ADC AD-200 Service Manual

AD-200 Phase 7Non-TiltService Manual050801DMG/calbert ADC Part No. 450034American Dryer Corporation88 Currant RoadFall River, MA 02720-4781Telephone:

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

96NOTE: SPRINKLER MUST HAVE POWER FOR THE DRYER TO OPERATE.B. Drive motor is not operating (does not start)...* Microprocessor controller (computer) r

97f. 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. Faile

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

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

1002) Failure in drive motor circuit.b. Faulty rotation sensor.c. Broken wire or connection between rotation sensor and microprocessor controller (com

10114. Undersized load, dryer requires a minimum load size of approximately 125 lbs (57 kg) for maximum dryingefficiency.R. Excessive noise and vibrat

ADC 450034 1- 08/29/01-25

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

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 squirrel cage fan shaft must be lubricated. Use Shell Alvania #2 grease orits equivalent

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

11SECTION IIISPECIFICATIONS AND DIMENSIONSA. SPECIFICATIONS (GAS AND STEAM MODELS)* Dryer must be provided with a clean, dry, regulated 80 PSI +/- 10

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

13SECTION IVINSTALLATION REQUIREMENTSInstallation should be performed by competent technicians in accordance with local and state codes. In theabsenc

14B. ELECTRICAL AND GAS REQUIREMENTSIt is your responsibility to have ALL electrical connections made by a properly licensed and competent electricia

15SECTION VCOMPONENT DESCRIPTION/REPLACEMENTA. HEAT SECTIONThe dryer uses three (3) types of heat sources: natural gas, liquid propane (L.P.) gas, an

Retain This Manual In A Safe Place For Future ReferenceAmerican Dryer Corporation products embody advanced concepts in engineering, design, and safety

16330º F (166º C) ThermostatMAN3484Sail Switch Assemblya. The Direct Spark Ignition(DSI) Module is a 24 VACdevice designed to be the“controller” of th

17e. The Manual Reset Basket (Tumbler) Hi-Limit Switch is athermostat type switch located above the Lint Basket. Its functionis to discontinue heat (

18Is 24 VAC availableat transformer?Is 24 VAC present from terminalTHS2 to ground?Is power availableto primary?Are thermostat contacts andlimit contro

19i. Troubleshooting Flowchart - Quick Reference...Second Visual CheckSpark Present But Main Burner Does Not Come OnIs main valve wiring securelyattac

20j. Troubleshooting Flowchart - Quick Reference...Third Visual CheckMain Burner Lights But Will Not Stay OnIs flame sensor cablesecurely attachedto t

21B. TROUBLESHOOTING THE DIRECT SPARK IGNITION (DSI) SYSTEMNOTE: The troubleshooting information provided in this manual is intended for use by quali

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

23If the dryer repeatedly has Direct Spark Ignition (DSI) module “LOCKOUT” failures, the causemay be due to high voltage (HV) not getting into the DSI

24c. Three (3) Visual Checks1) Does the Direct Spark Ignition (DSI) Ignitor/Flame-Probe Assembly start sparking?If not, refer to the FIRST VISUAL CHEC

25First Visual Check(Does Ignitor Spark?)Is spark evident (on)at Ignitor Assembly?Is 24 Voltspresent across DSI ModuleterminalsTH and COM?CheckHigh Vo

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

26e. Troubleshooting Flowchart - Quick Reference...Second Visual Check(Does Main Burner Ignite?)Doesmain burnerlight?Is manualknob on the Gas Valvein

27f. Troubleshooting Flowchart - Quick Reference...Third Visual Check(Does Main Burner Ignite?)Doesmain burnerremainlit?Doesthe Flame Probehave carbon

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

29a) 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

30(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

313) Air TurbulenceIf there is sail switch flutter due to air turbulence or improper blower (squirrel cage fan) rotation ora restriction in the exhaus

32CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THEBURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORTOUT.6) Direct Spark Ignition (DS

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

34a) 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

35(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

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

363) Air TurbulenceIf there is sail switch flutter due to air turbulence or improper blower (squirrel cage fan) rotation ora restriction in the exhaus

37CAUTION: DO NOT LET THE IGNITOR/FLAME-PROBE ASSEMBLY TOUCH THEBURNER TUBES; OTHERWISE THE ENTIRE ASSEMBLY WILL SHORTOUT.6) Direct Spark Ignition (DS

38C. NATURAL GAS AND LIQUID PROPANE (L.P.) GAS CONVERSION INSTRUCTIONSIMPORTANT: CONVERSION MUST BE PERFORMED BY COMPETENT TECHNICIANSIN ACCORDA

3911. 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

401. 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

41The steam damper plate should open and close slowly and smoothly. The speed can be modulated byadjusting the needle valve knob. Turning the knob c

425) 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

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

44E. SPRINKLER SYSTEM DESCRIPTIONThe dryer’s sprinkler system is monitored by a microprocessor based temperature controller as a designated“FAIL-SAFE

45MAN3488d. Sprinkler Digital Temperature ControllerThe sprinkler digital temperature controller is a programmablemicroprocessor used to monitor tempe

Table of ContentsAD-200 REFERENCE GUIDE (Basket [Tumbler] Section) ...3AD-200 REFERENCE GUIDE (Base Section)...

465) Remove the wires of the Resistive Temperature Device (RTD) from the terminal strip.NOTE: Identify the wires removed for proper reinstallation.6)

47c. 3 HP (2.24 kw) Control Relay ReplacementWARNING: THE SPRINKLER CIRCUIT HAS A SEPARATE POWER SUPPLY (than the powersupply for the dryer). DISCONN

486) 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

49

50F. 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

515) 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

52G. BLOWER (SQUIRREL CAGE FAN) MOTOR ASSEMBLY1. Blower (Squirrel Cage Fan) Motor DescriptionThe dryer uses a 15-inch (38.1 cm) diameter, blower (squ

532. Blower (Squirrel Cage Fan) and Fan Motor Component Replacementa. Blower (Squirrel Cage Fan) Motor Replacement1) Discontinue electrical power to t

5418) 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

55c) Mark the inside of the motor shaft before removing the bushing.d) Loosen the setscrews on the bushing.e) Remove the bushing and the pulley.11) Re

SECTION VIPROCEDURE FOR FUNCTIONAL CHECKOF REPLACEMENT COMPONENTS ...86SECTION VIIPHASE 7 OPL

567) 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) motor shaft.a) Slide the blower (squirrel cage

57a) Thermal Magnetic Starter (TMS) Replacement(1) Discontinue electrical power to the dryer.(2) Mark L1, L2, L3, and T1, T2, T3 on the wires to the T

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

59H. FILTER/REGULATOR ASSEMBLYThe purpose of the filter is to remove bulk liquids and solid particles from the compressed air stream. The filterelem

60I. DOOR SYSTEMSThe dryer utilizes one (1) style of doors, which is Pneumatic Automatic Doors.1. Pneumatic Automatic Description/Operationa. Descrip

612. Door Component Replacement and/or Removala. Pneumatic Automatic Door Replacement or RemovalAUTOMATIC DOORS1) Discontinue electrical power to the

62b. Cable Cylinder Replacement and/or Removal1) Discontinue electrical power to the dryer.2) Remove the two (2) 1/4-20 x 1/2” bolts from each side of

63c. 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

64e. 4-Way Valve, 3-Way Valve, and Supply Air Enable Valve Replacement1) Discontinue electrical powerto the dryer.2) Disconnect compressed airsupply f

65J. CONTROL AND ELECTRICAL SYSTEMLadder Diagram

3AD-200 Reference Guide(Basket [Tumbler] Section)

66

67CAUTION: WHEN SERVICING THE HIGH VOLTAGE (HV) SECTION OF THE DRYER,THE ELECTRICAL POWER MUST BE DISABLED. THE “EMERGENCYSTOP” (E-Stop) BUTTON DOES

683) 24 VAC TransformerThe 24 VAC transformer consists of CB5 (Circuit Breaker), which is the primary fusing for thetransformer. For the proper ratin

69c) Lint drawer closed circuit branch...The lint drawer closed switch is located in the front of the dryer. When the lint drawer is closed,it closes

70Next reverse leads to temperature sensor black to black and red to white. At that point, you willmeasure approximately 1.8 amps, this is the turn o

71a) The Programmable Logic Controller (PLC) module has thirteen (13) input relays, which arelabeled #0 through #13 and nine (9) output relays labeled

722. Electrical Component Replacementa. Control Voltage Transformer Replacement (refer to the illustration on page 74)1) Discontinue electrical power

73

74b. Programmable Logic Controller (PLC) Replacement1) Discontinue electrical power to the dryer.2) Mark and identify the wires that will be removedfo

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

4AD-200 Reference Guide(Base Section)

765) With figer tip, gently push and turn the bulb to unlock.NOTE: A piece of tubing with an inside diameter the size of bulb may assist in bulb remov

77

78WARNING: TO ENSURE THAT THE DRIVE IS NOT UNEXPECTEDLY STARTED, TURNOFF AND LOCKOUT AND/OR TAG POWER SOURCE BEFOREPROCEEDING. FAILURE TO OBSERVE THE

791) 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

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

814) Verify proper position of drive shaft components prior to tightening onto shaft.5) Reestablish electrical power to the dryer.f. Pillow Block Bear

829) Reinstall the drive shaft into the dryer.10) Secure the gear (speed) reducer to the drive shaft by reinstalling the three (3) bolts into the tape

834) Remove the bolts from the guard panel to gain access to the rear bottom retaining wheel.b. Retaining Wheel(s) Replacement1) Discontinue electrica

844. Basket (Tumbler) Electrical Component(s)a. Basket (Tumbler) Thermal Magnetic Starter (TMS) and Auxiliary Contact Block Replacement1) Discontinue

8511) Replace ALL wires removed in Step #5 (refer to the previous page).12) Mount the top of the thermal magnetic starter (TMS) to the top of the din

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

86SECTION VIPROCEDURE FOR FUNCTIONAL CHECKOF REPLACEMENT COMPONENTS1. For Models With Johnson Controls Direct Spark Ignition (DSI) Module (G760)Theory

872. For Direct Spark Ignition (DSI) System Models Manufactured With ADC Module Part No. 880815a. Upon completing installation of the replacementDSI m

88SECTION VIIPHASE 7 OPL SYSTEM DIAGNOSTICSIMPORTANT: YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLYAND THE GAS SUPPLY OR THE STEAM SUPPLY BEFOR

89CALL FOR SERVICE - Indicates a board failure.FRONT DOOR NOT CLOSED - A front door is open when it should be closed.REAR DOOR NOT CLOSED - A rear doo

90B. I/O BOARD INPUT AND OUTPUT L.E.D. INDICATORS

91Input/Output (I/O) Board Input Description (“Red” light emitting diode [L.E.D.])1. FDRC – (RED L.E.D.) This L.E.D. will indicate the status of the F

929. FAN – (RED L.E.D.) This L.E.D. will indicate the status of the Blower Fan. If the fan is on, then theL.E.D. is ON.10. RBHL – (RED L.E.D.) This L

93Input/Output (I/O) Board Output Description (“Green” light emitting diode [L.E.D.])1. R_HEAT – (GREEN L.E.D.) This L.E.D. will indicate the status o

9416. OCL5 – (GREEN L.E.D.) This L.E.D. will indicate the status of the Open Collector #5 output. If therequest to turn on the Open Collector #5 is m

95SECTION VIIITROUBLESHOOTINGIMPORTANT: YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLYAND THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANYCOVERS OR