AD-410 Phase 7 Service Manual 102600DMG/calbert American Dryer Corporation 88 Currant Road Fall River, MA 02720-4781 Telephone: (508) 678-9000 / Fax: (508) 678-9447 E-mail: techsupport@amdry.com www.amdry.com 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 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. 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.
WARNING DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER OR SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. IMPORTANT PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and specified in the installation manual included with the dryer. The wiring diagram for the dryer is located in the front electrical control box area.
Table of Contents AD-410 REFERENCE GUIDE (Basket [Tumbler] Section)................................. 3 AD-410 REFERENCE GUIDE (Base Section) ...................................................... 4 SECTION I SAFETY PRECAUTIONS ........................................................................................ 5 SECTION II ROUTINE MAINTENANCE .................................................................................... 7 A. Cleaning ................................................................
SECTION VI PHASE 7 OPL SYSTEM DIAGNOSTICS ........................................................... 97 A. Diagnostic (L.E.D. Display) Fault Messages .............................................................................. 97 B. Input/Output (I/O) Board Light Emitting Diode (L.E.D.) Indicators ............................................ 99 SECTION VII TROUBLESHOOTING .........................................................................................
AD-410 Reference Guide (Basket [Tumbler] Section) 3
AD-410 Reference Guide (Base Section) 4
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 solvents 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 ductwork, 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 ductwork 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.
WARNING: TO AVOID THE HAZARD OF ELECTRICAL SHOCK, DISCONTINUE ELECTRICAL SUPPLY TO THE DRYER. MONTHLY Empty the compressed air filter bowl. NOTE: REGULATOR PRESSURE IS TO BE SET AT 80 PSI (5.51 BARS). Clean any lint accumulation from the gas valve and 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.
B. LUBRICATION MONTHLY The two (2) bearings that support the impellor/fan shaft must be lubricated. Use Shell Alvania #2 grease or its equivalent. Generically, this grease would be described as a NLGI Grade 2 multipurpose industrial grease with a lithium thickener and mineral base oil. EVERY 3 MONTHS The four (4) bearings that support the drive and idler shafts must be lubricated. Use Shell Alvania #2 grease or its equivalent.
EVERY 6 MONTHS Change gear oil in basket (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 1.48 quarts (1.4 liters) of Mobil Oil DTE HH5G (I.S.O. viscosity grade 460), SAE 90, or its equivalent. C. ADJUSTMENTS 7 DAYS AFTER INSTALLATION and EVERY 6 MONTHS THEREAFTER Inspect bolts, nuts, screws, (bearing setscrews), nonpermanent gas connections (i.e.
SECTION III SPECIFICATIONS and DIMENSIONS A. SPECIFICATIONS (Gas and Steam Models) MAXIMUM CAPACITY (DRY WEIGHT) 410 lbs. 186.4 kg MINIMUM CAPACITY (DRY WEIGHT) 250 lbs. 113.39 kg BASKET (TUMBLER) DIAMETER 68-3/4” 174.62 cm BASKET (TUMBLER) DEPTH 66-3/8” 168.59 cm BASKET (TUMBLER) VOLUME 143 cu. ft. 4.05 cu. m. DRIVE MOTOR 7-1/2 HP 5.6 kw BLOWER MOTOR (GAS/STEAM) 15/25 HP 11.18/18.7 kw 40” wide x 50” high 101.
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.
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 15
SECTION IV INSTALLATION REQUIREMENTS Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, the installation must conform to applicable American National Standards: 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.
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 to local and state regulations or codes. In the absence of such codes, ALL electrical connections, materials, and workmanship must conform to the applicable requirements of the National Electrical Code ANSI/NFPA NO.
SECTION V COMPONENT DESCRIPTION/REPLACEMENT A. HEAT SECTION The dryer uses three (3) types 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. The gas dryers utilize a Direct Spark Ignition (DSI) module to monitor that a flame is established.
24 VAC Direct Spark Ignition (DSI) Modules 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. Johnson (DSI) Control Module P/N 128935 ADC (DSI) Control Module P/N 128973 b.
e. The manual reset basket (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 [107º C]). 225º F (107º C) 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 (1); one (1) in series with the other.
h. Troubleshooting Flowchart - Quick Reference... First Visual Check No Spark And System Does Not Work Is 24 VAC available at transformer? No Is 24 VAC present from terminal THS(2) to ground? Yes No Is power available to primary? No Yes Replace Transformer. Reset or replace hi-limits Determine why voltage is not present. Yes Are thermostat contacts and hi-limit control contacts closed? No Yes Check continuity of wiring to determine why voltage does not exist at THS(2).
i. Troubleshooting Flowchart - Quick Reference... Second Visual Check Spark Present But Main Burner Does Not Come On Is main valve wiring securely attached to terminal M.V.(3) and ground? No Yes Is 24 VAC present between terminals M.V.(3) and ground? No Secure wiring to M.V.(3) and ground. Yes Replace DSI module Check for continuity in wiring from M.V.(3) to gas valve, and gas valve to GR. Determine why continuity does not exist.
j. Troubleshooting Flowchart - Quick Reference... Third Visual Check Main Burner Lights But Will Not Stay On Is flame sensor cable securely attached to sense (4) terminal? No Does continuity exist from control to flame sensor? Yes No Reattach flame sensor wire to sense (4) terminal. Yes Replace sensor cable. Is flame sensor corroded or is ceramic cracked? Correct or replace sensor. Yes No Does continuity exist in ground path from burner to control? Check connection.
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-410 Phase 7 Tilting Installation Manual (ADC Part No. 113112) included with the dryer. IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY SAFETY or HEAT CIRCUIT DEVICES EVER BE DISABLED.
1. Direct Spark Ignition (DSI) Troubleshooting Terms (definitions) ADC (DSI) Control Module P/N 128973 a. DSI MODULE “RED” L.E.D. INDICATOR LIGHT - This “red” light emitting diode (L.E.D.) light is located in the upper right corner of the DSI module (refer to the top illustration on page 19). This is a diagnostic indicator that simplifies the operational and troubleshooting procedures of the DSI system. b. LOCKOUT MODE - DSI module “red” L.E.D. indicator light stays on continuously.
If the dryer repeatedly has Direct Spark Ignition (DSI) module “LOCKOUT” failures, the cause may be due to high voltage not getting into the DSI module ignitor probe assembly. 5) 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/flame-probe assembly). If the wires are touching one another, separate and secure in place AWAY FROM ONE ANOTHER.
c. Three (3) Visual Checks 1) Does the Direct Spark Ignition (DSI) ignitor/flame-probe assembly start sparking? If not, refer to the First Visual Check on page 28. 2) Does the main burner ignite? If not, refer to the Second Visual Check on page 29. 3) Does the main burner remain lit after ignition has been established (“FLAMEOUT”)? If not, refer to the Third Visual Check on page 30.
d. Troubleshooting Flowchart - Quick Reference... First Visual Check (Does Ignitor Spark?) Computer/Timer Calls For Heat Is spark evident (on) at Ignitor Assembly? No Is 24 Volts present across DSI Module terminals TH and COM? 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 Flowchart - 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 Flowchart - 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 For Johnson Direct Spark Ignition (DSI) Module P/N 128935 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 module light emitting diode (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.
a) Connect the water column test gauge (manometer) to the gas valve pressure tap (1/8” N.P.T.). Refer to the illustration on the previous page (page 31). b) Start the dryer...with the burner on, the correct water column (W.C.) pressure reading in inches should be : Natural Gas ------------------ 3.5 inches (8.7 mb) Water Column. Liquid Propane (L.P.) Gas - 10.5 inches (26.1 mb) Water Column.
(a) To check and/or set the 1/8” (3.175 mm) gap, use a Direct Spark Ignition (DSI) gap feeler gauge or similar device to determine gap size. DO NOT USE FEELER TO SET THE GAP, USE IT ONLY TO DETERMINE THE SIZE OF THE GAP. If an adjustment is necessary, bend the ground rod to achieve the correct gap, then recheck the 1/8” (3.175 mm) gap with a feeler gauge.
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 ductwork, the Direct Spark Ignition (DSI) module will cycle erratically. This in turn might cause the DSI module to “LOCKOUT” (where the light emitting diode [L.E.D.] indicator will BLINK “GREEN” CONTINUOUSLY).
CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THE BURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORT OUT. 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. This operates the DSI module. This transformer, 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...
4. Troubleshooting and System Detailed Diagnosis For ADC Direct Spark Ignition (DSI) Module P/N 128973 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 module light emitting diode (L.E.D.) indicator will LIGHT “RED” (for up to approximately 1.5-seconds [prepurge]) then the L.E.D.
a) Connect the water column (W.C.) test gauge (manometer) to the gas valve pressure tap (1/8” N.P.T.). Refer to the illustration on the previous page (page 36). b) Start the dryer...with the burner on, the correct water column pressure reading in inches should be: Natural Gas ------------------ 3.5 inches (8.7 mb) Water Column. Liquid Propane (L.P.) Gas - 10.5 inches (26.1 mb) Water Column.
(a) To check and/or set the 1/8” (3.175 mm) gap, use a Direct Spark Ignition (DSI) gap feeler gauge or similar device to determine gap size. DO NOT USE FEELER TO SET THE GAP, USE IT ONLY TO DETERMINE THE SIZE OF THE GAP. If an adjustment is necessary, bend the ground rod to achieve the correct gap, then recheck the 1/8” (3.175 mm) gap with a feeler gauge.
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 ductwork, the Direct Spark Ignition (DSI) module will cycle erratically. This in turn might cause the DSI module to “LOCKOUT” (where the light emitting diode [L.E.D.] indicator will LIGHT “RED” CONTINUOUSLY).
CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THE BURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORT OUT. 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. This operates the DSI module. This transformer, 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...
C. NATURAL GAS and LIQUID PROPANE (L.P.) 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) or the dryer. The water column (W.C.) gas pressure must be regulated 10.5 inches (26.1 mb) for safe and efficient dryer operation.
11. Reverse the procedure for reinstalling the gas valve/manifold assembly to the dryer. 12. Open ALL gas shutoff valves (closed in Step #2). 13. Reestablish electrical power 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 cycle to insure proper operation. D.
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. IMPORTANT: Coil failure due to improper PH level will VOID THE WARRANTY. 2.
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 airflow and slows the steam damper movement. Counterclockwise (CCW) adjustment speeds up the steam damper motion. Upon completion of the adjustment, tighten the needle valve’s locking nut. 3. Steam Damper Actuator System Service and Replacement a.
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 (Step #6 thru Step #1). 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 (Step #3 thru Step #1). d. Steam Coil Replacement 1) Discontinue electrical power to the dryer.
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 the steam coil. 11) Unbolt the steam coil and remove. WARNING: The steam coil is heavy. A crane may be needed to remove (and install) the steam coil.
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 temperature at the resistive temperature device (RTD) reaches 575º F (301.6º C), one (1) set of contacts 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.
5) Remove the wires of the resistive temperature device (RTD) from the terminal strip. NOTE: Identify the wires removed for proper reinstallation. 6) Loosen the cord grip cap. 7) Remove RTD. 8) To install new RTD, reverse above procedure (Step #7 thru Step #1). b. Sprinkler Valve Replacement 1) Turn the water supply to the dryer off. 2) Discontinue electrical power to the dryer. 3) Disconnect compressed air supply from the dryer. 4) Loosen and remove the hose clamp.
WARNING: THE SPRINKLER CIRCUIT HAS A SEPARATE POWER SUPPLY (than the power supply for the dryer). DISCONNECT and LOCKOUT BOTH POWER SUPPLIES BEFORE SERVICING THE DRYER. c. 3 HP (2.24 kw) Control Relay Replacement 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 faulty 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 overload to the setting specified on the dryer blueprints. 7) Inspect the work performed before reestablishing power (electrical power) to the dryer. 8) Reestablish electrical power to the dryer.
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F. TILTING SYSTEM DESCRIPTION The tilting system in the dryer, whether it is 1-way tilt or 2-way tilt, is controlled by the TSX-07 programmable logic controller (PLC). The PLC will determine if the dryer is safe to tilt based on inputs from several sources. If ALL conditions are met, the PLC will send a signal to the tilt relays, which energize the appropriate tilt solenoid valve. Compressed air is then allowed to enter the cylinders raising the basket (tumbler).
1. Tilting Solenoid Valve The dryer uses a 3-position/4-way/5-port, spring centering double solenoid valve. With no power applied to either solenoid, the valve is in a spring centered blocked post state. In this mode, the dryer’s tilting pistons will remain in their present state, not being able to exhaust air or receive air. When the left solenoid is energized with 24 VAC, the pilot air pushes the shuttle to the right enabling air to flow into the #2 port and exhausts #4 port.
a. Tilting Solenoid Replacement 1) Engage “EMERGENCY STOP” (E-Stop)... Discontinue electrical power 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 (Step #7 thru Step #1). b.
10) Remove the two (2) 3/8” mufflers. (Refer to the illustration on page 57.) Reinstall these mufflers on the new solenoid valve body. 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.
c. 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 electrical power 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.
9) Carefully remove the E-clips from the clevis pins. 10) Remove clevis pins. 11) Loosen the bottom setscrew in the piston rod eye. 12) Unscrew the piston rod eye from the tilting piston. 13) To install new tilting piston, reverse above procedure (Step #12 thru Step #1).
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 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 (Step #6 thru Step #1). b. Pneumatic Valve Muffler Replacement 1) Disconnect compressed air supply from the dryer. 2) Remove damaged or nonfunctional muffler (silencer) from valve body. 3) Replace muffler (silencer) by threading into valve body (snug fit).
H. BLOWER (Squirrel Cage Fan) MOTOR ASSEMBLY 1. Blower (Squirrel Cage Fan) Motor Description The dryer uses a 22-1/4” (56.51cm) 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) 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) Motor Component Replacement a. Blower (Squirrel Cage Fan) Motor Replacement 1) Discontinue electrical power 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 power to the dryer. b.
d) Loosen the setscrews on the bushing. e) Remove the bushing and the pulley. 11) Remove the pillow block bearing with shroud by removing the setscrew. 12) Replace the pillow block bearing with shroud on to the fan shaft... a) Secure the fan (blower) shaft bearing mount assembly. b) Tighten and secure the setscrews in the pillow block bearing with shroud. NOTE: Make certain that the squirrel cage fan (impellor/blower) can spin freely. 13) Reinstall the bushing and the pulley.
7) Remove the 1/4” x 1/4” x 1-3/4” (6.35 mm x 6.35 mm x 4.45 cm) key on the blower (squirrel cage fan) shaft. a) Slide the blower (squirrel cage fan) off of the shaft. NOTE: Install this 1/4” x 1/4” x 1-3/4” (6.35 mm x 6.35 mm x 4.45 cm) key to the fan shaft before installing the new blower (squirrel cage fan). 8) To install the new blower (squirrel cage fan), reverse above procedure (Step #7 thru Step #1). d. V-belt Replacement 1) Discontinue electrical power to the dryer.
a) Thermal Magnetic Starter (T.M.S.) Replacement (1) Discontinue electrical power to the dryer. (2) Mark L1, L2, L3, and T1, T2, T3 on the wires to the T.M.S. for correct replacement. (3) Set the amp rating on the T.M.S. according to the manufacturer’s electrical schematic on the new thermal magnetic starter. (4) To remove the T.M.S., pull the tab on the bottom and lift upward. (5) To install the new T.M.S., reverse above procedure (Step #4 thru Step #2). (6) Reestablish electrical power to the dryer.
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. An “Overload Fault” message will appear on the light emitting diode (L.E.D.) display on the Phase 7 microprocessor controller (computer). a) Auxiliary Contact Block Replacement (1) Discontinue electrical power to the dryer. (2) Remove the thermal magnetic starter (T.M.S.
I. 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.
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 October 19, 1999, there are trolley bolts located at the top of the doors to secure the doors onto the track.
3. Door Component Replacement and Removal a. Manual Door Replacement or Removal 1) Discontinue electrical power 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) Loosen the jam nut and screw down the trolley adjustment bolts. 4) Lift the door(s) off of the track(s) and remove. 5) To install new manual door(s) or to reinstall manual door(s), reverse above procedure (Step #3 thru Step #1).
b. Pneumatic Automatic Door Replacement or Removal AUTOMATIC DOORS 1) Discontinue electrical power 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. 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 power 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 70.) 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 power 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” (4.7625 mm +/- 0.79248 mm).
f. 4-Way Valve, 3-Way Valve, and Supply Air Disable Valve Replacement 1) Discontinue electrical power to the dryer. 2) Disconnect compressed air supply from the dryer. 3) Remove the 1/4-20 selftapping 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 goes 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 (HV) section of the dryer, the ELECTRICAL POWER MUST BE DISABLED. THE “EMERGENCY STOP” (E-Stop) BUTTON DOES NOT DISABLE THE HIGH VOLTAGE TO THE DRYER. 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 Circuit Breaker (CB5), which is the primary fusing for the transformer. For the proper rating of this circuit breaker 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) Dryer level switches circuit branch... (1) On 1-way tilt models, this switch is in series with the dry enable. (2) On 2-way tilt models...one (1) pole of each of the two (2) level switches (LS1-A and LS2A) is in series with the dryer level relay and the other pole is in series with the opposite piston. IF THE OPPOSITE SIDE IS NOT LEVEL, THE DRYER WILL NOT TILT. d) Lint drawer closed circuit branch... The lint drawer closed switch is located in the front of the dryer.
Next reverse leads to temperature sensor “black” to “black” and “red” to “white.” At that point you measure approximately 1.8-amps, this is the turn on voltage of the device. If you hold the temperature sensor in your hands and warm it the reading will decrease corresponding to a higher current flow (the decrease is very slight tenths of a volt). 2) The rotational sensor is a magnetic proximity switch that is mounted on the basket (tumbler) wrapper on the left side of the dryer.
a) The programmable logic controller (PLC) module has thirteen (13) input relays, which are labeled #0 through #13 and nine (9) output relays labeled #0 through #9. (1) Input Relays Input relays #0, #1, #2, and #3 are set up as user inputs to signal what specific function is to be performed (i.e., load, unload, tilt, and front identifier). These input relays are charted as 1 and 0 (1 is logic on and 0 is logic off).
2. Electrical Component Replacement a. Control Voltage Transformer Replacement (refer to the illustration on page 84). 1) Discontinue electrical power 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).
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b. Programmable Logic Controller (PLC) Replacement 1) Discontinue electrical power to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) To remove the PLC from the mounting rail, using a screwdriver, very carefully pull out the mounting clip on the bottom of the PLC and lift the unit out of the rail. 4) To replace the PLC, push in the top of the PLC into the rail and then snap in the bottom of the unit. 5) Replace the wires removed in Step #2.
5) To install new microprocessor controller (computer) input/output (I/O) board, reverse Step #4 thru Step #1. 6) Reestablish electrical power to the dryer. e. Keyboard (touch pad) Replacement 1) Discontinue electrical power to the dryer. 2) Disconnect keyboard (touch pad) ribbon cable from the Phase 7 microprocessor controller (computer) display board. 3) Peel existing keyboard (touch pad) from the door. 4) Remove as much of the remaining adhesive (from the removed keyboard [touch pad]) as possible.
5) With fingertip, gently push and turn the bulb to unlock. NOTE: A piece of tubing with an inside diameter the size of the bulb may assist in bulb removal and replacement. 6) To install new bulb, reverse Step #5 thru Step #1. h. End of Cycle Light Replacement 1) Discontinue electrical power 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.
Verify that the tilt switch arm is not in the vertical position or damage will result. 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 electrical power to the dryer. j. Tilt Switch Adjustment 1) Discontinue electrical power 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 THE BASKET (Tumbler/Drum) SECTION.
L. BASKET (Tumbler) SYSTEM 1. Basket (Tumbler) Drive System The basket (tumbler) is supported and driven by four (4) 11-inch (27.94 cm) diameter drive wheel assemblies. Two (2) of these wheels are attached to a 2-inch diameter idler shaft, while the other two (2) are attached to a 2-inch diameter drive shaft. Each of the wheels is fastened to the shafts by a taper lock bushing. The idler shaft and drive shaft are each supported by two (2) 2-inch diameter pillow block bearings.
WARNING: TO ENSURE THAT THE DRIVE IS NOT UNEXPECTEDLY STARTED, TURN OFF and LOCKOUT 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 Component(s) a. Drive Motor Replacement 1) Discontinue electrical power to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Loosen the turnbuckle and remove V-belts.
1) Discontinue electrical power to the dryer. 2) Loosen turnbuckle and remove V-belts. 3) Install new V-belts. NOTE: Replace V-belts in matched sets (both belts). 4) Tighten turnbuckle. IMPORTANT: DO NOT OVERTIGHTEN TURNBUCKLE. 5) Reestablish electrical power to the dryer. c. Taper Lock Bushing and Drive Motor Pulley Replacement 1) Discontinue electrical power to the dryer. 2) Loosen turnbuckle and remove V-belts. 3) Mark inside of the drive motor shaft.
3) Mark the position of the pillow block bearing on the mounting pad and loosen the setscrews. 4) Insert blocks of wood under the basket (tumbler) - 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 bolts from the pillow block bearing mounting pads as well as the adjustment bolts. 7) Remove drive motor from the dryer. (Refer to Drive Motor Replacement on page 89.
5) Reestablish electrical power to the dryer. f. Pillow Block Bearing(s) Replacement 1) Discontinue electrical power to the dryer. 2) Follow Step #2 thru Step #11 in the instructions on (page 90 and page 91). 3) Remove both drive wheels and taper lock bushings. 4) Carefully file the score marks on the drive shaft from the setscrews before removing the pillow block bearing(s). 5) To install new pillow block bearing(s), reverse Step #11 thru Step #2 in the instructions on (page 90 and page 91).
10) Secure the gear reducer to the drive shaft by reinstalling the three (3) bolts into the taper lock bushing and tighten evenly for proper mounting. 11) Repeat Step #12 to reinstall the other taper lock bushing. 12) Reinstall the bolt into the turnbuckle and mounting bracket. 13) Reinstall V-belts and tighten turnbuckle. 14) Prior to operating new gear (speed) reducer, fill with 1.48 quarts (1.4 liters) of SAE 90 gear oil. IMPORTANT: DO NOT OVERTIGHTEN TURNBUCKLE.
b. Retaining Wheel(s) Replacement 1) Discontinue electrical power 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.
4. Basket (Tumbler) Electrical Component(s) a. Basket (Tumbler) Thermal Magnetic Starter (T.M.S.) and Auxiliary Contact Block Replacement 1) Discontinue electrical power to the dryer. 2) Mark and identify the wires that will be removed for proper reinstallation. 3) Set the control of the T.M.S. to the “stop” position. 4) Press down on the T.M.S. and lift the bottom up and out of the din mounting rail. 5) Mark and identify the wires that will be removed for proper reinstallation.
11) Replace ALL wires removed in Step #5 (refer to the previous page [page 95]). 12) Mount the top of the thermal magnetic starter (T.M.S.) to the top of the din rail and press down and in. Inspect ALL of the work performed. 13) Set the control of the T.M.S. to the “start” position. 14) Reestablish electrical power to the dryer. 5. Rotational Sensor Assembly The Rotational Sensor Assembly is located on the right hand side of the dryer basket (tumbler) section.
SECTION VI PHASE 7 OPL SYSTEM DIAGNOSTICS IMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STANDARDS. ALL major circuits, including door, microprocessor temperature sensor, heat and motor circuits are monitored.
REAR SAIL SWITCH CLOSED FAULT - Rear sail switch is closed and should be opened. REAR SAIL SWITCH OPEN FAULT - Rear sail switch is open and should be closed. FAN CONTACTOR FAULT - The fan contactor was not pulled in. FRONT BURNER HIGH LIMIT FAULT - Indicates the temperature disk in the front burner has opened. REAR BURNER HIGH LIMIT FAULT - Indicates the temperature disk in the rear burner has opened. FRONT BURNER VALVE FAULT - Indicates front gas valve is not working or no gas is turned on or flameout.
B. INPUT/OUTPUT (I/O) BOARD LIGHT EMITTING DIODE (L.E.D.) INDICATORS INPUTS: (RED) OUTPUTS: (GREEN) 1. FDRC - Front Door Closed 1. R_HEAT - Rear Heat 2. FDRO - Front Door Open 2. AUDIO ALERT - Horn On 3. TBOL - Basket (Tumbler) Overload 3. FWD - Basket (Tumbler) Forward 4. FNOL - Fan Overload 4. REV - Basket (Tumbler) Reverse 5. RDWN - Rear Down 5. AIR JET - Air Jet On 6. FDWN - Front Down 6. FAN - Blower Fan On 7. RDRC - Rear Door Closed 7. F_HEAT - Front Heat 8.
INPUTS: 1. FDRC – (RED L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the front doors. If the doors are closed, then the L.E.D. is ON. 2. FDRO – (RED L.E.D.) This L.E.D. will indicate the status of the front doors. If the doors are open, then the L.E.D. is ON. 3. TBOL – (RED L.E.D.) This L.E.D. will indicate the status of the basket (tumbler) overload contact. If the contact is closed, then the L.E.D. is ON. If it faults open, then the L.E.D. is OFF. 4. FNOL – (RED L.E.D.
16. LINT – (RED L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the lint drawer. If the drawer is closed, then the L.E.D. is ON. 17. R_HE Supply power for rear heat output. 18. F_HE Supply power for front heat output. 19. 24VIN – (RED L.E.D.) This L.E.D. will indicate the status of the control voltage. If the POWER ON button is pressed (green button light is on), then the L.E.D. is ON. 20. SPR5 – (RED L.E.D.) This is for a spare input to be used with programmable outputs. 21.
OUTPUTS: 1. R_HEAT – (GREEN L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the rear heat output. If the request to turn on the rear heater is made, then the L.E.D. is ON. 2. AUDIO ALERT – (GREEN L.E.D.) This L.E.D. will indicate the status of the horn output. If the request to turn on the horn is made, then the L.E.D. is ON. 3. FWD – (GREEN L.E.D.) This L.E.D. will indicate the status of the basket (tumbler) forward direction output.
16. OCL5 – (GREEN L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the open collector output #5. If the request to turn on the open collector output #5 is made, then the L.E.D. is ON. (Programmable and defaulted to rear down). 17. OCL6 – (GREEN L.E.D.) This L.E.D. will indicate the status of the open collector output #6. If the request to turn on the open collector output #6 is made, then the L.E.D. is ON. (Programmable and defaulted to rear door open). 18. OCL7 – (GREEN L.E.D.
SECTION VII 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.
NOTE: SPRINKLER MUST HAVE POWER FOR THE DRYER TO OPERATE. 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 overloads. 2. Failed drive motor contactor. 3. Failed drive motor. 4. No 24 VAC present at drive motor contactor coil. * Microprocessor controller (computer) relay output indicator (neither forward “FWD” nor reverse “REV”) is on. 1.
f. V-belts are too tight. g. Dryer has an oversized load. h. Voltage to the dryer is incorrect...check dryer data label for specified voltage. 2. Failed overload protector... a. Incorrect overload setting. E. Impellor (fan) motor is not operating (does not start)... * Microprocessor controller (computer) input/output (I/O) board “FAN” relay output indicator is on. 1. Blown blower (fan and impellor) motor overloads. 2. Failed blower (fan and impellor) motor contactor (relay). 3.
2. Failed overload protector... a. Incorrect overload setting. 3. Blown drive motor and blower (fan and impellor) motor fuses or overloads. 4. Failed motors (both blower [fan and impellor] motor and drive motor). 5. Failed microprocessor controller (computer). G. Microprocessor controller (computer) display board light emitting diode (L.E.D.) display reads “BAD PROBE” continuously and the buzzer (tone) sounds every 30-seconds... 1. Fault in microprocessor heating sensing circuit... a.
5. Front or rear doors are opened during cycle. 6. Failed microprocessor controller (computer) input/output (I/O) board. J. Microprocessor controller (computer) light emitting diode (L.E.D.) displays “Lint Drawer Open”.. 1. Lint drawer is not closed ALL the way. 2. Lint drawer switch is out of proper adjustment. 3. Failed lint drawer switch. 4. Failed microprocessor controller (computer) I/O board. K. Microprocessor controller (computer) will not accept any keyboard (touch pad) entries, (i.e., L.E.D.
2) Failure in drive motor circuit. b. Faulty rotation sensor. c. Broken wire or connection between rotation sensor and microprocessor controller (computer) display board. d. Failure in rotational sensor circuit or magnet missing or gap too large. e. Basket (tumbler) rotation below 12 RPMs. P. Microprocessor controller (computer) reads “Exhaust High Temp Fault”... 1. Possible overheating condition...
13. Steam damper system is not functioning properly (for STEAM MODELS ONLY)... a. Steam damper sticking closed. b. Leak in pneumatic system. 14. Undersized load, dryer requires a minimum load size of approximately 125 lbs (57 kg) for maximum drying efficiency. R. Excessive noise and vibration... 1. Dryer is not leveled properly. 2. Impellor (fan/blower) out of balance... a. Excessive lint buildup on impellor (fan/blower)...check air jet. b. Failed impellor (fan/blower). 3. Loose motor mount. 4.
* Tilt to unload. 1. Correct door signals are not present... a. Door open to tilt down. b. Door closed to tilt level. 2. Defective proximity switch. 3. No (external) compressed air to pneumatic switches...80 PSI (5.51 bars) required (11 cf/hr [0.31 cm/hr]). 4. Lint drawer is open.
SECTION VIII PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. For Models With Johnson Controls Direct Spark Ignition (DSI) Module (G760) Theory Of Operation: Start the drying cycle. When the gas burner ignites within the chosen trial for ignition time (6-seconds), the flame sensor detects gas burner flame and signals the DSI module to keep the gas valve open...as long as there is a call for heat.
2. 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 light emitting diode (L.E.D.) indicator will light “red” for up to approximately 1.5-seconds (prepurge 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 450051 1- 08/30/01-25
