American Dryer Corp. | AD-840 | Operator`s manual | American Dryer Corp. AD-840 Operator`s manual

American Dryer Corp. AD-840 Operator`s manual
AD-840
Electrical Troubleshooting
Manual
1998
American Dryer Corporation
88 Currant Road
Fall River, MA 02720-4781
Telephone: (508) 678-9010 / Fax: (508) 678-9447
E-mail: techsupport@amdry.com
010998WS/tf
ADC Part No. 182731
Retain This Manual In A Safe Place For Future Reference
American Dispensing Company products embody advanced concepts in engineering, design, and safety. If
this product is properly maintained, it will provide many years of safe, efficient, and trouble-free operation.
ONLY properly licensed technicians should service this equipment.
OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the installation/operator's
manual included with the dryer.
WARNING: UNDER NO CIRCUMSTANCES should the door switch or the heat circuit devices
ever be disabled.
We have tried to make this manual as complete as possible and hope you will find it useful. ADC reserves the
right to make changes from time to time, without notice or obligation, in prices, specifications, colors, and material,
and to change or discontinue models.
Important
For your convenience, log the following information:
DATE OF PURCHASE
MODEL NO.
AD-840
DISTRIBUTORS NAME
Serial Number(s)
Replacement parts can be obtained from your distributor or the ADC factory. When ordering replacement parts
from the factory, you can FAX your order to ADC at (508) 678-9447 or telephone your orders directly to the
ADC Parts Department at (508) 678-9010. Please specify the dryer model number and serial number in
addition to the description and part number, so that your order is processed accurately and promptly.
IMPORTANT
YOU MUST DISCONNECT and LOCKOUT THE ELECTRIC
SUPPLY BEFORE ANY COVERS or GUARDS ARE REMOVED FROM
THE MACHINE TO ALLOW ACCESS FOR CLEANING, ADJUSTING,
INSTALLATION, or TESTING OF ANY EQUIPMENT per OSHA
(Occupational Safety and Health Administration) STANDARDS.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
AD-840. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION.
FOR YOUR SAFETY
THE SYSTEM IS SHIPPED WITH A PRESERVATIVE SOLUTION MADE
OF SODIUM BISULFITE AND (IN THE WINTER MONTHS) GLYCERINE.
MAKE SURE THE SYSTEM IS THOROUGHLY PURGED BEFORE LETTING ANYONE DRINK THE DISPENSED WATER.
REFER TO THE INSTALLATION SECTION ON PURGING PROCEDURE.
CAUTION
Never look directly into the unprotected parts of the U.V. chamber when there
is power to the sterilizer. Serious burns to the eyes and the skin may result.
Always unplug power to the sterilizer before working on it.
IMPORTANT
Please observe all safety precautions displayed on the equipment and / or specified
in the installation / operators manual included with the AD-840.
IMPORTANT
The wiring diagram for the water vending machine is located behind the coin
control door.
Water vending machine(s) must not be installed or stored in an area where it
will be exposed to water and / or weather.
Table of Contents
MICROPROCESSOR FAILURE CODES ....................................................................................... 2
1. Flow Meter ....................................................................................................................................... 2
2. R.O. Filter......................................................................................................................................... 2
3. Filter ................................................................................................................................................. 2
4. Overflow........................................................................................................................................... 2
5. Use Other Side ................................................................................................................................. 2
6. Changer Unplug ................................................................................................................................ 2
7. System Refill Please Wait ................................................................................................................... 2
8. System Purge Do Not Drink .............................................................................................................. 3
ELECTRICAL PROBLEMS ASSOCIATED with MICROPROCESSOR FAILURE CODES .... 4
1. Flow Meter Error .............................................................................................................................. 4
2. R.O. Filter Error................................................................................................................................ 6
3. Filter Error ........................................................................................................................................ 7
4. Overflow Error.................................................................................................................................. 8
A. U.V. Light ................................................................................................................................. 8
B. Base Float Switch ..................................................................................................................... 9
C. Containment Tank Overflow Switch ........................................................................................... 9
D. Vending Bay Tank Overflow Switch ......................................................................................... 10
5. Changer Unplug Error ..................................................................................................................... 11
6. System Refill Please Wait ................................................................................................................. 12
PUMP MOTORS .............................................................................................................................. 12
1. Dispensing Pump Motor .................................................................................................................. 12
2. Drain Pump Motor .......................................................................................................................... 13
3. 3/4 hp Motor .................................................................................................................................. 14
ELECTRICAL COMPONENT LIST .............................................................................................. 15
MICROPROCESSOR FAILURE CODES
The microprocessor continually monitors the machine operation. When an error occurs the machine will display
a variety of failure codes, which will lead the service technician to the potential problem. The messages displayed
do not pinpoint the problem within the wiring of the machine. However, they will indicate one or more possible
failures. Reference to the wiring diagram is necessary.
The possible “OUT OF ORDER” failure codes will consist of the following:
1. FLOW METER ... this failure indicates the machine has a dispensing problem. The microprocessor did
not detect a flow of water on either side (refer to Item #1 on page 4).
2. R.O. FILTER ... this failure indicates the R.O. membrane filter is in need of service, or may signify
a problem with the R.O. comparator. (refer to Item #2 on page 6)
3. FILTER ... this failure can indicate a variety of problems: (refer to Item #3 on page 7)
a. Sediment and/or carbon filters are in need of replacement.
b. High pressure switch has been triggered.
c. Supply water is continuously less than recommended installation specifications.
4. OVERFLOW ... this failure can indicate a variety of problems: (refer to Item #4 on page 8)
a. U.V. light has failed and is in need of service.
b. Base float switch has been triggered.
c. Tank overflow float switch has been triggered.
d. Vending bay tank overflow switch has been triggered.
e. Relay board failure.
5. CHNGR UNPLUG ... this failure indicates there is a problem communicating with the coin changer.
(refer to Item #5 on page 11)
6. SYSTEM REFILL PLEASE WAIT ... this message indicates the water in the containment tank is low
and is in the process of being refilled. The message will
automatically be reset when the system has enough water to
cover the maximum amount of water that can be dispensed in
one purchase. (refer to Item #6 on page 12)
2
7. SYSTEM PURGE DO NOT DRINK ... this message will appear upon turn on of the machine. It is not
actually a failure but an installation safeguard. This routine will
flush out the preservatives that keep the R.O. Membrane
contaminant free during storage. The flushing will be
accomplished by dispensing water for an extended period of
time which will stop automatically.
NOTE: With the exception of #6, ALL failure codes can be reset by entering the following key
combinations ([6 GAL.] , [5 GAL.] , [1 GAL.] ). If the trigger failure is still present, the
code will not reset.
DO NOT RESET THIS SAFETY ROUTINE FOR THE INSTALLATION.
3
ELECTRICAL PROBLEMS
ASSOCIATED with
MICROPROCESSOR FAILURE CODES
1. FLOW METER ERROR
The Flow Meter error message could be the result of the following:
a. Flow meter failure.
1) Flow meter sensor may need replacement.
2) Flow meter housing may need replacement.
b. A disconnected plug on the microprocessor panel.
c. Failures with the dispensing solenoid valves.
d. The trap door switch is defective or misadjusted.
e. Defective trap door solenoid.
f. Microprocessor output failure.
g. Faulty dispensing pump.
1) Unplugged dispensing pump.
2) Defective dispensing pump.
3) Defective relay board.
h. Polishing filter is in need of replacement.
4
Photo0029
Photo0017
Photo0036
NOTE: When a complete flow meter is changed some reprogramming is required. The machine is
relying on the information provided by the flow meter for accurate vending. The counts per
gallon in the program will have to be changed along with the flow meter. If just the sensor
element is replaced, the recalibration may not be necessary.
To set just the calibration on both vending bays using teach mode proceed as follows:
Step #1
a. Vend at least 1 gallon to purge out air pockets in the lines prior to calibration.
b. Turn the keypad program switch to the program mode.
c. Press the [1 GAL.] selection key then press the [6 GAL.] selection key. Both displays will flash
“TEACH MODE GALLON”.
d. Place calibrated 1 gallon containers in the vending bay.
5
e. Press and hold the [4 GAL.] selection key to activate the vending bay.
f. When the gallon has filled completely, release the key.
g. Press the [2 GAL.] selection key. This is necessary to retain the information in memory.
NOTE: After the counts have been derived the microprocessor will not override the previous values
that are stored in memory. The microprocessor needs an enter confirmation. By pressing the
[2 GAL.] selection key you will confirm the new entries.
i. The display will then show the new values.
j. Turn the keyed program switch back to the run position.
2. R.O. FILTER ERROR
The R.O. Filter Error message could be the result of the following:
a. The R.O. Membrane is in need of replacement or cleaning;
Take a TDS measurement of the inlet and product side of the R.O. membrane.
The product TDS measurement should be 25% or less of the input TDS measurement.
The TDS measurement can only be taken after the 3/4 HP pump has rn at least 1 minute.
b. The R.O. Comparator has failed;
Test the R.O. Comparator with an ADC comparator tester.
c. The test cell has failed;
Remove and inspect both test cells for broken leads and corrosion.
(Refer to wiring diagram SECTION A-1 through A-5 for electrical reference)
R.O. Comparator
Alarm / Power
Connection
Test Cells
Inlet Test Cell
Outlet Test Cell
Photo0031
Photo0032
Inlet Test Cell
Connection
Outlet Test Cell
Connection
6
Photo0033
3. FILTER ERROR
The Filter Error message could be a result of the following:
a. The sediment and/or carbon filters are in need of replacement;
Monitor the pressure gauges while the machine is in operation. Determine which filter has a 10
P.S.I. differential pressure while the R.O. pump is running.
b. The high pressure switch has been triggered;
Verify the pressure in the system is set at 175 psi. If the pressure exceeds 175 psi, check drain
is not restricted also determine if check valve is stuck closed.
c. The incoming water supply to the machine has decreased less than 35 psi;
Verify the incoming pressure while running, never drops less than 35 psi.
(Refer to wiring diagram SECTION C-6 through D-6 for high & low pressure switch wiring)
Low Pressure Switch
Pressure Gage and High Pressure Switch
Photo0008
Photo0007
Pressure Regulator
Photo0063
Low Pressure Switch Connections
Photo0039
Adjustment
Screw
Low Pressure Switch
Connection
7
4. OVERFLOW ERROR
A. U.V. Light
An Overflow Error triggered by the U.V. Light could be a result of the following:
a. The U.V. Light is not plugged in.
b. The U.V. Light is defective.
c. The alarm connection to the relay board is not plugged in.
d. The alarm on the U.V. Light has been triggered.
The bulb is not at the correct intensity and is in need of replacement (refer to Bulb Replacement in
the ADC Water Vending Machine Manual).
e. Defective Relay Board
(Refer to wiring diagram SECTIONS C-6 through D-6 for high & low pressure switch wiring)
Rear Electrical Box
U.V. Intensity Indicator
U.V. Intensity Indicator
Photo0035
U.V. Alarm
Connection
8
B . Base Float Switch
An Overflow Error triggered by the Base Float Switch could be a result of the following:
a. The Base Float Switch has been disconnected.
b. The Base Float Switch has been triggered due to water flood in cabinet.
c. The Base Float Switch has failed.
d. The relay board has failed.
Over Flow Switch
High Level Switch
Fill Level Switch
Low Level
Base Float Switch
Photo0054
C. Containment Tank Overflow Switch
An Overflow Error triggered by the Tank Overflow Switch could be a result of the following:
a. The Tank Overflow Float Switch has been disconnected.
b. The Tank Overflow Switch has failed.
Over Flow Switch
High Level Switch
Fill Level Switch
Low Level
Base Float Switch
Photo0054
9
D. Vending Bay Tank Overflow Switch
An Overflow Error triggered by the Vending Bay Overflow Switch could be a result of the following:
a. The Vending Bay Overflow Switch is disconnected.
b. The Vending Bay Overflow Switch has been triggered due to water not draining out of the tank.
c. The Vending Bay Overflow Switch has failed.
d. Unplugged drain pump.
e. Defective drain pump.
f. Defective relay board.
Verify that the drain pump is plugged in. Confirm ALL connections to and from the relay board.
Verify that the relay board is operational.
Photo0010
Switch Positioning
Draw Port
10
5. CHNGER UNPLUG ERROR
The CHNGER UNPLUG Error message could be a result of the following:
a. Coin changer is unplugged.
b. Defective coin changer.
c. Defective power supply.
Coin Changer
Microprocessor Panel
Photo0036
Photo0037
Power Supply
Photo0019
11
6. SYSTEM REFILL PLEASE WAIT
The “System Refill Please Wait” message could be a result of the water level in the containment tank is
below the low level switch. If the machine is functioning correctly it should be refilling. The message will
automatically reset 1 minute after the water level has reached the low level switch. A “System Refill Please
Wait,” message that does not reset could be the result of the following:
a. Shorted Low level float switch.
b. Inoperative 3/4 HP motor (refer to Item #3 on page 14)
c. Inadequate water supply to machine.
d. Filters are in need or replacement.
(Refer to wiring diagram SECTION A1-A3 for Tank Low Level Float Switch wiring)
Over Flow Switch
High Level Switch
Fill Level Switch
Low Level
Base Float Switch
Photo0054
PUMP MOTORS
1. DISPENSING PUMP MOTOR
An inoperable dispensing pump could be a result of the following:
a. The polishing filter is in need of replacement.
b. Unplugged Pump Motor
c. Vending problem (refer to SECTION 1 on page 4)
d. Defective relay board
Photo0025
NOTE: You must verify the dispensing pump is plugged in. Verify both the trap door and vending
solenoids are opening.
12
Dispensing Pump
Photo0012
2. DRAIN PUMP MOTOR
An inoperable drain pump could be a result of the following:
a. Clogged drain
b. Unplugged spill switch
c. Incorrect positioning of the spill switch.
d. Mechanical malfunction of the drain check valve.
When the spill switch is changed it is important that it is positioned correctly. Incorrect positioning will change
the switch into a normally closed contact causing the drain motor to continuously run.
Photo0010
Switch Positioning
Draw Port
13
3. 3/4 HP MOTOR
An inoperable drain pump could be a result of the following:
a. No water supply to machine
b. Unplugged or defective low and/or high pressure switches
c. Defective inlet solenoid
d. Defective relay board
e. Defective motor contactor
f. Defective 3/4 HP motor
g. Defective inlet water solenoid
Photo0038
14
ELECTRICAL COMPONENTS LIST
ADC Part No.
123000
123005
182455
132451
133356
137060
182000
182010
182012
182025
182016
182020
182049
182050
182060
182080
182081
182100
182128
182215
182298
182299
182305
182352
182355
182450
182451
182453
182468
182470
182471
182804
182820
Description
Indicator Light - 115 VAC
Indicator Light - 24 VAC
120/240V Primary 24 VAC Secondary 150 VA
Contactor - 24 VAC
Power Cord - 120 VAC
Arc Suppressor (A.S.) Board
Keypad Label
Display Board
Ribbon Connector
Microprocessor (Computer) Controller/Coin Changer Version
Relay Board - 24 VAC
Coin Changer Power Converter
Dispensing/Circulation Solenoid - 24 VAC
Main Water Solenoid - 24 VAC
Trap Door Solenoid - 24 VAC
Reverse OSmosis (R.O.) Comparator with Leads
Reverse OSmosis (R.O.) Comparator Test Cells
3/4 HP Motor - 115/240 VAC 60Hz
3.5 GPM Pump - 115 VAC 60Hz
Ultraviolet (U.V.) Light with Alarm
High Pressure Switch
Low Pressure Switch
Float Switch - 24 VAC Internal Mount
Flow Meter
Flow Meter Sensor
Ground Fault Interrupter
Push Mount Wire Tie
6-Amp (Fast Acting) Fuse
Keyed Program Switch
Flourescent Light
8 Watt Flourescent Lamp Replacement
Coin Changer
Bill Validator
15
ADC 182731
1- 02/25/98-25
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