American Dryer Corp AD-540 User Manual

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AD-540

Mechanical/Electrical

Service Procedure

American Dryer Corporation

88 Currant Road

Fall River, MA02720-4781

Telephone: (508) 678-9000 /Fax: (508)678-9447

e-mail: techsupport@amdry.com

www.amdry.com

090603SRS/tcosta

ADC Part No. 450246

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 manual included with the dryer.

The following “FOR YOUR SAFETY” cautionmust be posted near the dryer in a prominent location.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

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.

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.

Important

For your convenience, log the following information:

DATE OF PURCHASE ____________________________ MODEL NO.

__________________________________________AD - 540

RESELLER’S NAME

_______________________________________________________________________________________

Serial Number(s)

________________________________________________________________________________________

 

________________________________________________________________________________________

 

________________________________________________________________________________________

Replacement parts can be obtained from your reseller or the ADC factory. When ordering replacement parts from the factory, you can FAX your order toADC at (508)678-9447or telephone your order directly to theADC Parts Department at (508)678-9000.Please specify the dryermodel number andserial number in addition to thedescription andpart number, so that your order is processed accurately and promptly.

The illustrations on the following pages may not depict your particular dryer exactly. The illustrations are a composite of the various dryer models. Be sure to check the descriptions of the parts thoroughly before ordering.

“IMPORTANT NOTE TO PURCHASER”

Information must be obtained from your local gas supplier on the instructions to be followed if the user smells gas. These instructionsmust be posted in a prominent location near the dryer.

IMPORTANT

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.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

DO NOT DRY MOP HEADS IN THE DRYER.

DO NOT USE DRYER IN THE PRESENCE OF DRY CLEANING FUMES.

CAUTION

DRYERS SHOULD NEVER BE LEFT UNATTENDED WHILE IN OPERATION.

WARNING

CHILDREN SHOULD NOT BE ALLOWED TO PLAY ON OR NEAR THE DRYERS.

CHILDREN SHOULD BE SUPERVISED IF NEAR DRYER(S) IN OPERATION.

WARNING

The dryer must never be operated with any of the back guards or service panels removed. PERSONAL INJURY OR FIRE COULD RESULT.

WARNING

DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER OR SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED.

IMPORTANT

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.

 

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. Electrical and Gas Requirements .................................................................................................

7

C. Operational Service Check Procedure ........................................................................................

8

SECTION IV

 

DESCRIPTION OF PARTS ......................................................................................

9

A. Control Panel .............................................................................................................................

9

B. Control and Relay Panels ............................................................................................................

9

C. Coin Box ....................................................................................................................................

9

D. Door Switch (Hinge Block) .......................................................................................................

10

E.

MicroprocessorAssembly ........................................................................................................

10

F.

Basket (Tumbler) ......................................................................................................................

10

G. Basket (Tumbler) and Drive MotorAssemblyArrangement ........................................................

10

H. IdlerArm and Impellor MountAssembly ...................................................................................

11

I. Drive Motor and Idler PulleyArrangement ................................................................................

11

J.

Temperature Sensors ................................................................................................................

11

K. Gas Burner ...............................................................................................................................

12

L.

Sail Switch ...............................................................................................................................

12

M. Hi-LimitThermostat ..................................................................................................................

12

N. Lint Drawer Switch ...................................................................................................................

13

O. Lint Drawer ..............................................................................................................................

13

P. Front Thruster Wheel BracketAssembly ...................................................................................

13

Q. Rear Basket (Tumbler) Drive Wheels ........................................................................................

14

R. Rotational SensorAssembly ......................................................................................................

14

SECTION V

 

SERVICE ...................................................................................................................

15

A. Introduction ..............................................................................................................................

15

B. Controls (Computer) ................................................................................................................

15

C. Burner Controls (Gas) ..............................................................................................................

19

D. Thermostats and Temperature Sensor ........................................................................................

22

E.

Sail SwitchAssembly ................................................................................................................

24

F.

Front Panel and Main DoorAssemblies .....................................................................................

25

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. No Heat Condition (Blower is On) ............................................................................................

50

C. No Start Condition ...................................................................................................................

52

D. No Display Condition ...............................................................................................................

53

E.

“dSFL” Display Condition ........................................................................................................

54

F.

“dOOr” Display Condition ........................................................................................................

55

SECTION VIII

 

DATA LABEL INFORMATION .............................................................................

56

A. Data Label ...............................................................................................................................

56

B. Using a Manometer ..................................................................................................................

57

C. Light Emitting Diode (L.E.D.) Display Codes ............................................................................

58

SECTION I

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. The instructions should be posted in a prominent location.

3.Dryer(s) must be exhausted to the outdoors.

4.Although ADC produces a very versatile dryer, there are some articles that due to fabric composition or cleaning methodshould not be dried in it.

WARNING: Dry only water washed fabrics.DO NOT dry articles spotted or washed in dry cleaning solvents, a combustible detergent, or “all purpose” cleaners.EXPLOSION COULD RESULT.

WARNING: DO NOT dry rags or articles coated or contaminated with gasoline, kerosene, oil, paint, or wax.EXPLOSION COULD RESULT.

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 rubberlike materials. Drying in a heated basket (tumbler) may damage plastics or rubber and may be a fire hazard.

5.A program should be established for the inspection and cleaning of lint in the burner area and exhaust ductwork. The frequency of inspection and cleaning can best be determined from experience at each location.

WARNING: The collection of lint in the burner area and exhaust ductwork can create a potential fire hazard.

6.For personal safety, the dryer must be electrically grounded in accordance with local codes and/or the National Electrical Code ANSI/NFPA NO.70-LATESTEDITION or in Canada, the Canadian Electrical Codes Parts 1 & 2 CSAC22.1-1990or LATEST EDITION.

NOTE: Failure to do so willVOID THE WARRANTY.

7.UNDER NO CIRCUMSTANCES should the dryer door, lint drawer switches or heat safety devices ever be disabled.

8.READ AND FOLLOW ALL CAUTION AND DIRECTION LABELS ATTACHED TO THE DRYER.

WARNING: Childrenshould not be allowed to play on or in the dryers. Childrenshould be supervised if near dryers in operation.

3

SECTION II

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

WARNING: LINT FROM MOST FABRICS IS HIGHLY COMBUSTIBLE. THE ACCUMULATION OF LINT CAN CREATEAPOTENTIALFIRE HAZARD.

SUGGESTED INTERVAL

DAILY

Clean lint screen. Inspect lint screen and replace if damaged.

90 DAYS

Remove lint accumulation from lint chamber thermostats and sensors.

WARNING: TOAVOID THE HAZARD OF ELECTRICALSHOCK, DISCONTINUE ELECTRICALSUPPLYTO THE DRYER.

Remove lint from the motor air vents and surrounding area.

IMPORTANT: Lint accumulation will restrict internal motor airflow, causing overheating and irreparable damage. Motor failure due to lint accumulation willVOID THE WARRANTY.

120 DAYS

Remove lint from gas burner area with a dusting brush or vacuum cleaner attachment.

6 MONTHS

Inspect and remove lint accumulation in customer furnished exhaust ductwork system. Inspect exhaust back draft dampers to insure they are not binding. Inspect and remove ALL lint accumulation from in and around the control panel area, including the coin acceptors. Clean lint accumulation from around the basket (tumbler) wrapper area.

WARNING: LINT FROM MOST FABRICS IS HIGHLY COMBUSTIBLE. THE ACCUMULATION OF LINT CAN CREATEAPOTENTIALFIRE HAZARD.

4

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 beltsshould be replaced. Tighten loose drive belts when necessary, and check belt alignment. Complete operational check of control and valves. Complete operational check ofALL safety devices (door switches, sail switch and burner high limits and lint chamber thermostats).

12 MONTHS

Inspect bolts, nuts, screws, and nonpermanent gas connections, (unions, sail switch, burner, and lint chamber thermostats).

5

SECTIONIII

INSTALLATION REQUIREMENTS

Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, the installationmust conform to applicable American National Standards: ANSI Z223.1- LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO.70-LATESTEDITION (National Electrical Code) or in Canada, the installationmust conform to applicable Canadian Standards:CAN/CGA-B149.1-M91(Natural Gas) orCAN/CGA-B149.2-M91(Liquid Propane [L.P.] Gas) or LATEST EDITION (for General Installation and Gas Plumbing) or Canadian Electrical Codes Parts 1 & 2 CSAC22.1-1990or LATEST EDITION (for Electrical Connections).

A. ENCLOSURE, AIR SUPPLY, AND EXHAUST REQUIREMENTS

NOTE: The following information is very brief and general. For detailed description, refer to the Installation Manual supplied with the dryer (ADC PN 113044).

Bulkheads and partitions around the dryer should be made of noncombustible materials. (Refer to appropriate installation manual for recommended distances and minimum allowances required.)

When the dryer is operating, it draws in room air, heats it, passes this air through the basket (tumbler), and exhausts it out of the building. Therefore, the room air must be continually replenished from the outdoors. If themake-upair is inadequate, drying time and drying efficiencywill be adversely affected. Ignition problems and sail switch “fluttering” problems on gas dryers may result, and you could have premature motor failure from overheating. The air supplymust be given careful consideration to ensure proper performance of each dryer.

IMPORTANT: Make-upairmust be provided from a source free of dry cleaning solvent fumes.Make-upair that is contaminated by dry cleaning solvent fumes will result in irreparable damage to the motors and other dryer components.

Exhaust ductwork should be designed and installed by a competent technician. Improperly sized ductwork will create excessive back pressure, which will result in slow drying, increased use of energy, and shutdown of the burner by the airflow (sail) switch, burnerhi-limitor lint chamberhi-heatprotector thermostat. (Refer to appropriate installation manual for more details.)

CAUTION: IMPROPERLY SIZED OR INSTALLED EXHAUST DUCTWORK CAN CREATEAPOTENTIALFIRE HAZARD.

6