AD-464 / ML-460 Phase 7 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 www.amdry.com 031504SCOSTA/gbennett 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. Please observe all safety precautions displayed on the equipment and specified in the installation manual included with the dryer.
Reference Guide (Front) 2 American Dryer Corp.
Reference Guide (Left Side) 450260-1 www.amdry.
Reference Guide (Right Side) 4 American Dryer Corp.
Reference Guide (Right Side) 450260-1 www.amdry.
SAFETY PRECAUTIONS __________ Warning For your safety, the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury, or loss of life. ! The dryer must never be operated with any of the back guards, outer tops, or service panels removed. Personal injury or fire could result. Caution ! The dryer should never be left unattended while in operation.
ROUTINE MAINTENANCE _________ 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.
Every 6 Months Change gear oil in basket (tumbler) shaft gear reducer. Remove the drain plug (located at the bottom rear of the reducer). After oil is completely drained, replace the drain plug. 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. INSTALLATION REQUIREMENTS ____ Installation should be performed by competent technicians in accordance with local and state codes.
Important ! Failure to comply with these codes or ordinances and/or the requirements stipulated in this manual can result in personal injury or component failure. The BCM controls all of the gas burner ignition components, except for the motorized gas valve. When the drying set point temperature is reached, the dryers computer closes the top motorized gas valve, shutting off full flame. The dryer installation must meet the American National Standard, National Fuel Gas Code ANSI Z223.
Burner Controller Power On Indicator - Neon is lit when: Burner Controller has its supply voltage of 120 VAC. Burner for Air Switch Status Indicator - Neon is lit when: Air switch is closed after start-up of blower (fan) and interlocks are all closed. 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. Test/Reset Light Emitting Diode (L.E.D.
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 0.59-inches (15 mm) of water column (W.C.) because of slight variances in spring tension characteristics, range settings, and markings are nominal.
Sequence of Operation With dryer power on, a 120 volt signal is sent to terminal #1 and terminal #2 of the burner controller module (BCM). A power indicator light has been added to the controller base for troubleshooting. Drying cycle is started Dryer computer calls for heat. The spark plug will turn off 1.5-seconds after the pilot flame is detected. If the pilot flame should fail during the 10-seconds period that the pilot solenoid is open. The BCM will reenergize the spark.
When the pilot flame is ignited, the pilot gas pressure should measure 3.5-inches (38.1 mm) water column (W.C.) for natural gas and 1.5-inches (88.9 mm) W.C. for liquid propane (L.P.) gas. The pilot flame should be about the size of a 3-inch diameter ball. Once the pilot has been properly set, remove the pressure gauge from the pilot line connect a differential pressure gauge between the main gas pressure tap (HI port) and the air pressure tap (LO port) on the side of the gas burner box.
Burner Fan Motor Burner Fan Motor Replacement Auxiliary Contact Block 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. Remove the two (2) 1/2-20 left hand jam nuts as well as the 1/2-inch flat washer. 4. Remove the 6-1/4" squirrel cage fan. 5. Remove the motor cover plate to reveal the wiring. 6. Mark and identify wiring for correct replacement on to the new motor. 7.
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. 1. Loosen the screw on the high fire valve cap that doesnt have the paint drop. 2. Turn the cap to the + to increase the pressure or to the - to decrease the pressure. 3. Take the pressure reading at the outlet of the valve.
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. 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 setscrew from the clevis rod. 5.
Intake Air Damper/Cool Down Damper Steam model dryers require the use of both an intake air damper and a cool down damper. During the heat cycle, the intake air damper is opened to allow fresh air to be drawn across the steam coils. On the cool down cycle, the inlet air damper closes and the cool down damper opens. This draws fresh air into the tumbler (basket) section exhausting all of the 13,000 cfm (368 cmm) airflow, which insures a fast cool down of the load.
Tilting System Component Replacement Caution ! Never service pneumatic components with compressed air connected. Serious injury may result. Tilting Solenoid Replacement 1. Engage EMERGENCY STOP (E-Stop). Discontinue electrical power to the dryer. 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.
7. Remove the two (2) 1/4-20 hex head bolts that mount the solenoid valve. (Refer to the illustration on the top right of page 18.) 8. Remove the three (3) 3/8 straight connectors. (Refer to the illustration on the top right of page 18.) Reinstall these connectors on the new solenoid valve body. 9. Remove the two (2) 3/8 mufflers. (Refer to the illustration on the top right of page 18.) Reinstall these mufflers on the new solenoid valve body. 10.
Tilt Switch Replacement 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 the tumbler (basket/drum) section. Serious injury can result. 3. Unscrew tilt switch. 4. Loosen and remove the two (2) screws securing the junction cover. 5. Remove the junction cover. 6. Mark each wire for proper replacement. 7. Remove wires from terminal. 10. Remove cord grip. 11.
Blower (Squirrel Cage Fan) Motor Assembly _____________________________ Air Jet Valve Air Jet Valve Replacement Discontinue air supply to the dryer. Discontinue electrical service to the dryer. Remove the poly-flow tubing from the brass tee and the Blower (Squirrel Cage Fan) Motor Description Remove 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. brass cross.
19. Tighten (hand tight only) the bolts for the new motor to the motor base. Leave enough movement for V-belt adjustment. 20. Replace the V-belts. Adjust to proper tension by adjusting the position of the new blower motor. Align the V-belts. 21. Tighten/secure the new motor to the motor base. 22. Reconnect the wires onto the new motor that were marked and disconnected in Step #3. A wiring diagram is usually affixed to the side of the motor. 23. Reinstall the belt guard removed in Step #2. 24.
Important ! Make certain that the blower (squirrel cage fan) rotates (spins) freely. 10. Reestablish electrical service to the dryer. 17. Reinstall the blower funnel removed in Step #7. 18. Reinstall the bushing and the pulley removed in Step #13: line up the bushing to the mark on the blower shaft, then secure/tighten the setscrew. Reinstall the bolts into the original holes and tighten evenly for correct pulley installation. 19.
Varistor (MOV [Metal Oxide Varistor]) Description Filter Maintenance The varistor (MOV) is used to suppress any inductive electrical spikes produced by the energizing and coil voltage. To remove filter element: twist the filter bowl 1/8 turn clockwise (CW). Then pull the bowl down to expose the filter element. To remove the filter element, unscrew the baffle (this will allow element removal). Varistor (MOV) Replacement To clean filter element use soap and water. 1.
Heat reclaimer adjustment 1. Remove electricity from the unit. 2. Loosen heat reclaimer adjustment nuts on all four (4) corners of the heat reclaimer piston. 3. Adjust the bottom heat reclaimer nuts down to their desired position which will give the proper piston stroke. Example: If the desired piston stroke is two (2) inches (5.1 cm), then the distance "x" in the illustration must be two (2) inches (5.1 cm). 4. Tighten top heat reclaimer nuts down onto the bottom heat reclaimer nuts.
The tilting piston valves are three (3) position valves. This means that, if no voltage is applied to both positions (top L3 and bottom L4) all five (5) valve ports are blocked. If the dryer is tilting or leveling and power to the dryer is shut off, the pistons will lock in position, holding the dryer in a partially tilted position. The dryer can be made to tilt faster or slower by adjusting the pistons 3/8-inch flow control valves which are located on the pneumatic control panel.
4. Remove the two (2) 1/4" x 1/4" poly connectors from the piston. 5. Loosen the turnbuckle so that the cable becomes slack. 6. Loosen the setscrew securing the cylinder clevis assembly to the piston shaft. 7. Remove the 5/16-24 x 1/4" socket head cap screw and 5/16" lock washer from the piston base. 8. Unscrew the piston shaft from the cylinder clevis assembly. 9. To install new door piston, reverse Step #8 through Step #3. 10. Reestablish the air supply to the dryer. 11.
Load Door Open/Closed Switch Replacement 1. Discontinue electrical service to the dryer. 2. Loosen and remove the two (2) screws securing the mounting bracket 3. Remove the switch from the mounting bracket. 4. Depress the tabs on the 2 PIN connector and pull apart from the harness. 5. Install the new switch by connecting the plug to the harness. 6. Place one (1) adjustment nut onto the sensor switch and insert into the mounting bracket. 7. Place the second adjustment nut on the switch but do not tighten. 8.
Control And Electrical System ______ Ladder Diagram 450260-1 www.amdry.
30 American Dryer Corp.
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. ! Control/Electrical System Description 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 front right cabinet.
Phase 7 Microprocessor Controller (Computer) The temperature sensor probe is a bullet shaped device that is located in the exhaust duct by the heat reclaimer. This temperature sensor probe is used to sense the temperature in the exhaust of the dryer. The temperature sensor is a two (2) terminal monolithic integrated circuit temperature transducer that provides an output current proportional to absolute temperature. The transducer acts as a high impedance temperature dependent current source of 1mA/ºK.
Output Relays Output relay #0 (drive forward) and output relay #1 (drive reverse) are used to perform jog functions. Output relay #2 controls the open front door function. When this signal is energized, the pneumatic valve opens allowing air into the two (2) door cable cylinders, which in turn opens the front doors. Output relay #3 controls the front UP solenoid. Programmable Logic Controller (PLC) Replacement 1. Discontinue electrical power to the dryer. 2.
End of Cycle Light Bulb Replacement Switch Replacement 1. Discontinue electrical power to the dryer. 2. Mark and identify the wires that will be removed for proper reinstallation. 3. Remove wires. 4. To remove a contact block, loosen and remove the mounting screw. ! Note Contact block #1 and contact block #2 is normally closed (N.C.) while contact block #3 and contact block #4 is normally open (N.O.). 5. To remove or replace operator, use a small screwdriver to fit in the slot on top of the base body.
Basket (Tumbler) System ____________ Drive Motor Component(s) 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.
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. 4. Remove the bolts securing the taper lock bushing. 5. Insert bolts into the threaded holes on the motor pulley and tighten evenly for pulley removal. 6. Loosen the setscrews on the taper lock bushing and remove the bushing. 7. Measure the mark on the drive motor shaft to the end of the shaft. 8.
6. Check the position of the drain plug and the breather plug. 7. Check the turnbuckle mount pad on the gear reducer for the correct application. 8. Install the new gear (speed) reducer on the drive shaft along with the taper lock bushing, the pillow block bearing (setscrews in the pillow block bearing face the end of the drive shaft), the taper lock bushing, and the drive wheels. 9. Reinstall the drive shaft into the dryer. 10.
Retaining Wheel(s) Adjustment 1. With the dryer operating, turn offset hex hub on retaining wheel until wheel is at proper tension. 2. Snug nut against offset hex hub and then tighten. 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).
Safety Devices _______________________ The dryer is equipped with numerous safety devices to ensure that the dryer operates safely. The chart on the following page lists each device with its location, function, computer display message, and result of tripping. Proximity Switch Replacement 1. Discontinue electrical service to the dryer. 2. Remove the screws securing the junction box cover. 3. Mark and identify the wires that will be removed for proper reinstallation. 4.
Safety Devices Locations/Functions/Messages _________ 6DIHW\ 'HYLFHV &RPSXWHU 5HVXOW RI 'LVSOD\ 0HVVDJH 7ULSSLQJ /RFDWLRQ ) X Q F WLR Q /HIW VLGH RI ( QV XUH V G U\H U OR D G ) 5217 ' 225 /RDG GRRU G R R UV D UH FOR V H G 23( 1 8QORDG GRRU VZLWFK 5LJKW VLGH RI ( QV XUH V G U\H U XQOR D G 5( $ 5 ' 225 7ZR GRRU XQL W RQO\ XQORDG GRRU G R R UV D UH FOR V H G 23( 1 /RDG ' RRU 6 ZL WFK 7LOWL QJ 6 ZL WFKHV ' UXP 5RWDWL RQ 6 HQVRU 7RS OHIW VLGH RI EDVH PRGXOH /HIW VLGH R
PHASE 7 NON-COIN SYSTEM DIAGNOSTICS __________________ Important YOU MUST DISCONNECT AND LOCK OUT 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.
Outputs: (Green) 12. 1. FSS - Fire Suppression 2. PRG2 - Programmable Output #2 3. R_HEAT - Rear Heat 4. AUDIO ALERT - Horn On 13. 5. FWD - Basket (Tumbler) Forward 6. AIR JET - Air Jet On 14. EXHL (RED L.E.D.) This L.E.D. will indicate the status of the exhaust high limit disk. If the disk is closed (temperature below 225º F [107º C]), then the L.E.D. is ON. 15. DRY (RED L.E.D.) This L.E.D. will indicate the status of the programmable logic controller (PLC).
Outputs: 1. FSS (GREEN LIGHT EMITTING DIODE [L.E.D.]) This L.E.D. indicates the activation of the water system. When the system is activated the L.E.D. is ON. 2. PGR2 (GREEN L.E.D.) This is for a spare output to be programmed. 3. R_HEAT (GREEN L.E.D.) This 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. 4. AUDIO ALERT (GREEN L.E.D.) This L.E.D. will indicate the status of the horn output.
TROUBLESHOOTING AND REPLACEMENT _________________ Important YOU MUST DISCONNECT AND LOCK OUT 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.
Blower (Fan and Impellor) Motor Operates Okay for a Few Minutes and Then Either Repeatedly or Occasionally Trips the Overload Protector _____________________________ Note When the overload protector trips, the microprocessor controller (computer) I/O board red light emitting diode (L.E.D.) FNOL will be off and the display will read Fan Overload Fault. ! Motor is overheating. Motor air vents clogged with lint. Failed motor. Basket (tumbler) is binding; check for an obstruction.
Microprocessor Controller (Computer) Display Reads Rotation Fault _________________________________ Rotational sensor circuit failure: fault somewhere in the basket (tumbler) rotation or circuit. Basket (tumbler) is not rotating. Broken basket (tumbler) drive belts. Failure in drive motor circuit. Faulty rotation sensor. Broken wire or connection between rotation sensor and microprocessor controller (computer) display board.
PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS __________________ SENSOR ACTIVATED FIRE EXTINGUISHING (S.A.F.E.) SYSTEM _____________ For Models with Direct Spark Ignition (DSI) Module (Type I) ________________ The S.A.F.E. system consists of a temperature probe, water pressure switch, and a solenoid valve. Once 40 to 100 psi of water is connected, the system is activated. Theory of Operation: 20-seconds after the heat turns off, the Phase 7 control monitors the S.A.F.E.
PENDANT ASSEMBLY ____________ Pendant Assembly Description ______ The pendant assembly is used on both the gas and steam model dryer. Within the pendant assembly there is jog forward/ jog reverse push buttons. When depressed individually, these buttons will cause the tumbler (basket) to turn clockwise (CW) for forward and counterclockwise (CCW) for reverse. If both push buttons are depressed together the jog feature is disabled due to the mechanical interlock with the pendant assembly.
Notes _______________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ __________________________________________________________________________________
ADC 450260 1- 4/21/04-0
