AD-200 Non-Tilting Installation Manual 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 death. AVERTISSEMENT: Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.
Retain This Manual In A Safe Place For Future Reference American Dryer Corporation products embody advanced concepts in engineering, design, and safety. If this product is properly maintained, it will provide many years of safe, efficient, and trouble-free operation. ONLY qualified technicians should service this equipment. OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the installation manual included with the dryer.
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 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. WARNING DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER/SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. IMPORTANT PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and/or specified in the installation and operator's manual included with the dryer.
Table of Contents SECTION I IMPORTANT INFORMATION .......................................................................... 3 A. RECEIVING and HANDLING ..................................................................... 3 B. SAFETY PRECAUTIONS ........................................................................... 4 SECTION II SPECIFICATIONS/DIMENSIONS and COMPONENT IDENTIFICATION . 6 A. SPECIFICATIONS (Gas and Steam Models)................................................ 6 B.
SECTION VI ROUTINE MAINTENANCE ............................................................................ 36 A. CLEANING ............................................................................................... 36 B. ADJUSTMENTS........................................................................................ 38 C. LUBRICATION ......................................................................................... 38 SECTION VII COMPONENT SYSTEM DESCRIPTIONS ..................................
SECTION I IMPORTANT INFORMATION A. RECEIVING and HANDLING The dryer is shipped in a protective stretch wrap cover with protective cardboard corners and top cover (or optional box) as a means of preventing damage in transit. Upon delivery, the dryer and/or packaging, and wooden skid should be visually inspected for shipping damage. If any damage whatsoever is noticed, inspect further before delivering carrier leaves. Dryers damaged in shipment: 1.
B. SAFETY PRECAUTIONS WARNING: For your safety, the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury, or loss of life. WARNING: The dryer must never be operated with any of the back guards, outer tops, or service panels removed. 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.
WARNING: DO NOT use heat for drying articles that contain plastic, foam, sponge rubber, or similarly textured rubber materials. Drying in a heated tumbler (basket) may damage plastics or rubber and also may be a fire hazard. 7. A program should be established for the inspection and cleaning of lint in the heating unit area, exhaust duct work, and inside the dryer. The frequency of inspection and cleaning can best be determined from experience at each location.
SECTION II SPECIFICATIONS/DIMENSIONS and COMPONENT IDENTIFICATION A. SPECIFICATIONS (GAS and STEAM Models) MAXIMUM C APACITY (DRY WEIGHT) 200 lbs. 90.9 kg BASKET DIAMETER 62-1/2" 158.75 cm TUMBLER (BASKET) DEPTH 42" 106.7 cm TUMBLER (BASKET) MOTOR 3 HP 2.24 kw DOOR OPENING (DIAMETER) 36-3/4" w x 43" h 93.35 cm x 109.2 cm DOOR SILL HEIGHT TUMBLER (BASKET) VOLUME 36-1/2" 92.71 cm 74.5 cu. ft. 2.11 cu. m. VOLTAGE AVAILABLE Gas HEAT INPUT 750,000 btu/hr 189,000 kcal/hr 7-1/2 HP 5.
B.
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SECTION III INSTALLATION PROCEDURES Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, the installation must conform to applicable American National Standards: ANSI Z223.1LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electrical Code) or in Canada, the installation must conform to applicable Canadian Standards: CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (liquid propane [L.P.
1. Reconnect the four (4) pin/socket connectors at the bottom of the right control box. 2. Reconnect the three (3) pin/socket connectors at the bottom of the left control box. 3. Reconnect the two (2) pin/socket connectors within the left control box. 4. Rewire the drive motor by inserting the three (3) black wires into the T1, T2, and T3 connections of the telemecanique drive contactor. 5.
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B. LOCATION REQUIREMENTS The model AD-200 dryer requires 18-inches (45.72 cm) of space on each side of the dryer and 24-inches (60.96 cm) of space behind the unit for ease of maintenance. A minium of 12-inches (30.48 cm) must be allowed between the top of a gas dryer and the ceiling. A ceiling height of 120-inches (304.8 cm) is required for gas dryers, and a ceiling height of 130-inches (330.2 cm) is required for a steam dryers. The dryer must be leveled for proper operation.
C. FRESH AIR SUPPLY When the dryer is operating, it draws in room air, heats it, passes the air through the tumbler (basket), and exhausts it out of the building. Therefore, the room air must be continually replenished from the outdoors. If the make-up air is inadequate, drying time and drying efficiency will be adversely affected. Ignition problems and sail switch “fluttering” problems may result, as well as premature motor failure from overheating.
D. EXHAUST REQUIREMENTS 1. General Exhaust Duct Work Information Exhaust duct work should be designed and installed by a qualified professional. Improperly sized duct work will create excessive back pressure which results in slow drying, increased use of energy, over heating of the dryer, and shutdown of the burner by the airflow (sail) switches, burner hi-limits, or tumbler (basket) hi-heat thermostats. CAUTION: DRYER MUST BE EXHAUSTED TO THE OUTDOORS.
a. Outside Duct Work Protection 1) To protect the outside end of horizontal duct work from the weather, a 90° elbow bent downward should be installed where the exhaust exits the building. If the duct work travels vertically up through the roof, it should be protected from the weather by using a 180° turn to point the opening downward. In either case, allow at least twice the diameter of the duct between the duct opening and the nearest obstruction.
E. COMPRESSED AIR SUPPLY SYSTEM A clean, dry, regulated air supply of 80 psi (5.51 bars) compressed air must be supplied to the dryer. The connection size is 1/8-inch N.P.T. No air filtering or pressure regulating devices are provided with the standard AD-200 Non-Tilt dryer. 1. Gas Dryers The air line supply connection is made into the 1/8-inch N.P.T. port on the air jet solenoid valve which is located in the base of the dryer. (Refer to the illustration below.) 2.
F. ELECTRICAL INFORMATION 1. Electrical Requirements It is your responsibility to have ALL electrical connections made by a properly licensed and competent electrician to assure that the electrical installation is adequate and conforms with local and state regulations or codes. In the absence of such codes, ALL electrical connections, material, and workmanship must conform to the applicable requirements of the National Electrical Code ANSI/NFPA NO.
2. Electrical Service Specifications ADG-200 (G AS) 7.5 HP B LOW ER /3 HP DRIVE M OTOR ELECTRIC SERVICE SPECIFICATION (PER DRYER) IMPORTANT: 208 VAC and 230 VAC ARE NOT THE SAME. When ordering, specify exact voltage. NOTES: A. Fuse ratings are dual element-time delay-current limiting, class RK1 or RK5 ONLY. B. Circuit breakers are thermal magnetic (industrial) type ONLY. For others, calculate/verify correct breaker size according to appliance amp draw rating and type of breaker used. C.
ADS-200 (STEAM ) 15 HP B LOWER/3 HP DRIVE M OTOR ELECTRIC SERIVICE S PECIFICATIONS (PER DRYER) IMPORTANT: 208 VAC and 230 VAC ARE NOT THE SAME. When ordering, specify exact voltage. NOTES: A. Fuse ratings are dual element-time delay-current limiting, class RK1 or RK5 ONLY. B. Circuit breakers are thermal magnetic (industrial) type ONLY. For others, calculate/verify correct breaker size according to appliance amp draw rating and type of breaker used. C.
3. Electrical Connections NOTE: A wiring diagram is included with each dryer and is affixed to the panel inside the right side control cabinet. The only electrical input connections to the dryer are the 3-phase (3ø) power leads (L1, L2, and L3), GROUND, and in the case of 4 wire service, the Neutral. These electrical connections are made at the power distribution block located in the left side control cabinet.
G. GAS INFORMATION your responsibility to have ALL plumbing connections made by a qualified professional to assure that the gas plumbing installation is adequate and conforms with local and state regulations or codes. In the absence of such codes, ALL plumbing connections, materials, and workmanship must conform to the applicable requirements of the National Fuel Gas Code ANSI Z223.1-LATEST EDITION, or in Canada, the Canadian Installation Codes CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.
2. Technical Gas Data a. Gas Specifications TYP E G AS OF Natural Gas Manifold Pressure* Inline Pressure Liquid Propane (L.P.) Gas 3.5 - 4.0 inches W.C. 8.7 - 9.9 mb 10.5 inches W.C. 26.1 mb 6.0 to 12.0 inches W.C. 14.92 - 29.9 mb 10.5 inches W.C. 26.1 mb Shaded areas are stated in metric equivalents * Measured at the gas valve pressure tap when the gas valve is on. b. Gas Connections: Inlet connection ----- 1-1/4 inch N.P.T. Inlet Supply Size ----- 1-1/2 inch N.P.T.
3. Piping/Connections ALL components/materials must conform to National Fuel Gas Code Specifications ANSI Z223.1LATEST EDITION, or in Canada, CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (L.P. Gas) or LATEST EDITION (for General Installation and Gas Plumbing), as well as local codes and ordinances and must be done by a qualified professional.
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H. STEAM INFORMATION It is your responsibility to have ALL steam plumbing connections made by a qualified professional to assure that the installation is adequate and conforms with local and state regulations or codes. IMPORTANT: Failure to comply with the requirements stipulated in this manual can result in component failure which will VOID THE WARRANTY. NOTE: The ADS-200 is manufactured with a pneumatic (piston) damper system which requires an external supply of air (80 psi +/- 10 psi [5.51 bars +/- 0.
b. The steam supply piping to the dryer must include a 12-inch (30.48 cm) rise along with a drip trap and check valve. This will prevent any condensate from entering the steam coil. c. Flexible hoses or couplings must be used. The dryer vibrates slightly when it runs and this will cause the steam coil connections to crack if they are hard piped to the supply and return mains. d. Shut-off valves for each dryer should be installed in the supply, return, and drip trap return lines.
4. STEAM DAMPER AIR SYSTEM CONNECTIONS The ADS-200 is manufactured with a pneumatic (piston) damper system which requires an external supply of compressed air. The air connection is made to the steam damper solenoid valve which is located on the outer top, at the rear left hand corner of the dryer. a. Air Requirements Compressed Air Supply Air Pressure Normal 80 PSI 5.51 bars Minimum Supply 70 PSI 4.82 bars Maximum Supply 90 PSI 6.20 bars Shaded areas are stated in metric equivalents b.
Diagram 1 shows the damper in the heating (open) mode, allowing heat into the tumbler (basket). Diagram 2 shows the damper in the cool down (closed) mode, pulling ambient air directly into the tumbler (basket) without passing through the coils. NOTE: With the dryer off or with no air supply, the damper is in the cool down mode as shown in Diagram 2. 6. STEAM DAMPER AIR PISTON (Flow Control) OPERATION ADJUSTMENT Steam damper operation was tested and adjusted prior to shipping at 80 psi (5.51 bars).
I. PREPARATION FOR OPERATION/START-UP The following items should be checked before attempting to operate the dryer: 1. Read ALL “CAUTION,” “WARNING,” and “DIRECTION” labels attached to the dryer. 2. Check incoming supply voltage to be sure that it is the same as indicated on the dryer data label affixed behind the right control box door. In case of 208 VAC or 230 VAC for dryers with sprinkler option verify 1-phase (1ø) voltage is correct, the supply voltage must match the electric service exactly. 3.
J. PREOPERATIONAL TESTS ALL dryers are thoroughly tested and inspected before leaving the factory. However, a preoperational test should be performed before the dryer is publicly used. It is possible that adjustments have changed in transit or due to marginal location (installation) conditions. 1. Turn on electric power to the dryer. 2. Make sure loading doors are closed and the lint drawer is closed. 3. Microprocessor controller (computer) system operational test -- to start the dryer; a.
5. Heat Circuit Operational Test a. Gas Models 1. When the dryer is first started (during initial start-up), the burners have a tendency not to ignite on the first attempt. This is because the gas supply piping is filled with air, so the dryer may have to be stopped and restarted several times for this air to be purged from the lines. 2. The dryer is equipped with a direct spark ignition (DSI) system which has internal diagnostics.
8. Each dryer should be operated through one (1) complete cycle to assure that no further adjustments are necessary and that ALL components are functioning properly. 9. Microprocessor controller (computer) programs/selections... a. Each microprocessor controller (computer) has been preprogrammed by the factory with the most commonly used parameter selections. If computer program changes are required, refer to the computer programming manual which was shipped with the dryer. K.
SECTION IV SERVICE/PARTS INFORMATION A. SERVICE 1. Service must be performed by a qualified trained technician, service agency, or gas supplier. If service is required, contact the reseller from whom the ADC equipment was purchased. If the reseller cannot be contacted or is unknown, contact the ADC Service Department for a reseller in your area.
SECTION V WARRANTY INFORMATION A. RETURNING WARRANTY CARD(S) 1. Before any dryer leaves the ADC factory test area, a warranty card is placed on the back side of the main door glass. These warranty cards are intended to serve the customer where we record the individual installation date and warranty information to better serve you, if you file a warranty claim. a. If a warranty card did not come with your dryer, contact the ADC Warranty Department or ADC Service Department at (508) 678-9000. B.
2. Each part must be tagged with the following information: a. Model number and serial number of the dryer from which part was removed. b. Nature of failure (be specific). c. Date of dryer installation. d. Date of part failure. e. Specify whether the part(s) being returned is for a replacement, a credit, or a refund. NOTE: If a part is marked for a credit or a refund, the invoice number covering the purchase of the replacement part must be provided. NOTE: Warranty tags (ADC Part No.
SECTION VI 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 airflow.
STEAM DRYERS ONLY Clean the steam coil lint screen located on top of the steam coil. (This may have to be done more frequently.) MONTHLY Apply a high-temperature grease to the four (4) 1-1/2”diameter tumbler drive shaft pillow block bearings. (Use Shell Alvania #2 grease or equivalent.) Retighten set screws in the collars of the four (4) 1-1/2”diameter tumbler drive shaft bearings.
B. ADJUSTMENTS 7 DAYS AFTER INSTALLATION and EVERY 6 MONTHS THEREAFTER Inspect bolts, nuts, screws (bearing set screws), nonpermanent gas connections (unions, shut-off valves, orifices, and grounding connections). Motor and drive belts should be examined. Cracked or seriously frayed belts should be replaced. Tighten loose V-belts when necessary. Complete operational check of controls and valves.
SECTION VII COMPONENT SYSTEM DESCRIPTIONS A. TUMBLER DRIVE SYSTEM The tumbler (basket) is supported and driven by four (4) 11-inch diameter drive wheels. Two (2) of these wheels are attached to a 1-1/2”diameter idler shaft, while the other two (2) are attached to a 1-1/2”diameter drive shaft. Each of the wheels is fastened to the shafts by a locking bushing. The taper lock is made up of two (2) pieces; an inner collar, and an outer sleeve. The inner and outer elements have matching opposing tapers.
D. SAFETY DEVICES 1. LOAD DOOR SWITCHES There are two (2) of these switches located under the main loading doors. These switches ensure that the doors are closed before the dryer can start. If the dryer is started when the load doors are open, the microprocessor controller (computer) light emitting diode (L.E.D.) display will show “door.” 2. LINT BASKET SWITCH This switch ensures that the lint basket is closed before the dryer can start.
E. STEAM DAMPER ACTUATOR SYSTEM The system consists of a hinged damper plate, pneumatic piston, and 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 pistons. The piston rod extends, pushing the hinged steam damper plate to the opened position.
SECTION VIII TROUBLESHOOTING IMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR 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.
2. Failed drive motor contactor. 3. Failed drive motor. 4. Failed microprocessor controller (computer). C. Drive motor operates in one direction only ... stops and restarts in same direction... * Appropriate microprocessor controller (computer) relay output indicator is on. 1. Failed reversing contactor (relay). * Appropriate microprocessor controller (computer) relay output indicator is off. 1. Failed microprocessor controller (computer). D.
* Microprocessor controller (computer) “MTR” relay output indicator is off. 1. Failed microprocessor controller (computer). F. Blower (fan/impellor) motor operates okay for a few minutes, then either repeatedly or occasionally trips the overload protector ... NOTE: When the Overload Protector Trips, the Microprocessor Controller (computer) light emitting diode (L.E.D.) Display Will Read “door.” 1. Motor is overheating... a. Motor air vents clogged with lint. b. Low voltage to the motor. c. Failed motor. d.
a. Lint drawer switch is out of proper adjustment. b. Loose connection in the lint drawer switch circuit. J. Microprocessor controller (computer) light emitting diode (L.E.D.) display reads “dSFL” continuously and the buzzer (tone) sounds every 30-seconds... 1. Fault in microprocessor heat sensing circuit ... a. Failed microprocessor temperature sensor. b. Blown “dSFL” 1/8-amp fuse on the microprocessor controller (computer). c. Failed microprocessor controller (computer). d.
4. Blown 24 VAC control circuit fuse (fuse 3). L. Microprocessor controller (computer) light emitting diode (L.E.D.) display reads “door” and the microprocessor controller (computer) “Door” L.E.D. indicator is on... 1. Failed microprocessor controller (computer). M. Microprocessor controller (computer) will not accept any keyboard (touch pad) entries, i.e., display reads “FILL” and when keyboard (touch pad) entries are selected, the display continues to read “FILL”... 1.
2. Rotational sensor circuit failure...fault somewhere in the tumbler (basket) rotation or circuit... a. Tumbler (basket) not rotating... 1) Broken tumbler (basket) drive V-belt(s). 2) Failure in drive motor circuit...refer to Section B, Section C, and Section D on page 42 and page 43 b. Bad rotation sensor. c. Broken wire or connection between rotation sensor and microprocessor controller (computer). S. Microprocessor controller (computer) light emitting diode (L.E.D.) display reads “Hot”... 1.
U. Heating unit for GAS MODELS or STEAM MODELS is not operating (no heat) and the microprocessor controller (computer) light emitting diode (L.E.D.) heat indicator dot is on but the “HEAT” relay output L.E.D. is not on... 1. Failed microprocessor controller (computer). V. No heat for GAS MODELS ONLY ...ignitor sparks, burner goes on then off right away... 1. DSI ignitor/flame-probe out of adjustment...reposition closer to the flame area. 2. Sail switch is fluttering ... a. Lint drawer/screen is dirty. b.
6. Lint drawer/screen not being cleaned on a regular basis or often enough. 7. Extractors (washers) not performing properly. 8. Sail switch is fluttering...restriction in exhaust... for GAS MODELS ONLY . 9. Failed microprocessor controller (computer)...temprature calibration is inaccurate. 10. Failed microprocessor temperature sensor...calibration is inaccurate. 11. Failed burner hi-limit ... for GAS MODELS ONLY. 12. Failed 225º hi-limit (thermostat). 13. Steam damper system not functioning properly ...
AA. Tumbler (basket) jumps or makes excessive noise when dryer is first started or between forward and reverse cycles... 1. Tumbler (basket) out of alignment. BB. Blower (impellor/fan) air jet does not activate at the end of the cooling cycle... * With microprocessor controller (computer) “A JET” relay output light emitting diode (L.E.D.) on. 1. Fault in compressed air supply. 2. Failed air jet. * With microprocessor controller (computer) “A JET” relay output L.E.D. off. 1.
SECTION IX PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. Microprocessor Controller (computer) Board a. Upon completing installation of the replacement microprocessor controller (computer) board, reestablish power to the dryer. b. Start the drying cycle. c. Verify that the motor(s) and the heat indicator dots, in the microprocessor controller (computer) light emitting diode (L.E.D.) display are on. (Refer to the illustration below. ) d.
e. Open main door. The dryer must stop and ALL output indicator lights on the back side of the microprocessor controller (computer) board must go out. f. Try to restart the dryer with the main door open. g. The microprocessor controller (computer) board’s light emitting diode (L.E.D.) display must read“ DOOR.” h. Close the main door and restart the dryer. i. Functional check of microprocessor controller (computer) board is complete . 2.
3. For Direct Spark Ignition (DSI) System Models Manufactured with ADC Module Part No. 880815 a. Upon completing installation of the replacement DSI module, reestablish power to the dryer. b. Starting the drying cycle. c. The ignition DSI module’s L.E.D. (light emitting diode) indicator will light “red” for up to approximately 1.5-seconds (pre-purge time). d. The module’s indicator light will then turn “green.” The gas valve will be energized and the ignitor probe will spark for approximately 8-seconds.
ADC 112142 1- 06/18/92-100 4* 10/17/95-100 7* 06/16/99-25 2* 04/16/93-100 5* 11/01/96-100 8* 08/22/00-20 3* 07/08/94-100 6* 12/07/98-25 9- 11/10/00-25
