1. Manuals
  2. Brands
  3. American Dryer Corp. Manuals
  4. Dryer
  5. AD-540
  6. Service procedure

American Dryer Corp. AD-540 Service Procedure

American dryer corporation ad-540 mechanical/electrical service procedure
Hide thumbs
Table of Contents

Advertisement

Quick Links

AD-540
Mechanical/Electrical
Service Procedure
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
090603SRS/tcosta
ADC Part No. 450246

Advertisement

Table of Contents
loading

Related Manuals for American Dryer Corp. AD-540

Summary of Contents for American Dryer Corp. AD-540

  • Page 1 AD-540 Mechanical/Electrical Service Procedure 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 090603SRS/tcosta ADC Part No. 450246...
  • Page 2 These instructions must be posted in a prominent location near the dryer. POUR VOTRE SÉCURITÉ Ne pas entreposer ni utiliser d’essence ni d’autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil. Important MODEL NO. __________________________________________ AD-540...

  • Page 3: For Your Safety

    YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLY AND THE GAS 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 4 DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER OR SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED. PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment and specified in the installation manual included with the dryer. The wiring diagram for the dryer is located behind the left front control panel.

  • Page 5: Table Of Contents

    SECTION I IMPORTANT INFORMATION ... 3 A. Safety Precautions ... 3 SECTION II ROUTINE MAINTENANCE ... 4 A. Cleaning ... 4 B. Adjustments ... 5 SECTION III INSTALLATION REQUIREMENTS ... 6 A. Enclosure, Air Supply, and Exhaust Requirements ... 6 B.
  • Page 6 SECTION VI BCD-1 TYPE MODULE ... 29 A. Introduction ... 29 B. General System Information ... 29 C. G-760 Direct Spark Ignition (DSI) Flowchart ... 32 D. Troubleshooting ... 33 SECTION VII TROUBLESHOOTING ... 47 A. Phase 5 Coin System Diagnosis ... 47 B.

  • Page 7: Important Information

    IMPORTANT INFORMATION A. SAFETY PRECAUTIONS 1. DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. 2. Purchaser and/or user should consult the local gas supplier for proper instructions to be followed in the event the user smells gas.

  • Page 8: Routine Maintenance

    ROUTINE MAINTENANCE A. CLEANING A program and/or 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.

  • Page 9: Adjustments

    AS REQUIRED: In cleaning and care of the cabinet, avoid using harsh abrasives. A product intended for the cleaning of appliances is recommended. B. ADJUSTMENTS SUGGESTED INTERVAL 6 MONTHS Drive belts should be examined. Cracked or seriously frayed belts should be replaced. Tighten loose drive belts when necessary, and check belt alignment.

  • Page 10: Installation Requirements

    INSTALLATION REQUIREMENTS Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, the installation must conform to applicable American National Standards: ANSI Z223.1- LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electrical Code) or in Canada, the installation must conform to applicable Canadian Standards: CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (Liquid Propane [L.P.] Gas) or LATEST EDITION (for General Installation and Gas Plumbing) or Canadian Electrical Codes Parts 1 &...

  • Page 11: Electrical And Gas Requirements

    B. ELECTRICAL AND GAS REQUIREMENTS 1. Electrical 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 to local and state regulations or codes.

  • Page 12: Operational Service Check Procedure

    The dryer must be connected to the type of gas (natural or liquid propane [L.P.]) indicated on the dryer data label. If this information does not agree with the type of gas available, contact the reseller who sold the dryer or contact the ADC factory. The gas input ratings shown on the dryer data label are for elevations up to 2,000 feet (609.6 meters), unless elevation requirements of over 2,000 feet (609.6 meters) were specified at the time the dryer order was placed with the factory.

  • Page 13: Description Of Parts

    SECTION IV DESCRIPTION OF PARTS A. CONTROL PANEL The coin panel assembly consists of the coin operator, a display board, and the keyboard (touch pad) label. The coin acceptor is used to acknowledge that the proper coin has been put through the acceptor. The display board will just display the time and temperature in a readable number of letter characters.

  • Page 14: Door Switch (Hinge Block)

    D. DOOR SWITCH (HINGE BLOCK) The main door switch is located behind the main door on the right hand side. When the main door is opened, the switch will also open, preventing the dryer from operating. The main door switch is a safety device and should never be disabled.

  • Page 15: Idler Arm And Impellor Mount Assembly

    H. IDLER ARM AND IMPELLOR MOUNT ASSEMBLY The idler assembly is located in the back of the dryer, which is attached to the drive motor assembly. The main purpose of the idler assembly is to reduce the speed of the motor, in turn increasing the torque of the basket (tumbler) pulley.

  • Page 16: Gas Burner

    K. GAS BURNER The gas burner assembly consists of two (2) burner tube orifices (the orifice has a hole in it to allow gas to flow through). The hole size varies with different elevation Btus, gas valve (which can be up for natural or liquid propane [L.P.]), and a flame-probe assembly.

  • Page 17: Lint Drawer Switch

    N. LINT DRAWER SWITCH The lint drawer switch is located under the basket (tumbler) on the right side. It is another added safety device that stops the operation of the dryer, when the lint drawer is opened. This device and the door switch are the two (2) safety switches designed to halt the basket (tumbler).

  • Page 18: Rear Basket (Tumbler) Drive Wheels

    Q. REAR BASKET (TUMBLER) DRIVE WHEELS There is a left and right basket (tumbler) drive wheel bracket assembly. This allows the basket (tumbler) to spin freely without bearings or basket (tumbler) support shaft. R. ROTATIONAL SENSOR ASSEMBLY The Rotational Sensor Assembly is located in the rear of the dryer. It consists of a magnet and a rotational switch, which is mounted to the sail switch/rotational sensor bracket.

  • Page 19: Service

    A. INTRODUCTION ALL electrical or 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.
  • Page 20 5. Disconnect the keyboard (touch pad) connector from the computer board keyboard (touch pad) harness (simply pull straight out). 6. Disconnect the 9-pin main computer harness from the computer (squeeze the one [1] tab on the connector and pull straight back). 7.
  • Page 21 TO REMOVE OPTIC SWITCH 1. Disconnect power to the dryer. 2. Remove top or bottom coin panel. 3. Remove optic switch from the coin acceptor (one [1] screw). 4. Unplug optic switch connector. 5. Remove optic switch from the dryer. 6.
  • Page 22 REPLACE BURNER TUBE ASSEMBLY (Refer to the illustration below) 1. Discontinue power to the dryer. 2. Remove the four (4) hex nuts that hold the burner hood bracket to the burner box. 3. Remove the two (2) hex nuts that hold the burner tube to the burner box. 4.

  • Page 23: Burner Controls (Gas)

    C. BURNER CONTROLS (GAS) The illustration below shows you the gas valve assembly and the gas chamber. TO REPLACE MAIN BURNER ORIFICE 1. Discontinue power to the dryer. 2. Remove back guard. 3. Remove screws securing gas valve bracket to the burner box, and remove the two (2) screws securing pipe bracket.
  • Page 24 TO TEST AND ADJUST GAS (WATER COLUMN [W.C.]) PRESSURE There are two (2) types of devices commonly used to measure water column pressure. They are spring/ mechanical type gauges and manometers. The spring/mechanical type gauge is not recommended because it is easily damaged and not always accurate.
  • Page 25 TO CONVERT FROM NATURAL TO LIQUID PROPANE (L.P.) GAS 1. Disconnect electrical power to the dryer. 2. Close ALL shutoff valves in dryer gas supply line. 3. Disconnect gas valve wiring. NOTE: Identify location of each wire for correct reinstallation. 4.

  • Page 26: Thermostats And Temperature Sensor

    TO REPLACE DIRECT SPARK IGNITION (DSI) MODULE 1. Discontinue power to the dryer. 2. Remove the back guard. 3. Remove the wires connected to the terminal strip at the bottom of the module. 4. Remove the four (4) nuts securing the module to the mounting bracket.
  • Page 27 TO REMOVE THE TEMPERATURE SENSOR OR HIGH HEAT PROTECTOR 1. High Heat Protector a. Discontinue power to dryer. b. Remove the lint drawer from the dryer. c. Remove the two (2) free spin wash nuts that is securing the temperature sensor bracket to the dryer. d.

  • Page 28: Sail Switch Assembly

    E. SAIL SWITCH ASSEMBLY The sail switch is a heat circuit safety device, which controls the heat circuit only. When the dryer is operating and there is proper airflow, the sail switch damper pulls in and closes the sail switch, providing ALL the other heat related circuits are functioning properly.

  • Page 29: Front Panel And Main Door Assemblies

    F. FRONT PANEL AND MAIN DOOR ASSEMBLIES TO REPLACE MAIN DOOR SWITCH 1. Discontinue power to the dryer. 2. Open main door. 3. Remove the two (2) Phillips head screws holding the main door switch in place. 4. Disassemble door switch bracket by removing the two (2) nuts holding the door switch to the housing, and remove the door switch.
  • Page 30 TO REPLACE FRONT PANEL 1. Discontinue power to the dryer. 2. Remove the computer panels. 3. Remove the kick trim plate. 4. Remove lint screen drawers from the dryer. 5. Remove the screws securing the front panel to the dryer. 6.
  • Page 31 TO REPLACE ROTATIONAL SENSOR SWITCH 1. Discontinue electrical power to the dryer. 2. Remove the magnetic rotational sensor switch from the bracket by loosening the nuts. 3. Depress the tabs on the rotational sensor harness plug and pull apart, then remove the sensor switch. 4.
  • Page 32 BASKET (TUMBLER) REMOVAL 1. Disconnect power to the dryer. 2. Remove the control panels and kick trim plate. 3. Remove the front panel, and disconnect the door switches. 4. Now remove the motor separator panel if removing the top basket (tumbler). 5.

  • Page 33: Bcd-1 Type Module

    A. INTRODUCTION The Direct Spark Ignition (DSI) system operates at 24 VAC and is a discrete component based gas ignition control (DSI module) system, which utilizes a line frequency spark as an ignition source. Safe proof of flame is accomplished through flame rectification. The DSI module has a diagnostic light emitting diode (L.E.D.) indicating light, which simplifies troubleshooting in the event of a fault.
  • Page 34 The module also provides for safe proof of ignition. If a flame is not sensed by the flame-probe electrode (of the ignitor/flame-probe assembly) within a specified time frame, the module will de-energize the gas valve and the ignitor/flame-probe assembly, and go into the LOCKOUT mode. If a flame is established (sensed) but then lost (flame out due to possible air turbulence), the Direct Spark Ignition (DSI) module will wait 30-seconds then restart the ignition sequence.
  • Page 35 IMPORTANT: THE GAP SETTING ON THE IGNITOR/FLAME-PROBE ASSEMBLY IS CRITICAL. d. The Direct Spark Ignition (DSI) 24 VAC gas valve(s) used are of the redundant type, which means the gas valve is actually two (2) gas valves in one (1); one (1) in series with the other.

  • Page 36: G-760 Direct Spark Ignition (Dsi) Flowchart

    C. G-760 DIRECT SPARK IGNITION (DSI) FLOWCHART POWER REMOVED VALVES, SPARK SWITCHED OFF 3-TRIAL MODEL? HAS THIRD TRIAL BEEN COMPLETED? INTERPURGE * SECONDS 1. Normal Operation (Summary) On a call for heat by the dryers’ controls, 24 VAC is applied to the DSI module at which time the modules’ light emitting diode (L.E.D.) indicator will light “GREEN”...

  • Page 37: Troubleshooting

    D. TROUBLESHOOTING The troubleshooting information provided in this manual is intended for use only by qualified service technician. Observe ALL safety precautions displayed on the equipment or specified in the installation/operator’s manual included with the dryer. IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY SAFETY OR HEAT CIRCUIT DEVICE EVER BE DISABLED.
  • Page 38 DSI IGNITOR GAP FEELER GAUGE (1/8”) For checking the gap between ignitor assembly ground rod and spark electrode. Available from ADC - Part No. 305410 1. Direct Spark Ignition (DSI) Troubleshooting Terms (Definitions) a. LOCKOUT Mode - DSI module “GREEN” light emitting diode (L.E.D.) indicator light blinks continuously.
  • Page 39 2) Direct Spark Ignition (DSI) module light emitting diode (L.E.D.) indicator lights “GREEN” for up to approximately 1.5-seconds (prepurge). This indicates that ALL the controls (including ALL the safety circuits) are functioning and power is being supplied to the DSI module. a) DSI module L.E.D.
  • Page 40 1) To effectively use this information or the flowcharts (on page 37, page 38, and page 39), each step must be completed in sequence, performing whatever tests are suggested. After the completion of each test, the guide will direct the service technician to the next logical step in the troubleshooting sequence based on the outcome of the previous check.

  • Page 41: No Spark And System Does Not Work

    d. Troubleshooting Flowchart - Quick Reference... First Visual Check NO SPARK AND SYSTEM DOES NOT WORK Is power available at primary? Replace transformer. Determine why voltage is not present. Open thermostat contacts for 30 seconds. Close contacts and wait for prepurge (if applicable) period.
  • Page 42 e. Troubleshooting Flowchart - Quick Reference... Second Visual Check SPARK PRESENT BUT MAIN BURNER DOES NOT COME ON Is main valve wiring securely attached to terminal M.V.3 and ground? Is 24 VAC present between terminals M.V.3 and ground? Correct Replace Johnson Control module G760/761 Check for continuity in...
  • Page 43 f. Troubleshooting Flowchart - Quick Reference... MAIN BURNER LIGHTS BUT DOES NOT STAY ON Is flame sensor cable securely attached to terminal 4? Correct Replace sensor cable. Correct or replace sensor. Is flame sensor positioned per manufacturer’s Correct Third Visual Check Does continuity exist from control to flame sensor?
  • Page 44 3. Troubleshooting/System Detailed Diagnosis When the dryer calls for heat, 24 VAC from the step down transformer is applied to the “THS” and “GND” (ground) terminals of the Direct Spark Ignition (DSI) module. The DSI module light emitting diode (L.E.D.) indicator will light “GREEN.”...
  • Page 45 a) Connect water column (W.C.) test gauge (manometer) to the gas valve pressure tap (1/8” N.P.T.). b) Start the dryer...with the burner on, the correct water column reading in inches should be: Natural Gas ... 3.5 inches (8.7 mb) water column. Liquid Propane (L.P.) Gas ...
  • Page 46 NOTE: To reset the Direct Spark Ignition (DSI) module if it is in the LOCKOUT mode, open and close the main door, then restart the dryer. (a) To check and/or set the 1/8” gap, use a DSI Ignitor gap feeler gauge (refer to the illustration on page 41) or similar type device to determine the gap size.
  • Page 47 NOTE: To reset the Direct Spark Ignition (DSI) module if it is in the LOCKOUT mode, open and close the main door, then restart the dryer. 4) DSI Module If there is some sort of operational interference in the DSI system, the DSI module (acting as the “controller”...
  • Page 48 a) Primary Side This is the incoming voltage side -120 VAC, 208 VAC, 230/240 VAC - of the transformer. b) Secondary Side This is the step down side - 24 VAC - of the transformer. WARNING: 208 VAC and 230/240 VAC ARE NOT THE SAME. ALL voltage connections should be checked and confirmed according to the wiring diagram provided with the individual dryer.
  • Page 49 (e) One (1) YELLOW or ORANGE wire supplies the 24 VAC signal for the control and/ or DSI circuit. (Refer to specific wiring diagram with the dryer for connection point.) 7) Direct Spark Ignition (DSI) 24 VAC Redundant Gas Valve There are three (3) DSI 24 VAC Redundant Gas Valves in use (refer to the illustration below and on the next page.
  • Page 50 DIRECT SPARK IGNITION (DSI) SYSTEM COMPONENTS 24 VAC DIRECT SPARK IGNITION (DSI) G760 DIRECT SPARK MODULE TRANSFORMER ADC PN 128935 ADC PN 141403...

  • Page 51: Troubleshooting

    The information provided will help isolate the most probable components associated with the difficulty described. The experienced technician realizes that a loose connection or broken or shorted wire may be at fault where electrical components are concerned, however, not necessarily the suspected component itself. Electrical parts should always be checked for failure before returned to the factory.
  • Page 52 IMPORTANT: The Phase 5 coin microprocessor controller (computer) has its own internal heat sensing circuit fuse protection, located on the back side of the controller. If a “dSFL” condition occurs, check to see if this fuse has blown. If it has, DO NOT replace the entire microprocessor controller (computer);...
  • Page 53 NOTE: If the dryer is started (the light emitting diode [L.E.D.] display indicator dots are on) and there are no outputs (heat and/or motor output L.E.D.s are off) and the “dOOr” input L.E.D. is on, the fault is in the Phase 5 microprocessor controller (computer) itself. If the L.E.D. display indicators are on and the door L.E.D.

  • Page 54: No Heat Condition (Blower Is On)

    B. NO HEAT CONDITION (BLOWER IS ON) The following procedure must be performed with the microprocessor controller (computer) display in the normal operating mode, the heat indicator dot on, and the light emitting diode (L.E.D.) output light is on. Voltage is 24 VAC unless otherwise specified.
  • Page 55 1. With the heat indicator on check for voltage at J1 connector 9-pin connector pin #8 (orange wire to ground) if 24 volt is present. 2. If no voltage (24 VAC) check for loose connection at 9-pin connector or problem may be faulty microprocessor. 3.

  • Page 56: No Start Condition

    C. NO START CONDITION Follow this test procedure, providing that the microprocessor controller (computer) is functioning where the display is in the normal operating mode and the motor indicator dot is on, and the light emitting diode (L.E.D.) motor output light is on.

  • Page 57: No Display Condition

    D. NO DISPLAY CONDITION NOTE: Regardless of the voltage (120-240 VAC) make sure the voltage selector switch is set to 115 VAC. 1. Check power supply. (Dryer voltage 110v, 208v, 220v) (Circuit breaker box or fuse panel) 2. Check fuse 2 (3/4-amp Slo-Blo) if blown, replace it. 3.

  • Page 58: Dsfl" Display Condition

    E. “dSFL” DISPLAY CONDITION When the display reads “dSFL” this condition indicates a fault in the microprocessor controller (computer) heat circuit. This circuit includes the microprocessor controller (computer), microprocessor temperature sensor (located in lint compartment) and wires to and from these two (2) points. 1.

  • Page 59: Door" Display Condition

    F. “dOOr” DISPLAY CONDITION When the display reads “dOOr,” this indicates that there is a fault (open circuit) somewhere in the microprocessor controller’s (computer’s) door switch circuit. Include the door switch, microprocessor controller (computer) and the wires to end from these two (2) points. Before following this test procedure, check the component side of the computer to see if light emitting diode (L.E.D.) input light is on.

  • Page 60: Data Label Information

    DATA LABEL INFORMATION A. DATA LABEL Contact American Dryer Corporation When contacting American Dryer Corporation, certain information is required to ensure proper service or parts information from ADC. This information is on the data label, which is affixed to the left side panel/wall area behind the bottom control panel.

  • Page 61: Using A Manometer

    4. TYPE OF HEAT This describes the type of heat for your particular dryer: gas (either natural gas or liquid propane [L.P.] gas), electric, or steam. 5. HEAT INPUT (for GAS DRYERS) This describes the heat input in British Thermal Units per Hour (Btu/hr). 6.

  • Page 62: Light Emitting Diode (L.e.d.) Display Codes

    C. LIGHT EMITTING DIODE (L.E.D.) DISPLAY CODES Automatic Cycle (Slope Program Factor) ACOn Accumulative Coin Adrt Maximum Auto Dryness Time AFAt Amount For Additional Time Active Anti-Wrinkle Guard Time AtIn Accumulative Time AtSt Amount Start AUtO Automatic Mode (Patent No. 4,827,627) Automatic Cycle (Heat loss [offset] Factor) bCLO Bad Coin Lockout...
  • Page 63 The revision number is located on the top right hand corner of the diagram. It is a six (6) digit number followed by a letter to distinguish the version dates (refer to the illustration). Your particular model will be different depending on the date of manufacturing and options available. The correct wiring diagram for your dryer is folded and placed inside of the computer area.
  • Page 65 ADC 450246 1 - 09/08/03-0...

Table of Contents