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ADC AD-310 Service Manual

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AD-310 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
123098DMG/abe
ADC Part No. 450413

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  • Page 1 AD-310 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 123098DMG/abe ADC Part No. 450413...
  • Page 2 We have tried to make this manual as complete as possible and hope you will find it useful. ADC reserves the right to make changes from time to time, without notice or obligation, in prices, specifications, colors, and material, and to change or discontinue models.

  • Page 3: For Your Safety

    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, ADJUST- ING, INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STANDARDS.
  • Page 4 The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJURY or FIRE COULD RESULT. DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER/SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and/or specified in the installation and operator's manual included with the dryer.

  • Page 5: Table Of Contents

    AD-310 REFERENCE GUIDE Base Section ... 4 INTRODUCTION ... 5 AD-310 MACHINE OPERATION SUMMARY ... 5 AD-310 OPERATOR CONTROLS/INDICATORS ... 5 AD-310 MACHINE OPERATION TROUBLESHOOTING INFORMATION ... 8 SECTION I SAFETY PRECAUTIONS ... 16 SECTION II ROUTINE MAINTENANCE ... 18 A.
  • Page 6 SECTION VI TROUBLESHOOTING ... 105 SECTION VII PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS ... 113...

  • Page 7: Reference Guide

    AD-310 Reference Guide (Tumbler Section)

  • Page 8: Ad-310 Reference Guide Base Section

    AD-310 Reference Guide (Base Section)

  • Page 9: Introduction

    AD-310 MACHINE OPERATIONAL SUMMARY The model AD-310 incorporates one (1) “EMERGENCY STOP (E-Stop) BUTTON” located centrally on the Right Front Control Door. This "RED" MUSHROOM PUSH-BUTTON is “PUSH TO STOP” the machine and “TURN TO RELEASE” or “PULL TO RELEASE” type control device. This button must be in the released mode to power the machine.
  • Page 10 EMERGENCY (E-Stop) STOP BUTTON This "red" mushroom push-button, located in the center of the Right Front Control Door almost directly under the Phase 5 Microprocessor Controller (computer) is a “Push To Stop” and “Turn To Release” type push- button. This button must be in the released mode to power the machine (enable the machine to run). (Forward/Reverse Push-Buttons) These two (2) push-buttons, located towards the left side of the Right Front Control Door, are for either loading or unloading the tumbler.
  • Page 11 CONTROL POWER (Off) This "RED LIGHTED OPERATOR," located on the Right Front Control Door, is for disabling the dryer’s output control voltage. This push-button is mainly for use as a troubleshooting function. END OF CYCLE / HEATER FAULT INDICATOR / AIR JET This amber colored indicator located on the front/top of the dryer has two (2) functions: 1.

  • Page 12: Machine Operation Troubleshooting Information

    AD-310 MACHINE OPERATION TROUBLESHOOTING INFORMATION END OF CYCLE/HEATER FAULT INDICATOR The “END OF CYCLE” light located on the top/front of the dryer, is triggered by the Air Jet Signal of the Phase 5 Microprocessor Controller (computer) to the input of the PLC (Programmable Logic Controller). If this signal is not sensed by the PLC the light will not turn on.
  • Page 13 2. Check to see that the Air Jet L.E.D. (light emitting diode) is on at the end of the drying cycle. If the L.E.D. is not on may be an indication of a failed Phase 5 Microprocessor Controller (computer). 3. If Air Jet L.E.D. is on then check the wiring from the Phase 5 Microprocessor Controller (computer) to the air valve.
  • Page 14 2. Check that 80 PSI of compressed air is supplied to the machine and that the “Front Up” solenoid is being actuated by the PLC (Programmable Logic Controller). Refer to the PLC (Programmable Logic Controller) signal information included in the ladder diagrams and schematics supplied with the machine.
  • Page 15 When a “HEATER FAULT” occurs after the first twenty-five (25) seconds of the drying cycle, a “CLEAR/ STOP” will be sent to the Phase 5 Microprocessor Controller (computer), a “FILL” message will be displayed on the Phase 5 Microprocessor Controller’s (computer’s) display, and both the “HEATER FAULT” button and the “END OF CYCLE"...

  • Page 16: Important Information

    Once the flame has been established in both burner boxes, the natural gas outlet manifold pressure measured at each gas valve pressure tap must be 3-1/2 inches W.C. (water column) pressure. Connect a water tube manometer to the 1/8” F.P.T. gas pressure tap on the downstream side of each gas valve. There is a pressure regulator in both gas valves so the manifold pressure can be adjusted to 3-1/2”...
  • Page 17 ONE (1) BURNER WILL NOT IGNITE AT THE BEGINNING OF A CYCLE This condition can be caused by the following: • DEFECTIVE DSI (Direct Spark Ignition) MODULE • DEFECTIVE SPARK IGNITOR/FLAME-PROBE ASSEMBLY • DEFECTIVE GAS VALVE • INSUFFICIENT GAS PRESSURE •...
  • Page 18 The dryer system is divided into a number of “electrical” sections which are as follows: 1. Right Front Control Panel The RIGHT FRONT CONTROL PANEL is located in the Right Front Control Cabinet of the dryer. This panel is the heart of the drying system, where ALL control signals interface to or from this panel. The signals that interface to this panel are too many to list here, however, they are ALL identified on TB1 of its’...
  • Page 19 4. Optional Sprinkler Circuit The OPTIONAL SPRINKLER CIRCUIT main control panel will be located in the left front electrical enclosure. If a SPRINKLER OPTION is included with the dryer, this panel will include an “AUTOMATIC EMERGENCY STOP” feature. This feature requires that the Sprinkler Circuit be functional for the dryer to be powered.

  • Page 20: Section I

    4. Installation and service must be performed by a qualified installer, service agency, or gas supplier. 5. Dryer(s) must be exhausted to the outdoors. 6. Although ADC produces a very versatile machine, there are some articles that, due to fabric composition or cleaning method, should not be dried in it.
  • Page 21 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.

  • Page 22: Routine Maintenance

    Maximum operating efficiency is dependent upon proper air circulation. The accumulation of lint can restrict this air flow. If the guidelines in this section are met, an ADC dryer will provide many years of efficient, trouble-free, and - most importantly - safe operation.
  • Page 23 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.

  • Page 24: Lubrication

    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.

  • Page 25: Adjustments

    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.

  • Page 26: Specifications And Dimensions

    * Dryer must be provided with a clean, dry, regulated 80 PSI (+/- 10 psi) air supply (equivalent volume - 11 cfh [0.3 cmh]). NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.

  • Page 27: Dimensions

    B. DIMENSIONS NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
  • Page 28 NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
  • Page 29 NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.
  • Page 30 ADG-310 (Gas) Non-Tilt NOTE: ADC reserves the right to make changes in specifications at any time, without notice or obligation.

  • Page 31: Installation Requirements

    Also, allowances should be made in the rear and sides for ease of maintenance. Refer to appropriate Installation Manual (AD-310 Non-Tilting Installation/Operator's Manual [ADC Part No. 112192] or the AD-310 Tilting Installation/Operator's Manual [ADC Part No.

  • Page 32: Electrical And Gas Requirements

    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.

  • Page 33: Component Description/Replacement

    A. HEAT SECTION The AD-310 dryer uses three (3) types of heat sources: natural gas, liquid propane (L.P.) gas, and steam. Natural Gas and L.P. (liquid propane) gas are not directly replaceable. The gas valves need to be modified to use other than the type of heat specified on the nameplate.
  • Page 34 a. The Direct Spark Ignition (DSI) Module is a 24 VAC device designed to be the "controller" of the DSI system. When activated by the dryer controls, this module constantly monitors and controls the functions of the DSI system (i.e., spark activation, gas valve off and on, flame verification, etc.).
  • Page 35 e. The Tumbler Hi-Limit Switch is a thermostat type switch located above the Lint Basket. Its function is to discontinue heat (flame) in the event of an over temperature situation (above 225º F). f. The gas valve used in the dryer is of the redundant type which means that the gas valve is actually two (2) gas valves in one;...
  • Page 36 ADC Direct Spark Ignition (DSI) Operation Flow Chart Computer/Timer Calls For Heat Power Applied to the DSI Module DSI Module Indicator lights "RED" for up to approximately 1.3 seconds (prepurge). DSI Module Internal Check DSI Module Indicator lights "GREEN", Gas Valve opens and spark bursts for approximately 8 seconds.

  • Page 37: Troubleshooting The Direct Spark Ignition (Dsi) System

    OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the AD-310 Non-Tilting Installation/Operator's Manual (ADC Part No. 112192) or the AD-310 Tilting Installation/Operator's Manual (ADC Part No. 112191) included with the dryer. IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY SAFETY or HEAT CIRCUIT DEVICES EVER BE DISABLED.
  • Page 38 1. Direct Spark Ignition (DSI) Troubleshooting Terms (definitions) a. DSI (Direct Spark Ignition) MODULE "RED" L.E.D. (Light Emitting Diode) INDICATOR LIGHT This "red" L.E.D. (light emitting diode) light is located in the upper right corner of the DSI (Direct Spark Ignition) module (refer to the top illustration on page 30).
  • Page 39 If the dryer repeatedly has DSI (Direct Spark Ignition) module "LOCK-OUT" failures, the cause may be due to high voltage not getting into the DSI module ignitor probe assembly. (1) Check to insure that the red high voltage wire (between the ignitor spark electrode and the DSI [Direct Spark Ignition] module) is not wrapped around the sensor probe wire (the wire between the DSI module FP terminal and the ignitor and flame-probe assembly).
  • Page 40 c. Three Visual Checks 1) Does the DSI ignitor/flame-probe assembly start sparking? If not, refer to the FIRST VISUAL CHECK on page 37. 2) Does the main burner ignite? If not, refer to the SECOND VISUAL CHECK on page 38. 3) Does the main burner remain lit after ignition has been established ("FLAME-OUT")? If not, refer to the THIRD VISUAL CHECK on page 39.
  • Page 41 d. Troubleshooting Flow Chart - Quick Reference... Computer/Timer Calls For Heat s spark evident (on) at Ignitor Assembly? Go To Chart 2 Replace the DSI Module. Energize system and check for proper operation. First Visual Check (Does Ignitor Spark?) Is 24 Volts present across DSI Module terminals TH and COM?
  • Page 42 e. Troubleshooting Flow Chart - Quick Reference... Does main burner light? Go To Third Visual Check Restore gas supply. Energize system and check for proper operation. gas available at the source? Energize system. Is 24 VAC present across leads at the Gas Valve? Replace the Gas Valve.
  • Page 43 f. Troubleshooting Flow Chart - Quick Reference... Does main burner remain lit? Does ignitor spark turn "OFF" with main burner flame still present? Control's heat requirements satisfied. DSI cycle is complete. Does ignitor spark continue with burner flame present? Third Visual Check (Does Main Burner Ignite?) Does the Flame Probe...
  • Page 44 3. Troubleshooting and System Detailed Diagnosis When the dryer calls for heat, 24 VAC from the step down transformer is applied to the "TH" and "GND" terminals of the DSI (Direct Spark Ignition) module. The DSI module L.E.D. (light emitting diode) indicator will light "red"...
  • Page 45 a. System Diagnosis 1) Gas Pressure A gas pressure test should be taken at the gas valve pressure tap provided on every gas valve to assure that the water column (W.C.) pressure is correct and consistent. There are two (2) types of devices commonly used to measure water column (W.C.) pressure.
  • Page 46 2) Ignitor and Flame-Probe Assembly The ignitor and flame-probe assembly consists of a ceramic insulated ignitor electrode, a ground rod, and a ceramic insulated flame-probe electrode. The GAP between the ignitor electrode and the ground rod is set, and must be maintained at 1/8" +/- 1/32" (.1250 +/- .03121). When the DSI (Direct Spark Ignition) module provides the high synchronous spark (14,000 volts) through the high voltage (HV) lead, a spark is produced over the GAP.
  • Page 47 NOTE: To reset the dryer when a "HEATER FAULT" occurs, press the ("amber") "HEATER FAULT" reset push-button. 3) Air Turbulence If there is sail switch flutter due to air turbulence, or improper impellor (fan/blower) rotation, or a restriction in the exhaust duct work, the DSI (Direct Spark Ignition) module will cycle erratically. This in turn might cause the DSI module to "LOCK-OUT"...
  • Page 48 Any damage done to dryer components due to improper voltage connections will automatically VOID THE WARRANTY. IMPORTANT: The ADC Service Department must be contacted prior to any wiring change or conversion because, depending on the change or conversion required, some parts may have to be added, deleted, or changed.

  • Page 49: Natural Gas And L.p. (Liquid Propane) Gas Conversion Instructions

    C. NATURAL GAS and L.P. (Liquid Propane) GAS CONVERSION INSTRUCTIONS IMPORTANT: CONVERSION MUST BE PERFORMED BY COMPETENT TECHNICIANS IN ACCORDANCE WITH LOCAL and STATE CODES. NOTE: Converting the dryer to L.P. Gas disables the internal regulator of the gas valve, therefore, an must be external regulator The water column (W.C.) gas pressure must be regulated to between 10.5 -inches and 11-inches...
  • Page 50 11. Reverse the procedure for reinstalling the gas valve/manifold assembly to the dryer. 12. Open ALL gas shut-off valves (closed in Step #2). 13. Reestablish electrical service to the dryer. a. Test ALL connections for leaks. IMPORTANT: est ALL connections for leaks by brushing on a soapy water solution (liquid detergent works well).

  • Page 51: Steam Coil System Operation

    D. STEAM COIL SYSTEM OPERATION General Overview The dryers' steam coil is constantly charged thereby eliminating repeated expansion and contraction and also provide instant heating to start the drying process. The steam damper, located on top of the steam coil, is the only temperature controlling device in this system.
  • Page 52 2. Steam Damper Actuator System The steam damper actuator system consists of a hinged damper plate, pneumatic piston, and a 24 volt solenoid valve with a needle valve to control the speed of the piston actuation. On a call for heat, a 24 volt signal is applied to the 3-way/2-position solenoid valve. This signal switches the valve so that compressed air is sent to the piston.
  • Page 53 3. Steam Damper Actuator System Service and Replacement a. Steam Damper Cylinder or Piston Replacement 1) Disconnect compressed air supply from the dryer. 2) Disconnect tubing from the piston. 3) Remove the spring clip from clevis pin then slide out the clevis pin. 4) Remove the steam damper cylinder (piston).
  • Page 54 d. Steam Coil Replacement 1) Discontinue electrical service to the dryer. 2) Disconnect compressed air supply from the dryer. 3) Shut off ALL steam supply lines and steam return valves that feed the steam coil. 4) Wait a sufficient amount of time until ALL of the steam lines and the steam coil is cool. 5) Open 1/2"...
  • Page 55 12) Remove the steam coil damper hinges from the old coil and install them on the new steam coil. 13) Hoist the new steam coil into place and bolt down. 14) Replace ALL of the panels removed in Step #10. 15) Reinstall ALL of the piping removed from the old steam coil in Step #9.

  • Page 56: Sprinkler System Description

    E. SPRINKLER SYSTEM DESCRIPTION The sprinkler system is monitored by a microprocessor based temperature controller as a designated "FAIL- SAFE." The microprocessor circuit must have power in order to engage main power to the dryer. When cycling the dryer, if the temperature at the Resistive Temperature Device (RTD) reaches 575º F, one (1) set of contact in the controller will open, disabling the power (electric supply) to the dryer.
  • Page 57 d) Sprinkler Digital Temperature Controller The sprinkler digital temperature controller is a programmable microprocessor used to monitor temperatures via a Resistive Temperature Device (RTD). NOTE: Operating parameters are preset at the factory and should not require any adjustment. 2. Sprinkler System Operation NOTE: Refer to the ladder diagram provided with the dryer for specific relay logic.
  • Page 58 3. Sprinkler System Component Replacement a. Resistive Temperature Device (RTD) Replacement 1) Turn the water supply to the dryer off. 2) Discontinue electrical service to the dryer. 3) Remove the 1/4" compression fitting. 4) Remove the two (2) screws from the junction box cover. 5) Remove the wires of the RTD (Resistive Temperature Device) from the terminal strip.
  • Page 59 b. Sprinkler Valve Replacement 1) Turn the water supply to the dryer off. 2) Discontinue electrical service to the dryer. 3) Disconnect compressed air supply from the dryer. 4) Loosen and remove the hose clamp. 5) Remove any residual water to the valve. 6) Remove 1/4"...
  • Page 60 c. 3 HP Control Relay Replacement WARNING: THE SPRINKLER CIRCUIT HAS A SEPARATE POWER SUPPLY (then the power supply for the dryer). DISCONNECT and LOCK-OUT BOTH POWER SUPPLIES BEFORE SERVICING THE DRYER. 1) Mark and identify the wires that will be removed for proper reinstallation. 2) Press down on the control relay and lift the bottom out and up to remove from the din rail.
  • Page 61 MAN3169...

  • Page 62: Tilting System Description

    F. TILTING SYSTEM DESCRIPTION The tilting system in the dryer, whether it be 1-way tilt or 2-way tilt, is controlled by the Micro-1 Programmable Logic Controller (PLC). The PLC (Programmable Logic Controller) will determine if the dryer is safe to tilt based on inputs from several sources.
  • Page 63 1. Speed Adjustment The speed of the tilting action can be regulated by adjusting the set of flow control valves located on the pneumatic panel. Each set of cylinders, both front and rear, will have two (2) flow control valves. One valve will be the extend (up) air line and the other valve will be retract (down) air line.
  • Page 64 3. Tilting Pistons The tilting piston is a double acting cylinder that has a 5-inch bore and an 14-inch stroke. When air is applied to the bottom port of the cylinder, the piston begins to extend and air is exhausted through the top port. Then, if air is applied to the top port, the bottom port will exhaust the air which will cause the piston to retract.
  • Page 65 b. Tilting Solenoid Replacement 1) Engage "EMERGENCY STOP" (E-Stop)... Discontinue electrical service to the dryer. 2) Remove panel covering the pneumatic controls. 3) Label the solenoid plugs as an aid when reconnecting. 4) Loosen screws from the solenoid plug. 5) Remove the solenoid plug (take notice of the gaskets). 6) Remove the E-Clip by gently prying off.
  • Page 66 11) The left orifice (marked #12 on the tilting solenoid valve) now must be configured for external pilot. NOTE: For 1-Way Tilt models proceed to Step #23. 12) Remove the two (2) Phillips head screws. 13) Carefully remove the end of the valve. NOTE: The pieces within the end of the valve are small.
  • Page 68 d. Tilting Piston Replacement 1) Disconnect compressed air supply from the dryer. 2) Tilt, then level the dryer to exhaust as much air as possible. 3) Disengage "EMERGENCY STOP" (E-Stop)... Discontinue electric service to the dryer. 4) Remove the six (6) screws holding the piston cover plate.

  • Page 69: Air Jet Assembly

    G. AIR JET ASSEMBLY 1. Air Jet Assembly Description The air jet assembly is located in the left front base of the dryer. The air jet is designed to operate at the end of each cycle for thirty (30) seconds, to remove lint which may have accumulated on the blower (impellor) fan blades.
  • Page 70 5) Remove the valve support. 6) Remove the two (2) #6-32 x 1" hex head machine bolts by removing the two (2) #6 hex nuts and the two (2) #6 star washers. 7) To install new air jet assembly, reverse above procedure. b.

  • Page 71: Blower (Squirrel Cage Fan) Motor Assembly

    H. BLOWER (Squirrel Cage Fan) MOTOR ASSEMBLY 1. Blower (Squirrel Cage) Motor Description The AD-310 uses an 18-inch diameter, blower (squirrel cage fan) wheel. It spins (turns) in a counterclockwise (CCW) direction when looking at the back of the blower housing.
  • Page 72 2. Blower (squirrel cage fan) and Fan Motor Component Replacement a) Blower (squirrel cage fan) 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 bolts from the motor to the motor base ... (a) Slide the blower (squirrel cage fan) motor forward.
  • Page 73 18) Replace the V-belts ... (a) Adjust to proper tension by adjusting position of the new blower (squirrel cage fan) motor. (b) Align the V-belts. 19) Tighten and secure the new motor to the motor base. 20) Rewire the new blower (squirrel cage fan) motor in the same order as the wiring from the motor that was removed.
  • Page 74 (d) Loosen the set screws on the bushing. (e) Remove the bushing and the pulley. 11) Remove the shrouded pillow block bearing by removing the set screw. 12) Replace the shrouded pillow block bearing on to the fan shaft ... (a) Secure the fan (blower) shaft bearing mount assembly.
  • Page 75 7) Remove the key on the blower (squirrel cage fan) shaft. (a) Slide the blower (squirrel cage fan) off of the shaft. NOTE: Install this key on to the fan shaft before installing the new 8) To install blower (new squirrel cage fan) , reverse above procedure. d) V-Belt Replacement 1) Discontinue electrical power to the dryer.
  • Page 76 (a) Thermal Magnetic Starter (TMS) Replacement (1) Discontinue electrical service to the dryer. (2) Mark L1, L2, L3, and T1, T2, T3 on the wires to the to the TMS for correct replacement. (3) Set the amp rating on the TMS according to the manufacturers electrical schematic on the new thermal magnetic starter.
  • Page 77 2) Auxiliary Contact Block The Auxiliary Contact Block is mounted on the side of the overload. Its' function is to sense an over- load trip, thereby triggering a safety fault which will disable the drying cycle. A "DOOR" message will appear on the L.E.D. (light emitting diode) display on the Phase 5 microprocessor controller (computer).

  • Page 78: Filter And Regulator Assembly

    I. FILTER and REGULATOR ASSEMBLY The purpose of the filter is to remove bulk liquids and solid particles from the compressed air stream. The filter element provides mechanical separation of solids. Centrifugal force inside the filter bowl separates bulk liquids and larger solid particles.

  • Page 79: Door Systems

    J. DOOR SYSTEMS The dryer utilizes two (2) styles of doors, which are Manual Doors and Pneumatic Automatic Doors. 1. Manual Door Description The Manual Doors run on a single aluminum track with a wheel assembly mounted above the doors and a channel with teflon strips mounted on the bottom of the doors ...
  • Page 80 3. Door Component Replacement and Removal a. Manual Door Replacement or Removal 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard and then remove the guard. a) For dryers manufactured as of November 1, 1995, loosen the jam nut and screw down the trolley adjustment bolts.
  • Page 82 b. Pneumatic Automatic Door Replacement or Removal 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard. Remove the middle guard. 3) Remove the three (3) 1/4-20 x 3/4" bolts from the bottom guard. Remove the bottom guard.
  • Page 83 c. Cable Cylinder Replacement or Removal 1) Discontinue electrical service to the dryer. 2) Remove the two (2) 1/4-20 x 1/2" bolts from each side of the middle guard. (Refer to the illustration on page 76.) Remove the middle guard. 3) Disconnect the cables in the top of the electrical panel.
  • Page 84 ALL foreign residue. 3) Carefully clean new door glass with alcohol prior to installation. 4) Apply a bead of silicone (ADC Part No. 170730) to the outer perimeter of the door glass opening. Carefully insert new door glass within door glass opening.
  • Page 85 f. 4-Way Valve, and 3-Way Valve and Supply Air Disable Valve Replacement 1) Discontinue electrical service to the dryer. 2) Disconnect compressed air supply from the dryer. 3) Remove the 1/4-20 self-tapping screws securing the pneumatic panel cover. 4) Remove the two (2) 1/4-20 screws securing the junction box cover.

  • Page 86: Control And Electrical System

    K. Control and Electrical System Ladder Diagram...
  • Page 88 CAUTION: When servicing the HIGH VOLTAGE section of the dryer, the ELECTRIC SERVICE MUST BE DISABLED. THE "EMERGENCY STOP" (E-Stop) BUTTON DOES NOT DISABLE THE HIGH VOLTAGE TO THE DRYER. 1. Control/Electrical System Description a. 3-Phase (3ø) Electrical Power The 3-phase (3ø) electrical power for the dryer enters the dryer through the power distribution block located in the dryer base electrical box.
  • Page 89 3) 24 VAC Transformer The 24 VAC transformer consists of fuse 1 (F1) and fuse 2 (F2) which is the primary fusing for the transformer. For the proper rating of these fuses refer to the specific electric diagram. The transformer is located in the right hand electrical cabinet.
  • Page 90 c) Front Doors Closed circuit branch. There are two (2) magnetic proximity switches mounted in the door closed position and a magnet mounted on top of the doors. When this magnet aligns with the proximity switch, the contacts in the proximity switch close. When both doors are closed, the front doors closed relay (CR2) turns (1) There are two (2) sets of contacts in the relay...one (1) set of contacts are in the dry enable circuit branch and the other set go to the PLC (Programmable Logic Controller) input front doors closed.
  • Page 91 2) The Rotational Sensor is a magnetic proximity switch that is mounted on the side of the right hand 11-inch drive wheels. There is a magnet mounted to the side of the wheel hub. After each rotation of the wheel, the magnet passes by the proximity switch causing the contacts to close and pulse the Phase 5 microprocessor controller (computer).
  • Page 92 b. PLC (Programmable Logic Controller) 1) The PLC (Programmable Logic Controller) can consist of one (1) or two (2) modules; a main module and in some cases an expansion module is used for additional inputs and outputs. NOTE: The information listed below is generic in nature, refer to blueprints for specific details. a) The main PLC (Programmable Logic Controller) module has eight (8) input relays which are labeled #0 through #7 and six (6) output relays labeled #200 through #205.
  • Page 93 Input #12 is the heat on status. It is used to monitor the Phase 5 microprocessor controller (computer) heat output. Input #12 in conjunction with input #13 (gas valve status), the PLC (Programmable Logic Controller) will monitor for a heater fault condition. Input #14 indicates that the drying cycle is done (air jet signal).
  • Page 95 2. Electrical Component Replacement a. Control Voltage Transformer (refer to the illustration on page 92) Replacement 1) Discontinue electrical service to the dryer. 2) Locate the correct schematic for the specific change(s) required and verify the wiring of the transformer using the schematic.
  • Page 96 b. PLC (Programmable Logic Controller) Replacement 1) Discontinue electrical service to the dryer. If there is an expansion module along side the main module carefully disconnect the ribbon cable connecting the two (2) units together. 2) Mark and identify the wires that will be removed for proper reinstallation.
  • Page 97 e. Keypad (touchpad) Replacement 1) Discontinue electrical service to the dryer. 2) Peel existing keypad (touchpad) from the door. 3) Remove as much of the remaining adhesive (from the removed keypad [touchpad] as possible. 4) Install and adhere new keypad (touchpad). 5) Reestablish electrical service to the dryer.
  • Page 98 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. 4) Loosen and remove the screw going into the lens. 5) Twist out lens and remove bulb/light.
  • Page 99 10) Holding the tilt arm, tighten up (snug up) on the nut. 11) Hold pivot point with a screwdriver and tighten the nut. 12) Replace base panel. 13) Reestablish power to the dryer. j. Tilt Switch Adjustment 1) Discontinue electrical service to the dryer. 2) Remove the base panel from the left hand side of the dryer.

  • Page 100: Tumbler (Basket) System

    L. TUMBLER (Basket) SYSTEM 1. Tumbler Drive System The tumbler (basket) is supported and driven by four (4) 11-inch diameter drive wheel assemblies. Two (2) of these wheels are attached to a 1-1/2" diameter idler shaft, while the other two (2) are attached to a 1-1/2" diameter drive shaft.
  • Page 101 WARNING: TO ENSURE THAT THE DRIVE IS NOT UNEXPECTEDLY STARTED, TURN OFF and LOCK OUT and/or TAG POWER SOURCE BEFORE PROCEEDING. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY. WARNING: Drive shaft assembly is heavy. IMPROPER HANDLING CAN CAUSE PERSONAL INJURY.
  • Page 102 3) Install new V-belts. NOTE: Replace V-belts in matched sets (both belts). 4) Tighten turnbuckle. IMPORTANT: DO NOT OVER TIGHTEN TURNBUCKLE. 5) Reestablish electrical service to the dryer. 3) Taper Bushing Assembly and Drive Motor Pulley Assembly Components a) Taper Bushing and Drive Motor Pulley Replacement 1) Discontinue electrical service to the dryer.
  • Page 103 4) Insert blocks of wood under the tumbler (basket) - access through the lint drawer - to take the weight off of the drive wheels. 5) Loosen the turnbuckle and remove the V-belts. Remove bottom turnbuckle mounting bolt. 6) Remove the trantorque from the drive wheels. (A chain wrench will be required to hold the drive shaft to remove the trantorque.) IMPORTANT: On reinstallation, the trantorque must be torqued to 2,300 foot-pounds (259 n-m (newton-meters).
  • Page 104 c) Pillow Block Bearing(s) Replacement 1) Discontinue electrical service to the dryer. 2) Follow Step #2 through Step #9 in the instructions on page 98 and page 99. 3) Remove both drive wheels and trantorques. 4) Carefully file the score marks on the drive shaft from the set screws before removing the pillow block bearing(s).
  • Page 105 11) Reinstall the drive shaft into the dryer. 12) Secure the gear reducer to the drive shaft by reinstalling the three (3) bolts into the taper bushing and tighten evenly for proper mounting. 13) Repeat Step #12 to reinstall the other taper bushing. 14) Reinstall the bolt into the turnbuckle and mounting bracket.
  • Page 106 b) Retaining Wheel(s) Replacement 1) Discontinue electrical service to the dryer. 2) Remove the four (4) Phillips pan head screws to remove the cover. 3) Remove the hardware (i.e., bolt, lock washer, and flat washer) from the hex nut and weld nut on the wheel mount.
  • Page 107 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). 6. Tumbler/Basket Electrical Components a) Tumbler (Basket) Thermal Magnetic Starter and Auxiliary Contact Block Replacement 1) Discontinue electric service to the dryer.
  • Page 108 11) Replace ALL the wires removed in Step #5 (refer to previous page [page 91]). 12) Mount the top of the thermal magnetic starter to the top of the din rail and press down and in. Inspect ALL of the work performed. Set the control of the thermal magnetic starter to the "start"...

  • Page 109: Troubleshooting

    IMPORTANT: YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPLY and THE GAS SUPPLY or THE STEAM SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) STANDARDS.
  • Page 110 B. Drive motor is not operating (does not start)... * Microprocessor controller (computer) relay output indicator (either forward “FWD” or reverse “REV” is on. 1. Blown drive motor contactor fuses or overloads. 2. Failed drive motor contactor. 3. Failed drive motor. * Microprocessor controller (computer) relay output indicator (neither forward “FWD”...
  • Page 111 2. Failed overload protector. E. Impellor (fan) motor is not operating (does not start)... * Microprocessor controller (computer) “MTR” relay output indicator is on. 1. Blown blower (impellor and fan) motor fuses or overloads. 2. Failed blower (impellor and fan) motor contactor (relay). 3.
  • Page 112 H. Both drive motor and blower (fan and impellor) motor are not operating...microprocessor controller (computer) L.E.D. (light emitting diode) motor indicator dots and the “door” L.E.D. indicator are on but the relay output L.E.D. indicators are off (microprocessor controller [computer] L.E.D. display does not read “door”). 1.
  • Page 113 K. Microprocessor controller (computer) L.E.D. display reads “door” and the microprocessor controller (computer) “DOOR” L.E.D. (light emitting diode) indicator is on... 1. Failed microprocessor controller (computer). L. Microprocessor controller (computer) will not accept any keyboard [touchpad] entries, (i.e., L.E.D. [light emitting diode] display reads "FILL" and when keyboard [touchpad] entries are selected, the L.E.D.
  • Page 114 Q. Microprocessor controller (computer) L.E.D. (light emitting diode) display reads “SEFL”... 1. Rotational sensor circuit failure... fault somewhere in the tumbler (basket) rotation or circuit ... a. Tumbler (basket) not rotating ... 1) Broken tumbler (basket) drive belts. 2) Failure in drive motor circuit. b.
  • Page 115 6. Extractors (washer) not performing properly. 7. Sail switch is fluttering...restriction in exhaust (for GAS MODELS ONLY). 8. Failed microprocessor controller (computer)...temperature calibration is inaccurate. 9. Failed microprocessor temperature sensor...calibration is inaccurate. 10. Failed burner hi-limit (for GAS MODELS ONLY). 11.
  • Page 116 V. Dryer will not tilt... 1. Tilt to unload -- 1-- door... a) Dryer will not tilt unless the front doors are completely open ... 1) No door open signal. 2) Defective proximity switch. 3) No (external) compressed air to pneumatic switches... 80 psi required (11 cf/hr). 2.

  • Page 117: Section Vii

    PROCEDURE FOR FUNCTIONAL CHECK OF REPLACEMENT COMPONENTS 1. Microprocessor (computer) Board a. Upon completing installation of the replacement microprocessor (computer) board, reestablish power to the dryer. b. Start the drying cycle. c. Verify that the motor and the heat indicator dots, in the microprocessor (computer) L.E.D. display are on.
  • Page 118 e. Open main door. The dryer must stop and ALL indicator lights on the back side of the micro- processor (computer) board must go out. (Refer to illustration on previous page [page 113].) f. Try to restart the dryer with the main door open. g.
  • Page 119 ADC 450413 1- 05/11/99-25 2- 01/31/00-5...

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