ML-82 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 082499MFM/tcosta 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 or specified in the installation/operator's manual included with the dryer.
Table of Contents SECTION I IMPORTANT INFORMATION ........................................................................................................ 3 A. Safety Precautions ................................................................................................................................... 3 SECTION II SPECIFICATIONS/COMPONENT IDENTIFICATION ................................................................. 5 A. Specifications .............................................................
SECTION VI PHASE 6 OPL SYSTEM DIAGNOSTICS ...................................................................................... 34 A. B. C. D. E. Diagnostic (L.E.D. Display) Failure Codes ........................................................................................... 34 L.E.D. (Light Emitting Diode) Display Indicators ................................................................................. 36 Phase 6 OPL Microprocessor Controller Relay Output L.E.D. Indicators ........................
SECTION I IMPORTANT INFORMATION A. SAFETY PRECAUTIONS WARNING: For your safety, the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury, or loss of life. WARNING: The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJURY or FIRE COULD RESULT. 1. DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. 2.
WARNING: DO NOT 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 rubber 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 heating unit area, exhaust duct work, and inside the dryer.
SECTION II SPECIFICATIONS/COMPONENT IDENTIFICATION A. SPECIFICATIONS BASKET (TUMBLER) DIAMETER BASKET (TUMBLER) DEPTH BASKET (TUMBLER) MOTOR BLOWER MOTOR DOOR OPENING (D IAMETER) BASKET (TUMBLER) VOLUME DRYERS PER 20'/40' CONTAINER DRYERS PER 6m/12m CONTAINER DRYERS PER 45'/48' TRUCK DRYERS PER 14m/15m TRUCK VOLTAGE AVAILABLE APPROX. WEIGHT (UNCRATED) APPROX. WEIGHT (CRATED) HEAT INPUT AIRFLOW INLET PIPE SIZE VOLTAGE AVAILABLE APPROX. WEIGHT (UNCRATED) APPROX.
Specifications MLG-82 (Gas) MLS-82 (Steam) NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
B. COMPONENT IDENTIFICATION 1. Dryer Front View Illus. No.
2. Dryer Rear View Illus. No. 1 2 3* 4 5 6 7 8 Description Heating Unit 1/8" Compressed Air Supply Inlet (behind Electric Service Relay Box for Steam Models Only) Electric Service Relay Box Tumbler Bearing Mount Assembly Idler Bearing Mount Assembly Basket (Drive) Motor Assembly (for Reversing Models Only) Blower Motor Assembly Dryer Exhaust * Electric service connections for Gas Models and Steam Models are made in this box.
SECTION III ROUTINE MAINTENANCE A. CLEANING A program or schedule should be established for periodic inspection, cleaning, and removal of lint from various areas of the dryer, as well as throughout the duct work system. The frequency of cleaning can best be determined from experience at each location. Maximum operating efficiency is dependent upon proper air circulation. The accumulation of lint can restrict this airflow.
90 DAYS 1. Remove lint from around basket (tumbler), drive motors, and surrounding areas. 2. Remove lint from gas valve burner area with a dusting brush or vacuum cleaner attachment. 3. Clean any lint accumulation in and around both the blower and drive motor casing openings. NOTE: To prevent damage, avoid cleaning or touching the hot surface ignitor assembly. EVERY 6 MONTHS Inspect and remove lint accumulation in customer furnished exhaust duct work system and from dryers internal exhaust ducting.
SECTION IV DESCRIPTION OF PARTS A. CONTROL PANEL ASSEMBLY The control panel assemble is made up of a keypad to enter your selections, and a Phase 6 main computer board. The computer controls all input and output functions of the machine. B. DOOR SWITCH ASSEMBLY The main door switch assembly is a safety device used to stop the tumbler in case the main door is opened during a cycle. C. LINT DRAWER AND LINT DRAWER SWITCH The lint door/drawer is located in the bottom front of the machine.
D. THE BASKET AND SUPPORT ASSEMBLY The basket and support assembly is designed for 80 lbs. (36 km) of dry material. It is supported by a shaft and two (2) bearings. E. TEMPERATURE SENSOR BRACKET ASSEMBLY This bracket assembly is equipped with two (2) important devices. One is the temperature probe and the other is the 225º F (107º C) basket hi-limit. The temperature probe senses the temperature in the basket and sends a signal to the computer to read that temperature.
G. IDLER ARM ASSEMBLY The idler arm/pulley has the purpose of taking the speed of the motor and reducing it. Adding tourque to the 18” (46 cm) basket pulley is also the function of the idler arm/pulley. H. BLOWER MOTOR The blower/fan motor has only one purpose in the dryer. It produces the airflow (cfm) throughout the machine. I. DRIVE/FAN MOUNT ASSEMBLY The drive motor is used to turn the basket in the forward and reverse motion.
J. HSI (HOT SURFACE IGNITION) BURNER BOX ASSEMBLY The HSI (Hot Surface Ignition) burner box assembly consists of a number of very important parts for the dryer. A gas valve, hot surface ignitor, hot surface module, flame sensor, sail switch, burner hi-limit. These parts are for the “heat” of the dryer. K. SAIL SWITCH ASSEMBLY The sail switch assembly is used on gas and electric heated machines.
M. REVERSING RELAY PANEL This panel is located in the back of the machine at the upper left hand corner. On this panel is an arc suppressor (A.S.) board which filters out “noise” that might go to the coils of the contactors. Also mounted on this panel are the drive and blower/fan contactors. The two (2) fuses mounted on the panel are protecting the L1 and L3 voltage. The transformer is stepping down the incoming voltage to 24 VAC to supply the voltage to the computer and controls.
SECTION V SERVICING INTRODUCTION ALL electrical and mechanical service or repairs should be made with the electrical power to the dryer disconnected (power off). WARNING: PERSONAL INJURY COULD RESULT. The information provided in this section should not be misconstrued as a device for use by an untrained person making repairs. Service work should be performed by competent technicians in accordance with local, state, and federal codes.
A. COMPUTER CONTROLS To Replace Computer Board 1. Disconnect electrical power to dryer. 2. Unplug keyboard ribbon from rear of computer. 3. Unplug all wiring harnesses connected to the computer board. 4. Remove the two (2) screws securing the computer to the computer panel. Remove the computer by pulling the other two corners off the clinch studs. 5. Install new computer by reversing this procedure. To Replace Keyboard Label Assembly 1. Discontinue electrical power to the dryer. 2.
4. Disassemble sensor probe from bracket assembly by removing the top push-on fastener securing the probe from bracket. Use a small screwdriver to slowly pry the fastener off. 5. Disconnect the two (2) orange wires from the high heat (225º F [107º C]) thermostat, and remove modular bracket connector, wires, and probe from bracket assembly. 6. Install new sensor probe assembly (ADC P/N 880251) by reversing procedure. 7. Reestablish electrical power to the dryer.
To Replace Gas Valve (Refer to burner illustration on page 14) 1. Discontinue electrical power to the dryer. 2. Close shut-off valves in gas supply line. 3. Disconnect gas valve wiring. NOTE: Identify location of each wire for correct reinstallation. 4. Break union connection before gas valve. 5. Loosen and remove four (4) screws securing pipe brackets to burner. 6. Remove valve and manifold assembly from dryer. 7. Remove valve mounting bracket, manifold and piping from gas valve. 8.
1. To test gas water column (W.C.) Pressure: a. Connect water column test gauge connection to gas valve pressure tap (1/8" NPT). This pressure tap is located on the outlet (manifold) side of the valve. b. Start dryer. With burner on, the correct water column reading in inches would be: Natural Gas - 3.5 Inches Water Column - 8.7 mb. L.P. Gas - 10.5 Inches Water Column - 26.1 mb. 2. To adjust water column pressure (natural gas only, L.P. gas must be regulated at source): a.
To Replace Burner Tubes 1. Refer to “Replace Gas Valve” and follow Steps #1 through Step #6. 2. Remove four (4) screws securing the Hot Surface Ignitor (HSI) module mounting bracket. 3. Remove front flanges of the burner tubes to the burner tube rest. 4. Remove the screws securing the burner tube rest to the oven and remove this rest. 5. Remove screws securing burner box cover plate to the oven and remove the cover. 6. Remove burner tubes by sliding them out. 7. Replace by reversing procedure.
1. Discontinue electrical power to the dryer. 2. Disconnect wires from hi-limit thermostat. 3. Remove the two (2) screws, washers and nuts securing thermostat to the bracket. Remove thermostat. 4. Reversing procedure for installing new thermostat. 5. Reestablish electrical power to dryer. To Replace Lint Compartment Hi-Heat Protector (225º F [107º C]) Thermostat This thermostat is part of the “sensor bracket assembly” and is secured to the underside of the basket wrapper in the lint compartment.
To Replace Sail Switch 1. Discontinue electrical power to the dryer. 2. Remove the two (2) screws which hold the sail switch box cover to sail switch box. 3. Disconnect the two (2) wires from the switch. 4. Disassemble sail switch from mounting bracket by removing the two (2) screws securing switch in place. 5. Reverse this procedure for installing new sail switch. Adjust sail switch described in the next section.
To Replace Main Door Assembly 1. Open main door. 2. Holding the door upward remove the two (2) screws from the top hinge block. 3. Lift the door up to remove. 4. Reverse this procedure for reinstalling new main door assembly. To Install New Main Door Glass 1. Remove main door assembly from dryer (follow main door removal procedure). 2. Lay main door on flat surface with back of door face down. 3. Remove glass and clean all old sealant off main door. This area must be completely clean for correct bonding.
7. After the curing period, install the main door on the dryer by reversing Step #4 through Step #1. NOTE: Once the silicone is cured you may want to trim any excess silicone on the inside of the main door assembly. To Replace Front Panel 1. Discontinue electrical power to the dryer. 2. Remove bottom lint door assembly. 3. Remove the front panel by removing the screws. IMPORTANT: When pulling the front panel off, the door switch harness in the upper right hand corner must be unplugged.
F. STEAM CONTROLS Installation Piping must be installed in accordance with good commercial steam system practice. See the illustration below for a typical pipe arrangement. To Replace Steam Coil (Damper System) 1. Discontinue electrical power to the dryer. 2. Remove the four (4) lock washers and hex nuts securing the hinges to steam coil. 3. Remove hinges from steam coil housing (these will be used on new assembly). 4. Remove six (6) washers and hex nuts securing steam coil to dryer. 5.
To Replace Piston 1. Discontinue electrical power to the dryer. 2. Discontinue the air supply to the dryer. 3. Remove left and right piston supports by removing two (2) washers and hex nuts and slide pin out. 4. Remove 1/8” M.P.T. connector from the piston and remove acorn nut on the end of piston shaft (this will be used on new piston). 5. Reverse procedure for installing new piston. To Replace The Needle Valve 1. Discontinue electrical power to the dryer. 2. Discontinue the air to the dryer. 3.
CAUTION: Steam coil and/or piping may be hot, allow time to cool. 4. Remove remaining piping from steam coil. 5. Remove six (6) screws holding coil to steam rack and lift core out. 6. Reverse procedures for installing new core. G. TUMBLER and BEARING ASSEMBLY (Remove back guard to access assembly) Reversing To Replace Tumbler Pulley (Reversing) 1. Loosen V-belts, then rotate pulley and roll V-belts out of grooves. 2. Remove cap screws securing taper lock hub to pulley. 3.
NOTE: If any rust has developed, use an emery cloth to polish the shaft. 5. Remove bolts securing bearing to bearing box and remove tumbler bearing. 6. Reverse procedure for installing new tumbler bearing. NOTE: Check alignment of pulleys before operating dryer. To Replace The Front Tumbler Bearing 1. Remove tumbler pulley and bearing box (follow “To Replace The Rear Tumbler Bearing” Step #1 through Step #4). 2. Loosen set screws on rear tumbler bearing. 3.
a. Remove two (2) bolts securing idler arm to the idler backup plate. b. Remove idler arm assembly. c. Loosen set screws on both the front and rear bearing and remove the idler shaft. d. Remove three (3) bolts securing the bearing to the idler arm and remove bearings. 3. Reverse procedure for installing new idler bearings. NOTE: Check tension and alignment of belts before operating dryer. I. DRIVE PULLEY (Remove back guard to access assembly) 1. Remove back guard. 2.
7. Leave a larger gap from the inside ring on the top of the front panel opening to the tumbler, and a smaller gap on the bottom to compensate for the weight of the clothes being dried. 8. Tighten the four (4) hex head bolts on the sides of the bearing box, and the two (2) Allen head adjustment screws. 9. Replace back guard. 10. Reestablish electrical power to the dryer. Tumbler Alignment (Lateral) 1. Discontinue electrical power to the dryer. 2. Remove back guard. 3.
f. Disconnect the main door switch harness at connector. IMPORTANT: When removing front panel assembly be careful not to damage door switch wires. 3. Loosen set screws on rear tumbler bearings. 4. Using a wheel puller gently push the tumbler shaft towards the front through the tumbler bearings. NOTE: An alternate method would be to place a block of wood on the end of the tumbler shaft and strike it with a heavy hammer. To prevent damage to the shaft, the wheel puller method is preferred. 5.
V-Belt Tension Alignment - Motor To Idler 1. Loosen two (2) bolts connecting idler arm to backup plate. 2. Back off on jam nut(s) on the adjusting bolt. 3. Loosen/tighten adjustment bolt to decrease/increase belt tension. 4. Tighten adjustment bolt jam nut(s). 5. Tighten the two (2) bolts loosened in Step #1. To Replace V-Belts 1. Loosen tension on V-belts, so that they can easily be rolled off pulleys. 2. Replace V-belts. 3. Retighten V-belts and adjust tension and alignment per previous instructions.
SECTION VI PHASE 6 OPL SYSTEM DIAGNOSTICS IMPORTANT: You must DISCONNECT and LOCKOUT THE ELECTRIC, GAS or 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.
microprocessor controller (computer) determines the ignition control has failed. If this occurs when the cycle is active the machine will display “bURNER CONTROL FAIL.” If the tumbler temperature is above 100º F (38º C) the machine will continue to display “bURNER CONTROL FAIL.” The machine will run with no heat for three (3) minutes or until the temperature drops below 100º F (38º C).
NOTE: RPM- This routine monitors the timing response from the existing rotational sensor input and derives a RPM measurement. To display this RPM measurement (press the “ENTER/ START” key once and release, then press the “ENTER/START” key a second time and hold. This will display the RPM measurement). The rotational sensor must be active for operation of this feature. 12.
C. PHASE 6 OPL MICROPROCESSOR CONTROLLER RELAY OUTPUT L.E.D. INDICATORS There are a series of five (5) L.E.D. (light emitting diode) indicators (ORANGE LIGHTS) located at the backside are of the Phase 6 OPL microprocessor controller (computer). These are identified or labeled (from top to bottom in the illustration below as: FAN-BLOWER, FOR-FORWARD, REV-REVERSE, AIR-AIR-JET, HT1HEAT OUTPUT. There are a series of seven (7) L.E.D.
1. “FAN” (BLOWER) Output L.E.D. (light emitting diode) Indicator A. If the dryer is started and the blower motor is not operating, yet the Phase 6 OPL microprocessor controller (computer) display fan indicator dot and power supply input L.E.D. are on, but the fan output L.E.D. is off, then the fault is the Phase 6 OPL microprocessor controller (computer) itself. 1. If the motor is not operating. The fan indicator dot and output L.E.D. are also on, then the problem (fault) is elsewhere (i.e.
7. “LINT” (LINT DOOR) Input L.E.D. (light emitting diode) Indicator A. Should be on ALL the time (unless the lint door is opened then the “LINT” L.E.D. indicator will go out). B. If the dryer is active (running) and the lint door is opened the “LINT” L.E.D. indicator will go out and the display will read “LINT dOOR.” The dryer will stop until the Lint Drawer has been closed, at which time the L.E.D. display will read “PRESS START.” At this time, to resume the drying cycle press “ENTER/START” key. 8.
12. “FLAME” (bURNER CONTROL FAIL) Input L.E.D. (light emitting diode) Indicator A. This routine monitors the ignition control’s gas valve output response. If the valve output signal is not present from the ignition control within the valve time limits the microprocessor determines the ignition control has failed. If this occurs when the cycle is active the “FLAME” output L.E.D. indicator will go out and the display will read “bURNER CONTROL FAIL.
D. L.E.D. CODES 1.
E.
SECTION VII TROUBLESHOOTING WARNING: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STANDARDS. The information provided will help isolate the most probable component(s) associated with the difficulty described.
C. Dryer will not start, but computer display indicators are on... 1. Failed contactors. 2. Failed arc suppressor (A.S.) board. 3. Failed microprocessor controller (computer). 4. Failed motors. D. Drive motor runs, burner is on, but basket will not turn... 1. Broken, damaged or loose V-belt. 2. Belts contaminated (oil, grease, etc.). 3. Loose or broken pulley. E. Dryer operates but is taking too long to dry... 1. Improperly programmed microprocessor controller (computer). 2.
6. Out of balance impellor (fan). 7. Insufficient make-up air. G. Overload for impellor (fan) motor is tripping... 1. Either an exceptionally low or high voltage supply. 2. Motor bearing failure. 3. Motor vents are blocked with lint. 4. Failed motor. 5. Failed overload. 6. Insufficient make-up air. H. Burner hi-limit safety thermostat is tripping... 1. Insufficient exhaust duct work, size, or restriction in exhaust system. 2. Insufficient make-up air. 3. Lint screen needs cleaning. 4. Damaged impellor. I.
K. There is excessive vibration coming from the basket... 1. Basket is out of adjustment. 2. Drive shaft or idler shaft is out of alignment. 3. Faulty pillow block bearing. 4. Faulty tumbler wheel. 5. Drive motor and shaft not aligned. 6. Faulty retaining wheel.
SECTION VIII ELECTRICAL TROUBLESHOOTING 47
1. No Display Condition a. Check fuse 1 or 2 and if either are blown, replace. b. Take voltage reading across the microprocessor (J7) 9-pin connector pins 1 and 2. If no voltage is present at pins 1 and 2, double check the secondary (24 VAC) side of transformer at the blower motor contactor number 13 to ground if voltage is present. Problem is bad wire or faulty connection from blower motor contactor #13 back through J2 9-pin connector and then to computer connector pin 1. c.
If there is voltage across the two BS3 terminals and no voltage across the coil of the reversing contactor (A1 and A2), the problem is bad wires or terminations between BS1 and the contactor coil. d. If there is no voltage between the two (2) BS3 terminals on the arc suppressor board, check for voltage across the two (2) AS3 terminals on the board. If there is voltage across the two (2) AS3 terminals and no voltage across the two (2) BS3 terminals, replace the arc suppressor board.
d. If no voltage is present at J7 9-pin connector no. 3 to ground, then voltage should not be present at no. 5 to ground. Replace the microprocessor controller (computer). 6. Main Door Condition NOTE: Make sure main door and lint door are closed. Also, if checking either switch, the plunger must be depressed. a. Check L.E.D. (light emitting diode) input light “MAIN” on the component side of the computer. If the light is on, replace the computer. b. Check voltage (24 VAC) from J7 9-pin connector no.
SECTION IX TECHNICAL INFORMATION The following section contains various technical information important to the service person in servicing and maintaining the dryer. A. MOTOR PLATE (HIGH and LOW VOLTAGE) The motor plate is located on the side of the drive motor (see illustration) and contains a graphical representation of the motor wiring for both low and high voltage ratings. Removing the cap reveals the wiring to the motor.
B. DATA LABEL Contact American Dryer Corporation When contacting American Dryer Corporation certain information is required to insure proper service/parts information from American Dryer. This information is on the data label located on the inside of the control door. When contacting American Dryer please have the model number and serial number available.
THE DATA LABEL 1. MODEL DRYER The model number is an ADC number which describes the size of the dryer and the type of heat (gas, electric, or steam). 2. SERIAL NUMBER The serial number allows ADC to gather information on your particular dryer. 3. MANUFACTURING CODE NUMBER The manufacturing code number is a number issued by ADC which describes ALL possible options on your particular model. 4.
IMPORTANT MANUAL RESET HI-LIMIT INSTRUCTIONS FOR PHASE 6 MODELS This dryer was manufactured with a manual reset burner hi-limit thermostat which is monitored by the Phase 6 computer. If the manual reset burner hi-limit thermostat is open prior to the start of the machine, the dryer will start momentarily and the shut down displaying “burner safety fail” with an audio indication.
C. COMPUTER LOGIC 1. Operator enters desired selections. 2. Information entered is sent to the microprocessor via the keyboard (touchpad). 3. The input information is sorted, processed and executed by the microcomputer chip. 4. The microcomputer output signal activates the contactors and HSI (Hot Surface Ignition) module which control machine functions. The wiring diagrams used in troubleshooting are specifically for dryers manufactured at the time of publishing.
SECTION X SERVICE/PARTS INFORMATION A. SERVICE 1. Service must be performed by a qualified trained technician, service agency, or gas supplier. If service is required, contact the distributor from whom the ADC equipment was purchased. If the distributor cannot be contacted or is unknown, contact the ADC Service Department for a distributor in your area.
SECTION XI WARRANTY INFORMATION A. RETURNING WARRANTY CARD(S) 1. Before any dryer leaves the ADC factory test area, a warranty card is placed on the back side of the main door glass. These warranty cards are intended to serve the customer where we record the individual installation date and warranty information to better serve you should you file a warranty claim. a. If a warranty card did not come with your dryer, contact the ADC Warranty Department or ADC Service Department at (508) 678-9000. B.
2. Each part must be tagged with the following information: a. Model number and serial number of the dryer from which part was removed. b. Nature of failure (be specific). c. Date of dryer installation. d. Date of part failure. e. Specify whether the part(s) being returned is for a replacement, a credit, or a refund. NOTE: If a part is marked for a credit or a refund, the invoice number covering the purchase of the replacement part must be provided. NOTE: Warranty tags (ADC Part No.
D.
ADC 450404 1- 12/21/99-50