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American Dryer Corp. AD-200 Clothes Dryer User Manual

1. Serial Number s Replacement parts can be obtained from your distributor or the ADC factory When ordering replacement parts from the factory you can FAX your order to ADC at 508 678 9447 or telephone your orders directly to the ADC Parts Department at 508 678 9010 Please specify the dryer model number and serial number in addition to the description and part number so that your order is processed accurately and promptly The illustrations on the following pages may not depict your particular dryer exactly The illustrations are a composite ofthe various dryer models Be sure to check the descriptions ofthe parts thoroughly before ordering INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE USER SMELLS GAS MUST BE POSTED IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE POSTED SHALL BE OBTAINED FROM THE LOCAL GAS SUPPLIER 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 STANDARDS CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGER OUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING CAUTION DRYER S SHOULD NEVER BE LEFT UNATTENDED WHILE IN OPERATION WARNING CHILDREN SHOULD NOT BE ALLOWED TO PLAY ON OR
2. b To clean filter element The filter element can be cleaned with soap and water NOTE Whenreplacing the filter element bowl care must be taken to ensure that the O ring does not get pinched 2 Regulator Operation FILTER REGULATOR The adjustment knob simply acts upon a spring rest located on the spring and directly compresses the spring as it is adjusted A non rising low torque adjustment screw is used on this type of filter regulator The upper spring rest is located on top of the regulator spring and transmits force from the adjustment screw to the spring Regulators use simple wire coil springs for controlling the downstream regulator pressure The bonnet houses the adjustment spring and is used to help retain the diaphragm The diaphragm moves up when the downstream pressure reaches its preset pressure level which in turn closes the valve A self relieving regulator is designed to automatically relieve overpressure in the secondary side of the regulator Dryer must be provided with a clean dry regulated 80 PSI 10 PSI air supply equivalent volume 6 cfh The regulator should be set at 80 PSI 10 PSI To set pressure pull the adjusting knob up and either turn the knob clockwise CW to increase the pressure or counterclockwise CCW to decrease the pressure 48 H Door Systems The AD 200 utilizes two 2 styles of doors which are Manual Doors and Pneumatic Automatic Doo
3. Discontinue electric service to the dryer Remove the two 2 1 4 20 x 1 2 bolts from each side of the middle guard and rear guard Remove the three 3 1 4 20 x 3 4 bolts from the bottom guard Remove the bottom guard Remove the two 2 8 32 x 3 4 screws on each door that connect attach the cable cylinder to the door Remove the two 2 1 4 20 x 1 1 4 hex head machine screws a Take notice to the wheel assembly configuration Lift the door s off of the track and remove To install new pneumatic automatic doors or to reinstall pneumatic automatic doors reverse above procedure steps 6 through 1 51 c Cable Cylinder Replacement or Removal 1 2 3 4 5 6 7 8 Discontinue electric service to the dryer Remove the two 2 1 4 20 x 1 2 bolts from each side of the middle guard Remove the middle guard Disconnect the cables in the top of the electrical panel Remove the hardware from the top guard Remove the top guard Remove the two 2 8 32 x 3 4 screws on each door that connect or attach the cable cylinder to the door Remove the four 4 8 32 x 2 1 2 screws that hold each cable cylinder Remove the flow control valve a The flow control valve has a quick disconnect on the poly flow tubing side Push the tubing in while holding in then pull the tubing out To install new cable cylinders or reinstall cable cylinders reverse above procedure steps 7 through 1
4. NOTE The Sprinkler System will remain on until the tumbler basket temperature falls below the set point and the reset button is manually activated 35 MAN3202 3 Sprinkler System Component Replacement a Resistive Temperature Device RTD Replacement 1 Turn the water supply to the dryer off 2 Discontinue electric service to the dryer 3 Remove the 1 4 compression fitting 4 Remove the two 2 screws from the junction box 5 Remove the wires of the RTD from the terminal strip 6 Loosen the cord grip cap 7 Remove Resistive Temperature Device RTD 8 install new RTD reverse above procedure steps 7 through 1 36 b Sprinkler Valve Replacement 1 2 3 4 5 6 7 8 9 Turn the water supply to the dryer off Discontinue electric service to the dryer Disconnect compressed air supply from the dryer Loosen and remove the hose clamp Remove any residual water to the valve Remove 1 4 air tubing going to the valve Remove the two 2 U bolts holding the sprinkler valve assembly Unscrew the sprinkler valve from the tubing To install new sprinkler valve reverse above procedure steps 8 through 1 NS lt a o TE T l MAN3190 c 3 HP Control Relay Replacement power supply for the dryer DISCONNECT and LOCK OUT BOTH POWER SUPPLIES BEFORE SERVICING
5. Visually inspect High Voltage HV Wire connections at both DSI Module and Ignitor Assembly Are connections secure No gt 5 Yes Cut the end off of the HV Wire 1 4 at a time until conductor Remove High Voltage HV Wire from DSI Module and visually inspect Is conductor becomes visible and is flush with the insulation No Reconnect the HV Wire to the Spike Terminal on the DSI Replace the DSI Module Energize system and check I Yes for proper operation Module Energize system and check for proper operation visible at end of HV Wire 19 e Troubleshooting Flow Chart Quick Reference Does main burner Second Visual Check Does Main Burner Ignite Is manual knob on the Gas Valve No light Yes To Chart 3 Restore gas supply Energize system and check for proper operation Is gas available at the source Yes Energize system Is 24 VAC present across leads at the Gas Valve Yes Y Replace the Gas Valve Energize the system and check for proper operation in the ON position Yes Is dryer Internal Gas Shut Off Valve and No Turn knob to ON OPEN position Energize system and check for proper operation ALL External Gas Shut Of
6. _ American Dryer Corp AD 200 Service Manual with Non Tilt Options 1993 thru 1998 MAN4521 American Dryer Corporation 88 Currant Road Fall River MA 02720 4781 Telephone 508 678 9000 Fax 508 678 9447 e mail techsupport amdry com 062599DMG cms ADC Part No 450310 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 properly licensed technicians should service this equipment OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the installation operator s manual included with the dryer WARNING UNDER NO CIRCUMSTANCES should the door switch or the heat circuit devices ever be disabled 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 We have tried to make this manual as complete as possible and hope you will find it useful ADC reserves the right to make changes from time to time without notice or obligation in prices specifications colors and material and to change or discontinue models Important For your convenience log the following information DATE OF PURCHASE MODEL NO AD 200 Non Tilti ng DISTRIBUTORS NAME
7. normally closed switch and supplies voltage to the Master On normally open switch When the Master On switch is momentarily engaged the master control relay MCR engages This closes the MCR A contactor which is in parallel with the Master On switch which will keep the MCR enabled If the power is interrupted or the Master Off switch is pressed the MCR will disengage The MCR B contactor supplies power to the rest of the 24 VAC circuits For dryers manufactured with Automatic Doors the supply air enables purpose is to relieve pressure on the automatic door pistons when an energizing stop is engaged Safety Circuits The following circuit branches are to verify various safeties if ALL conditions are met a The first two 2 items are the Auxiliary Contact located on the blower impellor fan motor and the Tumbler basket Motor Overload If either of these devices trip it will open up the safety circuit thereby preventing the dryer from operating b 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 two 2 sets of contacts in the relay one 1 set of contacts are in the dry enable circuit branch and the other set go to the PLC
8. Refer to the electrical specification diagram for correct current setting In this circuit the drive motor contac tor follows the thermal magnetic overload Providing the 24 A C volts for the DOOR input to the computer is present on pin 2 of the 15 pin computer harness the computer harness the computer is going to output that 24 volts on pin 3 forward or pin 8 reverse of the 15 pin connector Path of Voltage for the Drive Circuit Three phase voltage is applied to the power distribution block each line L1 L2 and L3 the voltage then travels to the drive motor thermal magnetic overload The voltage is then supplied to the reversing contactor marked L1 L2 and L3 As long as the overload is not tripped 208 600 volts will always be here at the contactor When the computer calls for the forward motion of the basket 24 A C volts will output of pin 3 of the computer This 24 A C volts will pass through it and J1 and J3 connectors pin 3 on both and travel to the forward coil of reversing contactor the contactor will be marked Al The other side of the coil A2 will be directly grounded When the 24 A C volts reaches the coil the contactor closes and the incoming voltage that is supplied to the top of the contactor L1 L2 and L3 meets the T1 T2 and T3 of the contactor which then travels down to the soft start via the drive motor The reversing action is projected the same way as the forward with the exception of the 24 A C volts will output f
9. fan impellor motors shaft 12 Slide the bushing on to the shaft until the inside of the bushing meets the mark from Step 11 on the new motors shaft 13 Tighten the set screws on the bushing PULLEY INSTALLATION 14 Insert bolts into the large holes on the bushing and thread them into the motor pulley 15 Tighten the bolts evenly for motor pulley installation 16 Aline the pulleys 17 Tighten hand tight only the bolts from the new motor to the motor base Leave enough movement for V belt adjustment 42 18 19 20 21 Replace the V belts a Adjust to proper tension by adjusting position of the new blower fan impellor motor b Align the V belts Tighten secure the new motor to the motor base Rewire the new blower fan and impellor motor in the same order as the wiring from the motor that was removed A wiring diagram is usually affixed to the side of the motor Reestablish electric service to the dryer b Shrouded Pillow Block Bearing Replacement 1 2 3 4 5 6 7 8 9 10 Discontinue electric service to the dryer Remove the bolts securing the blower fan and impellor motor a Slide the blower fan and impellor motor forward Remove the V belts from the motor pulley and the pulley on the fan blower shaft assembly Move the blower fan and impellor motor so as to be able to remove the fan blower shaft bearing mount assembly Rem
10. should a FLAME OUT occur 1 severe air turbulence forces the flame away from the ignitor and flame probe assembly the DSI module shut the gas valve off and immediately try to reestablish the burner flame The DSI module will attempt to light the burner ONLY ONCE If flame is not established the DSI module will LOCK OUT To reset or cancel the LOCK OUT condition open and close the main door then restart the dryer 13 i ADC Direct Spark Ignition DSI Operation Flow Chart Computer Timer Calls For Heat Power Applied to the 081 Module DSI Module Indicator lights RED for up to approximately 1 3 seconds prepurge DSI Module Internal Check DSI Module Indicator lights GREEN Gas Valve opens and spark bursts for approximately 8 seconds Flame Open and close the Main Door restart the dryer A Confirmed DSI Module Indicator light remains GREEN v Established Normal Heating Cycle x Flame Lost DSI Module LOCK OUT Indicator lights RED Flame Confirmed Yes _ DSI Module will immediately attempt to re light burner 14 B Troubleshooting The Direct Spark Ignition DSI System NOTE The troubleshooting information provided in this manual is intended for use by qualified service technicians only OBSERVE ALL SAFET
11. 52 d Proximity Switch Replacement 1 2 3 4 5 6 7 Discontinue electric service to the dryer Remove the two 2 1 4 20 x 1 2 bolts from each side of the middle guard and rear guard Remove the three 3 1 4 20 x 3 4 bolts from the bottom guard Remove the bottom guard Remove the two 2 8 32 x 3 4 screws on each door that connect attach the cable cylinder to the door Remove the two 2 1 4 20 x 1 1 4 hex head machine screws a Take notice to the wheel assembly configuration Lift the door s off of the track and remove To install new pneumatic automatic door s or to reinstall pneumatic automatic door s reverse above procedure step 6 through 1 e Right Load Door Glass Window Replacement 1 2 3 4 5 6 Remove ALL of the old silicone from around the door glass Clean glass door opening with alcohol to remove ALL of the old silicone Carefully clean new door glass with alcohol prior to installation Apply a bead of silicone ADC Part No 170730 to the outer perimeter of the door glass opening Carefully insert new door glass within door glass opening Allow a full 72 hours for the silicone to cure Trim excess silicone with razor blade after cure time 53 f 4 Way Valve and 3 Way Valve Supply Air Disable Valve Replacement 1 2 3 4 5 6 7 8 9 Discontinue elec
12. C volts that was supplied to the COM terminal of the relay to the N O terminal of that relay which in turn goes directly into the computer 15 pin connector 2 Path of the DOOR Circuit The DOOR circuit in the AD 200 is different than other ADC dryers This is a input circuit 24 A C volts into the computer pin 2 This is the control voltage that the computer will use to output at various times throughout the cycle to various components The voltage will first start at the incoming voltage L1 L2 and L3 from there L1 and L3 travel through the two protection fuses 5 amp slo blo to the ABC terminal block letters A and B The voltage at this point is still 208 240 volts here is where the 208 240 volts is cut down to 24 volt A C One of the secondary wires gets grounded while the other one is fused with a 4 amp buss type fuse and it s then present at terminal block C We should now be able to get the 24 volts A C between terminal block C and ground If the 24 volts is not present here then the problem could only be bad 4 amp fuse or the 24 volts transformer has failed The 24 volts leaves C and travels through the blower and the drum overloads this is the first place to check when the DOOR signal comes on the display when these overloads trip it immediately displays DOOR The voltage now travels through some connectors J1 and J3 pin 2 of each and lands on terminal block 2 connecting point 2 This here is where the voltage wil
13. a system malfunction and go into the LOCK OUT mode the L E D indicator will LIGHT RED CONTINUOUSLY 4 4 OF FLAME IV NI N NENA Sy NAN i OP OF BURNER TUBI 24 3 Air Turbulence If there is sail switch flutter due to air turbulence or improper impellor fan and blower rotation or a restriction in the exhaust duct work the DSI module will cycle erratically This in turn might cause the DSI module to LOCK OUT where the L E D indicator will LIGHT RED CONTINUOUSLY a If air turbulence cause the flame to move away from the flame probe electrode of the ignitor and flame probe assembly or if the flame goes out completely during the heat flame cycle the DSI module will attempt to reestablish a flame by going into a reignition cycle 4 Direct Spark Ignition DSI Module If there is some sort of operational interference in the DSI system the DSI module acting as the controller for the system will go into a LOCK OUT mode where the L E D light emitting diode indicator will LIGHT RED CONTINUOUSLY a Operational interference is any adverse condition whether internal or external to the system Electrical noise is considered external noise interference because it can cause the DSI module to cycle erratically NOTE To reset the DSI module if it is in the LOCK OUT mode open and close the main door then restart
14. body 4 Remove the two 2 10 16 x 1 2 Crimptite screws 40 4 Remove the two 2 10 16 x 1 2 Crimptite TEK screws Remove the valve support 5 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 6 To install new air jet assembly reverse above procedure steps 5 through 1 b Pneumatic Valve Muffler Replacement 1 Disconnect compressed air supply from the dryer 2 Remove damaged or nonfunctional muffler from valve body 3 Replace muffler by threading into valve body snug fit 41 2 Component Replacement a Blower impellor and fan Motor Replacement 1 Discontinue electric 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 fan and impellor motor forward b Remove the V belts c Remove loosened bolts 4 Remove the bolts from the bushing 5 Insert bolts into the threaded holes 6 Tighten the bolts evenly for motor pulley removal 7 Mark the inside of the motors shaft before removing the bushing 8 Loosen the set screws on the bushing py CNN RM N UE MAN3286 Pd LO PA 10 Measure the mark on the shaft from Step 7 to the end of the shaft and mark the new motors shaft 9 Remove the bushing 11 Slide the motor pulley on to the new blower
15. go through the overload if this overload is tripped i e DOOR the voltage will stop here and not proceed to the blower and fan motor If the overload is nt tripped the voltage will then proceed down to the blower and fan motor 70 5 Heat Circuit Gas Models f j vi f zc ppt CJ p2 IS bos A noe T 2 E M e HV 7 GND 6 WITCH SPARK SPARK 0 r 8 2 MI GAS VALVE a m 111 7 fon a 9 R 2 pm je ses 1 1 4 4 FEN HE 6 J2 B2 2 e e i3 3 QUT L c ey Tel OUT T 6 J2 2 Theory of the HEAT Circuit Gas When the computer senses a drop in temperature below the preset temperature it will send 24 A C volts out of pin 4 of the 15 pin computer harness There are 3 heat safety devices in the dryer that will stop the voltage from reaching the D S I direct spark module The first one the voltage must pass is the 225 thermostat The second one is the 330 burner hi limit thermostat and the third safety device is the sail switch When all three of these safety devices have been satisfied the voltage then arrives at the TH terminal of the D S I module The D S I technical manual P N 450142 will give you more information on what happens at this point once the voltage rea
16. supply air disable valve reverse steps 15 14 13 and 7 through 1 54 I Control Electrical System CAUTION When servicing the HIGH VOLTAGE section of the dryer the ELECTRIC SERVICE MUST BE DISABLED THE EMERGENCY STOP BUTTON 1 Control Electrical System Description a 3 Phase Electrical Power The 3 phase 39 electrical power for the dryer enters the dryer through the power distribution block located in the dryer base electrical box It is then distributed to the blower impellor and fan motor drive tumbler and basket motor and control circuits 1 Blower squirrel cage fan Motor The blower impellor and fan motor circuit consists of a blower motor thermal magnetic overload The overload current is adjustable by a dial located on the face of the overload Refer to the electrical specification diagram for correct current setting Attached to the thermal magnetic starter is an auxiliary contact used to sense an overload trip This produces a safety error so the dryer service is disabled the dryer will not start In series with the thermal magnetic overload is the blower motor contactor This device enables the supply voltage to reach the blower impellor and fan motor The blower motor contactor is controlled by the Phase 5 microprocessor controller computer When 24 VAC is applied to coil A1 A2 the contactor closes and enables the circuit The blower impellor and fan motor used for ADG 200 gas m
17. the dryer If the GAP the ALIGNMENT and the POSITION of the ignitor and flame probe assembly are correct if the gas flow and pressure is constant and consistent if there is no adverse air turbulence and if the DSI module remains in the LOCK OUT mode where the L E D indicator will LIGHT RED CONTINUOUSLY then there is a malfunction with the DSI module itself and it must be replaced 5 Wiring If the DSI module is in the LOCK OUT mode where the L E D indicator will LIGHT RED CONTINUOUSLY 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 DSI system wiring a Check ALL the wiring within the DSI system especially the ground connections at the DSI module and the ignitor and flame probe assembly NOTE Check for any possible damage to the ceramic insulators on the ignitor electrode and the flame probe electrode ofthe ignitor flame probe assembly b Make sure the flame probe electrode of the ignitor and flame probe assembly is positioned no more than one 1 inch maximum from the burner tube CAUTION DO NOT LET THE IGNITOR AND FLAME PROBE ASSEMBLY TOUCH THE BURNER TUBES OTHERWISE THE ENTIRE ASSEMBLY WILL SHORT OUT 25 6 Direct Spark Ignition DSI 24 VAC Transformer The DSI transformer is designed to step down the operating voltage of the dryer to 24 VAC to operate the DSI module This transform
18. the fault is in the Phase 5 OPL microprocessor controller itself If the motor is not operating and the MOTOR output indicator is on then the problem is elsewhere 1 external of the microprocessor controller 3 FWD Output LED Indicator a If the dryer is started and the blower motor is operating but the drive basket tumbler motor is not yet the Phase 5 OPL microprocessor controller display Forward indicator dot is on but the FWD forward motor output LED is off the fault is the Phase 5 OPL microprocessor controller itself b If the drive basket tumbler motor is not operating and the FWD indicator is on then the problem fault is elsewhere i e external of the Phase 5 OPL microprocessor controller 4 REV Output LED Indicator If the dryer is started and the blower motor is operating but the drive tumbler basket motor is not yet the Phase 5 OPL microprocessor controller s display REVERSE indicator dot is on but the REV reverse motor output LED is off the fault is the Phase 5 OPL microprocessor controller itself If the drive tumbler basket motor is not operating and the REV reverse indicator is on then the problem fault is elsewhere i e external of the Phase 5 OPL microprocessor controller 76 5 DOOR LED Indicator The indicator should be on all the time even if the dryer is not returning unless the main door or lint drawer is open or there is a problem open circuit in the ma
19. volts reaches the coil the contactor closes and the incoming voltage that is supplied to the top of the contactor L1 L2 and L3 meets the T1 T2 and T3 of the contactor which then travels down to the soft start via the drive motor The reversing action is projected the same way as the forward with the exception of the 24 A C volts will output from the computer through pin 8 and the connectors in the path of voltage are still J1 and J3 but now pin 8 on both 68 4 Blower Motor Circiut Theory of the Blower Motor Circuit The Blower squirrel cage fan Motor converts the 3 phase 3e power source entering the Blower Motor thermal magnetic overload The overload current is adjustable by a dial located on the face of the overload Refer to the electric specification diagram for correct setting The voltage is then supplied to the top half L1 L2 and L3 of the blower squirrel cage fan contactor Providing the 24 A C volts for the DOOR input to the computer is present on pin 5 of the 15 pin computer harness the computer is going to output that 24 volts on pin 5 upon the start of a cycle which will in turn travel through a couple of connectors and land on the Al marking of the blower and fan contactor This will shut closed sending the three phase voltage to the overload Providing the overload is not tripped the voltage will then travel to the blower and fan motor Path of Voltage for t
20. 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 stop relay which will disable the ENERGIZED POWERED THE DRYER WILL NOT OPERATE The Energizing Stop Push Button is located on the front right electrical panel On 2 Door models this Energizing Stop Push Button is located on the right rear side of the electrical panel when viewed from the rear On dryer models manufactured for 208 volt or 240 volt electric service the step down voltage for the Phase 5 microprocessor controller computer and the Programmable Logic Controller PLC is supplied from the primary side of the 24 VAC transformer On dryers that are manufactured for 380 volts and higher there is an additional secondary on the transformer that is used to supply the step down voltage required to operate the Phase 5 microprocessor controller computer and the Programmable Logic Controller PLC through fuse 4 F4 24 VAC Control Circuit The secondary side of the 24 VAC transformer supplies 24 VAC to various control circuits through fuse 3 F and a 20 amp fuse or an 8 amp fuse fuse amperage rating is dependent on the date that the dryer was manufactured The first circuit is the control voltage on off Control voltage 24 VAC goes through the Master Off
21. ACCESS FOR CLEANING ADJUSTING INSTALLATION OR TESTING OF ANY EQUIPMENT PER OSHA Occupational Safety and Health Administration STANDARDS The information provided will help isolate the most probable component s associated with the difficulty described The experienced technician realizes however that a loose connection or broken shorted wire may be at fault where electrical components are concerned not necessarily the suspect component itself Electrical parts should always be checked for failure before being returned to the factory IMPORTANT When replacing blown fuses the replacement must be of the exact rating as the fuse being replaced The information provided should not be misconstrued as a handbook for use by an untrained person in making repairs WARNING ALL SERVICE and TROUBLESHOOTING SHOULD BE PERFORMED BY A QUALIFIED PROFESSIONAL or SERVICE AGENCY WARNING WHILE MAKING REPAIRS OBSERVE ALL SAFETY PRECAUTIONS DISPLAYED ON THE DRYER or SPECIFIED IN THIS MANUAL A No Display 1 2 EMERGENCY STOP button pushed in Service panel fuses blown or tripped breaker Blown F1 fuse 1 or F2 fuse 2 on right hand control panel Blown F4 fuse 4 on right hand control panel Failed microprocessor controller computer Optional sprinkler circuit emergency relay not engaged a Service panel fuse blown or tripped breaker b Sprinkler circuit is activated NOTE SPRINKLER MUST HAVE POWER FOR T
22. HE DRYER TO OPERATE 58 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 neither forward FWD or reverse REV is on 1 Failed microprocessor controller computer C Drive motor operates in one direction only stops and restarts in the same direction Appropriate microprocessor controller computer relay output indicator is on 1 Failed reversing contactor relay 2 Failed electrical reversing contactor interlock Appropriate microprocessor controller computer relay output indicator is off 1 Failed microprocessor controller computer D Drive motor operates okay for a few minutes and then either repeatedly or occasionally trips the overload protector NOTE WHEN THE OVERLOAD PROTECTOR TRIPS THE MICROPROCESSOR CONTROLLER computer L E D light emitting diode DISPLAY WILL READ door 1 Motor is overheating a Motor air vents clogged with lint b Low voltage to motor c Failed motor d Tumbler basket is binding check for an obstruction e Tumbler bearings are binding f V belts are too tight g Dryer has an oversized load 59 h Voltage to the dryer is incorrect check dryer data
23. If fins are bent straighten by using afin comb which is available from any local air conditioning supply house Inspect and remove any lint accumulation in customer furnished exhaust duct work system and from the dryers internal exhaust ducting NOTE THE ACCUMULATION OF LINT IN THE EXHAUST DUCT WORK CAN CREATE A POTENTIAL FIRE HAZARD NOTE DO NOT OBSTRUCT THE FLOW OF COMBUSTION and VENTILATION AIR CHECK CUSTOMER FURNISHED BACK DRAFT DAMPERS IN THE EXHAUST DUCT WORK INSPECT and REMOVE ANY LINT ACCUMULATION WHICH CAN CAUSE THE DAMPER TO BIND or STICK Clean off any lint accumulation on top of the temperature probe and the hi limit switch located above the lint basket B LUBRICATION MONTHLY 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 fill plug NOTE LUBRICATOR SHOULD BE SET AT 1 DROP PER CYCLE NOTE REGULATOR PRESSURE IS TO BE SET AT 80 PSI Apply high temperature grease to the four 4 1 1 2 diameter tumbler drive shaft pillow block bearings and the two 2 1 3 8 diameter blower shaft pillow block bearings Use Shell Alvania 3 grease or equivalent CDCA E EITT MAN3203 ADJUSTMENTS 7 DAYS AFTER INSTALLATION and EVERY 6 MONTHS THEREAFTER Inspect bolts nuts screws bearing set screws
24. NEAR THE DRYER S CHILDREN SHOULD BE SUPERVISED IF NEAR DRYER S IN OPERATION 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 FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPOR AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE DO NOT DRY MOP HEADS IN THE DRYER DO NOT USE DRYER IN THE PRESENCE OF DRY CLEANING FUMES IMPORTANT PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and or specified in the installation operator s manual included with the dryer Dryer s must not be installed or stored in an area where it will be exposed to water and or weather The wiring diagram for the dryer is located in the front electrical control box area Table of Contents SAFETY PRECAUTIONS e e 09900900990990099099009009900900990990099099009009900900990990099099090999099999 2 ROUTINE MAINTENANCE PPP SPECIFICATIONS and DIMENSIONS tette torta tht eto etna tetro KK KAKA AA KAK KH 8 SECTION IV INSTALLATION REQUIREMEN IS etta ec tiger keke k rek ke ek rek 9 SECTION V COMPONENT DESCRIPTION 11 SECTION VI BASIC TROUBLESHOOTING kune rik k bak Ma eau e eode 58 SECTION VII ELECTRICAL TROUBLESHOOTING codensntonianssenestvensaccsneanatestds 65 SECTION
25. T VISUAL CHECK on page 19 2 Does the main burner ignite If not refer to the SECOND VISUAL CHECK on page 20 3 Does the main burner remain lit after ignition has been established FLAME OUT If not refer to the THIRD VISUAL CHECK on page 21 18 d Troubleshooting Flow Chart Quick Reference First Visual Check Does Ignitor Spark Computer Timer Calls For Heat Is 24 Volts present across DSI Module terminals TH and COM Open circuit to DSI System No Check 24 VAC power source Sail Switch Hi Limit Is spark evident on at Ignitor Assembly Yes Yes Y Go To Chart 2 Check High Voltage HV Lead for nicks or cracking where sparking to ground may occur Is this wire Repair or replace HV Lead Assembly Energize system and check for proper operation Yes damaged No Visually inspect Spark Electrode Assembly Is ceramic cracked or Spark Electrode incorrectly gapped If cracked replace Electrode Assembly Correct gap size Yes is 1 8 1 32 Energize system and check for proper operation No 1 At DSI Ignitor Assembly be sure HV Wire is secure in the boot as well as the connection to the Ignitor Probe Assembly At DSI Module center the end of the HV Wire with a Spike Terminal Energize system and check for proper operation
26. THE DRYER 1 Mark and identify the wires that will be removed for proper reinstallation 2 Press down on the control relay and lift the bottom out and up to remove from the din rail 3 Remove the wires 4 Replace the bad control relay 5 Replace the wires removed from Step 3 6 Mount the top of the control relay to the top of the din rail then press down and snap the bottom into the rail Set the over load 7 Inspect the work performed before reestablishing power electrical service to the dryer F Air Jet Assembly 1 Air Jet Assembly Description The AD 200 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 drawer is opened before the air jet cycle is complete 2 Air Jet Component Replacement a 24 VAC 3 Way Pressure Valve Replacement J VALVE OUrrUn eT MAN3285 1 Disconnect compressed air supply from the dryer 2 Discontinue electric service to the dryer 3 Remove the 1 4 x 1 8 M P T connection from the 3 way pressure valve
27. VIII PHASE 5 OPL SYSTEM DIAGNOSTICS kereke keke de pue KE KA YAR 74 SECTION I SAFETY PRECAUTIONS CAUTION The dryer should never be left unattended while in operation 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 PERSONAL INJURY or FIRE COULD RESULT 1 DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 2 Purchaser user should consult the local gas supplier for proper instructions to be followed in the event the user smells gas The instructions should be posted in a prominent location 3 WHAT TO DO IF YOU SMELL GAS a DO NOT try to light any appliance b DO NOT touch any electrical switch c DO NOT use any phone in your building d Clear the room building or area of ALL occupants e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f If you cannot reach your gas supplier call the fire department 4 Installation and service must be performed by a qualified installer service agency or gas supplier 5 Dryers must be exhausted to the outdoors 6 Although ADC produces a very versatile machine there are some articles that due to fabric composition or c
28. Y PRECAUTIONS displayed on the equipment or specified in the AD 200 Non Tilting Installation Operator s Manual ADC Part No 112142 included with the dryer THE FOLLOWING Pieces OF TEST EQUIPMENT WILL BE REQUIRED To TROUBLESHOOT THIS SYSTEM WITH MINIMAL TIME AND EFFORT DSI IGNITOR GAP FEELER GAUGE 1 8 USED For CHECKING GAP BETWEEN IGNITOR FLAME PROBE ASSEMBLY AND SPARK ELECTRODE MANOMETER USED To MEASURE Gas PRESSURE IN INCHES ee Or WATER COLUMN W C 1 8 E PRESSURE TAP GAS A EZ SEEN EI I es ba aN Y hs Toe PTN N f MA N 2 LL PLASTIC TUBING 1 8 NPT FITTING we Available From ADC fF WITH O ZERO VEL A Zer MULTIMETER VOLTMETER For MEASURING VOLTAGE lt 2 lt 3 lt 4 NNER TUBE 5 lt 8 lt 7 lt 8 8 OUTE UBE 10 t N0707 12 is 4 Available From ADC 15 1 Direct Spark Ignition DSI Troubleshooting Terms definitions a DSI MODULE RED L E D INDICATOR LIGHT this red L E D liquid emitting diode light is located in the upper right corner of the DSI module refer to the top illustration on page 12 This is a diagnostic indicator that simplifies the operational and troubleshooting procedures of the DSI system b LOCK OUT MODE DSI module red L E D indicator light stays on continuously This indicates there is a system fault and most likely the fault is the DSI mod
29. ches the TH terminal on the D S I module Path of Voltage for the HEAT Circuit The 24 A C voltage leaves the computer on pin 4 it then travels to terminal block 2 position 3 Now this voltage travels through connector J2 pin 3 and connector J6 pin 4 After this J6 connector the voltage now is present at the 225 thermostat the voltage then passes through the thermostat and travels through the same two connectors different pin s of course J6 PIN 3 and J2 pin 4 This voltage now is present back on terminal block 2 but now it s position 4 The voltage now passes through J8 pin 1 from here the voltage must go through the other two safety devices the burner thermostat hi limit and the sail switch air flow switch Before it reaches the TH thermostat connection on the D S I module The other side GND of the A C 24 volts from the D S I module travels through J8 pin 2 and then to TB2 7 GND 71 6 HEAT Circuit Steam Models Co N Theory of HEAT Circuit Steam When the computer senses a drop in temperature below the preset temperature it will send 24 A C volts out of pin 4 of the 15 pin computer harness There is one heat safety device in the dryer that will stop the voltage from reaching the steam damper valve The voltage must pass is the 225 thermostat If the 225 thermostat senses a temperature of 225 or higher the vo
30. ck for proper operation Does ignitor spark turn OFF with main burner flame still present Yes Y Control s heat requirements satisfied DSI cycle is complete Yes Does ignitor spark continue with burner flame present e Replace DSI Module t Yes De energize the system and disconnect Flame Sensor from the DSI Module Connect an ohmmeter across the Flame Sensor Sensor and ground Is resistance less than 50 mega ohms No Connect ohmmeter across Flame Sensor lead terminal and Flame Sensor Does continuity exist No Y Replace Flame Sensor Assembly Energize system and check for proper operation Is DSI Module GND terminal properly connected to ground No Y Correct ground wiring Is Flame Sensor Probe properly located in the flame Proper flame location would provide adequate flame current yet will not exceed maximum rod rod temperature Microammeter reads 2 or greater Reposition Flame Sensor Probe to achieve a 2ya or greater sensor current or if unattainable replace the Sensor Probe Assembly No 21 2 Troubleshooting System Detailed Diagnosis When the dryer calls for heat 24 VAC from the step down transformer is applied to the TH and GND terminals of the DSI module The DSI m
31. d be set in the nonactive mode nSEn 4 Hot indicates a possible overheating condition The Phase 5 OPL microprocessor controller monitors the temperature in the dryer at all times If the microprocessor controller detects that the temperature in the dryer has exceeded 220 F 104 C it will disable all outputs shut the dryer down the tone bUZ will sound for approximately 5 seconds and the LED display will read Hot until the temperature has dropped to 220 F or lower and the Phase 5 OPL microprocessor controller is manually reset by pressing the Clear Stop key 74 LED Display Indicators The LED indicator dots located at the top portion of the LED display as shown in the illustration below indicate the Phase 5 OPL microprocessor controller output functions while a cycle is in progress These indicator dots do not necessarily mean that the outputs are functioning They are only indicating that the function output should be active on 1 Blower Motor Circuit Indicator indicator dot is on whenever a cycle is in progress 2 Heat Controller Indicator indicator dot is on whenever the Phase 5 OPL microprocessor controller is calling for the heating circuit to be active on 3 Reversing Indicator indicator dot is on when the drive basket tumbler motor is operating in the reverse mode counterclockwise direction 4 Forward Indicator indicator dot is on when the drive basket tumbler motor is opera
32. d motors both blower fan impellor motor and drive motor Both drive motor and blower fan 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 1 Failed microprocessor controller computer I Microprocessor controller computer L E D light emitting diode display reads dSFL continuously and the buzzer tone sounds every thirty 30 seconds 1 Fault in microprocessor heating sensing circuit Failed microprocessor temperature sensor Blown dSFL 1 8 amp fuse on the microprocessor controller computer Failed microprocessor controller computer Broken wire or connection between the microprocessor controller computer and the micro processor temperature sensor J Microprocessor controller computer L E D light emitting diode display reads door and the microprocessor controller computer DOOR L E D indicator is off 1 Fault open circuit in main door lint drawer switch circuit g h Lint drawer not closed all the way Lint drawer switch is out of proper adjustment Failed lint drawer switch One 1 of the main door switches has failed 1 of the main door switch contact magnets is either missi
33. done by a qualified technician NOTE Undersized gas piping will result in ignition problems and slow drying and can create a safety hazard The dryer must be connected to the type of gas natural or L P indicated on the dryer data label If this information does not agree with the type of gas available contact the distributor who sold the dryer or contact the factory The gas input ratings shown on the dryer data label are for elevations up to 2 000 feet unless elevation requirements of over 2 000 feet were specified at the time the dryer order was placed with the factory The adjustment for dryers in the field for elevations over 2 000 feet are made by changing the burner orifices If this adjustment is necessary contact the distributor who sold the dryer or contact the factory NOTE Any burner changes must be made by a qualified technician C Operational Service Check Procedure After performing any service or maintenance function an operational check should be performed to insure that ALL components are performing properly 1 Make a complete operational check of ALL the operating controls to insure that the timing is correct temperature selection switches are functioning properly 2 Make a complete operational check of ALL safety related circuits door switch es hi limit thermostat sail switch cycling thermostats etc 10 SECTION V COMPONENT DESCRIPTION A Heat Section The AD 200 dryer uses three 3 ty
34. e Device RTD The RTD is located above the tumbler basket The probe is a 100Q ohm platinum RTD As the temperature increases or decreases the resistance value corresponds to the ambient temperature i e 100 32 F 0 1090 75 F 24 b Sprinkler Valve The sprinkler valve is a 2 way air piloted normally closed valve With pilot air pressure applied the valve opens allowing water to flow MAN3187 c Sprinkler Solenoid Valve The sprinkler solenoid valve is a 3 way 2 position solenoid valve that is used to supply pilot air to the sprinkler valve 34 d Sprinkler Digital Temperature Controller The sprinkler digital temperature controller is a programmable microprocessor used to monitor temperatures via a Resistive Temperature Device RTD Master Relay The coil in this relay must be energized in order to close the contacts needed to supply power to the dryers control system Relay 1 The coil in this relay energizes if the set point is reached closing Contact 1 and Contact 2 Contact latches Relay 1 on Contact 2 closes turning on the sprinkler the horn and the reset button light Relay 1 will remain energized until the reset button is pushed Relay 2 The coil in this relay energizes if the set point is reached closing Contact 3 de energizing the Master Relay and shutting power off to the dryer Relay 2 will remain energized until the reset button is pushed
35. e and efficient dryer operation Low inconsistent or too high a gas pressure will result in improper operation of the dryers heat and safety circuits POOR EFFICIENCY CAN CREATE A POTENTIAL SAFETY HAZARD 1 Discontinue electrical power to the dryer 2 Close ALL gas shut off valves in the dryers gas supply line Turn the gas cock dial to the off position on the gas valve 3 Disconnect the gas valve wiring Be sure to identify the correct location of each wire for correct reinstallation 4 Disconnect union connection in the gas supply line IMPORTANT Pipe joint compounds that resist the action of natural gas and L P gas must be used 5 Loosen and remove the screws from the brackets holding the gas valve and manifold assembly to the burner box 6 Remove the gas valve and manifold assembly from the dryer 7 Unscrew the main burner orifices and replace them with the L P orifices provided NOTE Use extreme care when handling removing or replacing orifices THESE ORIFICES ARE MADE OF BRASS and CAN BE EASILY DAMAGED 8 Remove the two 2 screws on the gas valve regulator Remove the regulator and the gasket 9 Install the new gasket and L P regulator Replace the two 2 screws 10 Reverse the procedure for reinstalling the gas valve and manifold assembly to the dryer 11 Open ALL gas shut off valves closed in Step 2 27 12 Reestablish electrical service to the dryer a Test ALL connections for l
36. e hinged steam damper plate to the open position This allows room air to be drawn through the hot steam coil and then through the basket tumbler When the temperature set point has been reached the 24 volt signal is removed from the solenoid valve so that the solenoid valve blocks the air supply to the piston and air in the piston is bled to the atmosphere The spring in the piston now retracts the piston rod closing the steam damper The steam damper plate now covers the steam coil and allows room air to bypass the coil before entering the basket tumbler for a rapid cool down The steam damper plate should open and close slowly and smoothly The speed can be modulated by adjusting the needle valve knob Turning the knob clockwise CW restricts the compressed air flow and slows the steam damper movement Counterclockwise CCW adjustment speeds up the steam damper motion Upon completion ofthe adjustment tighten the needle valve s locking nut 30 2 Steam Damper Actuator System Service and Replacement a Steam Damper Cylinder 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 To install new steam damper cylinder piston reverse above procedure steps 4 through 1 b Steam Solenoid Valve Replacement 1 Disconnect compres
37. e steam coil 11 Unbolt the steam coil and remove 12 Remove the steam coil damper hinges from the old coil and install them on the new steam coil 32 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 16 Reconnect ALL of the piping supply lines and return lines disconnected in Step 8 17 Reinstall steam damper cylinder piston removed in Step 6 18 Reestablish electrical service to the dryer 19 Close the 1 2 plug which was opened in Step 5 20 Open the return line then open the supply line 33 E Sprinkler System Description The AD 200 sprinkler system is monitored by a microprocessor based temperature controller as a designated FAIL 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 Temperature Device RTD reaches 575 F one 1 set of contact in the controller will open disabling the power electric supply to the dryer Another set of contacts will close sounding the alarm and turning on the sprinkler NOTE The sprinkler as well as the alarm will remain on until the amber colored sprinkler reset button is pressed and the temperature in the tumbler basket falls below 575 F 1 Description Of Components m l a Resistive Temperatur
38. eaks IMPORTANT Test ALL connections for leaks by brushing on a soapy water solution liquid detergent works well 28 D Steam Coil System Operation General Overview The ADS 200 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 damper is open ambient air is drawn through the coil providing heat to the dryer When the steam damper is closed ambient air is drawn directly into the tumbler bypassing the coil allowing a rapid cool down Airflow Heating Mode Airflow Airflow MAN3491 Cool Down Mode 1 Steam Coil PH Level The normal PH level for copper type steam coils must be maintained between a value of 8 5 to 9 5 For steel type steam coils the PH level must be maintained between a value of 9 5 to 10 5 These limits are set to limit the acid attack of the steam coils 29 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 compressed air is sent to the piston The piston rod extends pushing th
39. er like ALL transformers is two 2 sided a Primary Side This is the incoming voltage side 208 VAC 230 240 VAC 380 VAC 416 VAC 480 VAC of the transformer b Secondary Side This is the step down side 24 VAC of the transformer If the dryer is above 240 VAC a secondary voltage of 240 VAC will also be present should be checked and confirmed according to the wiring diagram provided with the individual dryer Any damage done to dryer components due to improper voltage connections will automatically VOID THE WARRANTY IMPORTANT The ADC Service Department must be contacted prior to any wiring change or conversion because depending on the change or conversion required some parts may have to be added deleted or changed When contacting the ADC Service Department they must be given the correct model and serial numbers for the dryers NOTE Any wiring changes or conversions should be accomplished by a QUALIFIED ELECTRICAL TECHNICIAN 26 C Natural Gas To L P Liquid Propane Gas Conversion Instructions IMPORTANT CONVERSION MUST BE PERFORMED BY COMPETENT TECHNICIANS IN ACCORDANCE WITH LOCAL and STATE CODES NOTE Converting the dryer to L P Gas disables the internal regulator of the gas valve there fore an external regulator must be provided at the source of the L P gas supply L P tank or the dryer The water column W C gas pressure must be regulated to between 10 5 inches and 11 inches for saf
40. etic starter simply remove the screw To remove the style with a clip simply push in the clip and remove 5 To install new auxiliary contact block reverse above procedure steps 4 through 1 b Varistor MOV The Varistor MOV Metal Oxide Varistor is used to suppress any inductive electrical spikes produce by the energizing and collapsing of the coil voltage 1 Varistor MOV Replacement a Discontinue electric service to the dryer b Loosen the screws marked Al and A2 from the varistor c Remove the varistor d Reverse procedure to install new varistor 47 Filter Regulator Assembly The purpose of the filter is to remove bulk liquids and solid particles from the compressed air stream The filter element provides mechanical separation of solids Centrifugal force inside the filter bowl separates bulk liquids and larger solid particles The filter consists of a louver which causes a centrifugal spinning action to separate contaminants A filter which mechanically separates contaminants is also present The filter bowl collects the contaminants and a baffle prevents turbulence from picking up contaminants at the bottom of the bowl and returning them to the air stream 1 Filter Maintenance a To remove filter element Twist the filter bowl 1 8 turn clockwise CW Then pull the bowl down to expose the filter element To remove the filter element unscrew the baffle this will allow element removal
41. f Valves in the open position Yes Y Turn manual knob on the Gas Valve to the OFF position Connect a manometer to the Gas Valve outlet pressure tap Correct supply pressure Energize system and check for proper operation Turn manual knob on the Gas Valve to the ON position Energize the system Is outlet pressure detected With System energized is 24 VAC present Yes Is outlet Water Column W C pressure correct Natural 3 5 4 0 W C L P 10 5 11 0 W C Yes Check Spark Electrode for proper gap and insure that the spark is in the path of the gas flow Refer To Service Section No across the MV and GND terminals of the DSI Module No Yes Y Y Replace High Replace Voltage HV DSI Module leads Energize system and check for proper operation 20 Make the necessary corrections Energize system and check for proper operation Troubleshooting Flow Chart Quick Reference Third Visual Check Does Main Burner Ignite Does the Flame Probe have carbon or dust build up Does main burner remain lit No No Yes Yes Remove Flame Sensor Assembly Clean the surface of the Flame Sensor Rod with fine steel wool or emery cloth then reinstall Energize system and che
42. from the gas valve a DSI Ignitor and Flame Probe Assembly Adjustments 1 The GAP on the ignitor and flame probe assembly must be set and held at 1 8 1 32 1250 03121 If this GAP is not maintained if the GAP is either to large or to small the DSI module will indicate a system malfunction and go into the LOCK OUT mode the L E D will LIGHT RED CONTINUOUSLY 23 a b To check or set the 1 8 GAP use DSI Feeler Gauge or similar device to determine 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 The ALIGNMENT of the ignitor and flame probe assembly in relation to the GAP on the ignitor electrode and ground rod must be maintained in as vertical straight line a position as possible refer to the illustration below otherwise the DSI module will indicate a system malfunction and go into the LOCK OUT mode the L E D light emitting diode indicator will LIGHT RED CONTINUOUSLY The POSITIONING of the ignitor and flame probe assembly is extremely important because it provides the necessary feedback information to the DSI module The flame probe electrode must be POSITIONED 1 4 minimum into the flame path refer to the illustration below and must be POSITIONED one 1 inch maximum from the burner tube refer to the illustration below otherwise the DSI module will indicate
43. he Blower Fan Motor Circuit Three phase voltage is applied to the power distribution block each line L1 L2 and L3 The voltage then travels to the Blower squirrel cage fan thermal magnetic overload The voltage is then supplied to the blower and squirrel cage contactor marked L1 L2 and L3 As long as the fuses overload is not tripped 208 600 volts will always be there at the contactor When the computer calls for the fan to come on 24 A C volts will output of pin 5 of the computer This 24 A C volts will pass through J1 and J3 connectors pin 5 on both and travel to the coil of the blower squirrel cage fan contactor the contactor will be marked Al The other side of the coil A2 will be directly grounded When the 24 A C volts reaches the coil the contactor closes and the incoming voltage that is supplied to the top of the contactor L1 L2 and L3 meets the T1 T2 and T3 of the contactor which then must go through the overload If this overload is tripped i e DOOR the voltage will stop here and not proceed to the blower squirrel cage fan motor If the overload is not tripped the voltage will then proceed down to the blower squirrel cage fan motor 69 Theory of the Blower Motor Circuit The incoming voltage L1 L2 and L3 are supplied to the power distribution block Each line of this 3 phase voltage is then fused with cartridge type fuses rated for the different incomings voltages The
44. he incoming voltage to the machine is applied to the power distribution block lines L1 L2 and L3 From there this voltage travels to the contactors drum and blower motor L1 and L3 branch off of this voltage and travel to a step down transformer if the incoming voltage is 380 volts or higher If your incoming voltage is 208 240 volts this transformer is not needed After the transformer if applicable the L1 and L3 lines are both fused with 5 amp slo blo fuses The L1 L3 voltage now travels to the little 3 position terminal block A B C letters A and B then to the J3 connector numbers 7 and 13 from there to the J1 connector 7 and 13 finally to the microprocessor 15 pin connector pin s 7 and 13 This is the path of voltage for the microprocessor s display Always check the two 5 amp fuses first these are the most common parts to fail when checking this circuit 65 IOPROSSESOR 2 DOOR Circuit Ak Theory of the DOOR Circuit Providing that the 4 amp fuse the 24 volt transformer and the overloads drive and blower are okay 24 A C volts will be supplied to the COM terminal of the door switch relay This 24 volts is branched off through the lint drawer switch and the two magnetic door switches to then supply the 24 volts to the coil of the door switch relay The relay will now close sending the 24 A
45. he module has confirmed that the DSI module is functional b DSI module L E D indicator lights red continuously LOCK OUT MODE This indicates that there is a system fault and most likely the fault is internal to the DSI module To make sure open and close the main door Restart the dryer if the module LOCKS OUT red L E D indicator light stay on continuously again replace the DSI module 16 If the dryer repeatedly has DSI module LOCK OUT failures the cause may be due to high voltage not getting into the DSI module probe circuit 1 Check to insure that the red high voltage wire between the ignitor spark electrode and the DSI module is not wrapped around the sensor probe wire the wire between the DSI module FP terminal and the ignitor and flame probe assembly f the wires are touching one another separate and secure in place AWAY FROM ONE ANOTHER 2 Check to insure that the dryer is properly grounded and that the ground connections GND to the DSI module are secure 3 If the problem persists it is most likely to be in the external components not the DSI module or wiring due to a FLAME OUT proceed as follows a Disconnect the electrical power to the dryer b Visually check the DSI module components for visual damage c Check wiring for loose connections nicks or cracking at the ceramic insulator or shorting of the sensor to the burner d Inspect the DSI ignitor and flame probe a
46. in door or lint drawer circuit NOTE Ifthe dryeris started LED display indicator dots are on and there are no outputs heat or motor output LEDs are off and the dOOr input LED is on the fault is inthe Phase 5 OPL microprocessor controller itself Ifthe failure was elsewhere 1 e dryer s door switch circuit the LED display would read dOOr if a keyboard entry was attempted If the LED display indicators are on the door LED input and motor or heat output LED s are on and the motor or heat is not active on then the problem is not the door switch circuit or the Phase 5 OPL microprocessor controller andis elsewhere in the dryer 77 American Dryer Corp ADC 450310 1 07 28 99 25
47. ing relay coil This cycle done latching relay closes passing through the 24 volts from the door switch circuit to the done light flasher causing the done light to flash Path of Voltage for the CYCLE DONE Circuit The 24 A C volts for this circuit is taken off the air jet terminal on the computer board The voltage then travels to TB1 8 from there it supplies the coil voltage for the air jet sense relay The COM terminal of the relay is connected to TB1 2 which is supplied with 24 A C volts when the door switch circuit is complete Now with the relay energized the 24 A C volts applied to the COM terminal of the relay will be present on the NO terminal via TB1 6 which now energizes the pin 1 of the 1 sec flasher The output of the flasher PIN 4 will be connected to the DONE LIGHT and with the other terminal of the DONE LIGHT grounded via TB1 7 the light will flash in 1 second intervals 73 SECTION VIII PHASE 5 OPL SYSTEM DIAGNOSTICS ALL major circuits including door microprocessor temperature sensor heat and motor circuits are monitored The Phase 5 OPL microprocessor controller will inform the user via the LED display of certain failure codes along with indicators both in the LED display and the outputs of each relay and door switch circuit to easily identify failures Diagnostic LED Display Failure Codes 1 door indicates door switch circuit is open a Keyboard entry was made while main door or lint dra
48. input front doors closed 56 c Lint Drawer Closed circuit branch The lint drawer closed switch is located in the front of the dryer When the lint drawer is closed it closes the switch contacts powering the lint drawer closed relay Then the dry enable relay will close supplying 24 VAC to the Phase 5 microprocessor computer door signal This sequence will occur only if the following conditions are met 1 Blower impellor and fan Motor Overload is not tripped 2 Drive tumbler and basket Motor Overload is not tripped 3 Doors are closed 4 Lint Drawer is closed 5 Dryer is level 6 Phase 5 Microprocessor Controller computer The Phase 5 microprocessor controller computer is powered by 240 VAC on pins 7 and 13 A jumper wire on pins 1 to 11 is required to configure the transformer for 240 VAC The temperature sensor probe is a bullet shaped device that is located above the lint basket This temperature probe is used to sense the temperature in the exhaust of the dryer The temperature sensor is a two 2 terminal monolithic integrated circuit temperature transducer that provides an output current proportional to absolute temperature The transducer acts as a high impedance temperature dependant current source of ImA K 57 SECTION VI BASIC TROUBLESHOOTING IMPORTANT YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW
49. l split From here it will go to the door switch relay com terminal and it will also travel through some connectors see the diagram above for particular connectors and there pin s and land on one terminal of the lint drawer switch This is another spot to check if DOOR appears on the display The voltage will then pass through the lint drawer switch providing the lint drawer is closed go through a few connectors see above diagram and land on one pin of the magnetic door switch Here we use two magnetic type door switches When the door is closed there are magnets on the door that should be adjusted so that when the door is closed the magnets are positioned above the pick ups door switches The two magnetic proximity switches door switches are in series they both need to sense the magnets or the voltage will stop here and read DOOR From the two door switches the voltage travels through a few more connectors see above diagram and it s final destination is one side of the coil of the door switch relay The other side of this coil is hard wired to ground to complete this circuit 66 3 Drive Motor Circuit Theory of the Drive Circuit The Drive tumbler and basket Motor converts the 3 phase 30 power source entering the drive motor thermal magnetic overload The overload current is adjustable by a dial located on the face of the overload
50. label touchpad assembly O Dryer stops during a cycle microprocessor controller computer buzzer tone sounds for five 5 seconds L E D light emitting diode display reads dSFL for approximately thirty 30 seconds and then returns to FILL 1 Loose connection somewhere between the microprocessor controller computer and the micro processor temperature sensor 62 P Dryer stops during a cycle microprocessor controller computer buzzer tone sounds for a few seconds and then microprocessor controller computer L E D light emitting diode returns to FILL 1 Loose connection somewhere in the main power circuit to the microprocessor controller computer 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 Tumbler basket not rotating 1 Broken tumbler basket drive belt 2 Failure in drive motor circuit b Bad rotation sensor c Broken wire or connection between rotation sensor and microprocessor controller computer d Magnet missing or gap to large R Microprocessor controller computer L E D light emitting diode reads Hot 1 Possible overheating condition microprocessor controller computer has sensed a temperature which has exceeded 220 F Hot display will not clear until temperature sensed has d
51. label for specified voltage 2 Failed overload protector E Impellor fan motor is not operating does not start door L E D is on Microprocessor controller computer MTR relay output indicator is on 1 Failed blower impellor and fan motor fuses or overloads 2 Failed blower impellor and fan motor contactor relay 3 Failed blower fan and impellor motor Microprocessor controller computer MTR relay output indicator is off 1 Failed microprocessor controller computer F Blower fan and impellor motor operates okay for a few minutes and then either repeatedly or occasionally trips the overload protector NOTE WHEN THE OVERLOAD PROTECTOR TRIPS THE MICROPROCESSOR CONTROLLER computer L E D light emitting diode DISPLAY WILL READ 66 d oor 99 1 Motor is overheating a Motor air vents clogged with lint b Low voltage to motor c Failed motor d Tumbler basket is binding check for an obstruction e Failed gear reducer or tumbler bearing f V belts are too tight h Motor is running at incorrect voltage 2 Failed overload protector Both drive motor and blower fan impellor motor are not operating microprocessor controller computer L E D light emitting diode motor indicator dots and the MTR relay output and forward FWD or reverse REV L E D indicators are on 1 Blown drive motor and blower fan and impellor motor fuses 60 2 Faile
52. lated 80 PSI 10 psi air supply equivalent volume 6 cfh SECTION IV INSTALLATION 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 NATIONAL STANDARDS National Fuel Gas Code ANSI Z223 1 LATEST EDITION or National Electric Code ANSI NFPA No 70 LATEST EDITION A Enclosure Air Supply and Exhaust Requirements NOTE The following information is very brief and general For detailed description refer to the AD 200 Non Tilting Installation and Operator s Manual ADC Part No 112142 included with the dryer Bulkheads and partitions around the dryer should be made of noncombustible materials Allowances should be made for the opening and closing of the control door and lint door Also allowances should be made in the rear for ease of maintenance Refer to appropriate Installation Manual ADC Part No 112142 for recommended distances and minimum allowances required When the dryer is operating it draws in room air heats it passes this air through the basket tumbler and exhausts it out of the building Therefore the room air must be continually replenished from the outdoors Ifthe make up air is inadequate drying time and drying efficiency will be adversely affected Ignition problems and sail switch fluttering problems on gas dryers may result and you also could have pre
53. leaning method should not be dried in it WARNING Dry only water washed fabrics DO NOT dry articles spotted or washed in dry cleaning solvents a combustible detergent or all purpose cleaner EXPLOSION COULD RESULT WARNING DO NOT dry mop heads Contamination by wax or flammable solvent will create a fire hazard WARNING 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 should be established for the inspection and cleaning of lint in the burner area exhaust duct work and area around the back of the dryer The frequency of inspection and cleaning can best be determined from experience at each location WARNING The collection of lint in the burner area and exhaust duct work can create a potential fire hazard 8 For personal safety the dryer must be electrically grounded in accordance with local codes and or the NATIONAL ELECTRIC CODE ANSI NFPA NO 70 LATEST EDITION NOTE Failure to do so will VOID THE WARRANTY 9 UNDER NO CIRCUMSTANCES should the dryer door switches lint drawer switch or heat safety circuit ever be disabled 10 This dryer is not to be used in the presence of dry cleaning solvents or fumes 11 Remove articles from the dryer as soon as the drying cycle has been completed WARNING Articles left in the dryer afte
54. ltage will stop here at the thermostat Once the temperature drops the thermostat closes and the voltage will now be able to reach the steam damper valve Path of Voltage for the HEAT Circuit Steam The 24 A C voltage leaves the computer on pin 4 it then travels to terminal block 2 position 3 Now this voltage travels through connector J2 pin 3 and connector J6 pin 4 After this J6 connector the voltage now is present at the 225 thermostat the voltage then passes through the thermostat and travels through the same two connectors different pin s of course J6 pin 3 and J2 pin 4 This voltage now is present back on terminal block 2 but now it s position 4 The voltage now passes through J8 pin 1 then directly to the steam damper valve The other side GND side of the A C 24 volts from the steam damper valve travels through J8 pin 2 and then to TB 7 GNDD 72 7 Cycle Done Circuit COM COM Theory of the CYCLE DONE Circuit When the dryer has come to the end of the drying cooling cycle of the dryer the air jet spade terminal on the microprocessor will be energized with 24 A C volts This 24 A C volts will then be present across the coil of the air jet sensor relay The relay closes and the 24 volts from the door circuit passes through the air jet sense relay via cycle done latch
55. mature motor failure from overheating The air supply must be given careful consideration to insure proper performance of each dryer IMPORTANT Make up air must be provided from a source free of dry cleaning fumes Make up air that is contaminated by dry cleaning fumes will result in irreparable damage to motors and other dryer components Exhaust duct work should be designed and installed by a competent technician Improperly sized duct work will create excessive back pressure which will result in slow drying increased use of energy and shutdown of the burner by the airflow sail switch burner hi limit or lint chamber hi heat protector thermostat Refer to appropriate Installation Manual ADC Part No 112142 for more detail CAUTION IMPROPERLY SIZED OR INSTALLED EXHAUST DUCT WORK CAN CREATE A POTENTIAL FIRE HAZARD B Electrical 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 ALE electrical connections material and workmanship must conform to the applicable requirements of the National Electric Code ANSI NFPA No 70 LATEST EDITION The dryer installation must meet the AMERICAN NATIONAL STANDARD National Fuel Gas Code ANSI Z223 1 LATEST EDITION as well as local codes and ordinances and must be
56. nd LIQUIDS NOTE Suggested time intervals shown are for average usage which is considered six 6 to eight 8 operational running hours per day SUGGESTED CLEANING SCHEDULE EVERY THIRD or FOURTH LOAD Clean the lint basket A clogged lint basket will cause poor dryer performance The lint basket is located in the lint drawer in the base of the dryer Pull out the lint drawer brush the lint off the lint basket and remove the lint Inspect the lint screen and replace if torn NOTE The frequency ofcleaning the lint screens can best be determined from experience at each location WEEKLY Open the hinged panels on each side of the tumbler section and remove any lint accumulation from the tumbler drive motor drive shafts drive wheels and drive shaft bearings Slide the lint basket all the way out of the dryer and clean any lint accumulation off of the temperature sensor bracket which is located above the lint basket WARNING TO AVOID THE HAZARD OF ELECTRICAL SHOCK DISCONTINUE ELECTRICAL SUPPLY TO THE DRYER MONTHLY Empty the compressed air filter bowl Clean any lint accumulation from the gas valve burner area at the top of the dryer the fan impellor motor and the fan impellor bearings located in the dryer base EVERY 6 MONTHS STEAM MODELS clean the steam coil fins We suggest using compressed air and a vacuum cleaner with brush attachment NOTE When cleaning steam coil fins be careful not to bend the fins
57. ng or is broken Failed door switch relay Broken wire or connection in main door or lint drawer switch circuit Drive motor or blower fan and impellor motor thermal overload reset has tripped 2 Failed 24 VAC step down transformer 3 Blown 24 VAC control circuit fuse 61 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 diode display reads FILL and when keyboard touchpad entries are selected the L E D light emitting diode display continues to read FILL 1 Failed keyboard label touchpad assembly 2 Failed microprocessor controller computer M Microprocessor controller computer will only accept certain keyboard touchpad entries 1 Failed keyboard label touchpad assembly 2 Failed microprocessor controller computer N Microprocessor controller computer locks up and L E D light emitting diode display reads erroneous message s or only partial segments 1 Transient power voltage spikes disconnect the electrical power to the dryer wait one 1 minute and reestablish power to the dryer If problem is evident a Failed microprocessor controller computer b Failed keyboard
58. nitor and Flame Probe Assembly is located in the burner flame area and is used to ignite the gas by use of a high voltage spark approximately 14 000 volts and to provide feedback information to the DSI Module as to whether the burner flame is evident on c The Burner Hi Limit Switch is a thermostat type switch located in the burner Its function is to discontinue heat flame in the event of an over temperature situation above 330 F d The Sail Switch Assembly is located on the burner downstream of the flame tubes Its function is to detect whether or not there is sufficient air flow through the dryer 12 9 Direct Spark 27 Ignition Control pe B ti 24 VAC Direct Spark Ignition DSI Module DSI IGNITOR FLAME PROBE VOLAGE CONNECTOR MAN3484 330 F_Thermostat Sail Switch Assembly e The Tumbler 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 225 MAN3484 225 Thermostat f The gas valve used in the ADG 200 is of the redundant type which means that the gas valve is actually two gas valves in one one in series with the other This is a safety feature which provides protection against gas flow in the event that one of the valves does not seat properly The val
59. nonpermanent gas connections i e unions shut off valves orifices and grounding connections Fan impellor V belts along with the motor and drive belts should be examined and replaced if necessary Tighten loose V belts when necessary Complete operational check of controls and valves Complete operational check of ALL safety devices 1 e door switches lint drawer switch sail switch burner and hi limit thermostats SECTION III SPECIFICATIONS and DIMENSIONS A SPECIFICATIONS Gas and Steam Models MAXIMUM CAPACITY DRY WEIGHT 200 lbs 90 9 kg BASKET TUMBLER DIAMETER 62 1 2 158 75 cm BASKET TUMBLER DEPTH 42 106 7 cm BASKET TUMBLER WOLUME 74 5 cu ft 2 11 cu m DRivE Motor 3 HP 2 24 kw BLOWER MOTOR GAS STEAM 7 1 2 HP 15 HP 5 6 kw 11 2 kw Door OPENING 36 3 4 Wm x 43 93 3 cm x 109 2 cm Door SILL HEIGHT LEVEL 37 1 4 94 6 cm COMPRESSED AIR 80 PSI 5 63 kg cu m COMPRESSED AIR CONNECTION 3 8 F P T 953 cm VOLTAGE AVAILABLE 208 460v 3g 3 4w 50 60 Hz pA 750 000 btu hr 189 000 kcal hr Approx WEIGHT UNCRATED 3 369 Ibs 1 528 kg _ E pus EDS 318 em 208 460v 3g 3 4w 50 60 Hz APPROX WEIGHT UNCRATED 3 719 Ibs 1 687 kg y 6 500 cfm 184 P 890 tov AAS REL 2 STEAM SUPPLY STEAM RETURN 125 psi 8 79 kg sq cm 1 1 2 3 81 cm 3 4 1 91 cm Shaded areas are stated in metric equivalents Dryer must be provided with a clean dry regu
60. o the dryer e Fan impellor Shaft Replacement The procedure to replace the Fan Shaft is the same procedure used to replace the Shrouded Pillow Block Bearing refer to pages 43 and 44 3 Blower impellor and fan Electrical Components a Blower impellor fan Controls and Overloads 1 Thermal Magnetic Starter TMS The thermal magnetic starter is used as a safety device to protect the motor from starting in a locked rotor condition The overload has a dial setting on the face of the device To set the overload refer to your specific electrical diagrams The overload is specifically designed for motor applications It has a current curve built into it so the initial high current draw by the motor will not trip the overload On the face of the overload there are two 2 push buttons START Black or Tan 1 and STOP Red 0 the overload has to be in the START mode for the motor to run 45 a Blower impellor fan Controls and Overloads 1 Thermal Magnetic Starter TMS The thermal magnetic starter is used as a safety device to protect the motor from starting in a locked rotor condition The overload has a dial setting on the face of the device To set the overload refer to your specific electrical diagrams The overload is specifically designed for motor applications It has a current curve built into it so the initial high current draw by the motor will not trip the overload On the face of the overload there are two 2 push butt
61. odel dryers is 7 1 2 HP horsepower and for ADS 200 steam model dryers is 15 HP horsepower The motor wiring configuration is dependent on the specific voltage of the dryer When wiring the motor refer to the motor nameplate 2 Drive tumbler basket Motor The drive tumbler and basket motor converts the 3 phase 30 power source entering the drive motor thermal magnetic overload The overload current is adjustable by a dial located on the face of the overload Refer to the electrical specification diagram for correct current setting In this circuit the drive motor contactor follows the thermal magnetic overload The drive motor has two 2 separate sets of coils and two 2 separate sets of contacts One 1 of these sets is for forward tumbler basket and drum rotation and the other for reverse tumbler basket and drum rotation The thermal magnetic overloads and the contactors are located in the left hand electrical cabinet The direction of the drive motor is determined by the phases going into the motor i e in a reverse direction phase L1 and L2 are switched When viewing this contactor the left hand block connections are for the forward rotation direction clockwise CW when viewed from the front of the dryer The drive tumbler and basket motor is a 3 HP horsepower motor Refer to the motor nameplate for specific terminal box wiring 55 3 4 5 24 VAC Transformer The 24 VAC transformer consists of fuse
62. odule L E D light emitting diode indicator will light red for up to approximately 1 5 seconds prepurge then the L E D indicator will light green the gas valve will be energized and the spark burst will be evident on for approximately 8 seconds at the tip of the electrode flame probe assembly Flame should now be established and confirmed If a flame is not sensed and confirmed by the ignitor and flame probe sensor after the approximate 8 second spark burst the DSI module will go into the LOCK OUT mode and the L E D will light red continuously THERE ARE NO RETRIES NOTE To reset the DSI module if it is in the LOCK OUT mode open and close the main door then restart the dryer If a flame has been established confirmed and then lost the DSI module L E D indicator will continue to light green and immediately a spark will be evident on for approximately 8 seconds The flame should now be established confirmed If a flame is not sensed confirmed by the ignitor flame probe sensor after the approximate 8 second spark burst the DSI module will go into the LOCK OUT mode and the L E D will light red continuously THERE ARE NO RETRIES NOTE To reset the DSI module if it is in the LOCK OUT mode open and close the main door then restart the dryer a System Diagnosis 1 Gas Pressure A gas pressure test should be taken at the gas valve pressure tap provided on every gas valve to assure that the water column W C pre
63. ons START Black or Tan 1 and STOP Red 0 the overload has to be in the START mode for the motor to run a Thermal Magnetic Starter TMS Replacement 1 Discontinue electric 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 To remove the thermal magnetic starter pull the tab its bottom and lift upward 5 To install new thermal magnetic starter reverse above procedure steps 4 through 1 MAN3283 46 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 computer a Auxiliary Contact Block Replacement 1 Discontinue electric service to the dryer 2 Remove the auxiliary contact block from the din rail by pulling the tab on the bottom of the contact block and lifting upward 3 Remove the two 2 wires going to the auxiliary contact block and label for correct reinstallation 4 There are two 2 types of auxiliary contact blocks one with a screw and the other with a clip To remove the style with the screw with a thermal magn
64. ove the bolts securing the fan blower shaft bearing mount assembly a Slide the fan shaft assembly with the fan impellor and blower backwards Remove the two 2 left hand jam nuts and the washer Remove the squirrel cage fan impellor and the 1 4 x 1 4 x 1 3 4 key Remove the four 4 bolts securing the shrouded pillow block bearing Remove the fan blower shaft assembly from the fan blower shaft bearing mount assembly a Remove the pillow block on the squirrel cage fan side of the fan shaft by loosening the set screws on the pillow block bearing To remove the pillow block bearing on the pulley side of the fan shaft the pulley must be removed first a Remove the V belts from the bushing b Insert bolts into the threaded holes d Mark the inside of the motors shaft before removing the bushing 43 e Loosen the set screws on the bushing f Remove the bushing and the pulley 11 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 the set screws in the shrouded pillow block bearing 13 Reinstall the bushing and the pulley a Line up the bushing to the mark on the motor shaft and tighten and secure the set screw b Reinstall the bolts into the original holes and tighten evenly for correct pulley installation 14 Reposition the blower fan and impello
65. pes of heat sources natural gas liquid propane L P gas and steam Natural gas and L P 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 ADG 200 gas dryers utilizes a Direct Spark Ignition DSI module to monitor that a flame is established If for some reason the flame signal is lost the DSI module will shut off the gas valve and not retry ignition no try to restart the flame A spark of approximately 14 000 volts is used to establish a flame The DSI module will turn the gas valve on and ignitor and flame probe will spark for 8 seconds attempting a flame Each time the dryer calls for heat the microprocessor controller computer will send a 24 VAC signal through the exhaust hi limit sail switch and oven hi limit At that point the DSI module will try for ignition DIRECT SPARK IGNITION DSI SYSTEM COMPONENTS FUNCTIONS LED LEL Q jb 11 a The Direct Spark Ignition DSI Module is a 24 VAC 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 on flame verification etc Additionally the DSI Module has self diagnostic capabilities b The Ig
66. piping is filled with air so it may take a few minutes for the air to be purged from the supply lines During this purge period there may be insufficient gas pressure for ignition which might cause the DSI module to go into the LOCK OUT mode the L E D light emitting diode will LIGHT RED CONTINUOUSLY NOTE During the purge period check to be sure that ALL shut off valves are open NOTE To reset the DSI module if it is in the LOCK OUT mode open and close the main door then restart the dryer c If gas pressure is low unscrew slotted regulator cover on top of the gas valve and turn regulator pressure adjustment screw located underneath the cover clockwise CW to increase the pressure 2 Ignitor and Flame Probe Assembly The ignitor and flame probe assembly consists of a ceramic insulated ignitor electrode a ground rod and a ceramic insulated flame probe electrode The GAP between the ignitor electrode and the ground rod is set and must be maintained at 1 8 1 32 1250 03121 When the DSI module provides the high synchronous spark 14 000 volts through the high voltage HV lead a spark is produced over the GAP When this spark is produced the gas valve is opened Upon ignition the flame probe electrode ofthe ignitor flame probe assembly has high voltage provided to it that supplies a small current to ground through the flame Once the current is sensed it initializes the DSI module to sustain the gas flow
67. r motor to its original position a Tighten hand tight only the bolts into the motor and the motor base b Slide the blower fan and impellor motor forward Align the pulleys before installing the V belts 15 When V belts are properly tensioned tighten the motor to the motor base 16 Reestablish electric service to the dryer c Squirrel Cage Fan impellor Replacement 1 Discontinue electric service to the dryer 2 Remove the bolts securing the blower fan and impellor motor 3 Remove the V belts 4 Slide the blower fan and impellor motor to the side 5 Remove the bolts from the fan blower shaft bearing mount assembly a Slide the fan blower shaft bearing mount assembly backwards 6 Remove the two 2 left hand jam nuts and the washer 7 Remove the 1 4 x 1 4 x 1 3 4 key on the fan impellor shaft a Slide the squirrel cage fan impellor off of the shaft 8 To install new squirrel cage fan impellor reverse above procedure steps 6 through 1 d V Belt Replacement 1 Discontinue electric service to the dryer 2 Loosen the bolts securing the blower fan and impellor motor a Ease off on the tension bolt 3 Slide the blower fan and impellor motor forward 4 Remove and replace V belts 5 Tighten the tension bolt 6 Using a straight edge make certain that the motor pulley and V belts are aligned straight 7 Tighten bolts from motor to motor base 8 Reestablish electric service t
68. r the drying and cooling cycles have been complete can create a fire hazard 1 12 READ and FOLLOW ALL CAUTION and DIRECTION LABELS ATTACHED TO THE DRYER WARNING 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 STANDARDS IMPORTANT Label ALL wires prior to disconnection when servicing the microprocessor controller computer and the ignition module WIRING ERRORS CAN CAUSE IMPROPER and DANGEROUS OPERATION 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 upon proper air circulation The accumulation of lint can restrict this air flow If the guidelines in this section are met an ADC dryer will provide may years of efficient trouble free and most importantly safe operation WARNING LINT FROM MOST FABRICS IS HIGHLY COMBUSTIBLE THE ACCUMULATION OF LINT CAN CREATE A POTENTIAL FIRE HAZARD WARNING KEEP DRYER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE and OTHER FLAMMABLE VAPORS a
69. rom the computer through pin 8 and the connectors in the path of voltage are still J1 and J3 but now pin 8 on both 67 FUSE 1 MAN4518 Theory of the Drive Circuit The incoming voltage L1 L2 and L3 are supplied to the power distribution block Each line of this 3 phase voltage is then fused with cartridge type fuses rated for the different incoming voltages The voltage is then supplied to the top half L1 L2 and L3 of the reversing contactor Providing the 24 A C volts for the DOOR input to the computer is present on pin 2 of the 15 pin computer harness the computer is going to output that 24 volts on pin 3 forward or pin 8 reverse of the pin computer connector Path of Voltage for the Drive Circuit Three phase voltage is applied to the power distribution block each line L1 L2 and L3 the voltage then travels to the drive motor thermal magnetic overload The voltage is then supplied to the reversing contactor marked L1 L2 and L3 As long as the overload is not tripped 208 600 volts will always be here at the contactor When the computer calls for the forward motion of the basket 24 A C volts will output of pin 3 of the computer This 24 A C volts will pass through it and J1 and J3 connectors pin 3 on both and travel to the forward coil of reversing contactor the contactor will be marked Al The other side of the coil A2 will be directly grounded When the 24 A C
70. ropped to 220 F or lower and the microprocessor controller computer is manually reset by pressing the CLEAR STOP key S No heat for STEAM MODELS ONLY both microprocessor controller computer L E D light emitting diode heat indicator dot and the HEAT relay output L E D are on 1 Fault in 225 hi heat limit switch circuit or thermostat 2 No external compressed air to steam damper 80 PSI required 3 Failed steam damper 24 VAC pneumatic solenoid valve 4 Failed steam damper pistons 5 Steam damper stuck closed T Dryeroperates but is taking too long to dry 1 Exhaust duct work run is too long or is undersized back pressure cannot exceed 3 inches water column W C 2 Restriction in duct work check duct from the dryer all the way to the outdoors 3 Low and or inconsistent gas pressure for GAS MODELS ONLY 63 10 11 12 13 14 Insufficient make up air Poor air gas mixture at burner yellow or poor flame pattern Burner orifices not aligned properly in burner tubes for GAS MODELS ONLY Lint drawer screen is not being cleaned on a regular basis or often enough Extractors washer not performing properly Sail switch is fluttering restriction in exhaust for GAS MODELS ONLY Failed microprocessor controller computer temperature calibration is inaccurate Failed microprocessor temperature sensor calibration is inaccurate Failed burner hi limi
71. rs 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 November 1 1995 there are trolley bolts located at the top of the doors to secure the doors onto the track b For dryers manufactured prior to November 1 1995 there are two 2 adjustment plates located at the top of the doors to secure the doors onto the track In the center portion on the top of the doors there is a magnet used in conjunction with proximity sensors which are mounted above the doors 2 Pneumatic Automatic Description and Operation a Description The Pneumatic Automatic Doors run on a single aluminum track mounted above the doors and a split track mounted on the bottom of the doors The doors are held on the track by four 4 stainless steel wheel assemblies located on the top of the doors Additionally in the center portion on the top of the doors there is a magnet used in conjunction with proximity sensors which are mounted above the doors b Operation There are two 2 1 bore x 18 3 8 stroke cable cylinders attached to the top of the doors to pneumatically open and close the doors When air is applied into the outside ports of these cable cylinders the doors will open If air is applied into the inside ports of these cable cylinders the doors will close On each of the four 4 ports i
72. s a flow control valve used for adjusting the opening and closing speeds of the doors These flow controls only vary the speed in the exhaust direction Air to the cable cylinders is supplied through a 4 way valve When 24 VAC is applied to the valve the doors open if no power is applied the doors close A 3 way is used to supply air to the 4 way valve If the EMERGENCY STOP is engaged the air is automatically exhausted so that the doors can be opened manually 1 In a 2 Door application there are two 2 additional cable cylinders a 4 way added for the operation of the rear doors 49 3 Door Component Replacement Removal a Manual Door Replacement or Removal 1 2 3 4 Discontinue electric service to the dryer Remove the two 2 1 4 20 x 1 2 bolts from each side of the middle guard and rear guard 1 4 20 X 3 4 BOLT MAN3280 a For dryers manufactured as of November 1 1995 loosen the jam nut and screw down the trolley adjustment plates b For dryers manufactured prior to November 1 1995 remove the two 2 trolley adjustment plates Lift the doors off of the tracks and remove To install new manual door s or to reinstall manual door s reverse above procedure steps 3 through 1 MAN3279 b Pneumatic Automatic Door Replacement or Removal 1 2 3 4 5 6 7
73. sed air supply from the dryer 2 Discontinue electrical service to the dryer 3 Disconnect wires in junction box 4 Remove tubing from the inlet side of the valve 5 Remove the valve from the bracket 6 Unscrew the valve from the outlet side 7 To install new steam solenoid valve reverse above procedure LA steps 6 through 1 Pie ture c Needle Valve Replacement 1 Disconnect compressed air supply from the dryer 2 Remove tubing from the valve 3 Unscrew needle valve from the solenoid valve 4 To install new needle valve reverse above procedure steps 3 through 1 31 d Steam Coil Replacement 1 Discontinue electric 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 Wait 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 line to bleed off any residual steam pressure CAUTION MAKE CERTAIN THAT THE ENTIRE STEAM SYSTEM coil lines valves etc ARE COOLED TO AVOID HOT STEAM ESCAPING and TO AVOID PERSONAL INJURY CUT AWAY VIEW OF STEAM COIL ASSEMBLY 6 Remove steam coil damper cylinder piston 7 Remove the steam coil damper by unbolting from its hinges 8 Disconnect steam supply lines and steam return lines at the unions 9 Remove the remaining piping from the steam coil 10 Remove ALL of the panels surrounding th
74. ssembly check electrode for visible cracking at the ceramic insulator or shorting of sensor to burner check to insure that the flame sensor rod is positioned over the flame area check for carbon deposits on the flame sensor rod check to insure that there is a 1 8 gap between the ground rod and the ignitor spark electrode b After preforming these inspections and making corrections if any restore power to the dryer start the dryer and operate through one 1 complete cycle to insure that ALL components are functioning properly If a no heat condition persists refer to the Troubleshooting Flow Charts on pages 19 20 and 21 1 To effectively use this information or the flow charts each step must be completed in sequence performing whatever test are suggested After the completion of each test the guide will direct the Service Technician to the next logical step in the troubleshoot sequence based on the outcome of the previous check 2 Components should be replaced only after each step has been completed and replacements after each step has been completed and replacement is suggested in the flow chart However the experienced technician realizes that a loose connection or broken or shorted wire may be at fault where electrical components are concerned and not necessarily the suspected component itself 17 c Three Visual Checks 1 Does the DSI ignitor flame probe assembly start sparking If not refer to the FIRS
75. ssure is correct and consistent There are two 2 types of devices commonly used H to measure water column W C pressure They Ly ELE WITH WATER TO ZERO LEVEL are the spring and mechanical type gauge and the MAGNE alle water column test gauge manometers The use of the spring and mechanical type gauges is NOT i RECOMMENDED because they are not Ka always accurate The preferred type of gauge is the manometer because it is a simple device to use and is highly accurate A manometer is simply a INNER TUB glass or transparent plastic tube with a scale graduated in inches When it is filled with water and pressure is applied the water in the tube rises showing the exact water column W C pressure lt 5 T 8 WARNING Test ALL connections for leaks by lr brushing on a soapy water solution 22 a Connect the water column test gauge manometer to the gas valve pressure tap 1 8 N P T Refer to the illustration on previous page page 22 b Start the dryer with the burner on the correct water column pressure W C reading in inches should be Natural 3 5 4 inches liquid propane Gas 10 5 11 inches W C When a gas dryer in first started during initial time of installation and start up it has a tendency not to ignite on the first ignition attempt This is due to the fact that the gas supply
76. t for GAS MODELS ONLY Failed 225 hi limit thermostat Steam damper system is not functioning properly for STEAM DRYER ONLY a Steam damper sticking closed b Leak in pneumatic system Undersized load dryer requires a minimum load size of approximately 125 lbs for maximum drying efficiency Excessive noise and vibration 1 Dryer is not leveled properly Impellor fan and blower out of balance a Excessive lint build up on impellor fan and blower check air jet b Failed impellor fan and blower Loose motor mount Failed idler bearings or tumbler bearings V belts either too tight or too loose Tumbler basket drive wheels are worn or are loose Set screws of tumbler drive shaft bearings are loose Failed motor bearing Drive wheel trantorque is loose 64 SECTION VII ELECTRICAL TROUBLESHOOTING 1 Microprocessor Display Power Circuit i pal Theory of the Microprocessor Display Power Circuit The power distribution block is where the incoming voltage is applied to L1 and L3 are branched off to supply the 208 240 volts single phase to the two 5 amp slo blo fuses This voltage might be stepped down by a step down transformer if the incoming voltage is 380 volts or higher This 208 240 volts is then supplied to the computer Path of Voltage for the Microprocessor Display Power Circuit T
77. ting in the forward mode clockwise direction Phase 5 OPL Microprocessor Controller Relay Output LED Indicators There are five 5 LED indicators red lights located at the lower backside area of the Phase 5 OPL microprocessor controller They are identified labeled from left to right as shown in the illustration on this page as HEAT MTR blower motor FWD forward REV reversing and DOOR These LEDs indicate that the outputs of the Phase 5 OPL microprocessor controller or in the case of the door switch are functioning 1 HEAT Output LED Indicator If the dryer is started and there is no heat yet the microprocessor controller display heat circuit indicator dot is on but the heat output LED indicator is off then the fault is in Phase 5 OPL microprocessor controller itself If both display heat indicator dot and the heat output LED indicator are on then the problem is elsewhere i e external of the microprocessor controller 73 m ap ALLL TT OQ Ue 2 MTR Output LED Indicator If the dryer is started and the motor is not operating yet both the microprocessor controller display motor indicator dot and the dOOr input LED indicator are on but the motor output LED indicator is off then
78. tric service to the dryer Disconnect compressed air supply from the dryer Remove the 1 4 20 self tapping screws securing the pneumatic panel cover Remove the two 2 1 4 20 screws securing the junction box cover ve PN Loosen the cord grip cap that the valve 2 pu wire go through p UFFLER Loosen the appropriate wire on the g Q j AN328 terminal strip Identify these wires and make note of their placement Loosen the bolts holding the assembly to the pneumatic panel For 3 way valve supply air disable valve replacement proceed to Step 13 Remove the two 2 1 4 poly compression fittings door open door close Remove the two 2 1 4 poly x 1 8 M P T connectors from the valve body 10 Twist remove the 4 way valve body off of the 1 8 street elbow 11 Remove the muffler off of the valve body 12 To install new 4 way valve reverse above procedure steps 11 through 1 13 Remove the 1 4 poly compression fitting 14 Remove the 3 way valve supply air disable valve from the 1 8 M P T nipple 15 Remove the muffler off of the valve body 16 To install new 3 way valve
79. ule itself c FLAME OUT burner flame shut down by the DSI module due to lack of flame verification This condition occurs only after ignition is evident but is lost The DSI system will immediately attempt to relight the burner d RECYCLE flame has been sensed but lost Initiate a new sequence THERE ARE NO RETRIES 2 Troubleshooting and System Basic Diagnosis a Preliminary Steps The following steps must be preformed to minimize the time required to isolate cause of fault 1 DSI module L E D indicator light is off no red light or no green light a Check for voltage approximately 24 VAC across the DS N DSI model terminals TH and GND If voltage approximately 24 VAC is evident then there 0 N is amalfunction within the DSI module itself and it must be replaced 17 E us If there is no voltage and then problem is not the DSI module or the ignition system then the problem else where in the dryer 1 e dryers heat circuit sail switch quis hi limit circuits etc er VOLT METER 2 DSI module L E D indicator lights red for approximately 1 5 seconds prepurge This indicates that ALL the controls including ALL the safety circuits are functioning and power is being supplied to the DSI module a DSI module L E D indicator lights green This indicates a normal heating cycle This also indicates that the preliminary diagnostics of t
80. ve also regulates the incoming gas pressure Redundant Gas Valve g Normal Operation of the Direct Spark Ignition DSI System refer to the illustration on page 14 1 The DSI System consists of a microprocessor based control module along with an Ignitor Flame Probe Assembly This control utilizes a high voltage synchronous spark ignitor and a rectified flame sensor probe signal to locally control ALL basic functions in the gas burner On a call for heat by the dryers controls 24 VAC is applied to the DSI module at which time the modules L E D light emitting diode indicator will light RED indicating that power has been established to the module Almost immediately up to approximately 1 5 seconds pre purge the indicator will light GREEN the gas valve opens and the spark burst will be evident on for approximately 8 seconds The burner flame should now be established confirmed If at this time the flame has not been established and confirmed the DSI module will LOCK OUT and the modules L E D indicator will light RED and stay on continuously To reset or cancel the LOCK OUT condition open and close the main door then restart the dryer Once the burner flame is established and confirmed the DSI module indicator will light GREEN and the burner system will continue through a normal heating cycle where the DSI system will cycle on and off as required by the dryers controls During the normal heating cycle
81. voltage is then supplied to the top half L1 L2 and L3 of the blower and fan contactor Providing the 24 A C volts for the DOOR input to the computer is present on pin 5 of the 15 pin computer harness the computer is going to output that 24 volts on pin 5 upon the start of a cycle which will in turn travel through a couple of connectors and land on the Al marking of the blower and fan contactor This contactor will shut closed sending the three phase voltage to the overload Providing the overload is not tripped the voltage will then travel to the blower and fan motor Path of Voltage for the Blower Fan Motor Circuit Three phase voltage is applied to the power distribution block each line L1 L2 and L3 are fused with cartridge type fuses The voltage is then supplied to the blower and fan contactor marked L1 L2 and L3 As long as the fuses and the circuit breakers are okay this voltage 208 600 volts will always be there at the contactor When the computer calls for the fan to come on 24 A C volts will output of pin 5 of the computer This 24 A C volts will pass through J1 and J3 connectors pin 5 on both and travel to the coil of the blower and fan contactor the contactor will be marked A1 The other side of the coil A2 will be directly grounded When the 24 A C volts reaches the coil the contactor closes and the incoming voltage that is supplied to the top of the contactor L1 L2 and L3 meets the T1 T2 and T3 of the contactor which then must
82. wer is open or b There is a fault in the door switch circuit external of the Phase 5 OPL microprocessor controller 2 dSFL indicates a fault in the microprocessor temperature circuit If fault is detected in the microprocessor heat sensor circuit the display will read dSFL and the tone buzzer will sound for approximately 5 seconds every 30 seconds until a The problem is corrected or b Power to the dryer is discontinued and the problem is then corrected IMPORTANT The Phase 5 OPL microprocessor controller has its own internal heat sensing circuit fuse protection located on the back side ofthe Phase 5 OPL computer If a dSFL condition occurs check to see if this fuse has blown Ifit has DO NOT replace the entire Phase 5 OPL microprocessor controller replace the fuse and do so with a 1 8 amp Slo Blo fuse ONLY NOTE Once the Phase 5 OPL microprocessor controller detects a problem in the heat circuit it updates every 30 seconds If the problem was a loose connection in this circuit which corrected itself the dSFL condition would automatically be cancelled 3 SEFL indicates rotational sensor circuit failure meaning that there is a fault somewhere in the basket tumbler rotation detection circuit or the Phase 5 OPL microprocessor controller program related to this circuit Program Location 2 is set incorrectly in the active mode SEn where the dryer is not equipped with the optional rotational sensor and shoul

American Dryer Corp. AD-200 Clothes Dryer User Manual

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