American Dryer Corp. ML-145 manual

122999SL/tcosta ADC Part No. 450429 ML-145 / ML-170 Service Manual Phase 6 Microprocessor Controls and Timer Controls American Dryer Corporation 88 Currant Road Fall River, MA 02720-4781 Telephone: (508) 678-9000 / Fax: (508) 678-9447 e-mail: techsupport@amdry.com[...]

Retain This Manual In A Safe Place For Future Reference American Dryer Corporation products embody advanced concepts in engineering, design, and safety. If this product is properly maintained, it will provide many years of safe, efficient, and trouble-free operation. ONLY qualified technicians should service this equipment. OBSERVE ALL SAFETY PRECA[...]

IMPORTANT YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUST- ING, INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STANDARDS. CHILDREN SHOULD NOT BE ALLOWED TO PLAY [...]

WARNING The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJURY or FIRE COULD RESULT. IMPORTANT PLEASE OBSERVE 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 stored [...]

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

SECTION V SER VICING ....................................................................................................... 16 Introduction .................................................................................................................................... 16 A. Computer Controls ....................................................[...]

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

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

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: To prevent damage, avoid cleaning and/or touching ignitor/flame-probe assembly. Remove lint accumulation from inside control box and at rear area behind control box. 6 MONTHS Inspect and remove lint accumulation in customer furnished exhaust duct work system and from dryer’s internal exhaust ducting. WARNING: THE ACCUMULA TION OF LINT IN [...]

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-LATEST EDITION or National Electrical Code ANSI/NFPA No. 70-LATEST ED[...]

8 IMPORTANT: 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 Standard, National Fuel Gas Code ANSI Z223.1- LATEST EDITION, or in Canada, the Canadian Electrical Codes Parts 1 & 2 CSA C[...]

9 NOTE: Water column pressure requirements (measured at the pressure tap on the gas valve body): Natural Gas - 3.5 inches water column (8.7 mb). L.P. Gas - 10.5 inches water column (26.1 mb). 6. If computer program changes are required, refer to the Phase 6 OPL Operator’s Manual ( ADC Part No. 1 12147) for details. 7. The dryer should be operated[...]

10 SECTION IV DESCRIPTION OF PAR TS A. CONTROL PANEL (MICROPROCESSOR) Opening the control panel will allow access to the major components which include the microprocessor computer board and the keyboard (touchpad). The keyboard (touchpad) inputs to the computer what temperature and program has been selected. The computer controls the entire operati[...]

11 D. HSI (HOT SURF ACE IGNITION) MODULE (Gas Models ONL Y ) The HSI (Hot Surface Ignition) system consists of a microprocessor (computer) based control module, along with an ignitor/flame-probe assembly. This control utilizes a 24 V carbide ignitor and a rectified flame sensor/probe signal to locally control ALL basic functions in the gas burner. [...]

12 G . BLOWER MOT OR and IMPELLOR (GAS and STEAM) The impellor is shaft driven. The blower motor drives the shaft on which the impellor is mounted. This enables the impellor to run at a higher RPM, thereby producing a higher airflow. (CFM). H. IDLER ASSEMBL Y (Viewing from the rear of the dryer.) The idler assembly is located approximately on the l[...]

13 J. TUMBLER (BASKET) The tumbler (basket) consists of four (4) ribs and four (4) perforated panels, along with a front and back, which are screwed together as an assembly. The tumbler (basket) also consists of tie rods, which support the tumbler (basket) from the front to back. The tumbler (basket) support is used to mate the tumbler (basket) to [...]

14 M. HI-LIMIT (Gas Models ONL Y ) A hi-limit thermostat is located at the burner. This is a manual reset disc-type thermostat set at 330º F (166º C). If the flame in the burner should get too hot, this thermostat will shut off the burner. This is generally caused by low airflow through the dryer. N. AUT OMA TIC RESET THERMOST A T This is located[...]

15 P . LINT DRA WER SWITCH The lint drawer switch is located in the lint compartment and attached to the side of the lint drawer track. The lint drawer switch insures that the dryer will operate only when the lint drawer is completely closed. This is a safety device and should never be disabled. Q. STEAM DAMPER SYSTEM The newest type system is call[...]

16 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). WARNING: PERSONAL INJURY COULD RESULT. The information provided in this section should not be misconstrued as a device for use by an untrained person making repairs. Service work shoul[...]

17 8. Reestablish electrical power to the dryer. To Replace Keyboard (Touchpad) Label Assembly 1. Discontinue electrical power to the dryer. 2. Unplug keyboard (touchpad) ribbon from rear of the microprocessor computer. 3. Slowly peel off and remove keyboard (touchpad) label assembly from control panel. 4. Peel paper backing off new keyboard (touch[...]

18 B. IGNITION CONTROLS To Remove Hot Surface Ignitor (Refer to above burner illustration) 1. Discontinue electrical power to the dryer. 2. Disconnect the two (2) wires connecting the ignitor to the HSI module. 3. Disassemble ignitor from burner by removing the self tapping screw. 4. Reverse procedure for installing new ignitor. To Remove Flame Pro[...]

19 7. Remove valve mounting bracket, manifold, and piping from gas valve. 8. Reverse procedure for installing new gas valve. WARNING: Test ALL connections for leaks by brushing on a soapy water solution. WARNING: NEVER TEST FOR LEAKS WITH A FLAME !!! To Replace Main Burner Orifices 1. Refer to “To Replace Gas Valve” and follo w Step #1 through [...]

20 2. To Adjust Water 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. Turn the slotted adjustment screw located on the top of the valve next to the terminals. Turn clockwise (CW) to increase manifold pressure and counterclockwise (CCW) to decrease. NOTE: If correct[...]

21 5. Remove the screws securing the burner tube rest to the oven and remove this rest. 6. Remove screws securing the flame probe, and HSI Ignitor burner box cover plate to the oven. 7. Remove burner tubes by sliding them out. 8. Replace by reversing procedure. WARNING: Test ALL connections for leaks by brushing on a soapy water solution. W ARNING:[...]

22 To Replace Lint Compartment Hi-Heat Protector (225º F [107º C]) Thermostat This thermostat is part of the “sensor bracket assembly” and is secured to the underside of the tumbler (basket) wrapper in the lint compartment. As a safety device, this thermostat will open (shut off) the heating unit circuit if an excessive temperature occurs. Th[...]

23 To Adjust Sail Switch With the dryer operating at a high temperature setting, pull the sail switch away from the burner. The sail switch should open and extinguish the burner. Let the sail switch damper return to the burner wall. The sail switch should close to restart the burner ignition cycle. If the sail switch circuit does not operate as des[...]

24 To Install New Main Door Glass 1. Remove main door assembly from dryer (follow main door removal procedure). 2. Lay main door on flat surface with the front of the door facing up. 3. Remove the four (4) acorn nuts securing the glass. 4. Remove glass and clean ALL old sealant off main door. This area must be completely cleaned for correct bonding[...]

25 To Replace Main Door Hinge Blocks 1. Discontinue electrical power to the dryer. 2. Follow procedure for removal of main door assembly. 3. Disassemble bottom hinge block from front panel by removing the Allen head screws located inside the hinge block. 4. Reassemble by reversing removal procedure. 5. Reestablish electrical power to the dryer. F .[...]

26 To Replace Small Idler Pulley 1. Loosen V-belts. Rotate pulley and roll V-belts out of grooves. 2. Remove cap screws from the bushings. 3. Insert cap screws in tapped removal holes and tighten evenly until bushing becomes loose on shaft. Refer to figure “A” on previous page. 4. Remove bushing, pulley, and key. 5. Assemble bushing and sheave [...]

27 IMPORTANT: 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 15 ft-lbs. (20 Nm). If greater tightening forces are applied, excess pressures will be created in the hub of the mounted sheave which may cause[...]

28 5. Turn these bolts clockwise (CW) evenly to raise tumbler (basket) or counterclockwise (CCW) evenly to lower tumbler (basket). 6. Rotate tumbler (basket) from front and check alignment with front door opening. 7. Leave a larger gap from the inside ring on the top of the front panel opening to the tumbler (basket) and a smaller gap on the bottom[...]

29 5. Remove tumbler (basket) belts. 6. Remove tumbler (basket) pulley. 7. Remove tumbler (basket) assembly and support. a. Loosen the two (2) set screws on both the pillow block bearing collars. b. Remove the retaining rings from the grooves of the tumbler (basket) shaft. c. Remove the tumbler (basket) and support assembly from the front of the dr[...]

30 4. Loosen lateral adjustment jam nuts and bolts. (Refer to illustration in section G “Tumbler (Basket) Alignment”) 5. Loosen set screws (2) from rear pillow block bearing collar. 6. Remove the rear bearing bolts, securing bearing to bearing mount. Remove bearing. 7. Replace by reversing Step #3 through Step #6 . 8. Adjust both lateral and ve[...]

31 6. Slide bearing off the shaft. 7. Replace bearing by reversing procedure. 8. Align idler pulley with tumbler (basket) pulley before tightening bolts. 9. Reestablish electrical power to the dryer. To Replace Rear Idler Shaft Pillow Block Bearing 1. Follow Step #1 through Step #3 from “To Replace Front Idler Shaft Bearing.” 2. Remove retainin[...]

32 V-Belt Tension Adjustment (Motor to Idler) 1. Discontinue electrical power to the dryer. 2. Loosen the nuts on the four (4) studs holding the drive motor mount to the back of the dryer. 3. Loosen the jam nuts on the adjustment screw on the top of the motor mount. 4. Turn the adjustment screw to lower the motor mount (to tighten the belts) or rai[...]

33 9. Reestablish electrical power to the dryer. To Replace Impellor Motor (Fan Shaft Drive - Gas and Steam Models 50 & 60 Hz) 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 fro[...]

34 L. LINT DRA WER ASSEMBL Y To Replace Lint Screen 1. Pull out lint drawer. 2. Remove lint screen from lint drawer. 3. Drop new lint screen in place. 4. Slide lint drawer back into dryer. To Replace Lint Drawer Switch 1. Disconnect electrical power to the dryer. 2. Remove lint drawer and lint door. 3. Disconnect both 4-pin connectors at the rear o[...]

35 SECTION VI TROUBLESHOOTING IMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANIN G , ADJUSTIN G , INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STANDARDS. The in[...]

36 C. Display is reading “Rotation Sensor Fail.” 1. Magnet and rotation read switch are out of adjustment. 2. Trunnion shaft has moved forward. 3. Magnet is missing. 4. Rotation read switch is broken. 5. Broken V-belt. 6. Faulty drive motor. 7. Faulty wiring connection between read switch and computer. 8. Faulty drive contactor. 9. Faulty compu[...]

37 E. Display is reading “Sail Switch Fail.” 1. Sail switch is out of adjustment. 2. Sail switch is hung up. 3. Customer has an exhaust booster fan that draws too much air. 4. Faulty wiring connection between computer and sail switch. 5. Faulty computer. F. Display is reading “Drum Safety Fail” 1. Open tumbler (basket) hi-limit which is 225[...]

38 I. Display is reading “Burner Control Failure.” 1. Faulty flame probe. 2. Faulty HSI (Hot Surface Ignition) module. 3. Faulty wiring connection between HSI module and gas valve or between gas valve and Phase 6 computer. 4. Faulty computer. J. Display is reading “Burner Flame Failure.” 1. Clogged lint screen. 2. Clogged exhaust. 3. Faulty[...]

39 N. Display is reading “Hot.” 1. Lint screen is dirty. 2. Exhaust is clogged. 3. Lint drawer is not closed ALL the way. 4. Faulty computer. 5. Faulty temp sensor. O. Dryer operates but is taking too long to dry... 1. An inadequate exhaust duct work system. 2. Restriction in exhaust system. 3. Insufficient make-up air. 4. Poor housekeeping. a.[...]

40 Q. Overload for impellor (fan) 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. R. There is excessive vibration coming from the tumbler (basket)... 1. Tumbl[...]

41 SECTION VII ELECTRICAL TROUBLESHOOTING The information provided will help isolate the most probable components associated with the difficulty described. The experienced technician realizes, however, that a loose connection or broken or shorted wire may be at fault where electrical components are concerned...not necessarily the suspect component [...]

42 SECTION VIII PHASE 6 OPL SYSTEM DIAGNOSTICS IMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STAN[...]

43 6. bURNER CONTRL FAIL - 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 di[...]

44 11. ROTATE SENSOR FAIL - 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 (ROTATE SENSOR ACTIVE), if the dr[...]

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

46 1. “FAN” (BLOWER) Output L.E.D. (light emitting diode) Indicator a . If the dryer is started and the blower motor is not operating, yet both 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 co[...]

47 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. (light emitting diode) 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.[...]

48 12. “FLAME” (bURNER CONTROL FAIL) 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 “FL[...]

49 SECTION IX L.E.D. DISPLA Y/CODES The L.E.D. (light emitting diode) display informs the operator of cycle status, program verification, and displays important diagnostic codes and fault codes. A. L.E.D. DISPLA Y OPERA TING ST A TUS 1. Cycles in Progress a. While the dryer is operating, the L.E.D. display will read which cycle is in progress. For [...]

50 1) Illustration No. 1 a) FORWARD INDICATOR - this indicator dot is functional for dryer models with the Reversing Action Option ONLY. This indicator dot will be on when the tumbler (basket) is in the forward (clockwise [CW]) direction. Additionally, when the Anti-Wrinkle Program is active, this indicator dot will be on whenever the Phase 6 OPL m[...]

51 C. L.E.D. CODES 1. Display Codes A ALL REV ANTI WRINKL dELAY TIME ANTI WRINKL GUARd ACTIVE ANTI WRINKL GUARd ON TIME AUTO CYCLE b bURNER CONTROL FAIL bURNER FLAME FAIL bURNER SAFETY FAIL bUZZ bUZZ TIME CEL CHECK MAIN FUSE CLEAN LINT COOL COOL TIME_M COOL TEMP_ CYCLEA CYCLEb CYCLEC CYCLED CYCLEE CYCLEF dONE dRYING dRY LEVEL_ dRY TEMP F_ dRY TIME_[...]

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

53 D. COMPUTER LOGIC and WIRING DIAGRAM 1. Operator enters desired selection(s). 2. Information entered is sent to the microcontroller 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) module whi[...]

54 A. No Display Condition... 1. Check main fuses or circuit breaker. 2. Check blower motor overload...If tripped, reset. 3. Check fuse 1 or fuse 2 and if either are blown, replace. 4. Check to make sure “ EMERGENCY STOP” (E-Stop) button is not depressed. 5. Across nos. 6 and 8 you should be getting your 208 V or 240 V. The J12 connector pin 1 [...]

55 C. Drive motor works in forward mode but does not reverse, blower motor runs... 1. If computer dot (second one from left) does not come on, check program to see if set for reverse. 2. If set for reverse, replace computer. 3. Check for voltage across the coil of the reversing contactor located in the rear panel box. The contactor according to you[...]

56 E. “No Heat” Drive and Blower Motors Run (Gas Models)... 1. Check for voltage across L1 and GND of the HSI module. If no voltage is present, then check for voltage from terminal #14 on the blower contactor to ground. If no voltage is present, the problem is with blower contactor. If voltage is present, the problem is faulty wire or terminati[...]

57 G. “Door” Condition NOTE: Make sure main door is closed. Also, if checking either switch, the plunger must be depressed. 1. Check L.E.D. (light emitting diode) input light “door” on the component side of the computer. If the light is on, replace the computer. 2. Check voltage (24 VAC) between pin 5 and ground of the J7 9 pin connector. I[...]

58 SECTION X 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 wiri[...]

59 B. DA T A LABEL Contacting American Dryer Corporation (ADC) When contacting ADC , certain information is required to insure proper service/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 and ser[...]

60 C. USING A MANOMETER How to 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.[...]

61 D. ML-170 T OOL LIST Straight Head Screwdriver Phillips Head Screwdriver Sensor Pin and Socket Tool (P/N 122801) Pliers 1/4” Nut Driver 3/8” Open End Wrench 5/8” Open End Wrench 5/8” Deep Socket Wrench 3/8” Socket Wrench 1/2” Socket or Open End Wrench 1/4” Open End Wrench 5/16” Socket or Open End Wrench 1/2” Socket Wrench 7/16?[...]

ADC 450429 1 - 02/18/00-25[...]