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American Dryer Corp. AD-540 Service Procedure Download Page 1

AD-540

Mechanical/Electrical

Service Procedure

090603SRS/tcosta

ADC

 Part No. 450246

American Dryer Corporation

88 Currant Road

Fall River, MA 02720-4781

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

e-mail: [email protected]

www.amdry.com

Summary of Contents for AD-540

Page 1: ...ical Electrical Service Procedure 090603SRS tcosta ADCPartNo 450246 AmericanDryerCorporation 88 Currant Road Fall River MA02720 4781 Telephone 508 678 9000 Fax 508 678 9447 e mail techsupport amdry com www amdry com ...

Page 2: ...______________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ Replacement parts can be obtained from your reseller or the ADC factory When ordering replacement parts from the factory you can FAX your order to ADC at 508 678 9447 or telephone you...

Page 3: ...R OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE FOR YOUR SAFETY DO NOT DRY MOP HEADS IN THE DRYER DO NOT USE DRYER IN THE PRESENCE OF DRY CLEANING FUMES CHILDREN SHOULD NOT BE ALLOWED TO PLAY ON OR NEAR THE DRYERS WARNING CHILDREN SHOULD BE SUPERVISED IF NEAR DRYER S IN OPERATION DRYERS SHOULD NEVER BE LEFT UNATTENDED WHILE IN OPERATION CAUTION WARNING The dryer...

Page 4: ... and specified in the installation manual included with the dryer WARNING DRYER MUST NEVER BE OPERATED WITHOUT THE LINT FILTER OR SCREEN IN PLACE EVEN IF AN EXTERNAL LINT COLLECTION SYSTEM IS USED The wiring diagram for the dryer is located behind the left front control panel ...

Page 5: ...rocessorAssembly 10 F Basket Tumbler 10 G Basket Tumbler andDriveMotorAssemblyArrangement 10 H IdlerArmandImpellorMountAssembly 11 I DriveMotorandIdlerPulleyArrangement 11 J Temperature Sensors 11 K GasBurner 12 L SailSwitch 12 M Hi LimitThermostat 12 N LintDrawerSwitch 13 O LintDrawer 13 P FrontThrusterWheel BracketAssembly 13 Q RearBasket Tumbler DriveWheels 14 R RotationalSensorAssembly 14 SECT...

Page 6: ...ubleshooting 33 SECTION VII TROUBLESHOOTING 47 A Phase5CoinSystemDiagnosis 47 B No Heat Condition Blower is On 50 C No Start Condition 52 D NoDisplayCondition 53 E dSFL DisplayCondition 54 F dOOr DisplayCondition 55 SECTION VIII DATA LABEL INFORMATION 56 A Data Label 56 B UsingaManometer 57 C LightEmittingDiode L E D DisplayCodes 58 ...

Page 7: ...create a firehazard WARNING DO NOT use heat for drying articles that contain plastic foam sponge rubber or similarlytexturedrubberlikematerials Dryinginaheatedbasket tumbler maydamage 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 deter...

Page 8: ...n and replace if damaged 90 DAYS Remove lint accumulation from lint chamber thermostats and sensors WARNING TOAVOIDTHE HAZARD OFELECTRICALSHOCK DISCONTINUE ELECTRICALSUPPLYTOTHE DRYER Remove lint from the motor air vents and surrounding area IMPORTANT Lintaccumulationwillrestrictinternalmotorairflow causingoverheatingand irreparabledamage MotorfailureduetolintaccumulationwillVOIDTHE WARRANTY 120 D...

Page 9: ...racked or seriously frayed belts should be replaced Tighten loose drive belts when necessary and check belt alignment Complete operational check of control and valves Complete operational check of ALL 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 ch...

Page 10: ...ances 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 the make up air is inadequate drying time and drying efficiency will be adversely affected Ignition problems and sail switch fluttering problems on gas dryers may result an...

Page 11: ...nnections made by a qualified professional to assure that the gas plumbing installation is adequate and conforms to local and state regulations or codes In the absence of such codes ALL plumbing connections materials and workmanship must conform to the applicable requirements of the National Fuel Gas Code ANSI Z223 1 LATEST EDITION or in Canada the Canadian Installation Codes CAN CGA B149 1 M91 Na...

Page 12: ...levations over 2 000 feet 609 6 meters is made by changing the burner orifices If this adjustment is necessary contact the reseller who sold the dryer or contact the ADC factory NOTE Any burner changesmust bemade by a qualified technician C OPERATIONAL SERVICE CHECK PROCEDURE After performing any service or maintenance function an operational check should be performed to insure that ALL components...

Page 13: ...Press selection for the dryer to start B CONTROL AND RELAY PANELS The control and relay panels are located in the back of the dryer in the middle top selection The function of the control and relay panels is to compile signals from the computer or the incoming voltage and transfer the signals to the motor and heat circuit when the computer executes these various signals C COIN BOX The coin box ass...

Page 14: ...et tumbler which serve to adjust drive and support the basket tumbler The idler assembly has various nuts and bolts that are made to adjust the belt tension F BASKET TUMBLER The basket tumbler consists of three 3 ribs and a perforated basket tumbler along with a front and back which are riveted together as an assembly The basket tumbler also consists of pop rivets which attach the basket tumbler t...

Page 15: ...e torque of the basket tumbler pulley I DRIVE MOTOR AND IDLER PULLEY ARRANGEMENT The dryer has a different kind of drive system There is one 1 motor pulley one 1 drive belt and an idler arm assembly by the basket tumbler The drive motor drives the belt that rotates the basket tumbler J TEMPERATURE SENSORS The temperature sensor used in a transducer converts heat into microamps that the computer bo...

Page 16: ...es to the extent of causing the intense heat from the burner to trip the thermostat L SAIL SWITCH The sail switch consists of a round damper plate on a lever arm which acts like an actuator for a microswitch When the air blower comes on it draws air through the burner This creates a negative pressure inside the burner box and this negative pressure pulls in the round damper which activates the sai...

Page 17: ...NT THRUSTER WHEEL BRACKET ASSEMBLY Behind the front panel for each pocket there are two 2 basket tumbler drive wheels This supports the weight of the basket tumbler This also allows the basket tumbler to spin freely without bearings and basket tumbler support shaft O LINT DRAWER The lint drawer is located under the baskets tumblers of each pocket It is a fairly large drawer that is designed to be ...

Page 18: ...ENSOR 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 The magnetic rotational sensor switch senses the rotation of the basket tumbler If the gap between the sensor switch and the magnet is greater than a preset amount then the dryer will shutdown on SEFL rotatio...

Page 19: ...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 suspected component itself Electrical parts should always be checked for failure before being returned to the factory IMPORTANT YOU MUSTDISCONNECTAND LOCKOUTTHE ELECTRIC SUPPLY AND THE GAS SUPPLYBEFOREANYCOV...

Page 20: ...1 Discontinue power to the dryer 2 Open the coin panel and disconnect the keyboard touch pad ribbon connector from the ribbon cable it is plugged into 3 Peel the keyboard touch pad from the front of the control panel taking care to avoid scratching the panel 4 Clean any adhesive residue from the panel 5 Peel off paper backing from new keyboard touch pad 6 Align the display window on the keyboard t...

Page 21: ...actor in reverse procedure 6 Reestablish power to the dryer TO REPLACE GAS VALVE 1 Discontinue power to the dryer 2 Remove back guard 3 Close the union shutoff located just before the gas valve and remove the two 2 wires on top of the gas valve 4 Break and loosen union nut between union shutoff and gas valve 5 Remove the four 4 screws holding the two 2 pipe brackets on each side of the gas valve 6...

Page 22: ...ube is 1 8 1 32 3 175 mm 0 79248 mm TO REPLACE THE IGNITOR PROBE 1 Discontinue power to the dryer 2 To remove the ignitor probe remove the two 2 screws that hold them to the burner box 3 When replacing ignitor probe remove screws disconnect high voltage HV wire from DSI module and remove the probe and high voltage HV wire from the ignitor 4 Replace new items in reverse procedure IMPORTANT DO NOT w...

Page 23: ...the burner box and remove the two 2 screws securing pipe bracket 4 Move the manifold assembly to the left and hold 5 Unscrew main burner orifice and replace NOTE Use extreme care when removing and replacing orifice The orifice is made of brass and can beeasilydamaged 6 Reverse the removal procedure for reinstalling WARNING Test ALL connections for leaks by brushing on a soapy water solution WARNIN...

Page 24: ...water column pressure a Connect water column test gauge connection to gas valve pressure tap 1 8 N P T This pressure tap is located on the outlet downstream side of the valves b Start the dryer With burner on the correct water column reading in inches would be Natural Gas 3 5 Inches 8 7 mb W C Liquid Propane L P Gas 10 5 Inches 26 1 mb W C 2 To adjust water column pressure natural gas only L P gas...

Page 25: ...included in kit envelope f92 0737 supplied 9 Reverse procedure for installing valve manifold assembly to the dryer IMPORTANT External regulation of a consistent gas pressure of 10 5 inches 26 1 mb water column W C must be provided 10 Open ALL shutoff valves and test for leaks IMPORTANT DO NOT test for leaks with an open flame Use soapy water solution or a product intended for that purpose 11 Opera...

Page 26: ...D TEMPERATURE SENSOR TO REPLACE HI LIMIT THERMOSTAT 290 This thermostat is an important safety device serving as an added protection against failure of the airflow sail switch to open in the event of a motor failure or reduced airflow condition IMPORTANT UNDER NO CIRCUMSTANCES should the heat circuit safety devices ever be disabled 1 Discontinue power to the dryer 2 Remove the two 2 hex head screw...

Page 27: ... the 225 hi limit f Reverse the procedure for installation of new high heat protector 2 Temperature Sensor a Discontinue power to the dryer b Remove the lint drawer from the dryer c Remove the two 2 free spin wash nuts that are securing the temperature sensor bracket to the dryer d Disconnect the 4 pin connector on the temperature sensor bracket NOTE Be careful not to let the sensor harness that y...

Page 28: ...or installing new sail switch Adjust sail switch as described in the next section TO ADJUST SAIL SWITCH 1 Operate the installed dryer normally to verify that the heat system is fully operational 2 Open the main dryer door 3 Manually depress the door switch actuator 4 While continuing to depress the door switch actuator and with the door open start the dryer 5 If the heat system is not activated in...

Page 29: ...ring the hinge pin to the front panel NOTE Be careful not to lose the plastic washer on the hinge pin 5 Reassemble by reversing steps TO INSTALL NEW MAIN DOOR GLASS 1 Remove main door assembly from the dryer follow main door hinge removal procedure 2 Place the main door on a flat surface with front of door face down 3 Remove glass and clean ALL old sealant off main door This area must be completel...

Page 30: ...oor switch harness connector from the lint drawer switch box top and bottom 7 Remove the front panel assembly from the dryer 8 Reverse this procedure for installing the new front panel TO REPLACE THE NYLON CATCH 1 Open the main door 2 Drill out the two 2 pop rivets holding nylon catch to front panel using 21 0 1590 drill bit 3 Using two 2 pop rivets PN 154215 install nylon catch PN 170330 to the f...

Page 31: ...o install a new sensor switch connect the plug of the new sensor switch to the sensor harness 5 Place one 1 adjustment nut onto the sensor switch 6 Place the second adjustment nut on but DO NOT tighten The magnet on the rear teflon plate and the sensor switch must be in a horizontal line to one another 7 The gap between the magnet and the sensor switch must be 1 8 inch 8 Tighten the adjustment nut...

Page 32: ...er Remove the retaining basket tumbler shoulder bolt that secures the rear teflon pad to the basket tumbler 7 Now return to the front of the dryer and pull the basket tumbler outwards 8 To install a new basket tumbler reverse the removal instructions BASKET TUMBLER WHEEL REMOVAL 1 Disconnect power to the dryer 2 Follow Step 2 through Step 7 in Basket tumbler Removal above 3 Loosen and remove the 9...

Page 33: ...tem When activated by the dryer s controls this module constantly monitors and controls the functions of the DSI system i e spark activation gas valve on off functions flame verification etc can be operated at either 50 Hz or 60 Hz and has self diagnostic capabilities The L E D indicator light on the DSI module simplifies the troubleshooting procedure in the event of a fault within the DSI system ...

Page 34: ...er has multi primary taps which allow for one 1 transformer to be used for any voltage application including 120 volts 208 volts or 240 volts Refer to the Service Information Section of this manual for specific transformer and wiring termination information c The ignitor flame sensor assembly is located in the burner flame area and is used to ignite the gas by the use of a high volt HV 14 000 sync...

Page 35: ...ulated liquid propane L P gas IMPORTANT The DSI gas valves are not field repairable There are no parts available for field repair Replace valve only with exact model and or type number as noted on gas valve 2 System Basic Electric Ratings Specifications a Input Voltage 18 VAC to 30 VAC must be grounded b Line Frequency 50 Hz or 60 Hz c Maximum Input Current 0 100 amps valve load 25 VAC d Valve Loa...

Page 36: ...nce the burner flame is established confirmed the DSI module L E D indicator will stay GREEN and the burner system will continue through a normal heating cycle where the DSI system will cycle on and off as required by the dryer s controls During the normal heating cycle should a flameout occur i e severe air turbulence forces the flame away from the ignitor assembly flame probe the DSI module will...

Page 37: ...NT UNDER NO CIRCUMSTANCES SHOULDANYSAFETYOR HEAT CIRCUIT DEVICE EVER BE DISABLED The following troubleshooting guide provides systematic procedures for isolating equipment problems and again is intended for use by a qualified service technician TEST EQUIPMENT The following pieces of test equipment will be required to troubleshoot this system with minimal time and effort MANOMETER Used to measure g...

Page 38: ...teps The following steps must be performed to minimize the time required to isolate cause of fault 1 DSI module L E D indicator is off no GREEN light a Check for voltage approximately 24 VAC across the DSI module terminals THS and GND ground If voltage approximately 24 VAC is evident then there is a malfunction within the DSI module itself and it must be replaced b If there is no voltage and the p...

Page 39: ...NE ANOTHER 2 Check to insure that the dryer is properly grounded and that the ground connections GND to the DSI module are secure 3 If the problem persists it is most likely to be in the external components not the DSI module or wiring or due to flame out proceed as follows NOTE Preliminary steps DO NOT OMIT to minimize the time required to troubleshoot this system a Disconnect electric power to t...

Page 40: ...nly after each step has been completed and replacement is suggested in the flowchart However the experienced technician realizes that a loose connection or broken or shorted wire may be at fault where electrical components are concerned and not necessarily the suspected component itself c Three 3 Visual Checks 1 No spark and system does not work If not proceed to First Visual Check on page 37 2 Sp...

Page 41: ...rminal 5 to ground NO YES Install jumper Open thermostat contacts for 30 seconds Close contacts and wait for prepurge if applicable period Is spark now present NO YES Correct Replace Turn off supply voltage Check high voltage cable Is it securely attached to spark transformer NO YES Is condition of high voltage cable good not brittle burnt or cracked NO YES Is spark electrode ceramic cracked or is...

Page 42: ...nd NO YES Is 24 VAC present between terminals M V 3 and ground NO YES Correct Replace Johnson Control module G760 761 Check for continuity in wiring from M V 3 to gas valve and gas valve to GR NO YES Is Spark gap 0 1 in and in gas stream NO YES Replace gas valve Correct Correct Determine why continuity does not exist Is inlet gas pressure per manufacturer s specifications NO YES ...

Page 43: ...ES Is flame sensor corroded or is ceramic cracked NO YES Does continuity exist in ground path from burner to control NO YES Check flame sensing current during trial Is current greater than 0 3µ A DC NO YES Is flame sensor positioned per manufacturer s specifications NO YES Correct Correct Correct Replace Johnson Control module G760 761 Replace Johnson Control module G760 761 Replace sensor cable C...

Page 44: ...try two 2 more times then if it is still not established it will go into LOCKOUT NOTE To reset the DSI module if it is in the LOCKOUT mode open and close the main door then restart the dryer a System Diagnosis 1 Gas Pressure A gas pressure test should be taken at the gas valve pressure tap provided on every gas valve to assure that the water column W C pressure is correct and consistent There are ...

Page 45: ...main door then restart the dryer 2 Ignitor Flame ProbeAssemblyAdjustments The ignitor flame probe assembly consists of a ceramic insulated ignitor electrode a ground rod and a ceramic insulated flame probe electrode The gap between the ignitor electrode and the ground rod is set and must be maintained at 1 8 1 32 3 175 mm 0 79248 mm When the DSI module provides the high voltage HV synchronous spar...

Page 46: ...r c The positioning of the ignitor flame probe assembly is extremely important because it provides the necessary feedback information to the DSI module The flame probe electrode must be positioned 1 4 minimum into the flame path refer to the illustration below and must be positioned 1 inch 2 54 cm maximum from the burner tube refer to the illustration below otherwise the DSI module will indicate a...

Page 47: ...BLINK GREEN CONTINUOUSLY then there is a malfunction within the DSI module itself and it must be replaced 5 Wiring If the DSI module is in the LOCKOUT mode where the L E D will BLINK GREEN CONTINUOUSLY and the mechanical components have been checked i e the ignitor flame probe assembly the gas valve etc then there may be a problem somewhere in the DSI system wiring a Check ALL the wiring within th...

Page 48: ...ect model number and serial number for the dryer s NOTE Any wiring change s and or conversion s should be accomplished by a QUALIFIED ELECTRICALTECHNICIAN 1 Transformer Wiring There are six 6 color coded wires coming from the 24 VAC Transformer There are four 4 wires coming from the primary incoming voltage side of the transformer Their application and color coding are as follows a For 120 VAC app...

Page 49: ...RE NOTavailable Replace with exact model and type number ONLY a ADC PN 128927 1 To check the resistance values on this particular gas valve a Disconnect the terminations at the gas valve from the DSI module WARNING Whentakingohmreadings theterminationsfromDSImodule must bedisconnected removed otherwise the readings obtained will be incorrect and or erroneous 2 With a meter either a multimeter or o...

Page 50: ...46 DIRECTSPARK IGNITION DSI SYSTEM COMPONENTS 24 VAC DIRECT SPARK IGNITION DSI TRANSFORMER ADC PN 141403 G760 DIRECT SPARK MODULE ADC PN 128935 ...

Page 51: ...ding door microprocessor temperature sensor heat and motor circuits are monitored The Phase 5 coin microprocessor controller computer will inform the user by the light emitting diode L E D display of certain failure codes along with indicators both in the L E D display at the outputs of each relay and door switch circuit to easily identify failures DIAGNOSTICS L E D DISPLAY FAILURE CODES 1 dOOr In...

Page 52: ...L E D temperature sensor has dropped to 220 F 104 C or lower and the microprocessor controller computer is manually reset by closing and opening the program switch PS on the back side of the controller MICROPROCESSOR CONTROLLER COMPUTER RELAY OUTPUT L E D INDICATORS There are three 3 L E D indicators red lights located at the lower backside area of the controller they are identified and labeled dO...

Page 53: ...rocessor controller computer the problem is elsewhere in the dryer L E D DISPLAY INDICATORS The L E D indicator dots located at the top portion of the L E D display refer to the illustration below indicate the Phase 5 coin microprocessor controller computer output functions while a cycle is in progress These dots DO NOT necessarily mean that the outputs are functioning They are only indicating tha...

Page 54: ...ollowing 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: ...a loose connection going back to the burner hi limit or the burner hi limit itself may be faulty If voltage 24 VAC is present at the TH and GnD terminals proceed to the next step 6 If no spark is present check for any hairline cracks at the base of the ignitor If cracks are present replace the ignitor If no cracks are present then the module PN 128935 may be faulty If spark is occurring then proce...

Page 56: ...OOr in the Troubleshooting Section 2 Check for voltage at the microprocessor pin 7 If no voltage check for a loose connection or the microprocessor itself is faulty If no voltage is present proceed to the next step 3 Check for voltage across the coil connections of the motor relay If no voltage is evident check for a loose connection going back to J5 6 pin connector 3 If voltage is evident proceed...

Page 57: ...2 white wire If no voltage check for a loose connection 4 Check for voltage at the microprocessor pin 6 black wire and pin 3 white wire If no voltage check for a loose connection If voltage is present the problem may be a faulty microprocessor 5 Check for voltage across the computer s 9 pin connector pin numbers 6 and 3 110v 208v 220v If no voltage is evident problem is bad wire or termination fro...

Page 58: ...croprocessor 9 position connector at the microprocessor controller computer 3 Discontinue power to dryer Disconnect the microprocessor 9 position connector from microprocessor controller computer and locate connector holes 1 and 4 Disconnect sensor harness from sensor bracket assembly located in the lint compartment Check for continuity across each wire from harness connector in lint compartment J...

Page 59: ...ger pushed in If no continuity replace the door switch If continuity is evident reassemble door switch back on dryer a Repeat the above procedure for the lint door switch 2 Make sure both the main and lint doors are closed and the plungers are pushed in Check for voltage across pin 4 blue wire J5 6 pin connector to ground If no voltage is evident problem could be faulty transformer or fuse 1 is bl...

Page 60: ...anel wall area behind the bottom control panel When contacting ADC please have the model number and serial number handy 1 MODEL NUMBER The model number is an ADC number which describes the size of the dryer and the type of heat gas electric or steam 2 SERIAL NUMBER The serial number allows ADC to gather information on your particular dryer 3 MANUFACTURING CODE NUMBER The manufacturing code number ...

Page 61: ...ational B USING A MANOMETER HOW TO USE A MANOMETER ADC PN 122804 1 With dryer in nonoperating mode remove plug on the gas valve pressure tap 2 Attach plastic tubing to pressure tap Fitting is supplied with manometer refer to the illustration 3 Attach manometer to dryer using magnet NOTE Place manometer in a position so that readings can be taken at eye level 4 Fill manometer as shown in illustrati...

Page 62: ...is Open dSFL Dryer Sensor Circuit Failure FAr Degree in Fahrenheit FILL No Cycle in Progress FLS Flash DisplayActive FrEE Free Dry Mode GdLY Anti Wrinkle Delay Time Gont Anti Wrinkle On Time Grd Anti Wrinkle ProgramActive HICd High Cool Down Temp Hot Overheating Condition LCC Left Coin Count LCde Left Coin Denomination LOCd Low Cool Down Temp nbUZ No Buzzer Tone nFLS No Flash Display Ngrd NoAnti W...

Page 63: ...tinguish 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 Diagrams for this book are as follows including ALL revisions of the numbers listed below ...

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