AD-464 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 020399DMG/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 SECTION I SAFETY PRECAUTIONS .................................................................................................................. 3 SECTION II ROUTINE MAINTENANCE ............................................................................................................. 5 A. Cleaning ..................................................................................................................................... 5 B. Lubrication ..........................................
SECTION VIII SPRINKLER SYSTEM .................................................................................................................... 81 A. Sprinkler System Description .................................................................................................... 81 SECTION IX AIR JET SYSTEM ............................................................................................................................ 85 A. Air Jet System ......................................................
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 A. GAS MODELS (ADG-464) MAXIMUM CAPACITY (DRY W EIGHT ) 460 lbs. 209.09 kg TOTAL WEIGHT 9,695 lbs. 4,397.65 kg TOTAL SHIPPING WEIGHT 9,850 lbs. 4,467.96 kg TILT HEIGHT 137-1/4" 348.6 cm OPERATING HEIGHT 114-1/2" 290.83 cm FULL TILT DEPTH 117-1/2" 298.45 cm OPERATING DEPTH 95" 241.3 cm WIDTH 122" 309.88 cm TILT LOAD ( REAR TILT ) TILT UNLOAD ( FRONT 15º TILT ) 15º UNLOADING HEIGHT FROM FLOOR 43-3/4" 111.12 cm LOADING HEIGHT FROM FLOOR 65-5/8" 166.
B. STEAM MODELS (ADS-464) MAXIMUM CAPACITY (DRY W EIGHT ) 460 lbs. 209.09 kg 11,000 lbs. 4,949.6 kg 11,162 lbs. 5,063.08 kg TILT HEIGHT 137-1/4" 348.6 cm OPERATING HEIGHT 114-1/2" 290.83 cm FULL TILT DEPTH 117-1/2" 298.45 cm OPERATING DEPTH 95" 241.3 cm WIDTH 122" 309.88 cm TOTAL WEIGHT TOTAL SHIPPING WEIGHT ( STRETCH TILT LOAD ( REAR WRAP / SKID ) TILT ) TILT UNLOAD ( FRONT 15º TILT ) 15º UNLOA DING HEIG HT FROM FLOOR 43-3/4" 111.
C. ELECTRICAL SERVICE SPECIFICATIONS 1. Gas Models ADG-464 (GAS) ELECTRICAL SERVICE SPECIFICATIONS (PER DRYER)* IMPORTANT: 208 VAC and 240 VAC ARE NOT THE SAME. When ordering, specify exact voltage. NOTES: A. Fuse ratings are dual-element, time-delay, current limiting, class RK1 or RK5 ONLY. B. Circuit breakers are thermal magnetic (industrial) type ONLY. For others, calculate/verify correct breaker size according to appliance amp draw rating and type of breaker used. C.
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. TUMBLER SUPPORT and DRIVE SYSTEM IMPORTANT: Always keep the tumbler (basket) section of the dryer in an upright position when moving it. 1. Tumbler The tumbler is made of five (5) 14 gauge stainless steel perforated panels, five (5) stainless steel lifting ribs, and two (2) outer tumbler rings. The tumbler is a completely welded assembly so the perforated panels are not removable. 2.
3. Tumbler and Basket Drive System There are two (2) 5 HP tumbler drive motors. Each motor drives one of the 2-inch diameter tumbler drive shafts, and the motors spin simultaneously so that ALL four (4) sets drive wheels work together to spin the tumbler. Each motor is connected to the drive shaft by two (2) “A” section V-belts, driving a shaft-mounted (5.6 to ratio) gear reducer. This produces a tumbler shaft speed of 200 RPM to 205 RPM and a tumbler speed of 31.5 RPM.
B. MAIN AIR BLOWER/HEAT RECLAIMER SYSTEM The fan which moves the exhaust air through the dryer is a 22-inch diameter, squirrel cage fan that is driven at 1,100 rpm by a 25 HP motor. This fan moves a maximum of 13,000 cfm air through the dryer.
The dryer is equipped with a pneumatically operated heat reclaimer damper, which when opened, will recirculate approximately fifteen percent (15%) of the dryer’s exhaust air. The heat reclaimer dampener is closed until ignition of flame has been established. Then, the damper piston is actuated, opening the damper and recirculating fifteen percent (15%) of the exhaust air back over the gas burner and into the tumbler. The damper remains open for the rest of the drying cycle.
C. COMPRESSED AIR SYSTEM The compressed air system of the dryer consists of a number of pneumatic pistons located throughout the dryer, an FRL (Filter/Regulator/Lubricator) assembly, and pneumatic control panel. 1. Air Pistons The pistons are actuated by solenoid and flow control valves that are under computer control. The pneumatic pistons are used to: • Tilt the dryer for loading and unloading. • Open and close load and unload doors • Operate heat reclaimer.
b. Regulator Operation The adjustment knob simply acts upon a spring rest located on the spring and directly compresses the spring as it is adjusted. A non-rising low torque adjustment screw is used on this type of filter and regulator. The upper spring rest is located on top of the regulator spring and transmits force from the adjustment screw to the spring. Regulators use simple wire coil springs for controlling the downstream regulator pressure.
To tilt the dryer back, a 120 volt signal is applied to the front pistons solenoid connector #S5, and no voltage is applied to the solenoid connector #S8. The internal spool in the valve will move and 80 PSI of air will enter the bottom port of the front tilting pistons, extending the front tilting piston rods and tilting the dryer back for loading. The top piston ports are bled to the atmosphere. To level the dryer after loading, the voltage signals are reversed.
To open the front loading door, a 120 volt signal is applied to S1, the coil of the valve that supplies air to the load door or the heat reclaimer’s bottom port. The valve will open, and 80 PSI of air is supplied to the bottom port of the piston. The piston rod will extend, and the door will open. No voltage is applied to S2, the coil of the valve that controls the air supply to the door pistons top port so that this line is bled to the atmosphere.
D. SAFETY DEVICES The dryer is equipped with numerous safety devices to ensure that the dryer operates safely. The chart on the following page (page 23) lists each device with its location, function, computer display message, and result of tripping.
1.
E. BLOWER (Squirrel Cage Fan) MOTOR ASSEMBLY 1. Blower (Squirrel Cage Fan) Motor Description The dryer uses a 22-1/4 inch diameter blower (squirrel cage fan). It rotates (spins) in a counterclockwise (CCW) direction, when viewed at the blower motor. The blower shaft is mounted on two (2) 1-3/4 inch diameter pillow block bearings and is driven by two (2) BX type V-belts which are connected to a 25 HP blower motor. The blower motor is mounted on a adjustable base.
5) Remove the bolts from the bushing. PULLEY REMOVAL 6) Insert the bolts into the threaded holes. 7) Tighten the bolts evenly for motor pulley removal. 8) Mark the inside of the motors' shaft before removing the bushing. 9) Loosen the set screws in the bushing. MAN3286 10) Remove the bushing. 11) Measure the mark on the motors' shaft (from Step #8) to the end of the shaft and mark the new motors' shaft. 12) Install new blower on to the motor base.
b. Shrouded Pillow Block Bearing Replacement 1) Discontinue electrical service to the dryer. 2) Remove the belt guard. 3) Loosen the bolts securing the blower motor to the motor base. 4) Remove the V-belts from the motor pulley and the pulley on the blower shaft. CAUTION: THE BLOWER (Squirrel Cage) FAN IS LOCATED IN THE LINT COMPARTMENT. PROPERLY LOCK and TAG OUT THE ELECTRICAL SERVICE BEFORE ENTERING THE LINT COMPARTMENT. 5) Remove both lint drawers.
15) Replace the shrouded pillow block bearing on the blower shaft... a) Secure the blower shaft to the blower shaft bearing mount. b) Tighten/secure the set screws in the shrouded pillow block bearing. NOTE: Install the 3/8" x 3/8" x 3" key on to the blower shaft before installing the blower (squirrel cage fan). c) Reinstall the blower (squirrel cage fan) removed in Step #9. IMPORTANT: MAKE CERTAIN THAT THE BLOWER (Squirrel Cage Fan) ROTATES (Spins) FREELY.
5) Remove the two (2) left hand jam nuts and the washers. 6) Remove the blower (squirrel cage fan) along with the 3/8" x 3/8" x 3" key from the blower shaft. NOTE: Install the 3/8" x 3/8" x 3" key on to the blower shaft before installing the blower (squirrel cage fan). 7) To install new blower (squirrel cage) fan, reverse Step #7 thru Step #1. d.V-Belt Replacement 1) Discontinue electrical service to the dryer. 2) Remove the belt guard. 3) Loosen the bolts securing the blower motor to the motor base; a.
F. BLOWER (Squirrel Cage Fan) ELECTRICAL COMPONENTS 1. Blower (Squirrel Cage Fan) Controls and Overloads a) Thermal Magnetic Starter (TMS) Description The thermal magnetic starter (TMS) is used as a safety device to manually disconnect the motor, thereby protecting the motor from being damaged in a locked rotor condition. The overload has a dial setting on the face of the device. To set the overload, refer to your specific electrical diagram. The overload is specifically designed for motor applications.
2. Auxiliary Contact Block Description 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 motor fault message will appear on the display of the Telemecanique XBT unit. a. Auxiliary Contact Block Replacement 1) Disconnect electrical service to the dryer.
G. TUMBLER (Basket) SYSTEM 1. Tumbler (Basket) Drive Description The tumbler (basket) is supported and driven by four (4) 11-inch diameter heavy duty rubber roller wheels. The rubber wheels are molded onto each of four (4) steel hubs. The steel hubs are fastened to the 2-inch diameter tumbler drive shafts by taper lock bushings. Each drive shaft is supported by two (2) 2-inch diameter heavy duty pillow block bearings.
2. Tumbler (Basket) Drive System Replacement a. Tumbler (Basket) Drive Wheel Replacement 1) Discontinue electrical service to the dryer. 2) Disconnect air supply to the dryer. 3) Remove front panels or rear panels that are secured to the front or rear tumbler section of the dryer by removing the access bolts. 4) Remove the eight (8) 3/8-16 x 1" hex head bolts, along with the 3/8" flat washers and 3/8" lock washers securing the panel to the tumbler (basket) section frame and swing the hinged panel out.
16) Remove the taper lock bushing. 17) Remove the drive wheel. 13) Tighten the bolts evenly for wheel removal. 18) To install new drive wheel, reverse Step #17 thru Step #3. 19) Reconnect air supply disconnected in Step #2. 20) Reestablish electrical power to the dryer. b. 5 HP 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 the V-belts.
14 Check that the motor pulley is properly aligned. 15) Secure the drive motor to the motor mount. 16) Tighten the turnbuckle. IMPORTANT: DO NOT OVERTIGHTEN TURNBUCKLE. 17) Rewire the new drive motor in the same sequence as the wiring that was removed in Step #2. A wiring diagram is usually affixed to the side of the motor. 18) Reestablish electrical service to the dryer. c. V-Belt Replacement 1) Discontinue electrical service to the dryer. 2) Loosen the turnbuckle a tighten the V-belts.
10) Insert bolts into the holes of the taper lock bushing and thread into the motor pulley, then tighten evenly. 11) Check that the motor pulley is properly aligned. 16) Reinstall the V-belts removed in Step #2. 17) Tighten the turnbuckle. IMPORTANT: DO NOT OVERTIGHTEN TURNBUCKLE. 18) Reestablish electrical service to the dryer. e. Pillow Block Bearing Removal 1) Discontinue electrical service to the dryer.
CAUTION: Replacement gear (speed) reducers are shipped without oil. Add proper amount (1.4 liters) of recommended lubricant before operating. FAILURE TO OBSERVE THESE PRECAUTIONS WILL RESULT IN DAMAGE TO THE DRYER AND WILL VOID THE WARRANTY. CAUTION: TO MUCH OIL IN THE GEAR REDUCER WILL CAUSE OVERHEATING and TOO LITTLE OIL WILL RESULT IN GEAR FAILURE. CHECK THE OIL LEVEL REGULARLY. FAILURE TO OBSERVE THESE PRECAUTIONS WILL RESULT IN DAMAGE TO THE DRYER AND WILL VOID THE WARRANTY.
17) Reinstall V-belts and tighten the turnbuckle. IMPORTANT: DO NOT OVERTIGHTEN TURNBUCKLE. 18) Prior to operating the new gear (speed) reducer, fill with 1.4 liters of SAE 90 gear oil. 19) Mount the pillow block bearing on the mounting pads (using the bolts that were removed). IMPORTANT: DO NOT OVERTIGHTEN BOLTS. 20) Reverse Step #3 from the Pillow Block Removal instructions on page 35. IMPORTANT: Remove the wooden blocks that were inserted under the tumbler (basket).
WARNING: ALL SERVICE and TROUBLESHOOTING SHOULD BE PREFORMED BY A QUALIFIED PROFESSIONAL or SERVICE AGENT. WARNING: WHILE MAKING ADJUSTMENTS, OBSERVE ALL SAFETY PRECAUTIONS DISPLAYED ON THE DRYER or SPECIFIED IN THIS MANUAL. 6) Reestablish electrical service to the dryer. Proceed to Retaining Wheel Adjustment instructions immediately below. h.
H. ROTATIONAL SENSOR ASSEMBLY The rotational sensor is a self-contained, motion detector proximity sensor, designed to detect a predetermined stopped drum (basket/tumbler) condition. The rotational sensor is used as a safety device, once the drum has stopped rotating for more than 12-seconds. After this 12-second interval has been reached, the sensor goes into an open state, removing power to PLC (Programmable Logic Controller) input #10.
(1) Rotational Sensor Adjustment Distance Adjustment; • Pull the rotational sensor as far away from the basket (tumbler) as possible. • Spin/rotate the basket (tumbler) until the target (target lines up behind one of the basket ribs) is aligned with the rotational sensor. Mark basket (tumbler) rib with tape. • The rotational sensor has to be adjusted towards the target until there is a 3/16" gap. Time Adjustment; • Jog basket (tumbler) for 10-seconds.
I. TOP OF TUMBLER (Basket) TEMPERATURE DOOR ASSEMBLY 1. Intake Temperature Probe/Sprinkler Temperature Probe The intake temperature probe and sprinkler temperature probe are 100 ohm (100 Ω) Resistive Temperature Device (RTD) probes located on the top of the tumbler (basket) section of the dryer. The intake temperature probe measures the intake temperature of the dryer and is monitored by the hi-temperature controller.
J. TUMBLER (Basket) ELECTRICAL COMPONENTS 1. Drive Motor Controls and Overloads a) Thermal Magnetic Starter (TMS) Description The thermal magnetic starter (TMS) is used as a safety device to manually disconnect the motor, thereby protecting the motor from being damaged in a locked rotor condition. The overload has a dial setting on the face of the device. To set the overload, refer to your specific electrical diagram. The overload is specifically designed for motor applications.
2. Auxiliary Contact Block Description 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 motor fault message will appear on the display of the Telemecanique XBT unit. a. Auxiliary Contact Block Replacement 1) Discontinue electrical service to the dryer.
SECTION VI PLC (PROGRAMMABLE LOGIC CONTROLLER) SYSTEM A. PLC (Programmable Logic Controller) DESCRIPTION The heart of the dryer is a TSX17 PLC (Programmable Logic Controller) with twenty-one (21) inputs and twelve (12) outputs. The TSX17 PLC also uses two (2) expansion modules, a relay output module with six (6) outputs, and a 4 mA - 20 mA (milliamphere) analog input module with four (4) inputs. The operator interface for the TSX17 PLC is the XBT digital display unit.
• Input 0,9 is used to sense if the burner doors are closed. This is accomplished through DS4A and DS5A (Door Switch 4, A and Door Switch 5 , A) contact sets. If a drying cycle is attempted, the XBT unit will display "DOOR OPEN." • Input 0,10 is used to monitor a stopped tumbler (basket) condition. An inductive proximity sensor is located in the left wrapper of the tumbler (basket) section. Behind one of the ribs on the front side of the tumbler (basket), a steel target is mounted.
The main module of the TSX17 PLC (Programmable Logic Controller) also has eleven (11) outputs to control various functions of the dryer. The outputs are relay contacts, whereby each of the relays have a common terminal tied to 110 VAC. • Output 0,0 is used to control the Main Blower Contactor. On a call for fan, the output supplies 110 VAC to the coil of the fan motor contactor. As long as none of the overloads have tripped, the contactor will engage (pull in) starting the dryer.
• Output 1,4 is the blower (fan) Air Jet which is used to clean lint off of the fan (blower). At the end of a cycle, the Air Jet turns on for 30-seconds. • Output 1,5 is the End of Cycle light. Once the dryer has reached the end of a cycle, the output turns on, illuminating the End of Cycle light. The output will turn off once a load or unload command is asserted on the pendant. ANALOG INPUT MODULE The Analog Input Module is used to measure the temperature in the exhaust of the dryer.
B. PLC (Programmable Logic Controller) COMPONENT REPLACEMENT 1. TSX17 PLC (Programmable Logic Controller) Assembly The TSX17 Programmable Logic Controller (PLC) is made up of three (3) components. The first and main component is the TSX17 PLC, then the Relay Outputs, and the Analog Inputs. The TSX17 PLC has a ram back-up lithium battery. a. TSX17 PLC (Programmable Logic Controller) Component Replacement 1) Discontinue electrical service to the dryer. 2) Remove the coaxial (coax) cable from the TSX17 PLC.
3. Lithium Battery a. Lithium Battery Replacement 1) Discontinue electrical service to the dryer. 2) Remove the battery cover which is located directly above the buss terminator on the TSX17 PLC (Programmable Logic Controller) by sliding the cover in an upward direction. NOTE: The lithium battery is attached to the cover and plugged into the module. 3) Remove the plug from the module, then remove the battery from the cover. 4) To install new lithium battery, reverse Step #3 thru Step #1.
4. Under Voltage Disconnect The dryer uses a 110 VAC under voltage disconnect. This 110 VAC is supplied from the sprinkler circuit. The sprinkler circuit is part of the safety circuit of the dryer. If the sprinkler circuit is in an alarm condition, the 110 VAC supply to the under voltage disconnect will become discontinued, shutting down the dryer. NOTE: For steam models that do not have the sprinkler option skip Step #4. a.
5. Hi-Limit Controller The dryer utilizes six (6) channel controller (HLC-1) to monitor various locations on the dryer for over temperature faults. The hi-limit controller enables the dryer to continually monitor up to six (6) Resistive Temperature Devices (RTD's) at one time. Each channel is individual with set points. The hi-limit controller scans each channel, and in the event of an alarm, the scanning will halt (stop), and the Single-Pole-DoubleThrow (SPDT) will change states signaling a fault.
6. Gas Burner and Ignition System The dryer's gas burner system operates on a on or off gas rate sequences to accurately control the tumbler’s (basket's) drying temperature. Maximum firing rate is 2.8 million btu/hr. Upon a call from heat, the dryer computer sends a 120 volt signal to the burner controller module (BCM) which initiates and controls the ignition sequences.
a. Major Burner Components 1) Burner Controller Module (BCM) The burner controller module (BCM) provides effective burner flame safeguard control through adjustable purge and trial-for-ignition timing. The BCM insures that ALL dryer safety switch circuits are closed, delays ignition to allow the combustion chamber to vent, and insures that a healthy pilot flame is established before opening the main gas valves. Five (5) L.E.D.’s (light emitting diodes) on the cover of the BCM allow for easy troubleshooting.
b. L.E.D. (Light Emitting Diode) and Neon Displays of the BCM (Burner Controller Module) 1) Operating Interlock - L.E.D. is lit when; ALL safety interlock switches are closed, applying a 110 VAC signal to terminal #7 of the burner controller module (BCM). 2) Operating Interlock - L.E.D. is not lit when; One (1) or more safety interlock switches (burner doors, load door, optional unload door, gas pressure, lint pressure, hi-temp alarm contacts, tumbler [basket] stopped, and lint drawer) are open.
8) Burner Fan Air Switch Status Indicator - Neon is not lit; • • • • Air switch is not closed after start-up of burner fan. Door interlocks are open. A Combustion burner screen is clogged. A door on the dryer is open. 9) Test/Reset Button When this button is pushed in, the burner controller module (BCM) will halt the ignition sequence, once the pilot flame is established. This allows the pilot flame to be adjusted. c.
1) Burner Fan Air Switch The differential in air pressure is measured by the burner fan air switch, which is located next to the burner fan motor. If the combustion air is inadequate, this switch will prevent ignition. The setting of this switch is adjustable, and it should be set at approximately .59-inches (15 mm) of water column (W.C.) because of slight variances in spring tension characteristics, range settings, and markings are nominal.
4) Combustion Air Damper To produce the required combustion airflow, this damper can be adjusted. Remove the screen to get access to the damper. Moving the damper closer to the blower inlet opening will reduce the combustion airflow, and moving it away from the blower inlet opening will increase the airflow. To measure the combustion airflow, attached a manometer to the air pressure tap on the burner box. The air pressure should measure 1.25- inches (31.75 mm) to 1.5-inches (38.1 mm) water column (W.C.). e.
Top Motorized Gas Valve The valve sets the gas rate of 2,800,000 btu/hr (705,290 kcal/hr). To achieve this rate, the gas pressure must be set for 2.5-inches (63.5 mm) water column for natural gas and 1.25-inches (31.8 mm) water column for L.P. (liquid propane) gas. To adjust. loosen the pan head screw located on the front of the top motorized valve, while holding the valve body, turn the flow adjustment clockwise (CW) for less gas and counterclockwise (CCW) for more gas.
c) The burner controller module (BCM) checks that ALL of the dryer’s safety circuits are closed (terminal #7 of the [BCM]). If this is the case, then the green “operating interlocks” L.E.D. (light emitting diode) on the BCM will light. If a safety switch is open, the green L.E.D. will not light, and the red “SYSTEM UNSAFE” L.E.D. will light. The ignition sequence will stop. If ALL safety switches are closed, the BCM will start the burner fan motor (BCM terminal #8).
(5) If signal is less than 3 volts DC, then the pilot may be too small or too large, there may be a wiring connection between the flame rod and burner controller module (BCM), the flame rod may be dirty, (wash it with soap and water) or defective, or the grounding may be faulty. Once the flame probe signal is detected by the BCM, it waits 5-seconds to allow the pilot to stabilize and then opens the main motorized gas valves (terminal #5 on the BCM) in sequence. The lower valve opens first.
h. Burner Air Switch The dryer uses a burner air switch on its burner components. The differential air pressure is measured by this air switch, which is located next to the burner fan motor. If the combustion air is inadequate, this switch will prevent ignition. The setting of this burner air switch is adjustable, and is preset at the factory. 1) Burner Air Switch Replacement (a) Discontinue electrical service to the dryer. (b) Remove the two (2) 1/4" x 1/8" M.P.T.
i. Burner Squirrel Cage Fan Components The combustion air is produced by a 6-1/4" squirrel cage fan, attached to a 1-1/2 HP, 3,600 RPM motor. This motor must spin counterclockwise (CCW) as viewed from the rear of the motor. 1) Burner Fan Motor a) Burner Fan Motor Replacement (1) Discontinue electrical service to the dryer. (2) Remove the four (4) #8-18 x 7/16" TEK screws which secure the inlet ring to the combustion air blower housing.
(3) For replacement of new 6-1/4" squirrel cage fan, reverse Step #4 thru Step #2 of the Burner Fan Motor Replacement instructions on the previous page (page 62). (4) Reestablish electrical service to the dryer. 3) Burner Fan Electrical Components a) Burner Fan Thermal Magnetic Starter (TMS) The thermal magnet starter (TMS) is used as a safety device to manually disconnect the motor so that it will be protected from damage in the event of a locked rotor condition.
(5) To install the new auxiliary contact block, reverse Step #4 thru Step #2. (6) Reestablish electrical service to the dryer. (3) Varistor (Metal Oxide Varistor [MOV]) The metal oxide varistor (MOV) is used to suppress any inductive electrical spikes produced by the energizing and collapsing of coil voltage. (a) Varistor (Metal Oxide Varistor [MOV]) Replacement ((1)) Discontinue electrical service to the dryer. ((2)) Loosen the screws marked A1 and A2 on the contactor.
b) Burner Door Switch Replacement 1) Discontinue electrical service to the dryer. 2) Loosen the 1/4-20 x 3/4" hex head machine bolts as well as the 1/4-20 hex nut. 3) Remove the four (4) Phillips head screws securing the burner switch cover plate to the switch body. 4) Mark, identify, and remove the wires from the burner door switch for correct replacement. 5) Remove the cord grip from the switch body. 6) To install new burner door switch, reverse Step #5 thru Step #2.
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Heat Reclaimer - the dryer is equipped with a pneumatically operated heat reclaimer, which when open, will recirculate approximately fifteen percent (15%) of the dryers' exhausted air. The heat reclaimer damper is closed until ignition of flame has been established. a. Heat Reclaimer Piston Replacement 1) Discontinue electrical service to the dryer. 2) Discontinue the air supply to the dryer. 3) Remove the C-clip from one end of the clevis pin. 4) Remove the set screw from the clevis rod.
3) Adjust the bottom heat reclaimer nuts down to their desired positions to obtain the proper piston stroke. Example: If the desired piston stroke is 2-inches (5.1 cm), then the distance "X" in the illustration below must be 2-inches (5.1 cm). 4) Tighten the top heat reclaimer nuts down onto the bottom heat reclaimer nuts. HEAT RECLAIMER S ETTINGS Z = 1-5/8 Y+Z=X Y %HR Inches Reclaimed 1-1/8" 1/2" 7.46 1-1/4" 2-5/8" 1" 15.67 2-5/8" 3-1/8" 1-1/2" 25.37 4-1/4" 3-5/8" 2" 34.
b. Cool Down Damper Piston Replacement 1) Discontinue electrical service to the dryer. 2) Discontinue the air supply to the dryer. 3) Remove the two (2) 1/4" poly x 1/4" M.P.T. connectors from the piston. 4) Loosen the 1/4-20 x 3/8" set screw from the clevis and remove the clevis pin. 5) Remove the piston from the damper cylinder mounting plate. 6) To install new cool down damper piston, reverse Step #8 thru Step #3. 7) Reestablish the air supply to the dryer. 8) Reestablish electrical service to the dryer.
b. Cable (Wire Rope) Replacement 1) Discontinue electrical service to the dryer. 2) Discontinue the air supply to the dryer. 3) Block the bottom load door in the closed position prior to disassembly of any parts. IMPORTANT: FAILURE TO BLOCK THE BOTTOM LOAD DOOR SECURELY IN THE CLOSED POSITION MAY RESULT IN PERSONAL INJURY. 4) Loosen the turnbuckle so that the cable becomes slack. 5) Remove the two (2) cable (wire rope) clamps from the wire rope.
NOTES: For proper cable (wire rope) routing, starting at the piston; A. Replace the cable (wire rope) thimble and wire rope clamp to one side of the cable. B. Secure the cable (wire rope) to the piston mount with the 3/8-16 x 1" bolt, 3/8" fender washer, 3/8" lock washer, and 3/8-16 hex nut. C.
d. Load Door Closed Switch Replacement 1) Discontinue electrical service to the dryer. 2) Loosen and remove the two (2) screws securing the junction cover. 3) Remove the junction cover. 4) Mark and identify the wires that will be removed for proper reinstallation. 5) Remove the wires from the terminals. 6) Loosen and remove the two (2) mounting screws. 7) Loosen and remove the cord grip cap. 8) Remove the cord grip. 9) To install the new load door closed switch, reverse Step #8 thru Step #2.
e. Load Door Closed Switch Adjustment 1) Discontinue electrical service to the dryer. 2) To adjust the coil spring lever arm, hold the arm with a #10 metric (10 mm) wrench and loosen the nut. 3) Place the coil spring lever arm in the 1 o'clock position. IMPORTANT: Verify that the load door closed switch is not in the vertical position or damage will result. 4) Hold the coil spring lever arm and tighten up (snug up) on the nut. 5) Hold pivot point with a screwdriver and tighten the nut.
5) With finger tip, gently push and turn 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 #2. (Refer to previous page [page 73].) 7) Reestablish electrical service to the dryer. 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.
11) Place pivot arm in the 1 o'clock position for the front tilt switch and in the 11 o'clock position for the rear tilt switch. Verify that the body orientation and head orientation are correct. Verify that the tilt switch arm is not in the vertical position or damage will result. 12) Holding the tilt arm, tighten up (snug up) on the nut. 13) Hold pivot point with a screwdriver and tighten the nut. 14) Replace base panel. 15) Reestablish electrical service to the dryer. j.
SECTION VII BASE SECTION A. LINT DRAWER/LINT CHAMBER SWITCHES 1. Lint Drawer Switches The dryer utilizes two (2) magnetic proximity switches (wired in series) to indicate a lint drawer closed status. The magnetic proximity switch is a device whereby the contacts within the device close when it comes in to close proximity of a magnetic field. If either of the proximity switches are opened, the entire circuit will be open.
2. Lint Chamber Air Pressure Switch The lint chamber air pressure switch utilized in the dryer is used to insure that there is proper air flow through the dryer. If there is a problem with this air pressure switch an "AIR FAULT" error message will be displayed via the L.E.D. (light emitting diode) on the Telemecanique XBT digital display unit. a. Probable causes for an "AIR FAULT" error message; 1) Clogged lint screen. 2) Air pressure setting incorrect.
c. Lint Chamber Air Switch Replacement 1) Discontinue electrical service to the dryer. 2) Remove the 1/4" x 1/8" M.P.T. straight connector. 3) Remove the 5/16-18 x 3/4" tap bolt, as well as the 5/16" lock washer. 4) Mark and identify the wires that will be removed for proper reinstallation. 5) Remove the cord grip from the lint chamber air switch. 6) To install new lint chamber air switch, reverse Step #5 thru Step #2. 7) Reestablish electrical service to the dryer.
B. RESISTIVE TEMPERATURE DEVICE (RTD) 1. RTD (Resistive Temperature Device) The gas dryer utilizes five (5) Resistive Temperature Devices (RTD's); • • • • • One (1) RTD probe is used to control the drying temperature in the tumbler (basket). One (1) RTD probe is used to detect an over temperature condition in the dryers' intake. One (1) RTD probe is used to monitor for an over temperature condition in the over burner.
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SECTION VIII SPRINKLER SYSTEM A. SPRINKLER SYSTEM DESCRIPTION The sprinkler circuit on the dryer requires a dedicated single-phase (1ø) supply from the dryers' voltage. The sprinkler hi-limit temperature is 700º F (371.11º C). In the event of a hi-limit condition, contact #7 and contact #8 on the sprinkler controller will open, disabling the 120 volt supply to the under voltage disconnect. The disconnect will open thereby disabling the power (electrical supply) to the dryer.
d. Sprinkler Digital Temperature Controller The sprinkler digital temperature controller is a programmable microprocessor (computer). It is used to monitor temperature via a Resistive Temperature Device (RTD). NOTE: Operating parameters are preset at the factory and should not require any adjustment.
2. Sprinkler System Component Replacement a. Resistive Temperature Device (RTD) Replacement The sprinkler digital temperature controller is a programmable microprocessor (computer). It is used to monitor temperature via a Resistive Temperature Device (RTD). NOTE: For RTD (Resistive Temperature Device) probe location, refer to the top illustration on page 80. 1) Discontinue water supply to the dryers' sprinkler system. 2) Discontinue electrical service to the dryer.
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SECTION IX AIR JET SYSTEM A. AIR JET SYSTEM The dryer utilizes an air jet system so that at the end of each drying cycle 80 PSI of compressed air is blown across the blower squirrel cage fan to remove any lint build up that occurred during the drying cycle. 1. Air Jet Valve a. Air Jet Valve Replacement 1) Discontinue air supply to the dryer. 2) Discontinue electrical service to the dryer. 3) Remove the poly-flow tubing from the brass tee and the brass cross.
SECTION X STACK VALVE ASSEMBLY A. PNEUMATIC VALVE The stack valve assembly consists of two (2) styles of pneumatic solenoids; • The first type of solenoid is a 2-position/4-way/4-port single operator with a spring return. This valve has a 120 VAC coil and spring return. With no power to the coil, air goes out of the B port and the A port gets exhausted. When the coil is energized, air enters the A port and the B port gets exhausted.
1. Solenoid Coil a. Coil Replacement 1) Discontinue air supply to the dryer. 2) Discontinue electrical service to the dryer. 3) For models with a sprinkler system, discontinue water supply to the dryers' sprinkler system. 4) Loosen coil plug screw and remove the plug. 5) Carefully remove the coil mounting screw. IMPORTANT: TAKE NOTICE ... small components!!! 6) Note the sequence of the plunger components (i.e., return spring, plunger, etc.). 7) Install new coil making sure that component reinstallation (i.
2. Solenoid Valve a. Valve Replacement 1) Discontinue air supply to the dryer. 2) Discontinue electrical service to the dryer. 3) For models with a sprinkler system, discontinue water supply to the dryers' sprinkler system. 4) Loosen coil plug screw and remove the plug. 5) Carefully remove the two (2) valve mounting screws. Take notice of the gasket. 6) Install new valve body. CAUTION: DO NOT pinch the gasket. 7) Replace coil plug remove in Step #4. 8) Reestablish water supply to the dryer.
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4. Internal Pilot and External Pilot Air Supply On two-way tilt dryers, a pneumatic safety circuit is incorporated to prevent both front and rear tilting pistons from extending their rods at the same time. When 120 volts is supplied to the “S5” side of the front tilting piston solenoid valve coil, the round internal spool in the core of the solenoid will move, allowing 80 PSI air to flow into the bottom ports of the front tilting pistons, while the top ports of these pistons are bled to the atmosphere.
SECTION XI PENDANT ASSEMBLY A. PENDANT ASSEMBLY DESCRIPTION The pendant assembly is used on both the gas and steam model dryer. Within the pendant assembly there is a three (3) position selection switch used to tilt the dryer in the load tilted, unload tilted, or level position. When the load tilted or unload tilted selection is made, the load/unload door will open once the door signal has been received, and the dryer will tilt.
ADC 450186 1- 05/27/99-25 2- 01/14/00-15
