ML-202 Service Manual

American Dryer Corporation88 Currant Road

Fall River MA 02720-4781 USATelephone: +1 (508) 678-9000 / Fax: +1 (508) 678-9447

e-mail: [email protected]

www.adclaundry.com

ML-202Service Manual

Phase 7Microprocessor Controls

ADC Part No. 450457-1

mailto:[email protected]/

http://www.adclaundry.com/

2 American Dryer Corporation 450457-1

Retain This Manual in a Safe Place for Future ReferenceThis product embodies advanced concepts in engineering, design, and safety. If this product is properlymaintained, 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 installationmanual included with the dryer.

The following �FOR YOUR SAFETY� caution must be posted near the dryer in a prominent location.

FOR YOUR SAFETY

Do not store or use gasolineor other flammable vaporsand liquids in the vicinity ofthis or any other appliance.

POUR VOTRE SÉCURITÉ

Ne pas entreposer ni utiliser d�essenceni d�autres vapeurs ou liquidesinflammables à proximité de cetappareil ou de tout autre appareil.

�IMPORTANT NOTE TO PURCHASER�

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

We have tried to make this manual as complete as possible and hope you will find it useful. The manufacturerreserves 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. The illustrations included in this manual maynot depict your particular dryer exactly.

IMPORTANTFor your convenience, log the following information:

DATE OF PURCHASE ________________________________________________ MODEL NO. _____________________

RESELLER�S NAME __________________________________________________________________________________

SERIAL NUMBER(S) __________________________________________________________________________________

____________________________________________________________________________________________________

____________________________________________________________________________________________________

Replacement parts can be obtained from your reseller or the ADC factory. When ordering replacement partsfrom the factory, you can FAX your order to ADC at +1 (508) 678-9447 or telephone your order directly to theADC Parts Department at +1 (508) 678-9000. Please specify the dryer model number and serial number inaddition to the description and part number, so that your order is processed accurately and promptly.

ML-202

450457-1 www.adclaundry.com 3

Table of Contents ________

List of Acronyms _____________________DSI Direct Spark Ignition

in WC Inches of Water Column

L.E.D. Light Emitting Diode

L.P. Liquid Propane

OPL On-Premise Laundry (Non-Coin)

OSHA Occupational Safety and Health Administration

T.E.F.C. Totally Enclosed, Fan-Cooled

IMPORTANTYou must disconnect and lockout the electricsupply and the gas supply or the steam supplybefore any covers or guards are removed fromthe machine to allow access for cleaning,adjusting, installation, or testing of anyequipment per OSHA standards.Please observe all safety precautions displayedon the equipment and/or specified in theinstallation manual included with the dryer.

CAUTIONDryer(s) should never be left unattended whilein operation.

�Caution: Label all wires prior to disconnectionwhen servicing controls. Wiring errors can causeimproper operation.�

«Attention: Au moment de l�entretien descommandes, étiquetez tous les fils avant de lesdébrancher. Des erreurs de câblage peuvententraîner un fonctionnement inadéquat etdangereux.»

WARNINGChildren should not be allowed to play on or nearthe dryer(s). Children should be supervised ifnear dryer(s) in operation.Under no circumstances should the dryer doorswitch(es), lint door/drawer switch(es), or heatsafety circuit(s) ever be disabled.The dryer must never be operated with any ofthe back guards, outer tops, or service panelsremoved. Personal injury or fire could result.The dryer must never be operated without thelint filter/screen in place, even if an external lintcollection system is used.

FOR YOUR SAFETYDo not dry mop heads in the dryer. Do notuse dryer in the presence of dry cleaningfumes.The dryers must not be installed or stored inan area where it will be exposed to waterand/or weather.The wiring diagram for the dryer is located inthe front electrical control box area.

Important Information ...................................... 4Safety Precautions .......................................... 4

Routine Maintenance ...................................... 4Cleaning .......................................................... 4Adjustments .................................................... 5Lubrication ....................................................... 5

Installation Requirements .............................. 5Enclosure, Air Supply,and Exhaust Requirements............................. 5Electrical and Gas Requirements ................... 6Operational Service Check Procedure ........... 6

Description of Parts ........................................ 6

Servicing ........................................................ 10

Troubleshooting ............................................ 19

Phase 7 OPL System Diagnostics ................ 20Diagnostic (L.E.D. Display) Fault Messages 20F.S.S. System Diagnostic Conditions ........... 22I/O Board L.E.D. ............................................ 23Keypad Layout .............................................. 25F.S.S. System Theory Of Operation.............. 25Static Pressure ............................................. 26Using a Magnehelic ....................................... 26

Technical Information.................................... 28



▲ WARNING!Dry only water-washed fabrics. Do not dry articlesspotted or washed in dry cleaning solvents, acombustible detergent, or �all purpose� cleaners.Fire or explosion could result.Do not dry rags or articles coated with gasoline,kerosene, paint, or wax.Do not dry mop heads. Contamination by wax orflammable solvents will create a fire hazard.Do not use heat for drying articles that contain plastic,foam, sponge rubber, or similarly textured rubberlikematerials. Drying in a heated tumbler may damageplastic or rubber and also may be a fire hazard.

A program should be established for the inspection andcleaning of lint in the burner area and exhaust ductwork. Thefrequency of cleaning can best be determined fromexperience at each location.

▲ WARNING!The collection of lint in the burner area and exhaustductwork can create a potential fire hazard.

For personal safety, the dryer must be electrically groundedin accordance with local codes and/or the National ElectricalCode ANSI/NFPA No. 70-LATEST EDITION.

NOTE: Failure to do so will void the warranty.

Under no circumstances should the dryer door or lint drawerswitch(es) or heat safety devices ever be disabled.

▲ WARNING!Personal injury or fire could result.

Important Information ________________Safety PrecautionsDo not store or use gasoline or other flammable vapors andliquids in the vicinity of this or any other appliance.

Purchaser/user should consult the local gas supplier forproper instructions to be followed in the event the user smellsgas. The instructions should be posted in a prominentlocation.

Dryer must be exhausted to the outdoors.

Although ADC�s dryer is a very versatile machine, there aresome articles, that due to fabric composition or cleaningmethod, should not be dried in it.

Articles should never be left unattended for an extendedperiod of time in the tumbler after completion of the dryingand cooling cycles.

▲ WARNING!Articles left in the dryer after the drying and coolingcycles have been completed can create a fire hazard.

This dryer is not to be used in the presence of dry cleaningsolvents or fumes.

Read and follow all caution and direction labels attached tothe dryer.

▲ WARNING!Children should not be allowed to play on or in thedryer(s). Children should be supervised if neardryer(s) in operation.

▲ WARNING!Lint from most fabrics is highly combustible. Theaccumulation of lint can create a potential firehazard.Keep dryer area clear and free from combustiblematerials, gasoline, and other flammable vapors andliquids.

NOTE: Suggested time intervals shown for average usage,which is considered six to eight operational (running) hoursper day.

Clean lint drawer/screen every third or fourth load.

NOTE: Frequency can best be determined at eachlocation.

Do not operate dryers with more than 125 psi (8.62 bar) steampressure. Excessive steam pressure can damage steam coiland/or harm personnel.

Replace leaking flexible steam hoses or other steam fixturesimmediately. Do not operate dryer with leaking flexible hoses.Personal injury may result.

Routine Maintenance _________________CleaningA program and/or schedule should be established for periodicinspection, cleaning, and removal of lint from various areasof the dryer, as well as throughout the ductwork system. Thefrequency of cleaning can best be determined fromexperience at each location. Maximum operating efficiencyis dependent upon proper air circulation. The accumulationof lint can restrict this airflow. If the guidelines in this sectionare met, an ADC dryer will provide many years of efficient,trouble free, and � most importantly � safe operation.


Daily(Beginning) of each work shift.

Clean lint from the drawer/screen. Inspect lint screen andreplace if torn.

WeeklyClean lint accumulation from lint chamber, thermostat, andmicroprocessor temperature sensor (sensor bracket) area.

▲ WARNING!To avoid the hazard of electrical shock, discontinueelectrical supply to dryer.

Steam DryersClean steam coil fins using compressed air and a vacuumcleaner with brush attachment.

NOTE: When cleaning steam coil fins, be careful not tobend the fins. If fins are bent, straighten by using a fincomb, which is available from local air-conditioning supplyhouses.

90 DaysRemove lint from tumbler, drive motors, and surroundingareas. Remove lint from gas valve burner area with a dustingbrush or vacuum cleaner attachment.

NOTE: To prevent damage, avoid cleaning and/or touchingignitor/flame-probe assembly.

Remove lint accumulation from inside control box and at reararea behind control box.

6 MonthsInspect and remove lint accumulation in customer furnishedexhaust ductwork system and from dryer�s internal exhaustducting.

▲ WARNING!The accumulation of lint in the exhaust ductworkcan create a potential fire hazard.Do not obstruct the flow of combustion and ventilationair. Check customer furnished back draft damper inexhaust ductwork. Inspect and remove any lintaccumulation, which can cause damper to bind orstick.

NOTE: A back draft damper that is sticking partially closedcan result in slow drying and shut down of the heat circuitsafety switches or thermostats.

When cleaning dryer cabinet(s), avoid using harshabrasives. A product intended for the cleaning ofappliances is recommended.

Adjustments7 Days After Installation and Every 6 MonthsInspect bolts, nuts, screws, (bearing setscrews),nonpermanent gas connections (unions, shutoff valves,orifices, and grounding connections). Motor and drive beltsshould be examined. Cracked or seriously frayed belts shouldbe replaced. Tighten loose V-belts when necessary.Complete operational check of controls and valves. Completeoperational check of all safety devices (door switch, lint drawerswitch, sail switch, burner and hi-limit thermostats).

LubricationThe fan shaft bearings should be lubricated every threemonths. Use Shell Alvania #2 or its equivalent. The motorbearings, idler bearings and under normal/most conditionsthe tumbler bearings are permanently lubricated. It isphysically possible to re-lubricate the tumbler bearings ifyou choose to do so even though this practice is notnecessary. Use Shell Alvania #2 or its equivalent. Thetumbler bearings used in the dryer do not have a greasefitting. Provisions are made in the bearing housing for theaddition of a grease fitting, which can be obtainedelsewhere, or from ADC by ordering kit P/N 882159, whichincludes two fittings.

Installation Requirements ____________Installation should be performed by competent techniciansin accordance with local and state codes. In the absence ofthese codes, the installation must conform to applicableAmerican National Standards: ANSI Z223.1-LATESTEDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electrical Code) or in Canada,the installation must conform to applicable CanadianStandards: CAN/CGA-B149.1-M91 (Natural Gas) or CAN/CGA-B149.2-M91 (L.P. Gas) or LATEST EDITION (forGeneral Installation and Gas Plumbing) or CanadianElectrical Codes Parts 1 & 2 CSA C22.1-1990 or LATESTEDITION (for Electrical Connections).

Enclosure, Air Supply,and Exhaust RequirementsNOTE: The following information is very brief and general.For detailed description, refer to the �ML-202 InstallationManual� (ADC P/N 113289).

Bulkheads and partitions around the dryer should be madeof noncombustible materials. Allowances should be madefor the opening and closing of the control door and lint drawer.Also, allowances should be made in the rear for ease ofmaintenance. (Refer to appropriate Installation Manual forrecommended distances and minimum allowances required.)

When the dryer is operating, it draws in room air, heats it,passes this air through the tumbler, and exhausts it out ofthe building. Therefore, the room air must be continuallyreplenished from the outdoors. If the make-up air isinadequate, drying time and drying efficiency will be adverselyaffected. Ignition problems and sail switch �fluttering�problems on gas dryers may result, and you also could havepremature motor failure from overheating. The air supplymust be given careful consideration to ensure properperformance of each dryer.



IMPORTANT: Make-up air must be provided from asource free of dry cleaning fumes. Make-up air that iscontaminated by dry cleaning fumes will result inirreparable damage to motors and other dryercomponents.

Exhaust ductwork should be designed and installed by acompetent technician. Improperly sized ductwork will createexcessive back pressure, which will result in slow drying,increased use of energy, and shut down of the burner by theairflow (sail) switch, burner hi-limit or lint chamber hi-heatprotector thermostat. (Refer to appropriate InstallationManual for more details.)

CAUTION: Improperly sized or installed exhaustductwork can create a potential fire hazard.

Compressed Air RequirementsThe dryer requires an external supply of air (2.5 cfm @ 80psi [0.07 cmm @ 5.52 bar) on the steam models, the air isnecessary to operate the damper system. On both steam,as well as the gas model, the air is necessary/required forthe blower air jet operation to clean lint from the impellor/fan (squirrel cage type).

Electrical and Gas RequirementsIt is your responsibility to have all electrical connectionsmade by a properly licensed and competent electrician toassure that the electrical installation is adequate andconforms to local and state regulations or codes. In theabsence of such codes, all electrical connections, materials,and workmanship must conform to the applicablerequirements of the National Electrical Code ANSI/NFPA NO.70-LATEST EDITION or in Canada, the Canadian ElectricalCodes Parts 1 & 2 CSA C22.1-1990 or LATEST EDITION.

IMPORTANT: Failure to comply with these codes orordinances and/or the requirements stipulated in thismanual can result in personal injury or component failure.

The dryer installation must meet the American NationalStandard, National Fuel Gas Code ANSI Z223.1-LATESTEDITION, or in Canada, the Canadian Electrical Codes Parts1 & 2 CSA C22.1-1990 or LATEST EDITION (for ElectricalConnections) as well as, local codes and ordinances, andmust be done by a qualified technician.

NOTE: Undersized gas piping will result in ignitionproblems and slow drying and can create a safety hazard.

The dryer must be connected to the type of gas (natural orL.P.) indicated on the dryer data label. If this informationdoes not agree with the type of gas available, contact thereseller who sold the dryer or contact the factory.

The gas input ratings shown on the dryer data label are forelevations up to 2,000 feet (610 meters), unless elevationrequirements of over 2,000 feet (610 meters) were specifiedat the time the dryer order was placed with the factory. Theadjustment for dryers in the field for elevations over 2,000feet (610 meters) are made by changing the burner orifices.If this adjustment is necessary, contact the reseller whosold the dryer or contact the factory.

NOTE: Any burner changes must be made by a qualifiedtechnician.

Operational Service Check ProcedureTurn on electric power to the dryer.To start dryer:Display will read �READY.�Press �E� on the keypad of microprocessor controller(computer).The dryer will start to run.

NOTE: Pressing keypad �A,� �B,� �C,� �D,� or �F� will alsostart the dryer. Six preprogrammed drying cycles (�A�through �F�) have been stored in the computer�s memory.(Refer to Computer Operator�s Manual for details.)

Make a complete operational check of all the operatingcontrols to assure that the timing is correct, temperatureselection switches are functioning, etc.Make a complete operational check of all safety-relatedcircuits: door switch(es), hi-limit thermostat, sail switch,cycling thermostats, etc.For gas dryers, a gas pressure test should be taken at thegas valve pressure tap of each dryer to assure that the watercolumn pressure is correct and consistent.

NOTE: Water column pressure requirements (measuredat the pressure tap on the gas valve body):

Natural Gas � 3.5 in wc; L.P. Gas � 10.5 in wc

If computer program changes are required, refer to thePhase7 OPL Operator�s Manual (ADC P/N 113193) fordetails.The dryer should be operated through one complete cycleto assure that no further adjustments are necessary andthat all components are functioning properly.Check the electric service phase sequence. While the dryeris operating, check to see if the tumbler is rotating in theproper direction. Looking from the front, the tumbler shouldspin in the clockwise direction. If so, the phasing is correct.If the phasing is incorrect, reverse two leads at connectionsL1, L2, or L3 of power supply to the dryer.

Description of Parts __________________Control Panel (Microprocessor)Opening the control panel will allow access to the majorcomponents, which include the computer board and keypad.The keypad inputs to the computer what temperature andprogram has been selected. The computer controls theentire operation of the machine. It accepts inputs and givesoutputs to various parts throughout the machine.


Gas Burner AssemblyGas heated dryers are equipped with a gas burner assemblyconsisting of four burner tubes, gas valve, ignitor, flame-probe, sail switch, and hi-limit thermostat. The inlet pipingenters through the rear of the dryer on the left-hand side(viewing from the front) and runs to the front of the dryerwhere the gas valve is located.

Reversing Relay PanelLifting the control door will reveal the reversing relay box.Located on the back of the relay box is the reversing relaypanel. Included on this panel is a 4-position terminal block,blower overload, blower contactor, reversing contactor, 24VAC transformer, fuse or circuit breaker, ground lug, andpossibly an arc suppressor board.

Blower Motor and Impellor (Gas and Steam)The impellor is shaft driven. The blower motor drives theshaft on which the impellor is mounted.

Drive MotorThe T.E.F.C. drive motor is located in the right front handcorner of the dryer. It sits on an adjustable base so that themotor can be easily adjusted to the left or right.

NOTE: With the dryer off or no air supply to the damperpiston, the damper is in the cool down mode.

Steam Coil pH LevelNOTE: The normal pH level for copper type steam coilsmust be maintained between a value of 8.5 to 9.5. Forsteel type steam coils the pH level must be maintainedbetween a value of 9.5 to 10.5. These limits are set tolimit the acid attack of the steam coils.

IMPORTANT: Coil failure due to improper pH level willvoid the warranty.

Steam Coil and Damper SystemThe steam coil is constantly charged, thereby eliminatingrepeated expansion and contraction and also provide instantheating to start the drying process. The steam damper,located on top of the steam coil, is the only temperaturecontrolling device in this system. When the steam damperis open, ambient air is drawn through the coil providingheat to the dryer. When the steam damper is closed, ambientair is drawn directly into the tumbler, bypassing the coil,allowing a rapid cool down.



Idler Shaft AssemblyThe idler shaft is located on the left side of the machine andis just above the blower motor. The idler shaft assemblyconsists of one 11-inch (27.94 cm) drive wheel and two pillowblock bearings.

Drive ShaftThe drive shaft is located on the right side and is above thedrive motor. The drive shaft consists of one 11-inch (27.94cm) drive wheel, one pulley, and two pillow block bearings.The purpose of the drive shaft is to drive the tumbler.

Speed Reducing ShaftThe speed reducing shaft is located on the right side and isabove the drive motor. The idler assembly consists of twoidler pulleys. The idler�s main purpose is to reduce thespeed and increase torque provided to the tumbler.

Tumbler Shaft SupportThe tumbler shaft support is located in the rear,approximately at the center of the dryer. The arrangementconsists of a tumbler shaft support bracket, two high impactwheels, tumbler adjustment plate, Teflon® discs, and arotational sensor assembly.

Rotational Sensor AssemblyThe rotational sensor assembly is located in the rear of thedryer. It consists of a magnet and rotational sensor switch,which is mounted to the bearing cap. The magnet isscrewed to the shaft.

The magnetic rotational sensor switch senses the rotation ofthe tumbler.

TumblerThe tumbler consists of four ribs and four perforated panels,along with a front and back, which are welded together as anassembly. The tumbler also consists of a trunnion, whichsupports the tumbler in the rear.


Main Door SwitchWhen the main door opens, the switch will also open,preventing the dryer from operating. The main door switchis a safety device and should never be disabled.

Burner Hi-Limit (Gas Models Only)A burner hi-limit thermostat is located on the burner. This isa manual reset disc-type thermostat set at 330° F (165° C).If the flame in the burner should get too hot, this thermostatwill shut off the burner. This is generally caused by lowairflow through the dryer.

Sail Switch (Gas Models Only)The sail switch is located on the front of the burner box. Asail switch consists of a round damper plate on a lever arm,which is in contact with an electric switch. When the fan/blower comes on, it draws air through the burner box. Thiscreates a negative pressure inside the burner box, and thisnegative pressure pulls in the round damper and activatesthe sail switch.

Tumbler Hi-LimitThis is located in the lint compartment above the lint drawer.This bracket consists of two devices. One is a temperaturesensor probe and the other is a hi-limit thermostat, which isset at 225° F (107° C).



Lint DrawerThe lint drawer is located at the bottom of the dryer in the lintcompartment. Simply grab the lint drawer handle, slide outthe drawer, brush off the lint, and slide the drawer back in.

Lint Drawer SwitchThe lint drawer switch is located in the lint compartment andattached to the side of the lint drawer track. The lint drawerswitch ensures that the dryer will operate only when the lintdrawer is completely closed. This is a safety device andshould never be disabled.

Servicing ______________________________IntroductionAll electrical/mechanical service or repairs should be madewith the electrical power to the dryer disconnected (poweroff).

▲ WARNING!Personal injury could result.

The information provided in this section should not bemisconstrued as a device for use by an untrained personmaking repairs. Service work should be performed bycompetent technicians in accordance with local, state, andfederal codes.

When contacting the factory for assistance, always have thedryer model and serial numbers available.

CAUTION: Observe all safety precautions displayedon the dryer or specified in this manual before andwhile making repairs.

Before considering replacement, make sure that allconnectors are in place and making proper contact.

Computer ControlsTo Replace ComputerDisconnect electrical power to the dryer.

Disconnect main power harness, along with the three otherconnectors located on the computer board, from rear ofcomputer by squeezing locking tab and pulling connectorstraight back.

Disconnect the �green� ground wire and the air jet wire fromthe computer.

Disconnect keypad ribbon from the computer.

Remove the screws securing the computer to the sheetmetal control panel. Remove the board by pulling the othertwo corners off the clinch studs.

Install new computer by reversing this procedure.

Reestablish electrical power to the dryer.


To Replace Keypad Label AssemblyDiscontinue electrical power to the dryer.

Unplug keypad ribbon from rear of computer.

Slowly peel off and remove keypad label assembly fromcontrol panel.

Peel paper backing off new keypad label assembly.

Holding the new keypad label assembly close to the panel,insert the keypad ribbon through the rectangular slot in thecontrol panel. Align label assembly into position by matchingthe red viewing window on the label to the rectangular cutoutin the panel and gently press into place.

Connect keypad ribbon to the computer.


To Replace Microprocessor Temperature Sensor ProbeDiscontinue electrical power to the dryer.

Remove lint drawer. Remove six screws securing lint doorand remove lint door.

Remove microprocessor sensor bracket assembly fromdryer.

Disconnect sensor bracket harness connector.

Remove the four Hex head screws securing bracketassembly to dryer and remove bracket from dryer.

Disassemble sensor probe from bracket assembly byremoving the top push-on fastener securing the probe frombracket. Use a small screwdriver to slowly pry the fasteneroff.

Disconnect the two �orange� wires from the high heat(225° F [107° C]) thermostat, and remove modular bracketconnector, wires, and probe from bracket assembly.

Install new sensor probe assembly (ADC P/N 880251) byreversing procedure.


To Replace Spark Ignitor and Flame-ProbeDiscontinue power to the dryer.

Disconnect high voltage connector and flame-probeconnection from ignitor.

Disassemble ignitor from burner by removing the twoself-tapping screws.

Reverse procedure for installing the new ignitor probe.

NOTE: Before reestablishing power to the dryer, visuallycheck the following: (refer to the illustration below).

Ignition Controls

To Replace Gas Valve(Refer to burner illustration on the next page)Discontinue electrical power to the dryer.

Close shutoff valve(s) in gas supply line.

Disconnect gas valve wiring.

NOTE: Identify location of each wire for correctreinstallation.

Break union connection before gas valve.

Loosen and remove screws (4) securing pipe brackets toburner.

Remove gas valve/manifold assembly from dryer.



To Replace Main Burner OrificesRefer to �To Replace Gas Valve� and follow the steps untilmanifold is removed then unscrew main burner orifices andreplace.

NOTE: Use extreme care when removing and replacingorifices. These orifices are made of brass and are easilydamaged.

Reversing the removal procedure for reinstalling.

▲ WARNING!Test all connections for leaks by brushing on a soapywater solution.Never test for leaks with a flame!!!

To Test and Adjust Gas (Water Column) PressureThere are two types of devices commonly used to measurewater column pressure. They are spring/mechanical-typegauges and manometers. The spring/mechanical-type gaugeis not recommended, because it is easily damaged and notalways accurate. A manometer is simply a glass ortransparent plastic tube with a scale in inches. When filledwith water and pressure applied, the water in the tube risesshowing the exact water column pressure.

NOTE: Manometers are available from the factory byordering ADC P/N 122804.

To Test Gas Water Column Pressure:

Connect water column test gauge connection to gas valvepressure tap (1/8� N.P.T.). This pressure tap is located onthe outlet (manifold) side of the valve.

Start dryer. With burner on, the correct water column readingin inches would be:

Natural Gas � 3.5 in wc; L.P. Gas � 10.5 in wc

To Adjust Water Column Pressure (natural gas only, L.P. gasmust be regulated at source):

Remove the slotted vent cap on the top of the valve.

Turn the slotted adjustment screw, located on the top of thevalve next to the terminals clockwise to increase manifoldpressure and counterclockwise to decrease.

NOTE: If correct water column pressure cannot beachieved, problem may be due to an undersized gassupply line, a faulty or underrated gas meter, etc.

To Convert from Natural Gas to L.P. GasNOTE: All dryers are sold as natural gas, unless otherwisespecified at the time the dryer order was placed. For L.P.gas the dryer must be converted as follows.

Remove the four screws which secure the top cap assembly.This assembly contains the regulator adjustment screw andthe terminal connections.

Replace the top cap assembly with the L.P. version.

To install the new L.P. orifices refer to �Replace Main BurnerOrifices�.

NOTE: Use extreme care when removing and replacingorifices. These orifices are made of brass and are easilydamaged.

Reverse the procedure for reinstalling valve assembly to thedryer.



Remove valve mounting bracket, manifold, and piping fromgas valve.

Reverse procedure for installing new gas valve.

NOTE: There is no regulator provided in an L.P. dryer.The column pressure must be regulated at the source(L.P. tank) or an external regulator must be added to eachdryer.


To Replace Burner TubesRefer to �Replace Gas Valve� and follow the instructions upto �Remove gas valve/manifold assembly from dryer�.

Remove four screws securing manifold rest and removerest.

Remove the screws securing the front flanges of the burnertubes to the burner tube rest.

Remove the screws securing the burner tube rest to theoven and remove this rest.

Remove screws securing the burner box cover plate to theoven and remove this plate.

Remove burner tubes by sliding them out.

Replace by reversing procedure.

ThermostatsTo Replace Burner Hi-Limit Thermostat(Gas Models Only)

IMPORTANT: Under no circumstances should heat circuitsafety devices ever be disabled.

Discontinue electrical power to the dryer.

Disconnect wires from hi-limit thermostat.

Remove screw, washer, and nut securing thermostat to thebracket. Remove thermostat.

Reverse procedure for installing new thermostat.Reestablish electrical power to the dryer.

To Replace Lint CompartmentHi-Heat Protector (225° F [107° C) Thermostat

IMPORTANT: Under no circumstances should heat safetydevices be disabled.


To Replace DSI ModuleDiscontinue electrical power to the dryer.

Remove the wires connected to the terminal strip at thebottom of the module.

Remove the two pal nuts securing the module to the mountingbracket.

Replace module by reversing procedure.




Discontinue electrical power to the dryer.

Remove lint drawer. Remove two screws securing lint doorand remove lint door.

Locate sensor bracket assembly and the four Hex headscrews securing bracket assembly to the tumbler wrapper.

Disconnect sensor bracket harness connector and removebracket assembly from dryer.

Disconnect the two �orange� wires from the thermostat.

Disassemble thermostat from bracket assembly by removingthe two mounting screws, washers, and nuts.

Reverse this procedure for installing a hi-heat protectorthermostat.


NOTE: This is a manual reset thermostat. Beforechanging the thermostat make sure the reset button is in todetermine if the thermostat has failed.

Sail Switch Assembly (Gas Models Only)To Replace Sail SwitchDisconnect electrical power to the dryer.

Remove the two screws which hold sail switch box cover tosail switch box.

Disconnect the two wires from the switch.

Disassemble sail switch from mounting bracket by removingthe two screws securing switch in place.

Reverse this procedure for installing new sail switch. Adjustsail switch as described in the next section.

To Adjust Sail SwitchWith the dryer operating at a high temperature setting, pullthe sail switch away from the burner. The sail switch shouldopen and extinguish the burner. Let the sail switch damperreturn to the burner wall. The sail switch should close torestart the burner ignition cycle. If the sail switch circuit doesnot operate as described, bend the actuator arm of the sailswitch accordingly until proper operation is achieved. Tocheck proper �open� position of sail switch, open main door,manually depress main door switch, and start dryer. Withthe main door open and the dryer operating, the sail switchshould be open, and the burner should not come on.

IMPORTANT: Under no circumstances should heat safetydevices be disabled.

Main Door Assembly AdjustmentThe main door consists of several parts. This includes andupper and lower door, door switch, magnetic closure, cableassembly, turnbuckle, and pulleys. The cable assemblyconnects the two doors and allows them to move together.The turnbuckle is used to adjust the cable assembly andallow the doors to fully close and adjust any slack ifnecessary.

PulleysTo Replace Drive Shaft PulleysDiscontinue electrical power to thedryer.

Remove the lint drawer.

Remove the lint door.

Remove right lint coop wall.

Loosen V-belts, then rotate pulley androll V-belts out of its� grooves.

Remove cap screws from thebushings.

Insert cap screws in tapped removalholes and tighten evenly until bushingbecomes loose on shaft. Refer tofigure �A.�

Remove bushing, pulley, and key.

Assemble bushing and sheave asshown in figure �B�. When cap screwsare loosely inserted, bushingremains fully expanded to provide asliding fit on the shaft.

Insert key on the shaft, then slidesheave to desired position with capscrew heads to the outside.


Tighten cap screws progressively. There should remain agap between the sheave hub and the flange of the bushing.

IMPORTANT: Tighten screws evenly and progressively.Never allow the sheave to be drawn in contact with theflange of the bushing. This gap should measure from 1/8�to 1/4�. Proper cap screw torque is 30 ft.-lb. If greatertightening forces are applied, excess pressures will becreated in the hub of the mounted sheave, which maycause it to crack.

To Replace Motor PulleyDiscontinue electrical power to the dryer.



Loosen V-belts, then rotate pulley and roll V-belts out of its�grooves.

Remove cap screws from bushing.

Insert cap screws in tapped removal holes and tighten evenlyuntil bushing becomes loose on shaft. Refer to figure �A�on the previous page.

Remove bushing, pulley, and key.

Assemble bushing and sheave as shown in figure �B� onthe previous page. When cap screws are loosely inserted,bushing remains fully expanded to provide a sliding fit onthe shaft.

Insert key on the shaft, then slide sheave to desired positionwith cap screw heads to the outside.

Tighten cap screws progressively. There should remain agap between the sheave hub and the flange of the bushing.

IMPORTANT: Tighten screws evenly and progressively.Never allow the sheave to be drawn in contact with theflange of the bushing. This gap should measure from 1/8�to 1/4�. Proper cap screw torque is 6 ft.-lb., if greatertightening forces are applied, excess pressures will becreated in the hub of the mounted sheave, which maycause it to crack.

Tumbler AlignmentDiscontinue electrical power to the dryer.



Remove both the left hand and right hand lint coop walls.

Loosen the V-belts on drive shaft, then rotate pulley and rollV-belts out of its� grooves.

Tighten the two bolts under the drive shaft clockwise to raisethe tumbler and counterclockwise to lower the tumbler. Thebolts should be tightened in even increments in order toensure that the shaft runs parallel with the base of the dryer.

IMPORTANT: Side to side adjustment of the tumblershould be equal on either side of the front panel, butvertically the top of the tumbler should have a larger gapthan the bottom to compensate for the load.

Be sure to tighten the left idler side to the same height asthe right side/drive side. This length can be determined bytaking measurements from the bottom of each pillow blockbearing to the top of the bearing pad.



Remove the four bolts holding the two speed reducing shaftpillow block bearings in place and remove shaft assemblyfrom dryer.

To remove front or rear pulley follow steps in �To ReplaceDrive Shaft Pulleys�.

Loosen and remove the two setscrews in the front/rear pillowblock bearing.

Clean the shaft and slide the bearings off of the shaft.

Install new bearing by reversing these procedures.


To Replace Rear Tumbler Shaft Support WheelsDisconnect electrical power to the dryer.

Remove the four nuts securing the rear support box to thedryer.

Remove the center Allen head bolt and Teflon® washer.

Loosen the individual wheel bolts so the rear of the box canbe removed.

Remove the damaged wheel.

Replace with new wheel.

Reverse steps to replace support box.


NOTE: Don�t over tighten wheel bolts, which could bindbearings.

Clean the shaft and slide the pillow block bearings off of theshaft.

Reverse these steps to install new pillow block bearings.

NOTE: Check belt adjustment and readjust if necessary.

To Replace Speed Reducing Shaft BearingsDiscontinue electrical power to the dryer.



Loosen and roll V-belts off that connect speed reducing shaftto drive shaft.

Loosen and roll V-belts off that connect speed reducing shaftto the drive motor.

NOTE: If the axle height is not the same on the drive andidler side, then the tumbler will be either more to the rightor left side, depending on which axle is higher.

Tighten locking nuts on the adjustment bolts.

Reverse the first five steps for reassembly.

Check tumbler drive belt for proper tension. Adjust ifnecessary.


BearingsTo Replace Drive/Idler Shaft Pillow Block BearingsDiscontinue electrical power to the dryer.



Loosen and roll V-belts off that connect speed reducing shaftto drive shaft.

Place a piece of wood between the tumbler and wrapper tosupport the tumbler when shaft is removed.

Remove the four bolts holding the drive shaft assembly inthe dryer.

Remove cap screws from bushing of drive wheel.

Insert cap screws in tapped removal holes and tighten evenlyuntil bushing becomes loose on shaft.

Remove bushing and key.

Remove wheel from shaft.

Loosen the four setscrews in the pillow block bearings.


Rotational Sensor Switch ReplacementDiscontinue electrical power to the dryer.

Remove the bearing cap from the dryer.

Remove the adjustment nut from the bearing cap.

Remove the magnetic rotational sensor switch from thebearing cap.

Depress the tabs on the rotational sensor harness plugand pull apart, then remove the sensor switch.

To install a new sensor switch, connect the plug of the newsensor switch to the sensor harness.

Place one adjustment nut onto the sensor switch and insertinto the bearing cap.

Place the second adjustment nut on but do not tighten. Themagnet on the flange bearing and the sensor switch mustbe in a horizontal line to one another.

The gap between the magnet and the sensor switch mustbe 1/8-inch.

Tighten the adjustment nuts installed.


Basket and SupportTo Replace Tumbler and Tumbler SupportDiscontinue electrical power to the dryer.

Follow procedure for removal of main door assembly.

Follow procedure for removal of front panel assembly.

To remove tumbler assembly and support, remove the Allenhead bolt and Teflon® washer.

Remove the retaining ring from the groove of the tumblershaft.

Remove the rotational sensor magnet from the tumblersupport shaft.

Remove the tumbler and support assembly from the front ofthe dryer. If the tumbler cannot be removed freely, clean theshaft area and spray WD-40 or similar lubricant. With ablock of wood against the shaft end, strike the block of woodwith a hammer or mallet to move the shaft past any burrsmade by the setscrews.

IMPORTANT: Never strike the shaft directly with ahammer.

Reverse these steps for installation of new tumbler andtumbler support.


V-Belts(See illustrations in �Pulleys� section)V-Belts should have proper tension. If the pulleys are notproperly aligned, excessive belt wear will result. Properbelt tension will allow 1/2� displacement under normalthumb pressure at mid span of belt.

NOTE: Belts must always be replaced in pairs (matchedsets).

V-Belt Replacement(Drive Shaft To Speed Reducing Shaft)Discontinue electrical power to the dryer.



Loosen two bolts securing rear pillow block bearing on thedrive shaft.

Loosen adjustment bolt that is securing the rear pillow blockbearing of the drive shaft.

Loosen two bolts securing rear speed reducing shaftbearing.

Loosen adjustment bolt supplying pressure to the rearbearing on the speed reducing shaft.

Remove old V-belts.

Reverse these steps to install new V-belts.

NOTE: After tensioning the V-belts, check to make sureboth the drive shaft and speed reducing are parallel orlevel to the base of the dryer.

V-Belt Replacement(Motor To Speed Reducing Shaft)Discontinue electrical power to the dryer.



Loosen two bolts securing front bearing on speed reducingshaft.

Loosen tension bolt that is under the front bearing of thespeed reducing shaft.

Remove the V-belts.

Replace V-belts by reversing the above procedures.

V-Belt Replacement(From The Blower Motor To The Fan)Loosen the four bolts securing the motor to the base of thedryer.

Loosen the tension bolts.

Remove old V-belts.

Reverse these steps to replace V-belts.

NOTE: Always replace V-belts in pairs.



MotorsTo Replace Drive MotorDiscontinue electrical powerto the dryer.



Remove the left lint wall.

Remove the drive V-belts. Follow V-belt replacement frommotor to speed reducing shaft.

Loosen the four bolts securing the motor to the base of thedryer.

Disconnect the motor wiring.

Remove old motor pulley and bushing and place on newmotor. Follow �To Replace Motor Pulley�.

Reverse these steps to replace drive motor.

To Replace Impellor Motor(Fan Shaft Drive � 50/60 Hz Gas and Steam Models)Discontinue electrical power to the dryer.



Remove the left hand lint wall.

Loosen the four mounting bolts securing the motor.

Loosen the tension bolts.

Remove V-belts.

Disconnect motor wiring.

Remove the motor pulley and bushing.

Reverse these steps for installation of new motor.

To Replace Fan Shaft and/or Fan Shaft BearingsTo remove from the front, follow the instructions from �ToReplace Impellor Motor�.

Remove the two left-handed jam nuts that hold the impellorto the fan shaft.

Remove the impellor, washers, and the key.

Loosen the four bolts securing the fan shaft assembly tothe base of the dryer.

NOTE: Models with rear access, it may be easier toremove this plate, to remove the two rear fan shaftassembly bolts.

Remove the fan assembly through front access hole.

Loosen the setscrews in each bearing.

Loosen the four flange bolts and two pillow block bolts.

Using a pulley, remove the bearing needing replacing.

Reverse the procedures to reinstall new bearing.

ImpellorDiscontinue electrical power to the dryer.

Remove the left side lint wall if necessary for easier access.

Remove the six nuts securing the inlet cone to the blowerhousing.

Remove the two left-handed jam nuts that hold the impellorto the fan shaft.

Remove the impellor, washers, and the key.

Replace the impellor, key, washers, left-handed jam nuts,and the side panel.



To Replace Lint Drawer SwitchDisconnect electrical power to the dryer.

Remove lint drawer and lint door.

Disconnect both 4-pin connectors at the rear of the lint switchcover.

Remove the one or two screws holding the lint switch coveron.

Remove lint switch cover and disconnect the two terminalsof the switch.

Remove switch by pressing tabs together and push switchout.

Install new switch by reversing procedure.

Troubleshooting ______________________IMPORTANT: You must disconnect and lockout theelectric supply and the gas supply or the steam supplybefore any covers or guards are removed from themachine to allow access for cleaning, adjusting,installation, or testing of any equipment per OSHAstandards.

The information provided will help isolate the most probablecomponent(s) associated with the difficulty described. Theexperienced technician realizes, however, that a looseconnection or broken/shorted wire may be at fault whereelectrical components are concerned...and not necessarilythe suspected component itself.

IMPORTANT: When replacing blown fuses, thereplacement must be of the exact rating as the fuse beingreplaced. The information provided should not bemisconstrued as a handbook for use by an untrainedperson in making repairs.

Lint Drawer AssemblyTo Replace Lint ScreenPull out lint drawer.

Remove lint screen from lint drawer.

Drop new lint screen in place.

Slide lint drawer back into dryer.

▲ WARNING!All service and troubleshooting should be performedby a qualified professional or service agency.While making repairs, observe all safety precautionsdisplayed on the dryer or specified in this manual.

No L.E.D. display on microprocessor controller(computer)...Open circuit breaker switch or blown fuse.

Faulty wiring connection.

Faulty transformer.

Faulty microprocessor controller (computer).

Computer will not accept keypad entries...Keypad ribbon is not plugged into computer securely.

Faulty keypad.

Faulty microprocessor controller (computer).

Dryer will not start, but computerL.E.D. indicators are on...Failed contactors.

Failed arc suppressor board.

Failed microprocessor controller (computer).

Failed motors.

Blower motor runs, burner is on,but tumbler will not turn...Broken, damaged or loose V-belt.

Damaged or misadjusted drive wheels.

Loose or broken pulley.



Dryer operates but is taking too long to dry...Improperly programmed microprocessor controller(computer).

An inadequate exhaust ductwork system.

Restriction in exhaust system.

Insufficient make-up air.

Dirty or clogged lint screen.

Washing machine extractors are not performing properly.

The supply gas may have a low heating value, check withlocal gas supplier.

Failed temperature sensor (temperature calibration isincorrect).

Failed microprocessor controller (computer).

Thermal overload for drive motor is tripping...Either an exceptionally low or high voltage supply.

Motor bearing failure.

Motor vents are blocked with lint.

Failed motor.

Failed overload.


Overload for impellor (fan) motor is tripping...Either an exceptionally low or high voltage supply.

Motor bearing failure.

Motor vents are blocked with lint.

Failed motor.

Failed overload.

Out of balance impellor (fan).


Burner hi-limit safety thermostat is tripping...Insufficient exhaust ductwork, size or restriction in exhaustsystem.


Lint screen needs cleaning.

Damaged impellor.

Dryer does not start. Display reads �main door�or �lint door� with an audio indication...Main door is open.

Lint drawer is open.

Faulty main door or lint door switch.

Open circuit in either main door or lint drawer switchharnesses.

Faulty 24 VAC transformer.

There is excessive vibration coming from the tumbler...Tumbler is out of adjustment.

Drive shaft or idler shaft is out of alignment.

Faulty pillow block bearing or 4-inch (10.16 cm) rear wheel.

Faulty tumbler wheel.

Drive motor and shaft not aligned.

Phase 7 OPL System Diagnostics ___IMPORTANT: You must disconnect and lockout theelectric supply and the gas supply or the steam supplybefore any covers or guards are removed from themachine to allow access for cleaning, adjusting, installation,or testing of any equipment per OSHA standards.

All major circuits, including door, microprocessortemperature sensor, heat and motor circuits are monitored.The Phase 7 OPL microprocessor controller (computer) willinform the user, via the L.E.D. display of certain failuremessages, along with L.E.D. indicators on the Input/Outputboard on the back panel of the front right control door.

Diagnostic (L.E.D. Display) Fault MessagesBURNER CONTROL FAULT � This routine monitors the gasreturn valve signal and compares it with the DSI purge timesetting. If the gas return valve signal does not turn on beforethe DSI purge time expires, or if it turns on for less than 200ms, the Phase 7 non-coin microprocessor controller(computer) will turn off the heat output, increase a counter,and wait the interpurge time before reattempting to ignitethe burner. Once this fault condition occurs five (5)consecutive times, the Phase 7 non-coin microprocessorcontroller (computer) will interrupt the cycle and will display�BURNER CONTROL FAULT� and will go into a Fault Modewith a brief audio indication. If the tumbler temperature isabove 100° F (38° C) at the time of the failure, the Phase 7non-coin microprocessor controller (computer) will continueto display �BURNER CONTROL FAULT�, while the dryer coolsby running with no heat for 3 minutes or until the temperaturedrops below 100° F (38° C). If the tumbler temperature isbelow 100° F (38° C), or the 3 minutes expire, the Phase 7non-coin microprocessor controller (computer) will shut offall outputs and will remain in Fault Mode until the dryer isaddressed.


BURNER HIGH-LIMIT FAULT � This routine monitors theburner high-limit switch. If the switch opens during the cyclewhile the heat is on, the dryer will display �Burner High-Limit Fault� and will go into Fault Mode with a brief audioindication. The Phase 7 non-coin microprocessor controller(computer) will check the tumbler temperature. If the exhaustprobe temperature is above 100° F (38° C), the dryer willcontinue to display �Burner High Limit Fault�, while the dryercools by running with no heat for 3 minutes or until thetemperature drops below 100° F (38° C). Once the exhaustprobe temperature is below 100° F (38° C), or the 3 minutesexpire, the Phase 7 non-coin microprocessor controller(computer) will shut off all outputs and will remain in FaultMode until the dryer is addressed.

CHECK CONTROL BOARD FUSE #2 � This routine identifiesthe opening of the main fuse (fuse 2) on the Phase 7 non-coin microprocessor controller (computer) board. If the fusehas opened, the Phase 7 non-coin microprocessorcontroller (computer) will not allow a cycle to begin and willdisplay a �Check Control Board Fuse #2� condition. If thefuse has opened after the cycle has begun, it will still triggerthe check main fuse fault. The dryer will shut off all outputsand will go into Fault Mode with a brief audio indication.

CLEAN LINT � This routine monitors the opening of the lintdrawer switch and compares the time between openings tothe Lint Cleaning Frequency Setting. This routine will firstprompt the user to clean lint before locking out the dryer.Once the time between cleanings is equal to the LintCleaning Frequency Setting, the display will prompt the userto clean lint. The Lint Cleaning Frequency limits the amountof time the dryer will run before the Phase 7 non-coinmicroprocessor controller (computer) locks the dryer outfor further use. If the lint drawer is not cleaned within 2hours of run time, the Phase 7 non-coin microprocessorcontroller (computer) will be locked out.

EXHAUST HIGH-LIMIT FAULT � This routine monitors thetumbler safety over temperature switch. If the switch opens,the dryer will display �Exhaust High-Limit Fault� and will gointo Fault Mode with a brief audio indication. If the tumblertemperature is above 100° F (38° C) the dryer will continueto display �Exhaust High-Limit Fault�, while the Phase 7non-coin microprocessor controller (computer) cools byrunning with no heat for 3 minutes or until the temperaturedrops below 100° F (38° C). Once the tumbler temperatureis below 100° F (38° C), or the 3 minutes expire, the Phase7 non-coin microprocessor controller (computer) will shutoff all outputs and will remain in Fault Mode until the dryer isaddressed.

EXHAUST PROBE FAULT � This routine indicates a problemwith the temperature sensor circuit. This error will triggeran �Exhaust Probe Fault� condition and will go into a FaultMode with a brief audio indication. The dryer will run with noheat for 3 minutes. Once the 3 minutes expire, the Phase 7non-coin microprocessor controller (computer) will shut offall outputs and will remain in Fault Mode until the dryer isaddressed.

IGNITION FAULT � After the Phase 7 non-coin microprocessorcontroller (computer) receives a gas valve return for morethan 200 ms signal within the DSI purge time, the Phase 7non-coin microprocessor controller (computer) will begin aDSI proof time. The Phase 7 non-coin microprocessorcontroller (computer) will continue to recheck the gas valvereturn signal. If the signal is lost during the DSI proof time,the Phase 7 non-coin microprocessor controller (computer)will turn off the heat output and determine what the retrycount is set at. If the retry count is greater than zero, thePhase 7 non-coin microprocessor controller (computer) willwait through the interpurge time and attempt to reignite theflame. If the failure condition occurs again, the Phase 7non-coin microprocessor controller (computer) will retry untilthe retry count has been satisfied. Once the retry count hasbeen satisfied, the Phase 7 non-coin microprocessorcontroller (computer) will interrupt the cycle and display�Ignition Fault� condition and go into a Fault Mode with abrief audio indication. If the tumbler temperature is above100° F (38° C), the Phase 7 non-coin microprocessorcontroller (computer) will continue to display �Ignition Fault�,while the dryer cools by running with no heat for 3 minutesor until the temperature drops below 100° F (38° C). Oncethe tumbler temperature is below 100° F (38° C), or the 3minutes expire, the Phase 7 non-coin microprocessorcontroller (computer) will shut off all outputs and will remainin Fault Mode until the dryer is addressed.

FLAME FAULT � After the Phase 7 non-coin microprocessorcontroller (computer) has verified that the gas valve signalwas present throughout the DSI purge time and the DSIproof time, the Phase 7 non-coin microprocessor controller(computer) will continue to monitor the gas valve returnsignal. In the event that the gas valve return signal is lostanytime after the DSI proof time, the Phase 7 non-coinmicroprocessor controller (computer) will turn off the heatoutput and increase a counter. Once this fault conditionoccurs five (5) consecutive times, the Phase 7 non-coinmicroprocessor controller (computer) will interrupt the cycle,display �Flame Fault� condition, and go into a Fault Modewith a brief audio indication. If the tumbler temperature isabove 100° F (38° C), the Phase 7 non-coin microprocessorcontroller (computer) will continue to display �Flame Fault�,while the dryer cools by running with no heat for 3 minutesor until the temperature drops below 100° F (38° C). Oncethe tumbler temperature is below 100° F (38° C), or the 3minutes expire, the Phase 7 non-coin microprocessorcontroller (computer) will shut off all outputs and will remainin Fault Mode until the dryer is addressed.

BURNER PURGE FAULT � If the Phase 7 non-coinmicroprocessor controller (computer) detects the presenceof the gas return signal before sending the heat signal out,the Phase 7 non-coin microprocessor controller (computer)will trigger a �Burner Purge Fault� condition and will go intoFault Mode with a brief audio indication. The dryer will runwith no heat for 3 minutes or until the temperature dropsbelow 100° F (38° C). Once the tumbler temperature isbelow 100° F (38° C), or the 3 minutes expire, the Phase 7non-coin microprocessor controller (computer) will shut offall outputs and will remain in Fault Mode until the dryer isaddressed.



EXHAUST HIGH TEMP FAULT � This error routine indicatesa problem with overheating. This error will initiate an�Exhaust High Temp Fault� condition and will go into FaultMode with a brief audio indication. The Phase 7 non-coinmicroprocessor controller (computer) determines this errorby monitoring the temperature sensor input to have a steadygradual increase in temperature to a known upper limit(the limit typically is 20° over the maximum allowedprogrammable set point). The dryer will run with no heat for3 minutes or until the temperature drops below 100° F (38°C). Once the tumbler temperature is below 100° F (38° C),or 3 minutes expire, the Phase 7 non-coin microprocessorcontroller (computer) will shut off all outputs and remain inFault Mode until the dryer is addressed.

LINT ACCESS OPEN � Indicates the lint drawer is open andneeds to be closed.

MAIN DOOR OPENED � Indicates the main door is openwhen it should be closed.

MODEL ERROR, ENTER CORRECT MODEL � This routinemonitors the inputs, such as the sail switch and gas valve.Steam dryers do not use a sail switch or valve input, and anelectric dryer will not use a gas valve input. These signalsallow the Phase 7 non-coin microprocessor controller(computer) to interpret what type of dryer it is controlling.The Phase 7 non-coin microprocessor controller (computer)determines what the expected dryer responses should befor that specific heat type dryer. Anytime a model fault isdetected, the Phase 7 non-coin microprocessor controller(computer) will interrupt the cycle and will display �ModelError, Enter Correct Model�� and go into Fault Mode with abrief audio indication. If the tumbler temperature is above100° F (38° C) at the time of the failure, the Phase 7 non-coin microprocessor controller (computer) will continue todisplay �Model Error, Enter Correct Model�� while the dryercools by running with no heat for 3 minutes or until thetemperature drops below 100° F (38° C). Once the tumblertemperature is below 100° F (38° C), or the 3 minutes expire,the Phase 7 non-coin microprocessor controller (computer)will shut off all outputs and will remain in Fault Mode untilthe dryer is addressed.

NOTE: If a model error occurs, the Phase 7 non-coinmicroprocessor controller (computer) will always default tothe �gas� type for safety reasons. Also, the dryer will bestopped and forced into a restart condition to reevaluateall the expected responses.

ROTATION SENSOR FAULT � This routine monitors thepulses from the rotational sensor input. It basically timesthe dwell between signals. If the time between the pulsesexceeds 10-seconds, the Phase 7 non-coin microprocessorcontroller (computer) will trigger a �Rotation Sensor Fault�condition and will go into Fault Mode with a brief audioindication. Depending on the model type, the dryer will runthe fan with no heat for 3 minutes or until the temperaturedrops below 100° F (38° C) for GAS REVERSING, ELECTRICREVERSING and STEAM REVERSING models. Once thetumbler temperature is below 100° F (38° C), or the 3minutes expire, the Phase 7 non-coin microprocessorcontroller (computer) will shut off all outputs and remain inFault Mode until the dryer is addressed. If the dryer modelis a GAS NON-REVERSING, ELECTRIC NON-REVERSINGor STEAM NON-REVERSING model, the Phase 7 non-coinmicroprocessor controller (computer) will immediately shutoff all outputs, regardless of the tumbler temperature, andremain in Fault Mode until the dryer is addressed.

SAIL SWITCH CLOSED FAULT � This routine prevents thestart-up of the dryer unless the sail switch is in the openposition. If the sail switch is in the closed position prior tostarting, the Phase 7 non-coin microprocessor controller(computer) will display �PLEASE WAIT START UP INPROCESS� and will allow the Phase 7 non-coinmicroprocessor controller (computer) 10-seconds for thesail switch to open before faulting out on a �Sail SwitchClosed Fault�. Once the dryer faults out on the �Sail SwitchClosed Fault�, the dryer will not be allowed to start. Thisroutine is also monitored at every start-up, including a start-up after being in Pause Mode. If the sail switch is in theclosed position prior to starting from a Pause Mode, thePhase 7 non-coin microprocessor controller (computer) willdisplay, �PLEASE WAIT RESTART IN PROCESS� and allowthe Phase 7 non-coin microprocessor controller (computer)10-seconds for the sail switch to open before faulting outon a �Sail Switch Closed Fault�. Again, once the dryer faultsout on the �Sail Switch Closed Fault�, the dryer will not beallowed to start. Anytime the fault occurs, there will be anaudio indication and start/restart will be prevented.

SAIL SWITCH OPEN FAULT � If the sail switch does notclose within 8-seconds of starting or restarting a cycle, thePhase 7 non-coin microprocessor controller (computer) willdisplay �Sail Switch Open Fault� condition. Or, if the sailswitch opens during a cycle, the Phase 7 non-coinmicroprocessor controller (computer) will immediately shutoff the heat output and monitor how long the sail switch isopen for. If the sail switch is open for more than 30-seconds,the Phase 7 non-coin microprocessor controller (computer)will display �Sail Switch Open Fault� condition and go intoFault Mode with a brief audio indication. If the tumblertemperature is above 100° F (38° C), the Phase 7 non-coinmicroprocessor controller (computer) will continue to display�Open Sail Switch Fault� while the dryer cools by runningwith no heat for 3 minutes or until the temperature dropsbelow 100° F (38° C). Once the tumbler temperature isbelow 100° F (38° C), or the 3 minutes expire, the Phase 7non-coin microprocessor controller (computer) will shut offall outputs and remain in Fault Mode until the dryer isaddressed.

F.S.S. SYSTEM ACTIVATED � Indicates that the Phase 7 non-coin microprocessor controller (computer) has detected afire and is currently extinguishing the flame.

F.S.S. SYSTEM WAS ACTIVATED � Indicates that the Phase7 non-coin microprocessor controller (computer) detecteda fire and has extinguished the flame.

F.S.S. System Diagnostic ConditionsIn the event that the Phase 7 non-coin microprocessorcontroller (computer) detects a fault in the F.S.S. system,the Phase 7 non-coin microprocessor controller (computer)will display the message �F.S.S. SYSTEM DISABLED �READY�. To find the reason for the F.S.S. system disabling,press and hold the red �STOP/CLEAR� and green �START/ENTER� keys. Doing so will cause the Phase 7 non-coinmicroprocessor controller (computer) to display one (1) ofthe following diagnostic messages:

OPEN THERMISTOR PROBE � This message indicates thatthe F.S.S. system thermistor probe is either not connectedor is damaged. If this condition is detected, the Phase 7non-coin microprocessor controller (computer) willimmediately enter F.S.S. SYSTEM DISABLED Mode.


SHORTED THERMISTOR PROBE � This message indicatesthat the F.S.S. system thermistor probe is damaged or thewiring is shorted. If this condition is detected, the Phase 7non-coin microprocessor controller (computer) willimmediately enter F.S.S. SYSTEM DISABLED Mode.

DISCONNECTED WATER VALVE � This indicates that thewater valve is open or that it is not connected to the Phase 7non-coin microprocessor controller (computer). If thiscondition is detected, the Phase 7 non-coin microprocessorcontroller (computer) will continue to monitor the conditionfor a period of 5 minutes before entering F.S.S. SYSTEMDISABLED Mode. Once the condition is corrected, the Phase7 non-coin microprocessor controller (computer) willcontinue to monitor the condition for 1 minute before exitingF.S.S. SYSTEM DISABLED Mode.

SHORTED WATER VALVE � This indicates the water valve isshorted or the wiring to the valve is shorted. If this conditionis detected, the Phase 7 non-coin microprocessor controller(computer) will continue to monitor the condition for a periodof 5 minutes before entering F.S.S. SYSTEM DISABLEDMode. Once the condition is corrected, the Phase 7 non-coin microprocessor controller (computer) will continue tomonitor the condition for 1 minute before exiting F.S.S.SYSTEM DISABLED Mode.

WATER NOT CONNECTED � This indicates that there is nowater pressure at the water valve. This will occur if water isnot connected to the dryer or if there is low water pressurein the water line coming to the dryer. This could also be adefective pressure switch or wiring to the pressure switch.If this condition is detected, the Phase 7 non-coinmicroprocessor controller (computer) will continue tomonitor the condition for a period of 5 minutes beforeentering F.S.S. SYSTEM DISABLED Mode. Once thecondition is corrected, the Phase 7 non-coin microprocessorcontroller (computer) will continue to monitor the conditionfor 1 minute before exiting F.S.S. SYSTEM DISABLED Mode.

I/O Board L.E.D.INDICATORSInputs (Red L.E.D.)1. ESTOP � This L.E.D. will indicate the status of the E-

STOP. If the E-STOP has been pressed, then the L.E.D.is ON.

2. GAS_V � This L.E.D. will indicate the status of the gasvalve. If the gas valve is open (ON), then the L.E.D. isON.

3. BRHL � This L.E.D. will indicate the status of the burnerhigh limit disk. If the disk is closed (temperature below330° F [166° C]), then the L.E.D. is ON.

4. SAIL � This L.E.D. will indicate the status of the sailswitch. If the switch is closed, then the L.E.D. is ON.

5. EXHL � This L.E.D. will indicate the status of the exhausthigh limit disk. If the disk is closed (temperature below225° F [107° C]), then the L.E.D. is ON.

6. MAIN � This L.E.D. will indicate the status of the maindoor. If the door is closed, then the L.E.D. is ON.

7. LINT � This L.E.D. will indicate the status of the lintdrawer. If the drawer is closed, then the L.E.D. is ON.

8. FUSE � This L.E.D. will indicate the status of the Phase7 non-coin microprocessor controller (computer)voltage. If the power on button is pressed (green buttonlight is on), then the L.E.D. is ON.

9. H2O � This L.E.D. will indicate the status of the waterpressure switch on the F.S.S. system water line. If waterpressure is present, then the L.E.D. is ON.

A. The display reads �Exhaust High Limit Fault�.The temperature in the tumbler is above 220° F (104° C) orfollow Steps #1 through #3.

1. Check for voltage (24 VAC) at the computer on the J5connector from pin 1 to ground. If no voltage is present,either you have a poor connection at the J5 connector orthe computer board is faulty. If voltage (24 VAC) ispresent, proceed to Step #2.

2. Check for voltage at the exhaust high limit thermostat. Ifvoltage is present at only one side the thermostat isopen and needs to be replaced. If voltage is present atboth sides, proceed to Step #3.

3. Check for voltage at the J5 connector pin 2 to ground. Ifno voltage is present, check for a loose wire betweenthe J5 connector and thermostat. If voltage is presentthen the computer board is bad and needs to bereplaced.

B. The display reads �Burner High Limit Fault�.1. Indicates the tumbler hi-limit has tripped.

2. Check for a block or restriction in the exhaust.

3. Make sure the exhaust is properly sized.

4. Make sure location has adequate make-up air.

5. Check for voltage (24 VAC) at the computer board J4connector pin 3 red wire to ground. If no voltage (24VAC), check for a loose connection or change thecomputer board. If voltage is present, proceed to Step#6.

6. Check for voltage at the burner high limit thermostat(the sail switch must be closed at time of test). If voltageis present at only one side the thermostat is open andneeds to be replaced. If voltage is present at both sides,proceed to Step #7.

7. Check for voltage at the J4 connector pin 4 to ground. Ifno voltage is present, check for a loose wire betweenthe J4 connector and thermostat. If voltage is presentthen the computer board is bad and needs to bereplaced.

C. The display reads �Bad Exhaust Temp Probe�.1. Check for a loose connection or short between the

computer J3 connector pins 1 and 2, and the pinconnections 1 and 2 of P11 and J11, which lead to thetemperature sensor probe.

2. If connections are fine, next change the temperaturesensor probe.

3. If the display still reads �Bad Exhaust Temp Probe,�change the computer board.

D. The display reads �Sail Switch Open Fault�.1. The sail switch has opened while dryer is in the heating

mode. Is the blower motor running normally? If nottroubleshoot blower motor.

2. Check for block or restriction in the exhaust.



3. Make sure exhaust is sized properly.

4. Clean the lint screen.

5. Make sure all doors and access panels are closed andsealed well.

E. The display reads �Sail Switch Closed Fault�.1. Prior to start up, the sail switch is in the closed position.

Is the switch stuck, if so free up the mechanism andcheck for moisture or broken components.

2. Check the sail switch and readjust accordingly.

3. Replace sail switch, if necessary.

F. The display reads �Burner Ignition Control Fault�.1. Check for 24 VAC at the DSI module across MV and

GND during the ignition process. If no voltage, replacethe DSI module. If voltage is present, check for 24 VACat the gas valve on terminals 1 and 2. If no voltage,check for a loose connection on the wires going back tothe DSI module. If voltage is present, proceed to Step#2.

2. Check for voltage at J4 connector pin 6 during the ignitionprocess. If no voltage check for a loose connectionbetween the gas valve and computer connection at J4. Ifvoltage is present replace the computer board.

G. Tumbler will not rotate display reads�Rotation Fault�.

1. Does the tumbler turn? If so check the list below, If notproceed to step two.

a. Rotational sensor is out of adjustment.

b. Rotational sensor magnet is missing or broke.

2. Check the list of items that will stop the tumbler fromturning below.

a. Belt is broke, loose, or slipping

b. Check for 24 VAC at the computer board J8connector pin 8 brown wire to GND. If no voltage ispresent, check for a loose connection, if connectionis good, replace computer. If voltage is present,proceed to next step.

3. Check for 24 VAC on the motor contactor. If no voltage,check for a loose connection in the wire. If voltage ispresent, replace contactor.

H. Drive motor operates in forward mode,but does not reverse, blower motor runs.The display reads �Rotation Fault�.*

1. Possible causes:

a. Belt is loose or slipping.

b. Rotational sensor is out of adjustment.

c. Check for 24 VAC at the computer board J8connector pin 9 gray wire to GND. If no voltage ispresent, check for a loose connection, if connectionis good, replace computer. If voltage is present,proceed to next step.

2. Check for 24 VAC on the drive motor contactor. If novoltage, check for a loose connection in the wire goingback to the relay. If voltage is present, replace contactor.

I. The display reads �Cycle Paused, Main Door Open�.1. Make sure main door is closed.

2. Make sure main door has good contact with the maindoor switch.

3. Check for voltage (24 VAC) at the computer board J8connector pin 5. If no voltage, check for a looseconnection or change the computer board. If voltage ispresent, proceed to Step #4.

4. Check for voltage to the main door switch. If voltage ispresent check that the switch has continuity whendepressed, if not replace switch. If switch has continuityproceed to Step #5.

5. Check for voltage (24 VAC) at the computer board J8connector pin 6. If no voltage, check for a looseconnection between the switch and the computer. Ifvoltage is present change the computer board.

J. The display reads �Cycle Paused, Lint AccessOpen�.

1. Make sure lint drawer is closed.

2. Make sure lint drawer has good contact with the switch.

3. Check for voltage (24 VAC) at the computer board J8connector pin 3. If no voltage, check for a looseconnection or change the computer board. If voltage ispresent, proceed to Step #4.

4. Check for voltage to the lint drawer switch. If voltage ispresent check that the switch has continuity whendepressed, if not replace switch. If switch has continuityproceed to Step #5.

5. Check for voltage (24 VAC) at the computer board J8connector pin 4. If no voltage, check for a looseconnection between the switch and the computer. Ifvoltage is present change the computer board.


Keypad Layout1. Dot Matrix Display

2. A-F Preprogrammed Cycles

3. Stop/Pause Button

4. Start Button

5. Increment Button

6. Decrement Button

7. One time Auto (Dryness level) and Manual (Timed) Cycle

NOTE: Fuse 1 is for computer power rated at 1/2-Amp. Iffuse blows, it is a computer board fault. Fuse 2 is for 24Vcontrol power rated at 5-Amp. If fuse blows, it is a 24Vcontrol fault.

F.S.S. System Theory Of OperationWhile the dryer is in an idle state or 20-seconds after theheat turns off, the Phase 7 control monitors the F.S.S. systemprobe located in the top of the tumbler chamber and recordsthe minimum temperature. If the minimum recorded F.S.S.system probe temperature is no less than 120° F (48° C)and the control detects a 50° rise in temperature, this willbe the trip point and the F.S.S. system routine will activate.

While a drying cycle is in process and the heat has turnedon at least once, the Phase 7 control monitors the exhausttemperature transducer. If the drying cycle temperature setpoint is set greater than 160° F (71° C) and the control detectsan exhaust temperature rise 25° F greater than set point,this will be the trip point and the F.S.S. system routine willactivate. If set point is below 160° F (71° C) the trip point willbe 185° F (85° C).

Once the F.S.S. system routine is activated, water will beinjected into the tumbler chamber. Anytime water is beinginjected into the tumbler; the tumbler drive will turn the loadfor 1-second every 15-seconds. This process will continuefor a minimum of 2 minutes. After 2 minutes has elapsed,the control will check if the temperature remained above trippoint, if so water will remain on. The control will continue tocheck if temperature is above trip point every 30-seconds. Ifthe water has been on for a constant 10 minutes, the waterwill be turned off regardless of the temperature. If thetemperature has dropped below trip point, the control willturn off the water prior to 10 minutes.

System ResetAfter the microprocessor determines that the situation isunder control and shuts the water being injected into thetumbler off, the microprocessor display will read �F.S.S.System activated�, and the horn/tone will sound until resetmanually.

To reset the microprocessor once the control displays �F.S.S.System activated�, press the red key on the keypad.

Non-Coin F.S.S. System Check ProcedureThe operation of the water solenoid valve can be tested toensure that the water supply system and valve are functional.Before attempting system check, be sure that all water supplyshutoff valves to the dryer are in the OPEN position, and thedryer must be in the �READY� mode where no cycle is loadedor in progress.

The procedure is as follows:

1. Press and hold the RED STOP key (while in �READY�mode and no cycle in progress).

2. Press and hold the �A� key.

3. Water valve will open and water will be dispensed intotumbler area as long as both keys are held.

IMPORTANT: This is a test function only and the keysshould be held and system activated for only a second orso, otherwise water will accumulate in various places inthe dryer.



Static PressureThe pressure of the air in sheet metal ducts is of greatimportance for safe and efficient operation of the dryer. Theair pressures, as small as they are, have a large influenceupon the performance of the dryer. There are three (3)pressures present within a duct. The velocity pressure,which is the pressure due to the moving stream of air, thestatic pressure, which is the outward push of the air againstthe walls of the duct, and the total pressure, which is thesum of the static and velocity pressures. Only the total andstatic pressures can be measured. The velocity pressureis then calculated from the difference between the two. Thestatic pressure is the most influential and determining factorin the design of a dryer duct system. ADC recommends thatthe dryer exhaust duct static pressure not exceed 0.3 in WC(0.74 mb).

Gages used to measure such small air pressures utilizethe elevation of a column of water. This form of gage iscalled a manometer. One form of this gage is known as aU-tube and is shown in Illustration #1. When one end ofthe tube is connected to the duct, the static (outward)pressure within the duct forces the water column to bedepressed in one leg of the U-tube and up in the other. Theelevation of the water column in Illustration #1 is 3.2 inches(8 mb).

Illus. #1

Using a MagnehelicWhen measuring such small air pressures, the U-tube isoften not accurate enough. Such small differences inpressure are most often measured by an inclined tubemanometer or a Magnehelic pressure gage as shown inIllustration #2.

Illus. #2

For convenience and accuracy, an instrument known as aPitot tube is used with the gage. The Pitot tube, as shown inIllustration #3, consists of two tubes � one within the other.The inner tube measures the total pressure alone, whilethe outer tube measures the static pressure alone.

Illus. #3

To obtain the most accurate static pressure readings of adryer, the following guidelines should be conformed to. Thereading should be taken in a straight section of duct, aminimum of ten (10) times the diameter of the duct (i.e.10-inches [25.4 cm] diameter duct, a straight section100-inches [254 cm] in length). The reading should betaken a minimum of 8-1/2 times the diameter upstream ofthe dryer or nearest elbow, and 1-1/2 times the diameterdownstream of the Pitot tube. The following is an exampleshowing the proper location to take a static pressure reading.


In designing a dryer exhaust duct system, it is not necessaryto compute the friction loss of the ductwork. The frictionloss (static pressure) is predetermined to not exceed 0.7 inWC (1.7 mb). This maximum allowable static pressure isthe same for all model dryers and is calculated to providemaximum dryer efficiency. It is necessary to determine thetotal equivalent length of the duct system. The totalequivalent length of the duct system is the actual length ofthe duct added to the equivalent length of all the fittings.The equivalent length of a fitting, is the length of straightduct of the same size as the fitting in which the friction lossesare equal. Equivalent lengths must be determined for allelbows, as well as, any entries which may be incorporatedinto a common duct system for multiple dryers. The totalequivalent length is then used with the total cfm exhaustrating of the dryer(s) to calculate the minimum round ductdiameter. When designing a single common duct systemfor multiple dryers, each individual dryer exhaust duct entersthe main common duct.

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Data LabelWhen contacting ADC, certain information is required toensure proper service/parts information. This information ison the data label, located on the top right corner of the dryer,viewed from the rear (refer to illustration). When contactingADC, please have the model number and serial numberreadily accessible.

Information on the Data LabelA. Model number � The model number is an ADC number

which describes the size of the dryer and the type ofheat (gas or steam).

B. Serial number � The serial number allows ADC to gatherinformation on your particular dryer.

C. Manufacturing code number � The manufacturing codenumber is a number issued by ADC, which describesall possible options on your particular model.

D. Type of heat � Describes the type of heat; gas (naturalor L.P.), steam or electric.

E. Heat input � (For gas dryers) describes the heat inputin British Thermal Units.

F. Electric service � Describes the electric service for yourparticular models.

G. Gas manifold pressure � Describe the manifold pressureas taken at the gas valve pressure tap (refer to �Using aManometer�).

Tool List

Straight Head Screwdriver

Phillips Head Screwdriver

Sensor Pin and Socket Tool (P/N 122801)

Pliers

1/4� Nut Driver

3/8� Open End Wrench


5/8� Deep Socket Wrench

3/8� Socket Wrench

1/2� Socket or Open End Wrench



1/2� Socket Wrench


5/16� Nut Driver

12� Pipe Wrench (2)

1/8� �T� Shaped or �L� Shaped Allen Wrench

3/16� �T� Shaped or �L� Shaped Allen Wrench

Wire Cutters

1/2� Allen Wrench

3/8� Allen Wrench

Channel Locks

Manometer (ADC P/N 122804)

MP Pin Extraction Tool (ADC P/N 122800)

Technical Information ________________The following section contains various technical informationimportant to the service person in servicing and maintainingthe dryer.

Motor Plate (High and Low Voltage)The motor plate is located on the side of the drive motor(refer to the illustration below) and contains a graphicalrepresentation of the motor wiring for both low voltage ratingand high voltage rating.

Removing the cap reveals the wiring to the motor. On eachwire there is a number which corresponds to the numberson the motor plate. Depending on whether the dryer isoperating on low voltage or high voltage, the wiring shouldmatch the motor plate as follows:

The following is an example. You should follow theinformation on your specific motor.The dots and lines represent connections (refer to theillustration). For example:

On Low Voltage: wire #14 is connected to wire #4

� Wire #1 is connected to wire #7, which in turn are bothconnected to L1

On High Voltage: wire #14 is insulated or capped

� Wire #4 is connected to wire #7

� Wire #1 is connected to L1

Example


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ADC Part No. 450457 1 - 07/10/15

ML-202 Service Manual

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Transcript of ML-202 Service Manual