AD-310 Service Manual American Dryer Corporation 88 Currant Road Fall River, MA 02720-4781 Telephone: (508) 678-9000 / Fax: (508) 678-9447 e-mail: techsupport@amdry.com 123098DMG/abe ADC Part No.
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/operator's 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 AD-310 REFERENCE GUIDE Tumbler Section ............................................................................................................................. 3 AD-310 REFERENCE GUIDE Base Section .................................................................................................................................. 4 INTRODUCTION ...............................................................................................................................
SECTION VI TROUBLESHOOTING .................................................................................................................. 105 SECTION VII PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS ..............................................................................................................................
AD-310 Reference Guide (Tumbler Section) 3
AD-310 Reference Guide (Base Section) 4
INTRODUCTION AD-310 MACHINE OPERATIONAL SUMMARY The model AD-310 incorporates one (1) “EMERGENCY STOP (E-Stop) BUTTON” located centrally on the Right Front Control Door. This "RED" MUSHROOM PUSH-BUTTON is “PUSH TO STOP” the machine and “TURN TO RELEASE” or “PULL TO RELEASE” type control device. This button must be in the released mode to power the machine. The PHASE 5 MICROPROCESSOR CONTROLLER (Computer) display will light when the “EMERGENCY STOP (E-Stop) BUTTON” is in the released mode.
EMERGENCY (E-Stop) STOP BUTTON (Push To Stop/Turn To Release or Pull To Release) This "red" mushroom push-button, located in the center of the Right Front Control Door almost directly under the Phase 5 Microprocessor Controller (computer) is a “Push To Stop” and “Turn To Release” type pushbutton. This button must be in the released mode to power the machine (enable the machine to run).
CONTROL POWER (Off) This "RED LIGHTED OPERATOR," located on the Right Front Control Door, is for disabling the dryer’s output control voltage. This push-button is mainly for use as a troubleshooting function. END OF CYCLE / HEATER FAULT INDICATOR / AIR JET This amber colored indicator located on the front/top of the dryer has two (2) functions: 1. To indicate that a drying cycle has been completed and that the dried material is ready for attention. Once the dryer is attended (i.e.
AD-310 MACHINE OPERATION TROUBLESHOOTING INFORMATION END OF CYCLE/HEATER FAULT INDICATOR The “END OF CYCLE” light located on the top/front of the dryer, is triggered by the Air Jet Signal of the Phase 5 Microprocessor Controller (computer) to the input of the PLC (Programmable Logic Controller). If this signal is not sensed by the PLC the light will not turn on. The “1-second flashing” is accomplished by a “Flasher Module” located on the Main Control Panel in the Right Front Control Cabinet.
2. Check to see that the Air Jet L.E.D. (light emitting diode) is on at the end of the drying cycle. If the L.E.D. is not on it may be an indication of a failed Phase 5 Microprocessor Controller (computer). 3. If Air Jet L.E.D. is on then check the wiring from the Phase 5 Microprocessor Controller (computer) to the air valve. 4. Bad air valve.
2. Check that 80 PSI of compressed air is supplied to the machine and that the “Front Up” solenoid is being actuated by the PLC (Programmable Logic Controller). Refer to the PLC (Programmable Logic Controller) signal information included in the ladder diagrams and schematics supplied with the machine. DRY This selection prepares the machine for a “Material Drying Command” from the Phase 5 Microprocessor Controller (computer).
When a “HEATER FAULT” occurs after the first twenty-five (25) seconds of the drying cycle, a “CLEAR/ STOP” will be sent to the Phase 5 Microprocessor Controller (computer), a “FILL” message will be displayed on the Phase 5 Microprocessor Controller’s (computer’s) display, and both the “HEATER FAULT” reset pushbutton and the “END OF CYCLE" light will flash.
Once the flame has been established in both burner boxes, the natural gas outlet manifold pressure measured at each gas valve pressure tap must be 3-1/2 inches W.C. (water column) pressure. Connect a water tube manometer to the 1/8” F.P.T. gas pressure tap on the downstream side of each gas valve. There is a pressure regulator in both gas valves so the manifold pressure can be adjusted to 3-1/2” water column (W.C.).
ONE (1) BURNER WILL NOT IGNITE AT THE BEGINNING OF A CYCLE This condition can be caused by the following: • • • • • DEFECTIVE DSI (Direct Spark Ignition) MODULE DEFECTIVE SPARK IGNITOR/FLAME-PROBE ASSEMBLY DEFECTIVE GAS VALVE INSUFFICIENT GAS PRESSURE DEFECTIVE ELECTRICAL HEAT CIRCUIT Refer to the ladder diagram and the schematics provided with this machine for reference to the above listed information.
The dryer system is divided into a number of “electrical” sections which are as follows: 1. Right Front Control Panel The RIGHT FRONT CONTROL PANEL is located in the Right Front Control Cabinet of the dryer. This panel is the heart of the drying system, where ALL control signals interface to or from this panel. The signals that interface to this panel are too many to list here, however, they are ALL identified on TB1 of its’ schematic diagram. 2.
4. Optional Sprinkler Circuit The OPTIONAL SPRINKLER CIRCUIT main control panel will be located in the left front electrical enclosure. If a SPRINKLER OPTION is included with the dryer, this panel will include an “AUTOMATIC EMERGENCY STOP” feature. This feature requires that the Sprinkler Circuit be functional for the dryer to be powered. NOTE: There will be a dedicated electrical connection in the Right Electrical Junction Box for the Sprinkler Circuit.
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.
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.
SECTION II ROUTINE MAINTENANCE A. CLEANING A schedule should be established for periodic inspection, cleaning, and removal of lint from various areas of the dryer, as well as throughout the duct work system. The frequency of cleaning can best be determined from experience at each location. Maximum operating efficiency is dependent upon proper air circulation. The accumulation of lint can restrict this air flow.
MONTHLY Empty the compressed air filter bowl. Clean any lint accumulation from the gas valve and burner area at the top of the dryer, the fan (impellor/ blower) motor, and the fan (impellor) bearings located in the dryer base. EVERY 6 MONTHS STEAM MODELS - clean the steam coil fins. 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.
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 the fill plug. NOTE: LUBRICATOR SHOULD BE SET AT 1 DROP PER CYCLE. NOTE: REGULATOR PRESSURE IS TO BE SET AT 80 PSI.
EVERY 6 MONTHS Change gear oil in the tumbler shaft gear reducer. 1. Remove the drain plug (located at the bottom rear of the reducer). 2. After oil is completely drained replace the drain plug. 3. Remove the vent plug and pour in 1.4 liters of Mobil Oil DTE HH5G (I.S.O. viscosity grade 460), SAE 90, or equivalent. C. ADJUSTMENTS 7 DAYS AFTER INSTALLATION and EVERY 6 MONTHS THEREAFTER Inspect bolts, nuts, screws, (bearing set screws), nonpermanent gas connections (i.e.
SECTION III SPECIFICATIONS and DIMENSIONS A. SPECIFICATIONS (Gas and Steam Models) Steam* Gas* MAXIMUM C APACITY (DRY WEIGHT) BASKET (TUMBLER) DIAMETER BASKET (TUMBLER) DEPTH BASKET (TUMBLER) VOLUME DRIVE MOTOR BLOWER MOTOR (GAS/STEAM) DOOR OPENING DOOR S ILL HEIGHT - LEVEL COMPRESSED AIR COMPRESSED AIR C ONNECTION VOLTAGE AVAILABLE HEAT INPUT APPROX. WEIGHT (UNCRATED) AIRFLOW Inlet Pipe Size VOLTAGE AVAILABLE APPROX.
B. DIMENSIONS NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
25 NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
ADG-310 (Gas) Non-Tilt NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
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 and/or National Electric Code ANSI/NFPA No. 70-LATEST EDITION A. ENCLOSURE / AIR SUPPLY / EXHAUST REQUIREMENTS NOTE: The following information is very brief and general.
B. ELECTRICAL REQUIREMENTS and GAS REQUIREMENTS It is your responsibility to have ALL electrical connections made by a properly licensed and competent electrician to assure that the electrical installation is adequate and conforms with local and state regulations or codes. In the absence of such codes, ALL electrical connections, material, and workmanship must conform to the applicable requirements of the National Electric Code ANSI/NFPA No. 70-LATEST EDITION.
SECTION V COMPONENT DESCRIPTION/REPLACEMENT A. HEAT SECTION The AD-310 dryer uses three (3) types of heat sources: natural gas, liquid propane (L.P.) gas, and steam. Natural Gas and L.P. (liquid propane) gas are not directly replaceable. The gas valves need to be modified to use other than the type of heat specified on the nameplate. 1. ADG-310 (gas) dryers utilizes a Direct Spark Ignition (DSI) module to monitor that a flame is established.
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 and on, flame verification, etc.). Additionally, the DSI Module has self diagnostic capabilities. 24 VAC Direct Spark Ignition (DSI) Module b.
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 225º F). MAN3484 225º F Thermostat f. The gas valve used in the dryer is of the redundant type which means that the gas valve is actually two (2) 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.
h. ADC Direct Spark Ignition (DSI) Operation Flow Chart Computer/Timer Calls For Heat Power Applied to the DSI 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. Open and close the Main Door... restart the dryer. Flame Confirmed? DSI Module "LOCK-OUT" Indicator lights "RED".
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 SAFETY PRECAUTIONS displayed on the equipment or specified in the AD-310 Non-Tilting Installation/Operator's Manual (ADC Part No. 112192) or the AD-310 Tilting Installation/Operator's Manual (ADC Part No. 112191) included with the dryer.
1. Direct Spark Ignition (DSI) Troubleshooting Terms (definitions) a. DSI (Direct Spark Ignition) MODULE "RED" L.E.D. (Light Emitting Diode) INDICATOR LIGHT This "red" L.E.D. (light emitting diode) light is located in the upper right corner of the DSI (Direct Spark Ignition) module (refer to the top illustration on page 30). This is a diagnostic indicator that simplifies the operational and troubleshooting procedures of the DSI system. b. LOCK-OUT MODE - DSI (Direct Spark Ignition) module "red" L.E.D.
If the dryer repeatedly has DSI (Direct Spark Ignition) module "LOCK-OUT" failures, the cause may be due to high voltage not getting into the DSI module ignitor probe assembly. (1) Check to insure that the red high voltage wire (between the ignitor spark electrode and the DSI [Direct Spark Ignition] module) is not wrapped around the sensor probe wire (the wire between the DSI module FP terminal and the ignitor and flame-probe assembly).
c. Three Visual Checks 1) Does the DSI ignitor/flame-probe assembly start sparking? If not, refer to the FIRST VISUAL CHECK on page 37. 2) Does the main burner ignite? If not, refer to the SECOND VISUAL CHECK on page 38. 3) Does the main burner remain lit after ignition has been established ("FLAME-OUT")? If not, refer to the THIRD VISUAL CHECK on page 39.
d. Troubleshooting Flow Chart - Quick Reference... First Visual Check (Does Ignitor Spark?) Computer/Timer Calls For Heat Is spark evident (on) at Ignitor Assembly? Is 24 Volts present across DSI Module terminals TH and COM? No No Open circuit to DSI System. Check the 24 VAC power source Sail Switch and Hi-Limit . Yes Repair or replace HV Lead Assembly. Energize system and check for proper operation.
e. Troubleshooting Flow Chart - Quick Reference... Second Visual Check (Does Main Burner Ignite?) Does main burner light? Is manual knob on the Gas Valve in the "ON" position? No Yes Yes Go To Third Visual Check Is dryer Internal Gas Shut-Off Valve and ALL External Gas Shut-Off Valves in the open position? No Turn knob to "ON/OPEN" position. Energize system and check for proper operation. No Yes Restore gas supply. Energize system and check for proper operation.
f. Troubleshooting Flow Chart - Quick Reference... Third Visual Check (Does Main Burner Ignite?) Does main burner remain lit? No Yes Does the Flame Probe have carbon or dust build up? 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 Yes Remove Flame Sensor Assembly. Clean the surface of the Flame Sensor Rod with fine steel wool or emery cloth, then reinstall.
3. Troubleshooting and 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 (Direct Spark Ignition) module. The DSI module L.E.D. (light emitting diode) indicator will light "red" (for up to approximately 1.5-seconds [prepurge]) then the L.E.D.
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.) pressure is correct and consistent. There are two (2) types of devices commonly used to measure water column (W.C.) pressure. They are the spring and mechanical type gauge and the water column test gauge (manometers). The use of the spring and mechanical type gauges IS NOT RECOMMENDED because they are not always accurate.
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 (Direct Spark Ignition) module provides the high synchronous spark (14,000 volts) through the high voltage (HV) lead, a spark is produced over the GAP.
NOTE: To reset the dryer when a "HEATER FAULT" occurs, press the ("amber") "HEATER FAULT" reset push-button. 3) Air Turbulence If there is sail switch flutter due to air turbulence, or improper impellor (fan/blower) rotation, or a restriction in the exhaust duct work, the DSI (Direct Spark Ignition) module will cycle erratically. This in turn might cause the DSI module to "LOCK-OUT" (where the L.E.D. [light emitting diode] indicator will LIGHT "RED" CONTINUOUSLY).
5) Wiring If the DSI (Direct Spark Ignition) module is in the "LOCK-OUT" mode (where the L.E.D. [light emitting diode] indicator will LIGHT "RED" 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 Direct Spark Ignition (DSI) system, especially the ground connections at the DSI module and the ignitor and flame-probe assembly.
C. NATURAL GAS and 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, therefore, an external regulator must be provided at the source of the L.P. gas supply (L.P. tank) on the dryer. The water column (W.C.) gas pressure must be regulated to between 10.5 -inches and 11-inches for safe and efficient dryer operation.
11. Reverse the procedure for reinstalling the gas valve/manifold assembly to the dryer. 12. Open ALL gas shut-off valves (closed in Step #2). 13. Reestablish electrical service to the dryer. a. Test ALL connections for leaks. IMPORTANT: Test ALL connections for leaks by brushing on a soapy water solution (liquid detergent works well). WARNING: NEVER TEST FOR LEAKS WITH A FLAME!!! 14. Operate the dryer through one (1) complete drying cycle to insure proper operation.
D. STEAM COIL SYSTEM OPERATION General Overview The dryers' steam coil is constantly charged thereby eliminating repeated expansion and contraction and also provide instant heating to start the drying process. The steam damper, located on top of the steam coil, is the only temperature controlling device in this system. When the steam damper is open, ambient air is drawn through the coil providing heat to the dryer.
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 the hinged steam damper plate to the open position.
3. Steam Damper Actuator System Service and Replacement a. Steam Damper Cylinder or Piston Replacement 1) Disconnect compressed air supply from the dryer. 2) Disconnect tubing from the piston. 3) Remove the spring clip from clevis pin then slide out the clevis pin. 4) Remove the steam damper cylinder (piston). 5) To install new steam damper cylinder (piston), reverse above procedure. b. Steam Solenoid Valve Replacement 1) Disconnect compressed air supply from the dryer.
d. Steam Coil Replacement 1) Discontinue electrical service to the dryer. 2) Disconnect compressed air supply from the dryer. 3) Shut off ALL steam supply lines and steam return valves that feed the steam coil. 4) 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.
12) Remove the steam coil damper hinges from the old coil and install them on the new steam coil. 13) Hoist the new steam coil into place and bolt down. 14) Replace ALL of the panels removed in Step #10. 15) Reinstall ALL of the piping removed from the old steam coil in Step #9. NOTE: Thread sealant certified for steam piping must be applied to the threads. 16) Reconnect ALL of the piping (supply lines and return lines) disconnected in Step #8.
E. SPRINKLER SYSTEM DESCRIPTION The sprinkler system is monitored by a microprocessor based temperature controller as a designated "FAILSAFE." 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 575º F, one (1) set of contact in the controller will open, disabling the power (electric supply) to the dryer.
d) Sprinkler Digital Temperature Controller The sprinkler digital temperature controller is a programmable microprocessor used to monitor temperatures via a Resistive Temperature Device (RTD). NOTE: Operating parameters are preset at the factory and should not require any adjustment. 2. Sprinkler System Operation NOTE: Refer to the ladder diagram provided with the dryer for specific relay logic.
3. Sprinkler System Component Replacement a. Resistive Temperature Device (RTD) Replacement 1) Turn the water supply to the dryer off. 2) Discontinue electrical service to the dryer. 3) Remove the 1/4" compression fitting. 4) Remove the two (2) screws from the junction box cover. 5) Remove the wires of the RTD (Resistive Temperature Device) from the terminal strip. NOTE: Identify the wires removed for proper reinstallation. 6) Loosen the cord grip cap.
b. Sprinkler Valve Replacement 1) Turn the water supply to the dryer off. 2) Discontinue electrical service to the dryer. 3) Disconnect compressed air supply from the dryer. 4) Loosen and remove the hose clamp. 5) Remove any residual water to the valve. 6) Remove 1/4" air tubing going to the valve. 7) Remove the two (2) U-bolts holding the sprinkler valve assembly. 8) Unscrew the sprinkler valve from the tubing. 9) To install new sprinkler valve, reverse above procedure.
c. 3 HP Control Relay Replacement WARNING: THE SPRINKLER CIRCUIT HAS A SEPARATE POWER SUPPLY (then the power supply for the dryer). DISCONNECT and LOCK-OUT BOTH POWER SUPPLIES BEFORE SERVICING 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.
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F. TILTING SYSTEM DESCRIPTION The tilting system in the dryer, whether it be 1-way tilt or 2-way tilt, is controlled by the Micro-1 Programmable Logic Controller (PLC). The PLC (Programmable Logic Controller) will determine if the dryer is safe to tilt based on inputs from several sources. If ALL conditions are met, the PLC will send a signal to the tilt relays which energize the appropriate tilt solenoid valve. Compressed air is then allowed to enter the cylinders raising the tumbler.
1. Speed Adjustment The speed of the tilting action can be regulated by adjusting the set of flow control valves located on the pneumatic panel. Each set of cylinders, both front and rear, will have two (2) flow control valves. One valve will be the extend (up) air line and the other valve will be retract (down) air line. The speed of the cylinder is controlled by restricting the exhaust air flow from the cylinder.
3. Tilting Pistons The tilting piston is a double acting cylinder that has a 5-inch bore and an 14-inch stroke. When air is applied to the bottom port of the cylinder, the piston begins to extend and air is exhausted through the top port. Then, if air is applied to the top port, the bottom port will exhaust the air which will cause the piston to retract. 4. Tilting System Component Replacement CAUTION: NEVER SERVICE PNEUMATIC COMPONENTS WITH COMPRESSED AIR CONNECTED. SERIOUS INJURY MAY RESULT. a.
b. Tilting Solenoid Replacement 1) Engage "EMERGENCY STOP" (E-Stop)... Discontinue electrical service to the dryer. 2) Remove panel covering the pneumatic controls. 3) Label the solenoid plugs as an aid when reconnecting. 4) Loosen screws from the solenoid plug. 5) Remove the solenoid plug (take notice of the gaskets). 6) Remove the E-Clip by gently prying off. 7) Slide tilting solenoid valve up off of the post. 8) To install new tilting solenoid valve, reverse above procedure. c.
11) The left orifice (marked #12 on the tilting solenoid valve) now must be configured for external pilot. NOTE: For 1-Way Tilt models proceed to Step #23. 12) Remove the two (2) Phillips head screws. 13) Carefully remove the end of the valve. NOTE: The pieces within the end of the valve are small. Handle carefully to avoid losing parts. 14) Place the solenoid plug over the pilot orifice position of the solenoid valve end.
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d. Tilting Piston Replacement 1) Disconnect compressed air supply from the dryer. 2) Tilt, then level the dryer to exhaust as much air as possible. 3) Disengage "EMERGENCY STOP" (E-Stop)... Discontinue electric service to the dryer. 4) Remove the six (6) screws holding the piston cover plate. 5) Label the air lines as an aid when reconnecting. 6) Loosen the 3/8" compression fittings... Remove the air lines. 7) Remove the 3/8" straight connector. 8) Remove the 3/8" elbow.
G. AIR JET ASSEMBLY 1. Air Jet Assembly Description The air jet assembly is located in the left front base of the dryer. The air jet is designed to operate at the end of each cycle for thirty (30) seconds, to remove lint which may have accumulated on the blower (impellor) fan blades. This function will be interrupted if the main door or lint drawer is opened before the air jet cycle is complete. 2. Air Jet Component Replacement a.
5) Remove the valve support. 6) Remove the two (2) #6-32 x 1" hex head machine bolts by removing the two (2) #6 hex nuts and the two (2) #6 star washers. 7) To install new air jet assembly, reverse above procedure. 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). 4) Reconnect compressed air supply to the dryer.
H. BLOWER (Squirrel Cage Fan) MOTOR ASSEMBLY 1. Blower (Squirrel Cage) Motor Description The AD-310 uses an 18-inch diameter, blower (squirrel cage fan) wheel. It spins (turns) in a counterclockwise (CCW) direction when looking at the back of the blower housing. The blower (squirrel cage fan) shaft is mounted in two (2) 1-3/8" diameter pillow block bearings, and the shaft is driven by two (2) B-section V-belts connected to the blower motor). The blower (drive) motor is mounted on an adjustable base.
2. Blower (squirrel cage fan) and Fan Motor Component Replacement a) Blower (squirrel cage fan) Motor Replacement 1) Discontinue electrical service to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Loosen the bolts from the motor to the motor base ... (a) Slide the blower (squirrel cage fan) motor forward. (b) Remove the V-belts. (c) Remove loosened bolts. 4) Remove the bolts from the bushing. 5) Insert bolts into the threaded holes.
18) Replace the V-belts ... (a) Adjust to proper tension by adjusting position of the new blower (squirrel cage fan) motor. (b) Align the V-belts. 19) Tighten and secure the new motor to the motor base. 20) Rewire the new blower (squirrel cage fan) motor in the same order as the wiring from the motor that was removed. A wiring diagram is usually affixed to the side of the motor. 21) Reestablish electrical service to the dryer.
(d) Loosen the set screws on the bushing. (e) 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 and secure the set screws in the shrouded pillow block bearing. NOTE: Make certain that the squirrel cage fan (impellor and blower) can spin freely. 13) Reinstall the bushing and the pulley.
7) Remove the key on the blower (squirrel cage fan) shaft. (a) Slide the blower (squirrel cage fan) off of the shaft. NOTE: Install this key on to the fan shaft before installing the new blower (squirrel cage fan). 8) To install blower (new squirrel cage fan) , reverse above procedure. d) V-Belt Replacement 1) Discontinue electrical power to the dryer. 2) Loosen the bolts securing the blower (squirrel cage fan) motor. (a) Ease off on the tension bolt. 3) Slide the blower (squirrel cage fan) motor forward.
(a) Thermal Magnetic Starter (TMS) Replacement (1) Discontinue electrical service to the dryer. (2) Mark L1, L2, L3, and T1, T2, T3 on the wires to the to the TMS for correct replacement. (3) Set the amp rating on the TMS according to the manufacturers electrical schematic on the new thermal magnetic starter. (4) To remove the thermal magnetic starter, pull the tab on the bottom and lift upward. (5) To install new thermal magnetic starter, reverse above procedure.
2) Auxiliary Contact Block The Auxiliary Contact Block is mounted on the side of the overload. Its' function is to sense an overload 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 electrical power to the dryer.
I. FILTER and 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.
J. DOOR SYSTEMS The dryer utilizes two (2) styles of doors, which are Manual Doors and Pneumatic Automatic Doors. 1. Manual Door Description The Manual Doors run on a single aluminum track with a wheel assembly mounted above the doors and a channel with teflon strips mounted on the bottom of the doors ... a. For dryers manufactured as of November 1, 1995, there are trolley bolts located at the top of the doors to secure the doors onto the track. b.
3. Door Component Replacement and Removal a. Manual Door Replacement or Removal 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard and then remove the guard. a) For dryers manufactured as of November 1, 1995, loosen the jam nut and screw down the trolley adjustment bolts. b) For dryers manufactured prior to November 1, 1995, remove the two (2) trolley adjustment plates. 3) Lift the door(s) off of the track(s) and remove.
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b. Pneumatic Automatic Door Replacement or Removal 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard. Remove the middle guard. 3) Remove the three (3) 1/4-20 x 3/4" bolts from the bottom guard. Remove the bottom guard. 4) Remove the two (2) 8-32 x 3/4" screws on each door that connect/attach the cable cylinder to the door. 5) Remove the two (2) 1/4-20 x 1-1/4" hex head machine screws that hold the wheels on ...
c. Cable Cylinder Replacement or Removal 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard. (Refer to the illustration on page 76.) Remove the middle guard. 3) Disconnect the cables in the top of the electrical panel. 4) Remove the hardware from the top guard. Remove the top guard. 5) Remove the two (2) 8-32 x 3/4" screws on each door that attach the cable cylinder to the door.
d. Proximity Switch Replacement 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard and then remove the guard. 3) Remove the three (3) 1/4-20 x 3/4" bolts from the bottom guard. Take notice of the depth of the proximity switch. 4) Unscrew and remove the nut that is on the bottom of the proximity switch. 5) Install new proximity switch. 6) Set gap between the proximity switch and the magnet at 3/16" (+/- 1/32").
f. 4-Way Valve, and 3-Way Valve and Supply Air Disable Valve Replacement 1) Discontinue electrical service to the dryer. 2) Disconnect compressed air supply from the dryer. 3) Remove the 1/4-20 self-tapping screws securing the pneumatic panel cover. 4) Remove the two (2) 1/4-20 screws securing the junction box cover. 5) Loosen the cord grip cap that the valve wire go through. 6) Loosen the appropriate wire on the terminal strip. Identify these wires and make note of their placement.
K.
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CAUTION: When servicing the HIGH VOLTAGE section of the dryer, the ELECTRIC SERVICE MUST BE DISABLED. THE "EMERGENCY STOP" (E-Stop) BUTTON DOES NOT DISABLE THE HIGH VOLTAGE TO THE DRYER. 1. Control/Electrical System Description a. 3-Phase (3ø) Electrical Power The 3-phase (3ø) electrical power for the dryer enters the dryer through the power distribution block located in the dryer base electrical box.
3) 24 VAC Transformer The 24 VAC transformer consists of fuse 1 (F1) and fuse 2 (F2) which is the primary fusing for the transformer. For the proper rating of these fuses refer to the specific electric diagram. The transformer is located in the right hand electrical cabinet. Dryer models with an optional Sprinkler System have an energizing stop relay which will disable the dryer functions (shut the dryer down) in the event of a fire.
c) Front Doors Closed circuit branch. There are two (2) magnetic proximity switches mounted in the door closed position and a magnet mounted on top of the doors. When this magnet aligns with the proximity switch, the contacts in the proximity switch close. When both doors are closed, the front doors closed relay (CR2) turns on. (1) There are two (2) sets of contacts in the relay...
2) The Rotational Sensor is a magnetic proximity switch that is mounted on the side of the right hand 11-inch drive wheels. There is a magnet mounted to the side of the wheel hub. After each rotation of the wheel, the magnet passes by the proximity switch causing the contacts to close and pulse the Phase 5 microprocessor controller (computer). Whenever the magnet is over the proximity switch there should be contact closure.
b. PLC (Programmable Logic Controller) 1) The PLC (Programmable Logic Controller) can consist of one (1) or two (2) modules; a main module and in some cases an expansion module is used for additional inputs and outputs. NOTE: The information listed below is generic in nature, refer to blueprints for specific details. a) The main PLC (Programmable Logic Controller) module has eight (8) input relays which are labeled #0 through #7 and six (6) output relays labeled #200 through #205.
Input #12 is the heat on status. It is used to monitor the Phase 5 microprocessor controller (computer) heat output. Input #12 in conjunction with input #13 (gas valve status), the PLC (Programmable Logic Controller) will monitor for a heater fault condition. Input #14 indicates that the drying cycle is done (air jet signal). Once the output relay of the Phase 5 microprocessor controller (computer) turns on contact relay #4, input #14 is turned on.
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2. Electrical Component Replacement a. Control Voltage Transformer (refer to the illustration on page 92) Replacement 1) Discontinue electrical service to the dryer. 2) Locate the correct schematic for the specific change(s) required and verify the wiring of the transformer using the schematic. 3) Verify the voltage of the new transformer. 4) Loosen and then remove the four (4) wires for a 208-230/240 VAC dryer or the six (6) wires for a 380 VAC (and higher) dryer from terminal block #3 (TB3).
b. PLC (Programmable Logic Controller) Replacement 1) Discontinue electrical service to the dryer. If there is an expansion module along side the main module carefully disconnect the ribbon cable connecting the two (2) units together. 2) Mark and identify the wires that will be removed for proper reinstallation.
e. Keypad (touchpad) Replacement 1) Discontinue electrical service to the dryer. 2) Peel existing keypad (touchpad) from the door. 3) Remove as much of the remaining adhesive (from the removed keypad [touchpad] as possible. 4) Install and adhere new keypad (touchpad). 5) Reestablish electrical service to the dryer. f. Switch Replacement 1) Discontinue electrical service to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Remove wires.
h. End of Cycle Light Replacement 1) Discontinue electrical service to the dryer. 2) Loosen and remove the cap screw on the top of the cap. 3) Remove the cap. 4) Loosen and remove the screw going into the lens. 5) Twist out lens and remove bulb/light. 6) To install new bulb, reverse above procedure i. Tilt Switch Replacement 1) Discontinue electrical service to the dryer. 2) Remove the base panel from the left hand side of the dryer.
10) Holding the tilt arm, tighten up (snug up) on the nut. 11) Hold pivot point with a screwdriver and tighten the nut. 12) Replace base panel. 13) Reestablish power to the dryer. j. Tilt Switch Adjustment 1) Discontinue electrical service to the dryer. 2) Remove the base panel from the left hand side of the dryer. CAUTION: DO NOT PLACE HANDS BETWEEN THE DRYER BASE AND TUMBLER (Basket) SECTION. SERIOUS INJURY CAN RESULT.
L. TUMBLER (Basket) SYSTEM 1. Tumbler Drive System The tumbler (basket) is supported and driven by four (4) 11-inch diameter drive wheel assemblies. 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 trantorque keyless locking bushing. The trantorque is made up of three (3) pieces; an inner collar, an outer sleeve, and a locking nut.
WARNING: TO ENSURE THAT THE DRIVE IS NOT UNEXPECTEDLY STARTED, TURN OFF and LOCK OUT and/or TAG POWER SOURCE BEFORE PROCEEDING. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY. WARNING: Drive shaft assembly is heavy. IMPROPER HANDLING CAN CAUSE PERSONAL INJURY. 2. Drive Motor Components a) Drive Motor Replacement 1) Discontinue electrical service to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Loosen the turnbuckle and remove V-belts.
3) NOTE: Install new V-belts. Replace V-belts in matched sets (both belts). 4) Tighten turnbuckle. IMPORTANT: DO NOT OVER TIGHTEN TURNBUCKLE. 5) Reestablish electrical service to the dryer. 3) Taper Bushing Assembly and Drive Motor Pulley Assembly Components a) Taper Bushing and Drive Motor Pulley Replacement 1) Discontinue electrical service to the dryer. 2) Loosen turnbuckle and remove V-belts. 3) Mark inside of the drive motor shaft. 4) Remove the bolts securing the taper bushing.
4) Insert blocks of wood under the tumbler (basket) - access through the lint drawer - to take the weight off of the drive wheels. 5) Loosen the turnbuckle and remove the V-belts. Remove bottom turnbuckle mounting bolt. 6) Remove the trantorque from the drive wheels. (A chain wrench will be required to hold the drive shaft to remove the trantorque.) IMPORTANT: On reinstallation, the trantorque must be torqued to 2,300 foot-pounds (259 n-m (newton-meters).
c) Pillow Block Bearing(s) Replacement 1) Discontinue electrical service to the dryer. 2) Follow Step #2 through Step #9 in the instructions on page 98 and page 99. 3) Remove both drive wheels and trantorques. 4) Carefully file the score marks on the drive shaft from the set screws before removing the pillow block bearing(s). 5) To install the new pillow block bearing(s), reverse procedure in the instructions on page 99 and page 98. 6) Reestablish electrical service to the dryer.
11) Reinstall the drive shaft into the dryer. 12) Secure the gear reducer to the drive shaft by reinstalling the three (3) bolts into the taper bushing and tighten evenly for proper mounting. 13) Repeat Step #12 to reinstall the other taper bushing. 14) Reinstall the bolt into the turnbuckle and mounting bracket. 15) Reinstall V-belts and tighten turnbuckle. 16) Prior to operating new gear (speed) reducer, fill with 1.4 liters of SAE 90 gear oil. IMPORTANT: DO NOT OVER TIGHTEN TURNBUCKLE.
b) Retaining Wheel(s) Replacement 1) Discontinue electrical service to the dryer. 2) Remove the four (4) Phillips pan head screws to remove the cover. 3) Remove the hardware (i.e., bolt, lock washer, and flat washer) from the hex nut and weld nut on the wheel mount. 4) Install the new retaining wheel. Reinstall the lock washer then the flat washer onto the bolt and insert into lower mount hole through the retaining wheel and through the hex nut, then into the weld nut and snug up the bolt.
CAUTION: USE EXTREME CARE WHEN SETTING RETAINING WHEEL TENSION. PERSONAL INJURY MAY RESULT. NOTE: Proper retaining wheel tension has been achieved when the wheel spins and stops when slight pressure is applied (to the retaining wheel itself). 6. Tumbler/Basket Electrical Components a) Tumbler (Basket) Thermal Magnetic Starter and Auxiliary Contact Block Replacement 1) Discontinue electric service to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation.
11) Replace ALL the wires removed in Step #5 (refer to previous page [page 91]). 12) Mount the top of the thermal magnetic starter to the top of the din rail and press down and in. Inspect ALL of the work performed. 13) Set the control of the thermal magnetic starter to the "start" position. 14) Reestablish electrical power to the dryer. 7. Rotational Sensor Assembly The Rotational Sensor Assembly is located on the right rear drive wheel.
SECTION VI TROUBLESHOOTING IMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR 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 components associated with the difficulty described.
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...
2. Failed overload protector. E. Impellor (fan) motor is not operating (does not start)... * Microprocessor controller (computer) “MTR” relay output indicator is on. 1. Blown blower (impellor and fan) motor fuses or overloads. 2. Failed blower (impellor and fan) motor contactor (relay). 3. Failed blower (fan and impellor) motor. 4. Sail switch verification circuit not in open position prior to the start of the drying cycle. * Microprocessor controller (computer) “MTR” relay output indicator is off. 1.
H. Both drive motor and blower (fan and impellor) motor are not operating...microprocessor controller (computer) L.E.D. (light emitting diode) motor indicator dots and the “door” L.E.D. indicator are on but the relay output L.E.D. indicators are off (microprocessor controller [computer] L.E.D. display does not read “door”). 1. Failed microprocessor controller (computer). I. Microprocessor controller (computer) L.E.D.
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.
Q. Microprocessor controller (computer) L.E.D. (light emitting diode) display reads “SEFL”... 1. Rotational sensor circuit failure... fault somewhere in the tumbler (basket) rotation or circuit ... a. Tumbler (basket) not rotating ... 1) Broken tumbler (basket) drive belts. 2) Failure in drive motor circuit. b. Bad rotation sensor. c. Broken wire or connection between rotation sensor and microprocessor controller (computer). d. Failure in rotational sensor circuit or magnet missing or gap to large. R.
6. Extractors (washer) not performing properly. 7. Sail switch is fluttering...restriction in exhaust (for GAS MODELS ONLY). 8. Failed microprocessor controller (computer)...temperature calibration is inaccurate. 9. Failed microprocessor temperature sensor...calibration is inaccurate. 10. Failed burner hi-limit (for GAS MODELS ONLY). 11. Failed 225° F hi-limit (thermostat). 12. Steam damper system is not functioning properly (for STEAM DRYER ONLY) ... a. Steam damper sticking closed. b.
V. Dryer will not tilt... 1. Tilt to unload -- 1-- door... a) Dryer will not tilt unless the front doors are completely open ... 1) No door open signal. 2) Defective proximity switch. 3) No (external) compressed air to pneumatic switches... 80 psi required (11 cf/hr). 2. Tilting to unload -- 2-doors ... a) Dryer will not tilt to unload unless the front doors are closed. 3. Lint drawer is open. W. Dryer will not level from a tilt position... 1. Lint drawer is open. 2. Defective lint drawer switch. 3.
SECTION VII PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. Microprocessor (computer) Board a. Upon completing installation of the replacement microprocessor (computer) board, reestablish power to the dryer. b. Start the drying cycle. c. Verify that the motor and the heat indicator dots, in the microprocessor (computer) L.E.D. display are on. (Refer to the illustration below.) d.
e. Open main door. The dryer must stop and ALL indicator lights on the back side of the microprocessor (computer) board must go out. (Refer to illustration on previous page [page 113].) f. Try to restart the dryer with the main door open. g. The microprocessor (computer) board's L.E.D. display must read "DOOR." h. Close the main door and restart the dryer. i. Functional check of microprocessor (computer) board is complete. 2. Direct Spark Ignition (DSI) System a.
ADC 450413 1- 05/11/99-25 2- 01/31/00-5
