American Dryer Corp. ML-190HS manual

ML-190HS Service Manual Phase 6 Microprocessor Controls 112999SL/tcosta ADC Part No. 450410 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[...]

Retain This Manual In A Safe Place For Futur e 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. OBSER VE ALL SAFETY PR[...]

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 ANDARDS. DO NOT STORE OR USE GASOLINE OR O[...]

IMPOR T ANT PLEASE OBSER VE ALL SAFETY PRECAUTIONS displayed on the equipment and specified in the installation and operator's manual included with the dryer . Dryers must not be installed or stored in an area where it will be exposed to water or weather . The wiring diagram for the dryer is located in the front electrical control box area. DR[...]

Table of Contents SECTION I IMPOR T ANT INFORMA TION ............................................................................... 3 A. Safety Precautions ...................................................................................................................... 3 SECTION II ROUTINE MAINTENANCE .........................................[...]

SECTION V SER VICING .............................................................................................................. 1 6 A. Computer Controls ................................................................................................................... 17 B. Ignition Controls .....................................................[...]

3 SECTION I IMPOR T ANT INFORMA TION 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/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 promi[...]

4 8. Articles should never be left unattended for an extended period of time in the tumbler (basket) after completion of the drying and cooling cycles. W ARNING: AR TICLES LEFT IN THE DR YER AFTER THE DR YING and COOLING CYCLES HA VE BEEN COMPLETED CAN CREA TE A FIRE HAZARD. 9. This dryer is not to be used in the presence of dry cleaning solvents o[...]

5 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 duct work system. The frequency of cleaning can best be determined from experience at each location. Maximum operating efficiency is dependent[...]

6 90 DA YS Remove lint from tumbler (basket), drive motors, and surrounding areas. Remove lint from gas valve burner area with a dusting brush or vacuum cleaner attachment. NOTE: T o prevent damage, avoid cleaning and/or touching ignitor/flame-probe assembly . Remove lint accumulation from inside control box and at rear area behind control box. 6 M[...]

7 SECTION III INST ALLA TION REQUIREMENTS Installation should be performed by competent technicians in accordance with local and state codes. In the absence of these codes, installation must conform to applicable AMERICAN NA TIONAL ST ANDARDS: ANSI Z223.1-LA TEST EDITION National Fuel Gas Code and/or ANSI/NFP A No. 70-LA TEST EDITION National Elect[...]

8 IMPOR T ANT : Failure to comply with these codes or ordinances and/or the requirements stipulated in this manual can result in personal injury or component failure. The gas dryer installation must meet the AMERICAN NA TIONAL ST ANDARD, NA TIONAL FUEL GAS CODE ANSI Z223.1-LA TEST EDITION, as well as, local codes and ordinances, and must be done by[...]

9 NOTE: W ater column pressure requirements (measured at the pressure tap on the gas valve body): Natural Gas - 3.5 Inches W ater Column. L.P . Gas - 10.5 Inches W ater Column. 6. If computer program changes are required, refer to the Phase 6 OPL Operator  s Manual ( ADC Part No. 1 13022) for details. 7. The dryer should be operated through one [...]

10 SECTION IV DESCRIPTION OF PAR TS A. CONTROL PANEL (MICROPROCESSOR) Lifting the control door will reveal the control panel assembly . Opening the control panel will allow access to the major components which include the computer board and keyboard (touchpad). The keyboard (touchpad) inputs to the computer what temperature and program has been sel[...]

11 D. GAS BURNER ASSEMBL Y Gas-heated dryers are equipped with a gas burner assembly consisting of four (4) burner tubes, gas valve, HSI (Hot Surface Ignition) ignitor , flame probe, sail switch, and hi-limit thermostat. The inlet piping enters through the rear of the dryer on the left-hand side (viewing from the front) and runs to the front of the[...]

12 G . SPEED REDUCING SHAFT (V iewing from the front of the dryer). T he speed reducing shaft is located on the right side and is right above the drive motor . The idler assembly consists of two (2) idler pulleys, the small and large pulleys. The idler  s main purpose is to reduce the speed and increase torque provided to the tumbler (basket) be[...]

13 J. MAIN DOOR SWITCH The main door switch is located near the main door hinge. When the main door opens, the switch will also open, preventing the dryer from operating. The main door switch is a safety device and should never be disabled. K. SAIL SWITCH (GAS MODELS ONL Y) The sail switch is located on the front of the burner box. A sail switch co[...]

14 M. MANUAL RESET THERMOST A T This is located inside the dryer in the lint compartment above the lint drawer . This thermostat senses the heated air after it has passed through the tumbler (basket). If the air temperature gets too hot, the thermostat will shut off the burner . T umbler (basket) and blower will run, but dryer will not heat until t[...]

15 P . STEAM DAMPER SYSTEM The newest type system is called the steam damper . It is shown to the right and it uses a piston with compressed air to open and close the steam damper which in turn allows the air to flow either through the coil for heat, or under the coil for cool down. Air supply is 80 PSI (+/- 10 PSI). Q. COMPRESSED AIR REQUIREMENTS [...]

16 SECTION V SER VICING INTRODUCTION ALL electrical/mechanical service or repairs should be made with the electrical power to the dryer disconnected (power off). W ARNING: PERSONAL INJUR Y COULD RESUL T . The information provided in this section should not be misconstrued as a device for use by an untrained person making repairs. Service work shoul[...]

17 A. COMPUTER CONTROLS T o Replace Computer 1. Disconnect electrical power to the dryer . 2. Disconnect main power harness along with the three (3) other connectors located on the computer board, from rear of computer by squeezing locking tab and pulling connector straight back. 3. Disconnect the green ground wire and the air jet wire from t[...]

18 T o Replace Microprocessor T emperature Sensor Probe 1. Discontinue electrical power to the dryer . 2. Remove lint drawer . Remove six (6) screws securing lint door and remove lint door . 3. Remove microprocessor sensor bracket assembly from dryer . a . Disconnect sensor bracket harness connector . b. Loosen the two (2) Phillips head screws secu[...]

19 4. Reverse procedure for installation of new flame sensor probe. T o Replace Gas V alve (Refer to burner illustration on page 21 ) 1. Discontinue electrical power to the dryer . 2. Close shut-off valve(s) in gas supply line. 3. Disconnect gas valve wiring. NOTE: Identify location of each wire for correct reinstallation. 4. Break union connection[...]

20 1. T o T est Gas W ater Column (W .C.) Pressure: a . Connect water column test gauge connection to gas valve pressure tap (1/8 NPT). This pressure tap is located on the outlet (manifold) side of the valve. b. Start dryer . W ith burner on, the correct water column reading in inches would be: Natural Gas  3.5 Inches W ater Column L.P . Gas [...]

21 T o Replace Burner T ubes 1. Refer to Replace Gas V alve and follow S tep #1 through S tep #6 . 2. Remove four (4) screws securing manifold rest and remove rest. 3. Remove the screws securing the front flanges of the burner tubes to the burner tube rest. 4. Remove the screws securing the burner tube rest to the oven and remove this rest. 5[...]

22 IMPOR T ANT : UNDER NO CIRCUMST ANCES should heat circuit safety devices ever be disabled. 1. Discontinue electrical power to the dryer . 2. Disconnect wires from hi-limit thermostat. 3. Remove screw , washer, and nut securing thermostat to the bracket. Remove thermostat. 4. Reverse procedure for installing new thermostat. 5. Reestablish electri[...]

23 D. SAIL SWITCH ASSEMBL Y (GAS MODELS ONL Y) The sail switch is a heat circuit safety device which controls the burner 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 , ignition should now be [...]

24 7. Reestablish electrical power to the dryer . IMPOR T ANT : UNDER NO CIRCUMST ANCES should the door switch be disabled. T o Replace Main Door Assembly 1. Remove two (2) Allen head screws holding the top main door hinge block to the front panel. 2. Reverse this procedure for reinstalling new main door assembly . T o Install New Main Door Glass 1[...]

25 6. Unplug the door switch wires at the bottom of the front panel. 7. Disconnect the wires connecting the EMERGENCY STOP (E-Stop). The easiest place to do this would be in the left hand electrical box. Once the wires are disconnected, push them through the inner top. 8. Remove the twelve (12) Phillips head screws securing front panel to dry[...]

26 1 1. T ighten cap screws progressively . There should remain a gap between the sheave hub and the flange of the bushing. IMPOR T ANT : T ighten screws evenly and progressively . Never allow the sheave to be drawn in contact with the flange of the bushing. This gap should measure from 1/8 to 1/4. Proper cap screw torque is 30 ft.-lbs. If gr[...]

27 5. Loosen V -belts, then rotate pulley and roll V -belts out of its grooves. 6. Remove cap screws. 7. Insert cap screws in tapped removal holes and tighten evenly until bushing becomes loose on shaft. Refer to figure A on page 25 . 8. Remove bushing, pulley , and key . 9. Assemble bushing and sheave as shown in figure B on previou[...]

28 IMPOR T ANT : T ighten screws evenly and progressively . Never allow the sheave to be drawn in contact with the flange of the bushing. This gap should measure from 1/8 to 1/4. Proper cap screw torque is 6 ft.-lbs., if greater tightening forces are applied, excess pressures will be created in the hub of the mounted sheave which may cause it[...]

29 H. BEARINGS T o Replace Rear Drive Shaft Pillow Block Bearing 1. Follow S tep #1 through S tep #6 from T o Replace Front Drive Shaft Bearing. 2. Remove drive pulley . a . Remove cap screws from bushing. b. Insert cap screws in tapped removal holes and tighten evenly until bushing becomes loose on shaft. c . Remove set screws from bushing. [...]

30 1 1. Reestablish electrical power to the dryer . T o Replace Rear T umbler (Basket) Support Flange Bearing 1. Discontinue electrical power to the dryer . 2. Remove bearing back guard. 3. Block rear of tumbler (basket) up to take weight off of shaft and bearing. NOTE: This may be accomplished the easiest through the lint coop. 4. Remove the four [...]

31 NOTE: Check belt adjustment and readjust if necessary . 8. Remove wheel from shaft. 9. Loosen the two (2) set screws in the race of the pillow block bearing. 10 . Clean the shaft from the end up to the pillow block bearing and slide the pillow block bearing off of the shaft. 1 1. Reverse these steps to install new pillow block bearing. T o Repla[...]

32 5. Replace by reversing procedure. 6. Reestablish electrical power to the dryer . I. BASKET and SUPPOR T T o Replace T umbler (Basket) and T umbler (Basket) Support 1. Discontinue electrical power to the dryer . 2. Follow procedure for removal of main door assembly . 3. Follow procedure for removal of front panel assembly . 4. Remove bearing bac[...]

33 V -Belt T ension Adjustment (Drive Shaft to Speed Reducing Shaft) 1. Discontinue electrical power to the dryer . 2. Remove the lint drawer . 3. Remove the lint door . 4. Loosen two (2) bolts securing rear pillow block bearing on the drive shaft. 5. Loosen adjustment bolt that is securing the rear pillow block bearing of the drive shaft. 6. Loose[...]

34 K. MOTORS T o Replace Drive Motor 1. Discontinue electrical power to the dryer . 2. Remove the lint drawer . 3. Remove the lint door . 4. Remove the left lint wall. 5 . Remove the drive V -belts. Follow V -belt replacement from motor to speed reducing shaft. 6. Loosen the four (4) bolts securing the motor to the base of the dryer . 7. Disconnect[...]

35 2. Follow S tep #4 and Step #5 under T o Replace Impellor . 3. Loosen the four (4) bolts securing the fan shaft assembly to the base of the dryer . NOTE: Models with rear access, it may be easier to remove this plate, to remove the two (2) rear fan shaft assembly bolts. 4. Remove the fan assembly through front access hole. 5. Loosen the se[...]

36 T o Replace Lint Drawer Switch 1. Disconnect electrical power to the dryer . 2. Remove lint drawer and lint door . 3. Disconnect both 4-pin connectors at the rear of the lint switch cover . 4. Remove the one (1) or two (2) screws holding the lint switch cover on. 5. Remove lint switch cover and disconnect the two (2) terminals of the switch. 6. [...]

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

38 C . Dryer will not start, but computer display indicators are on and relay output lights are on... 1. Failed contactors. 2. Failed arc suppressor (A.S.) board. 3. Failed motors. 4. Loose wiring connection. D . Drive motor runs, burner is on, tumbler (basket) will not turn, and the computer is reading Rotational Sensor Failure... 1. Broken,[...]

39 6. Faulty gas valve. 7. No voltage to gas valve. 8. Poor airflow due to restriction in exhaust or dirty lint screen. H . Dryer operates but is taking too long to dry ... 1. An inadequate exhaust duct work system. 2. Restriction in exhaust system. 3. Insufficient make-up air . 4. Poor housekeeping...Dirty or clogged lint screen. 5. W ashing machi[...]

40 K. Dryer is tripping the burner hi-limit safety thermostat... 1. Insufficient exhaust duct work...size or restriction in exhaust system. 2. Insufficient make-up air . 3. Lint screen needs cleaning. 4. Damaged impellor (fan). 5. Impellor/fan spinning in the wrong direction. L . Display reads T emp Sensor Fail Check T emp Sensor Fuse. Dryer [...]

41 SECTION VII ELECTRICAL TROUBLESHOOTING The information provided will help isolate the most probable components associated with the difficulty described. The experienced technician realizes, however , that a loose connection or broken or shorted wire may be at fault where electrical components are concerned...not necessarily the suspect component[...]

42 SECTION VIII PHASE 6 OPL SYSTEM DIAGNOSTICS IMPOR T ANT : YOU MUST DISCONNECT and LOCKOUT ELECTRIC, GAS, or 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 ANDARDS. ALL major cir[...]

43 7. bURNER FLAME F AIL - this routine allows two (2) Flame Out retries to occur before proceeding into the error . The count of two (2) will be established every time the call for heat was to occur . Only if it reaches the count of two (2) before the tumbler (basket) temperature has reached the set temperature will this error be triggered. The ma[...]

44 NOTE: RP M - This routine monitors the timing response from the existing rotational sensor input and derives a RPM measurement. T o display this RPM measurement (press the ENTER/ST AR T Key once and release, then press the ENTER/ST AR T Key a second time and hold ...this will display the RPM measurement). The rotational sensor must b[...]

45 C. PHASE 6 OPL MICROPROCESSOR CONTROLLER RELA Y OUTPUT L.E.D. (light emitting diode) INDICA T ORS There are a series of five (5) L.E.D. (light emitting diode) indicators (ORANGE LIGHTS) located at the backside are of the Phase 6 OPL microprocessor controller (computer). These are identified or labeled (from top to bottom in the illustration belo[...]

46 SECTION IX L.E.D. DISPLA Y/CODES The L.E.D. (light emitting diode) display informs the operator of cycle status, program verification, and displays important diagnostic codes and fault codes. A. L.E.D. ( light emitting diode ) DISPLA Y OPERA TING ST A TUS 1. Cycles in Progress a . While the dryer is operating, the L.E.D. (light emitting diode) d[...]

47 1) Illustration No. 1 a) FOR W ARD INDICA TOR - this indicator dot is functional for dryer models with the Reversing Action Option ONL Y . This indicator dot will be on when the tumbler (basket) is in the forward (clockwise [CW]) direction. Additionally , when the Anti-W rinkle Program is active, this indicator dot will be on whenever the Phase [...]

48 C. L.E.D. CODES 1. Display Codes A SLOPE F ACTOR ALL REV AL W A YS REVERSING ANTI WRINKL dELA Y TIME ANTI-WRINKLE DELA Y TIME ANTI WRINKL GUARd ACTIVE ANTI-WRINKLE PROGRAM ACTIVE ANTI WRINKL GUARd ON TIME ANTI-WRINKLE GUARD ON TIME AUTO CYCLE AU TOMA TIC MODE b HEA T LOSS (OFF SET) F AC T OR bURNER CONTROL F AIL GAS ONL Y ... POWER (24V AC) IS N[...]

49 D. COMPUTER LOGIC and WIRING DIAGRAM 1. Operator enters desired selection(s). 2. Information entered is sent to the microcontroller via the keyboard (touchpad). 3. The input information is sorted/processed and executed by the microcomputer chip. 4. The microcomputer output signal activates the contactors and HSI (Hot Surface Ignition) module whi[...]

50 A . No Display Condition... 1. Check main fuses or circuit breaker . 2. Check blower motor overload...If tripped, reset. 3. Check fuse 1 or fuse 2 and if either are blown, replace. 4. Check to make sure the EMERGENCY STOP (E-Stop) button is not depressed. 5. Between pin 1 and ground of the 15 pin connector you should be getting 24 V . 6. I[...]

51 If there is voltage, replace the coil or the complete contactor . If there is no voltage, check for voltage across the two (2) BS3 terminals on the arc suppressor (A.S.) board. If there is voltage across the two (2) BS1 terminals and no voltage across the coil of the reversing contactor (A1 and A2), the problem is faulty wire(s) or termination(s[...]

52 If no voltage is present, check voltage at pin 5 and 8 of the J2 connector . Which is located in the front electrical box. If voltage is present then problem is a broken wire between 9 pin connector and HSI (Hot Surface Ignition) module or faulty termination. If no voltage is present, then there is a broken wire between computer and 9 pin connec[...]

53 I . Micropr ocessor r eads T emp Sensor Fuse. NOTE: Before continuing with this section check the .125 MA fuse on the computer board. 1. Replace the temperature sensor underneath the tumbler (basket) on a bracket (the bullet shaped device). 2. If it still reads T emp Sensor Fuse, unplug the 4 pin connector from the temperature sensor[...]

54 ºF = 9 (ºC + 3 2) 5 ºC = 5 (º F - 32 ) 9 T E MP E RATU RE S ENS OR C UR R E NT = ºC + ºK ( 2 7 3 .1 5 ) = MI C ROA MP S (µ A ) 1 ,00 0, 0 00[...]

55 SECTION X TECHNICAL INFORMA TION The following section contains various technical information important to the service person in servicing and maintaining the dryer . A. MOT OR PLA TE (HIGH and LOW VOL T AGE) The motor plate is located on the side of the drive motor (refer to illustration) and contains a graphical representation of the motor wir[...]

56 B. DA T A LABEL Contacting American Dryer Corporation (ADC) When contacting ADC , certain information is required to insure proper service/parts information. This information is on the data label, located on the top right corner of the dryer , viewed from the rear (refer to illustration). When contacting ADC , please have the model number and se[...]

57 C. USING A MANOMETER How T o Use A Manometer 1. W ith dryer in non-operating mode, remove plug on the gas valve pressure tap. 2. Attach plastic tubing to pressure tap. Fitting is supplied with manometer (refer to illustration). 3. Attach manometer to dryer using magnet. NOTE: Place manometer in a position so that readings can be taken at eye lev[...]

58 D. TOOL LIST Straight Head Screwdriver Phillips Head Screwdriver Sensor Pin and Socket T ool (P/N 122801) Pliers 1/4 Nut Driver 3/8 Open End W rench 5/8 Open End W rench 5/8 Deep Socket W rench 3/8 Socket W rench 1/2 Socket or Open End W rench 1/4 Open End W rench 5/16 Socket or Open End W rench 1/2 Socket W rench 7/16[...]

ADC 450410 1- 02/22/00-25[...]