequences to accurately control the tumblers (basket's) drying temperature. Maximum firing rate is 2.8 million Btu/hr . Upon a call from hea[...]

10 American Dryer Corp. 450260-1 Light Emitting Diode (L.E.D.) and Neon Displays of the BCM (Bur ner Contr oller Module)  Operating Interlock - L.E.D. is lit when: All safety interlock switches are closed, applying a 1 10 V AC signal to terminal #7 of the burner controller module (BCM).  Operating Interlock - L.E.D. is not lit when: One (1) o[...]

450260-1 www .amdry .com 11 Bur ner Fan Air Switch The differential in air pressure is measured by the burner fan air switch, which is located next to the burner fan motor . If the combustion air is inadequate, this switch will prevent ignition. The setting of this switch is adjustable, and it should be set at approximately 0.59-inches (15 mm) of w[...]

12 American Dryer Corp. 450260-1 Sequence of Operation With dryer power on, a 120 volt signal is sent to terminal #1 and terminal #2 of the burner controller module (BCM). A power indicator light has been added to the controller base for troubleshooting.  Drying cycle is started  Dryer computer calls for heat. The BCM checks that all of the d[...]

450260-1 www .amdry .com 13 Bur ner Air Switch The dryer uses a burner air switch on its burner components. The differential air pressure is measured by this air switch, which is located next to the burner fan motor . If the combustion air is inadequate, this switch will prevent ignition. The setting of this burner air switch is adjustable, and is [...]

14 American Dryer Corp. 450260-1 Burner Fan Motor Burner Fan Motor Replacement 1. Discontinue electrical service to the dryer . 2. Remove the four (4) #8-18 x 7/16" TEK screws which secure the inlet ring to the combustion air blower housing. 3. Remove the two (2) 1/2-20 left hand jam nuts as well as the 1/2-inch flat washer . 4. Remove the 6-1[...]

450260-1 www .amdry .com 15 Heat Mode Air Flow During a call for heat, solenoid S10 turns on and air first enters the dryer on the bottom right side of the dryer . The air then passes through the open inlet air damper , then passes through the six (6) steam coils to heat the air . Next, the air enters the tumbler (basket) heating the load inside. T[...]

16 American Dryer Corp. 450260-1 H EAT R ECL AI M ER S ETT I NG S Z = 1-5/8 Y+ Z =X Y % HR In ches R e clai me d 1- 1/8" 1/2" 7.46 1- 1/4" 2-5/ 8" 1" 15. 67 2- 5/8" 3- 1/8" 1-1 /2" 25.37 4- 1/4" 3- 5/8" 2" 34. 32 5-3/ 4" 4- 1/8" 2-1/2" 4 3 . 28 7-1/ 4" 4- 5/8" 3" 5[...]

450260-1 www .amdry .com 17 Tilting System Description __________ The tilting system in the dryer , whether it is 1-way tilt or 2-way tilt, is controlled by the programmable logic controller (PLC). The PLC 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 t[...]

18 American Dryer Corp. 450260-1 Tilting System Component Replacement Caution Never service pneumatic components with compressed air connected. Serious injury may result. Tilting Solenoid Replacement 1. Engage EMERGENCY S T OP (E-S top). Discontinue electrical power to the dryer . 2. Remove panel covering the pneumatic controls. 3. Label the [...]

450260-1 www .amdry .com 19 Tilting Piston Replacement 1. Disconnect compressed air supply from the dryer . 2 . Tilt, then level the dryer to exhaust as much air as possible. 3. Disengage EMERGENCY STOP (E-S top). Discontinue electrical power to the dryer . 4. Remove the six (6) screws holding the piston cover plate. 5. Label the air lines as[...]

20 American Dryer Corp. 450260-1 ! Tilt Switch Adjustment  Discontinue electrical service to the dryer .  Remove the base panel from the left hand side of the dryer . Caution Do not place hands between the dryer base and the tumbler (basket) section. Serious injury can result.  T o adjust the pivot arm; hold the arm and with a #10 metric w[...]

450260-1 www .amdry .com 21 Blow er (Squir r el Ca ge F an) Motor Assembly _____________________________ Blo wer (Squir r el Ca ge Fan) Motor Description The dryer uses a 22-1/4 inch diameter blower (squirrel cage fan). It rotates (spins) in a counterclockwise (CCW) direction, when viewed at the blower motor . The blower shaft is mounted on two (2)[...]

22 American Dryer Corp. 450260-1 19. Tighten (hand tight only) the bolts for the new motor to the motor base. Leave enough movement for V -belt adjustment. 2 0 . Replace the V-belt s. Adjust to proper tension by adjusting the position of the new blower motor . Align the V -belts. 21. Tighten/secure the new motor to the motor base. 22 . Reconnect th[...]

450260-1 www .amdry .com 23 Blower (Squir rel Cage F an) Electrical Components _________________________ Blo wer (Squir r el Cag e Fan) Contr ols and Overloads T hermal Magnetic Star ter (TMS) Description The TMS is used as a safety device to manually disconnect the motor , thereby protecting the motor from being damaged in a locked rotor condition[...]

24 American Dryer Corp. 450260-1 Filter Maintenance T o remove filter element: twist 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). T o clean filter element use soap and water . Note When replacing the filter element [...]

450260-1 www .amdry .com 25 Compressed Air System _____________ The compressed air system of the dryer consists of a number of pneumatic pistons located throughout the dryer , a regulator , and pneumatic control panel. Air Pistons The pistons are actuated by solenoid and flow control valves that are under computer control. The pneumatic pistons are[...]

26 American Dryer Corp. 450260-1 Solenoid V alv e V alve Replacement 1. Discontinue air supply to the dryer . 2. Discontinue electrical service to the dryer . 3. Loosen coil plug screw and remove the plug. 4. Carefully remove the two (2) valve mounting screws. T ake notice of the gasket. 5. Install new valve body . Caution Do not pinch the gasket. [...]

450260-1 www .amdry .com 27 Notes For proper cable (wire rope) routing, starting at the piston; A . Replace the cable (wire rope) thimble and wire rope clamp to one side of the cable. B . Secure the cable (wire rope) to the piston mount with the 3/8-16 x 1" bolt, 3/8" fender washer , 3/8" lock washer , and 3/8-16 hex nut. C. Feed the[...]

28 American Dryer Corp. 450260-1 Load Door Open/Closed Switch Replacement 1. Discontinue electrical service to the dryer . 2 . Loosen and remove the two (2) screws securing the mounting bracket 3. Remove the switch from the mounting bracket. 4. Depress the tabs on the 2 PIN connector and pull apart from the harness. 5 . Install the new switch by co[...]

450260-1 www .amdry .com 29 Control And Electrical System ______ Ladder Diagram[...]

30 American Dryer Corp. 450260-1[...]

450260-1 www .amdry .com 31 Caution When servicing the high voltage (H V) section of the dryer , the electrical power must be disabled. The Emergency Stop (E-Stop) button does not disable the high voltage to the dryer. Control/Electrical System Description 3-Phase (3ø) Electrical Power The 3-phase (3ø) electrical power for the dryer enters [...]

32 American Dryer Corp. 450260-1 Phase 7 Microprocessor Controller (Computer) The temperature sensor probe is a bullet shaped device that is located in the exhaust duct by the heat reclaimer . This temperature sensor probe is used to sense the temperature in the exhaust of the dryer . The temperature sensor is a two (2) terminal monolithic integrat[...]

450260-1 www .amdry .com 33 ! 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 . T o 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 t[...]

34 American Dryer Corp. 450260-1 End of Cycle Light Bulb Replacement 1. Discontinue electrical power to the dryer . 2. T wist lock ring counter clockwise (CCW) to remove the cap. 3. Remove the cap. 4. T wist and remove bulb/light. 5. T o install new bulb, reverse Step #5 through S tep #1. Switch Replacement 1. Discontinue electrical power to the dr[...]

450260-1 www .amdry .com 35 Bask et (T umbler) System ____________ Bask et (T umbler) Driv e System The basket (tumbler) is supported and driven by four (4) 1 1-inch (27.94 cm) diameter drive wheel assemblies. T w o (2) of these wheels are attached to a 2-inch diameter idler shaft, while the other two (2) are attached to a 2-inch diameter drive sha[...]

36 American Dryer Corp. 450260-1 ! T a per Lock Bushing and Driv e Motor Pulley Replacement 1. Discontinue electrical power to the dryer . 2. Loosen turnbuckle and remove V -belts. 3. Mark inside of the drive motor shaft. 4. Remove the bolts securing the taper lock bushing. 5. Insert bolts into the threaded holes on the motor pulley and tighten eve[...]

450260-1 www .amdry .com 37 6. Check the position of the drain plug and the breather plug. 7. Check the turnbuckle mount pad on the gear reducer for the correct application. 8. Install the new gear (speed) reducer on the drive shaft along with the taper lock bushing, the pillow block bearing (setscrews in the pillow block bearing face the end of th[...]

38 American Dryer Corp. 450260-1 Rotational Sensor Assembly The Rotational Sensor Assembly is located on the left hand side of the dryer basket (tumbler) section. It consists of a magnetic rotational switch, mounted on the bracket, which is bolted to the basket (tumbler) section. A magnet is riveted to the basket (tumbler) of the dryer. The magneti[...]

450260-1 www .amdry .com 39 Proximity Switch Replacement 1. Discontinue electrical service to the dryer . 2. Remove the screws securing the junction box cover . 3. Mark and identify the wires that will be removed for proper reinstallation. 4. Disconnect the two (2) leads of the defective proximity switch. 5. Remove the proximity switch from the cut[...]

40 American Dryer Corp. 450260-1 330º F (166º C) Thermostat MAN3484 Safety Devices Locations/Functions/Messages _________ T op of T umbler (Basket) _____________ The burner auto reset hi-limit switch is a thermostat type switch located in the burner . I t s function is to discontinue heat (flame) in the event of an over temperature situation (abo[...]

450260-1 www .amdry .com 41 P HASE 7 N ON -C OIN S Y STEM D IAGNOSTICS __________________ Impor tant YOU MUST DISCONNECT AND LOCK OUT 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 ([...]

42 American Dryer Corp. 450260-1 Outputs: (Green) 1. FSS - Fire Suppression 2. PRG2 - Programmable Output #2 3. R_HEA T - Rear Heat 4. AUDIO ALERT - Horn On 5. FWD - Basket (Tumbler) Forward 6. AIR JET - Air Jet On 7. PRG3 - Programmable Output #3 8. PRG1 - Programmable Output #1 9. F_HEA T - Front Heat 10. F AN - Blower Fan On 1 1. REV - Basket (T[...]

450260-1 www .amdry .com 43 Outputs: 1. FSS  (GREEN LIGHT EMITTING DIODE [L.E.D.]) This L.E.D. indicates the activation of the water system. When the system is activated the L.E.D. is ON. 2. PGR2  (GREEN L.E.D.) This is for a spare output to be programmed. 3. R_HEA T  (GREEN L.E.D.) This L.E.D. will indicate the status of the rear heat out[...]

44 American Dryer Corp. 450260-1 Drive Motor Operates in One (1) Direction Onl y; Stops and R estar ts in the Same Direction __________________ Appropriate microprocessor controller (computer) relay output indicator is on.  Failed reversing contactor (relay).  Failed electrical reversing contactor interlock. Appropriate microprocessor control[...]

450260-1 www .amdry .com 45 Microprocessor Controller (Computer) Board Display Reads FRONT DOORS NOT CLOSED or REAR DOORS NOT CLOSED ________  Fault (open circuit) in front or rear door switch circuit.  One (1) of the front or rear door switches has failed.  One (1) of the front or rear door switch contact magnets is either mis[...]

46 American Dryer Corp. 450260-1 Excessive Noise And Vibration ______  Dryer is not leveled properly .  Impellor (fan/blower) out of balance.  Excessive lint buildup on impellor (fan/blower); check air jet.  Failed impellor (fan/blower).  Loose motor mount.  Failed idler bearings or basket (tumbler) bearings.  V -belt(s) either[...]

450260-1 www .amdry .com 47 P ROCEDURE FOR F UNCTIONAL C HECK OF R EPLACEMENT C OMPONENTS __________________ F or Models with Direct Spar k Ignition (DSI) Module (Type I) ________________ T heor y of Operation: S tart the drying cycle. When the gas burner ignites within the chosen trial for ignition time (6-seconds), the flame sensor detects gas bu[...]

48 American Dryer Corp. 450260-1 P END ANT A SSEMBL Y ____________ Pendant Assembly Description ______ The pendant assembly is used on both the gas and steam model dryer . Within the pendant assembly there is jog forward/ jog reverse push buttons. When depressed individually , these buttons will cause the tumbler (basket) to turn clockwise (CW) for[...]

450260-1 www .amdry .com 49 Notes _______________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ ________________________________________________________________[...]

ADC 450260 1- 4/21/04-0[...]