American Dryer Non-Tilting Phase 5 ML-200 manual

ML-200 Non-Tilting Phase 5 Installation/Operator's Manual For replacement parts, contact the distributor from which the dryer was purchased or American Dryer Corporation 88 Currant Road Fall River MA 02720-4781 T elephone: (508) 678-9000 / Fax: (508) 678-9447 e-mail: techsupport@amdry .com 041800TS/tcosta ADC Part No. 113142 W ARNING: For your[...]

Retain This Manual In A Safe Place For Futur e Refer ence Replacement parts can be obtained from your distributor or the ADC factory . When ordering replacement parts from the factory , you can F AX your order to ADC at (508) 678-9447 or telephone your orders directly to the ADC Parts Department at (508) 678-9000. Please specify the dryer model num[...]

IMPOR T ANT YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPL Y and THE GAS SUPPL Y or THE STEAM SUPPL Y BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING , ADJUST - ING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) ST ANDARDS. CHILDREN SHOULD NOT BE ALLOW[...]

W ARNING The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJUR Y or FIRE COULD RESUL T . IMPOR T ANT PLEASE OBSER VE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the installation/operator's manual included with the dryer . Dryers must not be installed or stored [...]

Table of Contents SECTION I IMPOR T ANT INFORMA TION ............................................................................... 3 A . RECEIVING and HANDLING ................................................................................................. 3 B . SAFETY PRECAUTIONS .................................................................[...]

SECTION VI ROUTINE MAINTENANCE .................................................................................. 3 6 A . CLEANING ..................................................................................................................... ....... 36 B. ADJUSTMENTS ...........................................................................[...]

3 SECTION I IMPOR T ANT INFORMA TION A. RECEIVING and HANDLING The dryer is shipped in a protective stretch wrap cover with protective cardboard corners and top cover (or optional box) as a means of preventing damage in transit. Upon delivery , the dryer and/or packaging, and wooden skid should be visually inspected for shipping damage. If any dama[...]

4 B. SAFETY PRECAUTIONS W ARNING: For your safety , the information in this manual must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury , or loss of life. W ARNING: The dryer must never be operated with any of the back guards, outer tops, or service panels removed. PERSONAL INJUR Y or FIRE COULD [...]

5 W ARNING: DO NOT use heat for drying articles that contain plastic, foam, sponge rubber , or similarly textured rubber materials. Drying in a heated tumbler (basket) may damage plastics or rubber and also may be a fire hazard. 7. A program should be established for the inspection and cleaning of lint in the heating unit area, exhaust duct work, a[...]

6 SECTION II SPECIFICA TIONS/DIMENSIONS and COMPONENT IDENTIFICA TION A. SPECIFICA TIONS (GAS and STEAM Models) IMPOR T ANT : Gas dryers and steam dryers must be provided with a clean, dry , regulated 80PSI +/-10 PSI (5.51 bars +/- 0.68 bars) air supply . NOTE: A DC RESER VES THE RIGHT TO MAKE CHANGES IN SPECIFICA TIONS A T ANY TIME, WITHOUT NOTICE[...]

7 B. ML-200 DIMENSIONS and COMPONENT LOCA TION[...]

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9 SECTION III INST ALLA TION PROCEDURES Installation in a proper location 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-LA TEST EDITION (National Fuel Gas Code) or ANSI/NFP A NO. 70-LA TEST EDI[...]

10 1. Reconnect the four (4) pin/socket connectors at the bottom of the right control box. 2. Reconnect the three (3) pin/socket connectors at the bottom of the left control box. 3. Reconnect the two (2) pin/socket connectors within the left control box. 4. Rewire the drive motor by inserting the three (3) black wires into the T1, T2, and T3 connec[...]

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12 B. LOCA TION REQUIREMENTS The model ML-200 dryer requires 18-inches (45.72 cm) of space on each side of the dryer and 24-inches (60.96 cm) of space behind the unit for ease of maintenance. A minimum of 12-inches (30.48 cm) must be allowed between the top of a gas dryer and the ceiling. A ceiling height of 120-inches (304.8 cm) is required for ga[...]

13 C. FRESH AIR SUPPL Y When the dryer is operating, it draws in room air, heats it, passes this air through the tumbler (basket), and exhausts it out of the building. Therefore, the room air must be continually replenished from the outdoors. If the make-up air is inadequate, drying time and drying efficiency will be adversely affected. Ignition pr[...]

14 D. EXHAUST REQUIREMENTS 1. General Exhaust Duct W ork Information Exhaust duct work should be designed and installed by a qualified professional. Improperly sized duct work will create excessive back pressure which results in slow drying, increased use of energy , over heating of the dryer , and shut down of the burner by the airflow (sail) swit[...]

15 a . Outside Duct W ork Protection 1) T o protect the outside end of horizontal duct work from the weather , a 90º elbow bent downward should be installed where the exhaust exits the building. If the duct work travels vertically up through the roof, it should be protected from the weather by using a 180º turn to point the opening downward. In e[...]

16 E. COMPRESSED AIR SUPPL Y SYSTEM A clean, dry , regulated air supply of 80 PSI (5.51 bars) compressed air must be supplied to the dryer . The connection size is 1/8-inch N.P .T . No air filtering or pressure regulating devices are provided with the standard ML-200 Non-T ilt dryer . 1. Gas Dryers The air line supply connection is made into the 1/[...]

17 F . ELECTRICAL INFORMA TION 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 with local and state regulations or codes. In the absence of such codes, ALL electrical connections, material[...]

18 2. Electrical Service Specifications W ARNING: 208 V AC and 230 V AC ARE NOT THE SAME . Any damage done to dryer components due to improper voltage connections will automatically VOID THE W ARRANTY . IMPOR T ANT : The dryer must be connected to the electrical supply shown on the data label that is affixed to the back of the dryer , at the upper [...]

19 M L S-200 ( St e a m ) 15 H p B l o w e r / 3 H p D ri v e M o t o r E LECT R I C S E R IV IC E S PEC I FI C A TION S ( PE R DRYER ) I MP O R T ANT : 208 V AC and 230 V AC AR E NO T TH E SAME . When orde ring, s peci fy exact volt a ge . NO TES : A . F us e ra ting s a re du al e leme n t-time d ela y- cu rre nt limitin g , c las s R K 1 or R K [...]

20 3. Electrical Connections NOTE: A wiring diagram is included with each dryer and is affixed to the panel inside the right side control cabinet. The only electrical input connections to the dryer are the 3-phase (3Ø) power leads (L1, L2, and L3), GROUND, and in the case of 4 wire service, the Neutral. These electrical connections are made at the[...]

21 G . GAS INFORMA TION It is your responsibility to have ALL plumbing connections made by a qualified professional to assure that the gas plumbing installation is adequate and conforms with local and state regulations or codes. In the absence of such codes, ALL plumbing connections, materials, and workmanship must conform to the applicable require[...]

22 2. T echnical Gas Data a . Gas Specifications b. Gas Connections: Inlet connection ---- 1-1/4 inch N.P .T . Inlet Supply Size ---- 1-1/2 inch N.P .T . Btu/hr input --------- 750,000 (189,000 kcal/hr) 1) Natural Gas Regulation is controlled by the dryers gas valve internal regulator . I ncoming supply pressure must be consistently between a minim[...]

23 3. Piping/Connections ALL components/materials must conform to National Fuel Gas Code Specifications. It is important that gas pressure regulators meet applicable pressure requirements and that gas meters be rated for the total amount of ALL the appliance BTU's being supplied. The dryer is provided with a 1-1/4" F . P .T . inlet pipe c[...]

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25 H. STEAM INFORMA TION It is your responsibility to have ALL steam plumbing connections made by a qualified professional to assure that the installation is adequate and conforms with local and state regulations or codes. IMPOR T ANT : Failure to comply with the requirements stipulated in this manual can result in component failure which will VOID[...]

26 b. The steam supply piping to the dryer must include a 12-inch (30.48 cm) rise along with a drip trap and check valve. This will prevent any condensate from entering the steam coil. c . Flexible hoses or couplings must be used. The dryer vibrates slightly when it runs and this will cause the steam coil connections to crack if they are hard piped[...]

27 4. S team Damper Air System Connections The ML-200 is manufactured with a pneumatic (piston) damper system which requires an external supply of compressed air . The air connection is made to the steam damper solenoid valve which is located on the outer top, at the rear left hand corner of the dryer . a . Air Requirements b. Air Connection Air co[...]

28 6. S team Damper Air Piston (Flow Control) Operation Adjustment Steam damper operation was tested and adjusted prior to shipping at 80 PSI (5.51 bars). If steam damper adjustment is necessary , locate the flow control valve and make the necessary adjustments as noted below . Diagram 1 shows the damper in the heating (open) mode, allowing heat in[...]

29 I. PREP ARA TION FOR OPERA TION/ST AR T -UP The following items should be checked before attempting to operate the dryer: 1. Read ALL " CAUTION ," " W ARNING ," and " DIRECTION " labels attached to the dryer . 2. Check incoming supply voltage to be sure that it is the same as indicated on the dryer data label affixe[...]

30 J. PREOPERA TIONAL TESTS ALL dryers are thoroughly tested and inspected before leaving the factory . However , a preoperational test should be performed before the dryer is publicly used. It is possible that adjustments have changed in transit or due to marginal location (installation) conditions. 1. T urn on electric power to the dryer . 2. Mak[...]

31 5. Heat Circuit Operational T est a . Gas Models 1) When the dryer is first started (during initial start-up), the burners have a tendency not to ignite on the first attempt. This is because the gas supply piping is filled with air , so the dryer may have to be stopped and restarted several times for this air to be purged from the lines. 2) The [...]

32 8. Each dryer should be operated through one (1) complete cycle to assure that no further adjustments are necessary and that ALL components are functioning properly . 9. Microprocessor (computer) programs/selections... a . Each microprocessor controller (computer) has been preprogrammed by the factory with the most commonly used parameter select[...]

33 SECTION IV SER VICE/P AR TS INFORMA TION A. SER VICE 1. Service must be performed by a qualified trained technician, service agency , or gas supplier . If service is required, contact the distributor from whom the ADC equipment was purchased. If the distributor cannot be contacted or is unknown, contact the ADC Service Department for a distribut[...]

34 SECTION V W ARRANTY INFORMA TION A. RETURNING W ARRANTY CARD(S) 1. Before any dryer leaves the ADC factory test area, a warranty card is placed on the back side of the main door glass. These warranty cards are intended to serve the customer where we record the individual installation date and warranty information to better serve you, if you file[...]

35 2. Each part must be tagged with the following information: a. Model number and serial number of the dryer from which part was removed. b. Nature of failure (be specific). c . Date of dryer installation. d. Date of part failure. e . Specify whether the part(s) being returned is for a replacement, a credit, or a refund. NOTE: If a part is marked [...]

36 SECTION VI 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 t he duct work system. The frequency of cleaning can best be determined from experience at each location. Maximum operating efficiency is depende[...]

37 STEAM DRYERS ONL Y Clean the steam coil lint screen located on top of the steam coil. (This may have to be done more frequently .) MONTHL Y Retighten set screws in the collars of the four (4) 1-1/2" (3.81 cm) diameter tumbler drive shaft bearings. Clean lint accumulation from the gas valve/burner area at the top of the dryer, the fan (impel[...]

38 B. ADJUSTMENTS 7 DA YS AFTER INST ALLA TION and EVERY 6 MONTHS THEREAFTER Inspect bolts, nuts, screws (bearing set screws), non-permanent gas connections (unions, shut-off valves, orifices, and grounding connections). Motor and drive belts should be examined. Cracked or seriously frayed belts should be replaced. T ighten loose V -belts when nece[...]

39 SECTION VII COMPONENT SYSTEM DESCRIPTIONS A. TUMBLER (BASKET) DRIVE SYSTEM The tumbler (basket) is supported and driven by four (4) 1 1-inch (27.94 cm) diameter drive wheels. T wo (2) of these wheels are attached to a 1-1/2" (3.81 cm) diameter idler shaft, while the other two (2) are attached to a 1-1/2" (3.81 cm) diameter drive shaft.[...]

40 D. SAFETY DEVICES 1. Load Door Switches There are two (2) of these switches located under the main loading doors. These switches ensure that the doors are closed before the dryer can start. If the dryer is started when the load doors are open, the microprocessor controller (computer) L.E.D. (light emitting diode) display will show "door .&q[...]

41 E. STEAM DAMPER ACTUA T OR SYSTEM The system consists of a hinged damper plate, pneumatic piston, and 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[...]

42 SECTION VIII TROUBLESHOOTING IMPOR T ANT : YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC SUPPL Y and THE GAS SUPPL Y or THE STEAM SUPPL Y BEFORE ANY COVERS or GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS FOR CLEANING , ADJUSTING , INST ALLA TION, or TESTING OF ANY EQUIPMENT per OSHA (Occupational Safety and Health Administration) ST ANDARD[...]

43 2. Failed drive motor contactor . 3. Failed drive motor . 4. Failed microprocessor controller (computer). C . Drive motor operates in one direction only ... stops and restarts in same direction... * Appropriate microprocessor controller (computer) relay output indicator is on. 1. Failed reversing contactor (relay). * Appropriate microprocessor c[...]

44 * Microprocessor controller (computer) "MTR" relay output indicator is off. 1. Failed microprocessor controller (computer). F . Blower (fan/impellor) motor operates okay for a few minutes, then either repeatedly or occasionally trips the overload protector ... NOTE: When the overload protector trips, the microprocessor controller (comp[...]

45 a . Lint drawer switch is out of proper adjustment. b. Loose connection in the lint drawer switch circuit. J . Microprocessor controller (computer) L.E.D. (light emitting diode) display reads "dSFL" continuously and the buzzer (tone) sounds every 30-seconds... 1. Fault in microprocessor heat sensing circuit ... a . Failed microprocesso[...]

46 4. Blown 24 V AC control circuit fuse (fuse 3). L . Microprocessor controller (computer) L.E.D. (light emitting diode) display reads "door" and the microprocessor controller (computer) "DOOR" L.E.D. indicator is on... 1. Failed microprocessor controller (computer). M . Microprocessor controller (computer) will not accept any [...]

47 2. Rotational sensor circuit failure...fault somewhere in the tumbler (basket) rotation or circuit... a . T umbler (basket) is not rotating... 1) Broken tumbler (basket) drive V-belt(s). 2 ) Failure in drive motor circuit...refer to Section B , Section C , and Section D on page 42 and page 43 . b. Faulty rotation sensor . c . Broken wire or conn[...]

48 U. Heating unit for GAS MODELS or STEAM MODELS is not operating (no heat) and the microprocessor controller (computer) L.E.D. (light emitting diode) heat indicator dot is on but the "HEA T" relay output L.E.D. is not on... 1. Failed microprocessor controller (computer). V . No heat for GAS MODELS ONL Y ...ignitor sparks, burner goes on[...]

49 6. Lint drawer/screen is not being cleaned on a regular basis or often enough. 7. Extractors (washers) are not performing properly . 8. Sail switch is fluttering...restriction in exhaust... for GAS MODELS ONL Y . 9. Failed microprocessor controller (computer)...temperature calibration is inaccurate. 10 . Failed microprocessor temperature sensor [...]

50 AA . T umbler (basket) jumps or makes excessive noise when dr yer is first started or between forward and reverse cycles... 1. T umbler (basket) out of alignment. B B . Blower (impellor/fan) air jet does not activate at the end of the cooling cycle... * W ith microprocessor controller (computer) "A JET" relay output L.E.D. (light emitt[...]

51 SECTION IX 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 . V erify that the motor(s) and the heat indicator dots, in the microprocessor (computer) L.E.D. [...]

52 e . Open main door . The dryer must stop and ALL output indicator lights on the back side of the microprocessor (computer) board must go out . f . T ry to restart the dryer with the main door open. g. The microprocessor (computer) board's L.E.D. (light emitting diode) display must read " DOOR ." h. Close the main door and restart [...]

53 3. For Direct Spark Ignition (DSI) System Models Manufactured W ith ADC M odule Part No. 880815 a. Upon completing installation of the replacement Direct Spark Ignition (DSI) module, reestablish power to the dryer . b. Start the drying cycle. c . The ignition (DSI) module s L.E.D. (light emitting diode) indicator will be off for up to a[...]

54 SECTION X MANUAL RESET HI-LIMIT INSTRUCTIONS I M P O R T A N T MANUAL RESET HI-LIMIT INSTRUCTIONS FOR GAS MODELS WITH PHASE 5 This dryer was manufactured with a manual reset burner hi-limit and tumbler/lint chamber hi-limit thermostat which is monitored by the Phase 5 computer . If either manual reset thermostat is open prior to start of the dry[...]

ADC 113142 1 - 04/21/00-8[...]