ADC AD-410 Wartungshandbuch

AD-410 Phase 7Service Manual102600DMG/calbert ADC Part No. 450051American Dryer Corporation88 Currant RoadFall River, MA 02720-4781Telephone: (508) 67

6WARNING: DO NOT dry mop heads. Contamination by wax or flammable solvents will create afire hazard.WARNING: DO NOT use heat for drying articles that

9611) 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 to

97SECTION VIPHASE 7 OPL SYSTEM DIAGNOSTICSIMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY andTHE GAS SUPPLY or THE STEAM SUPPLY BEFORE

98REAR 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

99B. INPUT/OUTPUT (I/O) BOARD LIGHT EMITTING DIODE (L.E.D.) INDICATORSOUTPUTS: (GREEN)1. R_HEAT - Rear Heat2. AUDIO ALERT - Horn On3. FWD - Baske

100INPUTS:1. FDRC – (RED L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the front doors. If thedoors are closed, then the L.E

10116. LINT – (RED L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the lint drawer. If thedrawer is closed, then the L.E.D. is

102OUTPUTS:1. R_HEAT – (GREEN L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the rearheat output. If the request to turn on t

10316. OCL5 – (GREEN L.E.D.) This light emitting diode (L.E.D.) will indicate the status of the opencollector output #5. If the request to turn on th

104SECTION VIITROUBLESHOOTINGIMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY andTHE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or

105NOTE: SPRINKLER MUST HAVE POWER FOR THE DRYER TO OPERATE.B. Drive motor is not operating (does not start)...* Microprocessor controller (computer)

7SECTION IIROUTINE MAINTENANCEA. CLEANINGA schedule should be established for periodic inspection, cleaning, and removal of lint from various areas o

106f. 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. Fail

1072. Failed overload protector...a. Incorrect overload setting.3. Blown drive motor and blower (fan and impellor) motor fuses or overloads.4. Failed

1085. Front or rear doors are opened during cycle.6. Failed microprocessor controller (computer) input/output (I/O) board.J. Microprocessor controller

1092) Failure in drive motor circuit.b. Faulty rotation sensor.c. Broken wire or connection between rotation sensor and microprocessor controller (com

11013. Steam damper system is not functioning properly (for STEAM MODELS ONLY)...a. Steam damper sticking closed.b. Leak in pneumatic system.14. Under

111* 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.

112SECTION VIIIPROCEDURE FOR FUNCTIONAL CHECKOF REPLACEMENT COMPONENTS1. For Models With Johnson Controls Direct Spark Ignition (DSI) Module (G760)The

1132. For Direct Spark Ignition (DSI) System Models Manufactured With ADC Module Part No. 880815a. Upon completing installation of thereplacement DSI

ADC 450051 1- 08/30/01-25

8WARNING: TO AVOID THE HAZARD OF ELECTRICAL SHOCK, DISCONTINUEELECTRICAL SUPPLY TO THE DRYER.MONTHLYEmpty the compressed air filter bowl.NOTE: REGULAT

9B. LUBRICATIONMONTHLYThe two (2) bearings that support the impellor/fan shaft must be lubricated. Use Shell Alvania #2 grease or itsequivalent. Ge

10EVERY 6 MONTHSChange gear oil in basket (tumbler) shaft gear reducer.1. Remove the drain plug (located at the bottom rear of the reducer).2. After o

11SECTION IIISPECIFICATIONS and DIMENSIONSA. SPECIFICATIONS (Gas and Steam Models)* Dryer must be provided with a clean, dry, and regulated 80 PSI +/

12NOTE: ADC reserves the right to make changes in specifications at any time without notice orobligation.B. DIMENSIONS

13NOTE: ADC reserves the right to make changes in specifications at any time without notice orobligation.

14NOTE: ADC reserves the right to make changes in specifications at any time without notice orobligation.

15NOTE: ADC reserves the right to make changes in specifications at any time without notice orobligation

AD-410 Phase 7Retain This Manual In A Safe Place For Future ReferenceAmerican Dryer Corporation products embody advanced concepts in engineering, desi

16SECTION IVINSTALLATION REQUIREMENTSInstallation should be performed by competent technicians in accordance with local and state codes. In theabsenc

17B. ELECTRICAL and GAS REQUIREMENTSIt is your responsibility to have ALL electrical connections made by a properly licensed and competent electricia

18SECTION VCOMPONENT DESCRIPTION/REPLACEMENTA. HEAT SECTIONThe dryer uses three (3) types of heat sources: natural gas, liquid propane (L.P.) gas, an

19330º F (166º C) ThermostatSail Switch Assemblya. The Direct Spark Ignition (DSI)module is a 24 VAC devicedesigned to be the “controller” ofthe DSI s

20e. The manual reset basket (tumbler) hi-limit switch is a thermostattype switch located above the lint basket. Its function is todiscontinue heat (

21Is 24 VAC availableat transformer?Is 24 VAC present from terminalTHS(2) to ground?Is power availableto primary?Are thermostat contacts andhi-limit c

22i. Troubleshooting Flowchart - Quick Reference...Second Visual CheckSpark Present But Main Burner Does Not Come OnIs main valve wiring securelyattac

23j. Troubleshooting Flowchart - Quick Reference...Third Visual CheckMain Burner Lights But Will Not Stay OnIs flame sensor cablesecurely attachedto s

24B. TROUBLESHOOTING THE DIRECT SPARK IGNITION (DSI) SYSTEMNOTE: The troubleshooting information provided in this manual is intended for use by quali

251. Direct Spark Ignition (DSI) Troubleshooting Terms (definitions) ADC (DSI) Control Module P/N 128973a. DSI MODULE “RED” L.E.D. INDICATOR LIGHT - T

IMPORTANTYOU MUST DISCONNECT and LOCKOUT THE ELECTRICSUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANYCOVERS or GUARDS ARE REMOVED FROM THE MAC

26If the dryer repeatedly has Direct Spark Ignition (DSI) module “LOCKOUT” failures, the causemay be due to high voltage not getting into the DSI modu

27c. Three (3) Visual Checks1) Does the Direct Spark Ignition (DSI) ignitor/flame-probe assembly start sparking?If not, refer to the First Visual Chec

28d. Troubleshooting Flowchart - Quick Reference...First Visual Check(Does Ignitor Spark?)Is spark evident (on)at Ignitor Assembly?Is 24 Voltspresent

29e. Troubleshooting Flowchart - Quick Reference...Second Visual Check(Does Main Burner Ignite?)Doesmain burnerlight?Is manualknob on the Gas Valvein

30f. Troubleshooting Flowchart - Quick Reference...Third Visual Check(Does Main Burner Ignite?)Doesmain burnerremainlit?Doesthe Flame Probehave carbon

313. Troubleshooting and System Detailed Diagnosis For Johnson Direct Spark Ignition (DSI) Module P/N 128935When the dryer calls for heat, 24 VAC from

32a) 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

33(a) To check and/or set the 1/8” (3.175 mm) gap, use a Direct Spark Ignition (DSI) gapfeeler gauge or similar device to determine gap size. DO NOT

343) Air TurbulenceIf there is sail switch flutter due to air turbulence or improper impellor (fan/blower) rotation or arestriction in the exhaust duc

35CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THEBURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORTOUT.6) Direct Spark Ignition (DS

IMPORTANTPLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on theequipment and specified in the installation manual included with the dryer.The wiring d

364. Troubleshooting and System Detailed Diagnosis For ADC Direct Spark Ignition (DSI) Module P/N 128973When the dryer calls for heat, 24 VAC from the

37a) 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 pag

38(a) To check and/or set the 1/8” (3.175 mm) gap, use a Direct Spark Ignition (DSI) gapfeeler gauge or similar device to determine gap size. DO NOT

393) Air TurbulenceIf there is sail switch flutter due to air turbulence or improper impellor (fan/blower) rotation or arestriction in the exhaust duc

40CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THEBURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORTOUT.6) Direct Spark Ignition (DS

41C. NATURAL GAS and LIQUID PROPANE (L.P.) GAS CONVERSIONINSTRUCTIONSIMPORTANT: CONVERSION MUST BE PERFORMED BY COMPETENT TECHNICIANSIN ACCORDANCE WI

4211. Reverse the procedure for reinstalling the gas valve/manifold assembly to the dryer.12. Open ALL gas shutoff valves (closed in Step #2).13. Rees

431. Steam Coil PH LevelThe normal PH level for copper type steam coils must be maintained between a value of 8.5 to 9.5. Forsteel type steam coils t

44The steam damper plate should open and close slowly and smoothly. The speed can be modulated byadjusting the needle valve knob. Turning the knob c

455) 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

Table of ContentsAD-410 REFERENCE GUIDE (Basket [Tumbler] Section)... 3AD-410 REFERENCE GUIDE (Base Section) ...

466) Remove steam coil damper cylinder (piston).7) Remove the steam coil damper by unbolting from its hinges.8) Disconnect steam supply lines and stea

47E. SPRINKLER SYSTEM DESCRIPTIONThe sprinkler system is monitored by a microprocessor based temperature controller as a designated “FAIL-SAFE.” The

48MAN3488d. Sprinkler Digital Temperature ControllerThe sprinkler digital temperature controller is a programmablemicroprocessor used to monitor tempe

495) Remove the wires of the resistive temperature device (RTD) from the terminal strip.NOTE: Identify the wires removed for proper reinstallation.6)

50WARNING: THE SPRINKLER CIRCUIT HAS A SEPARATE POWER SUPPLY (than the powersupply for the dryer). DISCONNECT and LOCKOUT BOTH POWERSUPPLIES BEFORE S

516) Mount the top of the control relay to the top of the din rail, then press down and snap the bottom intothe rail.Set the overload to the setting s

52

53The tilting system in the dryer, whether it is 1-way tilt or2-way tilt, is controlled by the TSX-07 programmable logiccontroller (PLC). The PLC wil

541. Tilting Solenoid ValveThe dryer uses a 3-position/4-way/5-port, spring centering double solenoid valve. With no power applied toeither solenoid,

55a. Tilting Solenoid Replacement1) Engage “EMERGENCY STOP” (E-Stop)...Discontinue electrical power to the dryer.2) Remove panel covering the pneumati

SECTION VIPHASE 7 OPL SYSTEM DIAGNOSTICS ... 97A. Diagnostic (L.E.D. Display) Fault Messages .

5610) 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 o

57c. Tilting Piston Replacement1) Disconnect compressed air supply from the dryer.2) Tilt, then level the dryer to exhaust as much air as possible.3)

589) 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 pis

59G. AIR JET ASSEMBLY1. Air Jet Assembly DescriptionThe air jet assembly is located in the left front base of the dryer. The air jet is designed to

605) 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 thetwo (2) #6 star washe

61H. BLOWER (Squirrel Cage Fan) MOTOR ASSEMBLY1. Blower (Squirrel Cage Fan) Motor DescriptionThe dryer uses a 22-1/4” (56.51cm) diameter, blower (squ

622. Blower (Squirrel Cage Fan) Motor Component Replacementa. Blower (Squirrel Cage Fan) Motor Replacement1) Discontinue electrical power to the dryer

6318) 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) Tig

64d) 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

657) 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 cagefan) shaft.a) Slide the blower (squirrel cage fan)

3AD-410 Reference Guide(Basket [Tumbler] Section)

66a) 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 th

672) Auxiliary Contact BlockThe Auxiliary Contact Block is mounted on the side of the overload. Its function is to sense anoverload trip, thereby tri

68I. FILTER/REGULATOR ASSEMBLYThe purpose of the filter is to remove bulk liquids and solid particles from the compressed air stream. The filterelem

69J. DOOR SYSTEMSThe dryer utilizes two (2) styles of doors, which are manual doors and pneumatic automatic doors.1. Manual Door DescriptionThe manua

703. Door Component Replacement and Removala. Manual Door Replacement or Removal1) Discontinue electrical power to thedryer.2) Remove the two (2) 1/4-

71b. Pneumatic Automatic Door Replacement or RemovalAUTOMATIC DOORS1) Discontinue electrical power to the dryer.2) Remove the two (2) 1/4-20 x 1/2” bo

72c. Cable Cylinder Replacement or Removal1) Discontinue electrical power to the dryer.2) Remove the two (2) 1/4-20 x 1/2” bolts from each side of the

73d. Proximity Switch Replacement1) Discontinue electrical power to the dryer.2) Remove the two (2) 1/4-20 x 1/2” bolts fromeach side of the middle gu

74f. 4-Way Valve, 3-Way Valve, and Supply Air Disable Valve Replacement1) Discontinue electrical powerto the dryer.2) Disconnect compressed airsupply

75K. CONTROL and ELECTRICAL SYSTEMLadder Diagram

4AD-410 Reference Guide(Base Section)

76

77CAUTION: When servicing the HIGH VOLTAGE (HV) section of the dryer, theELECTRICAL POWER MUST BE DISABLED. THE “EMERGENCY STOP”(E-Stop) BUTTON DOES

783) 24 VAC TransformerThe 24 VAC transformer consists of Circuit Breaker (CB5), which is the primary fusing for thetransformer. For the proper ratin

79c) 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) p

80Next reverse leads to temperature sensor “black” to “black” and “red” to “white.” At that point youmeasure approximately 1.8-amps, this is the turn

81a) The programmable logic controller (PLC) module has thirteen (13) input relays, which are labeled#0 through #13 and nine (9) output relays labeled

822. Electrical Component Replacementa. Control Voltage Transformer Replacement (refer to the illustration on page 84).1) Discontinue electrical power

83

84b. Programmable Logic Controller (PLC) Replacement1) Discontinue electrical power to the dryer.2) Mark and identify the wires that will be removedfo

855) To install new microprocessor controller (computer) input/output (I/O) board, reverse Step #4 thruStep #1.6) Reestablish electrical power to the

5SECTION ISAFETY PRECAUTIONSCAUTION: The dryer should never be left unattended while in operation.WARNING: For your safety, the information in this ma

865) 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 r

87Verify 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)

88L. BASKET (Tumbler) SYSTEM1. Basket (Tumbler) Drive SystemThe basket (tumbler) is supported and driven by four (4) 11-inch (27.94 cm) diameter driv

89WARNING: TO ENSURE THAT THE DRIVE IS NOT UNEXPECTEDLY STARTED, TURNOFF and LOCKOUT and/or TAG POWER SOURCE BEFORE PROCEEDING.FAILURE TO OBSERVE THES

901) 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 (b

913) Mark the position of the pillow blockbearing on the mounting pad andloosen the setscrews.4) Insert blocks of wood under thebasket (tumbler) - acc

925) Reestablish electrical power to the dryer.f. Pillow Block Bearing(s) Replacement1) Discontinue electrical power to the dryer.2) Follow Step #2 th

9310) Secure the gear reducer to the drive shaft by reinstalling the three (3) bolts into the taper lockbushing and tighten evenly for proper mounting

94b. Retaining Wheel(s) Replacement1) Discontinue electrical power to the dryer.2) Remove the four (4) Phillips pan head screws to remove the cover.3)

954. Basket (Tumbler) Electrical Component(s)a. Basket (Tumbler) Thermal Magnetic Starter (T.M.S.) and Auxiliary Contact Block Replacement1) Discontin