Tommy Heated Dryer SUPPORT GUIDE

10/7/2024

TOMMY CAR WASH SYSTEMS| 581 OTTAWA AVE, HOLLAND, MI, 49423

Compatibility List...............................................................................................................................1

Section 1: Electrical............................................................................................................................2

1.1 -Electrical Enclosure Parts Location.......................................................................................................................2

1.2 -Diagnostic Panel.........................................................................................................................................................3

Section 2: Gas....................................................................................................................................4

2.1 –Gas Enclosure Parts Location...............................................................................................................................4

2.2 –High Temperature Limit Switch Reset..............................................................................................................5

2.3 –High Temperature Limit Switch Set Point.......................................................................................................6

2.4 –Burner...........................................................................................................................................................................7

2.5 –External Gas Gauge Assembly............................................................................................................................8

Section 3: Start-Up & Operation....................................................................................................9

3.1 –Mode Selection........................................................................................................................................................9

3.2 –Order of Operations.............................................................................................................................................10

3.3 –Adjusting HIGH FIRE (Winter Mode) Gas Pressure..................................................................................11

3.4 –Adjusting LOW FIRE (Summer Mode) Gas Pressure................................................................................12

Section 4: Spare Parts...................................................................................................................14

4.1 –Spare Parts List......................................................................................................................................................14

Section 5: Troubleshooting..........................................................................................................15

5.1 -Common Issues.....................................................................................................................................................15

Compatibility List

This document pertains to the following parts:

E-HD-2020-US-NG
E-HD-2020-US-PRO
E-HD-2020-CA-NG
E-HD-2020-US-NG-K
E-HD-2020-US-PRO-K
E-HD-2020-CA-NG-K
E-HD-2020-US-NG-R-K
E-HD-2020-US-PRO-R-K
E-HD-2020-CA-NG-R-K

Section 1: Electrical

1.1 -Electrical Enclosure Parts Location

Figure 1–Electrical Enclosure Parts Location

Item Number	Description	TCWS PN
1	Power Distribution Block
2	Fuses	KLDR01.6
3	Control Power Transformer	P-HD-1012
4	Motor Contactor	P-HD-1004
5	Overload Relay	P-HD-1005
6	Fenwal Flame Safeguard Control	P-HD-1011
7	24V Circuit Breaker	P-HD-1018
8	Relay base & relays	P-HD-1007 (base) P-HD-1006 (relay)
9	Diagnostic Panel	See Figure 2

1.2 -Diagnostic Panel

Figure 2-Diagnostic Panel

Item Number	Description	Function
1	Burner Lockout	Indicator will light if burner has faulted.
2	Burner ON	Indicator will light when burner is operating.
3	Air Flow Indicator	Indicator will light when proper air flow has been met
4	High Temp Indicator	Indicator will light when unit is functioning properly. If indicator does not light, high temp limit switch has been tripped.
5	Fan ON	Indicator will light if the fan is on.
6	Power ON	Indicator will light if unit has power.
7	High/Low Fire Selector	If the switch is in the UP position towards “HIGH FIRE” the unit will be in WINTER MODE. If the switch is in the down position the unit will be in SUMMER MODE.

Section 2: Gas

2.1 –Gas Enclosure Parts Location

Figure 3-Gas Enclosure Parts Location

Item Number	Description	TCWS PN
1	Airflow Switch	P-HD-1008
2	Pressure Gauge -6” WC to +10” WC	P-HD-1013
3	High Temp Limit Switch	P-HD-1010
4	Modulating Gas Actuator	P-HYD-2172
5	Modulating Gas Valve	P-HYD-2171
6	Main Gas Valve x 2 Valves	P-HD-1020
7	Pressure Regulator	P-HD-1000

2.2 –High Temperature Limit Switch Reset

Figure 4-P-HD-1010–High Temp Limit Switch

Reset High Temperature Limit Switch:

The high temperature limit switch (P-HD-1010) will trip when the temperature of the heated dryer reaches the set point. This switch is a safety feature of the heated dryer. The switch is a mechanical switch. If it trips, it will manually need to be reset. To reset it, press on the “PUSH” button on the top LH corner of the switch.

2.3 –High Temperature Limit Switch Set Point

Figure 5-Change the Set Point of the High Temp Limit Switch

Changing the Set Point:

The high temperature limit switch is factory set to100F. This should be adjusted to 160F. To adjust the switch, remove the cover. Stick a flat headed screwdriverin the brass screwof the center of the temperature adjuster and adjust the set point to 160F.Install the cover back on the switch.

DO NOT SET THE SETPOINT HIGHER THAN 160F. This puts the unit at risk of overheating!!!!

2.4–Burner

Figure 6-Burner Parts Location

Item Number	Description	TCWS PN
1	Burner	P-HD-1014
2	High Temp Limit Switch (Probe)	P-HD-1010
3	Spark & Flame Rod (single unit)	P-HD-1009
4	Propeller (CW)	P-HD-1002(behind burner)
5	3.0 HP Electric Motor	P-HD-1003(cannot see in image –behind propeller)
6	Inlet Guard	P-HD-1019 (guard on inlet of drum)

2.5 –External Gas Gauge Assembly

Figure 7-External Gas Gauge Assy (P-HD-1021)

The heated dryer ships with an external ball valve with an incoming gas pressure gauge. This assembly (P-HD-1021) ships loose with the heated dryer. It should either be in a box or inside the gas train cabinet during shipment.

This assembly allows gas pressure to be shut off to the individual unit, as well as measure the incoming gas pressure to the unit. The pressure gauge has units of inches of water column (I.W.C or “WC). This is a standard unit of measure for gas applications.

On the inside of the gas train cabinet door (lower cabinet), the incoming pressure requirements will be listed. The minimum gas pressure requirement is 8.5” W.C. The maximum incoming pressure is 1 psi or roughly 28” W.C.

Section 3: Start-Up & Operation

3.1 –Mode Selection

Figure 8-Diagnostic Panel

On the Diagnostic Panel, there is a toggle switch that changes between HIGH and LOW Fire modes.

HIGH FIRE –Winter Mode

When the switch is in the UP position towards HIGH FIRE, the heated dryer will operate in the maximum heating capacity (HIGH FIRE)
HIGH FIRE is for colder months only

LOW FIRE –Summer Mode

When the switch is in the DOWN position towards POWER ON, the heated dryer will operate in the minimum heating capacity (LOW FIRE)
LOW FIRE is for summer months only

3.2–Order of Operations

A. Before the ignition control sequence can be initiated, the following safety devices are checked for closure:

Air flow pressure switch ensures the air flow is at or below the maximum allowable to ensure clean combustion and reduced flame disturbance. This includes the fan is running.
The high temperature limit switch ensures the supply air temperature does not exceed the maximum allowable limit for safe operation.

B. With the safety devices described in the above steps verified, the flame safeguard control is enabled to initiate the ignition sequence.

After 10 seconds of pre-purge time, the ignitor is energized to produce spark ignition as follows:
The main valve(s) opens and with the modulating valve at minimum position, the burner is allowed to light with direct spark ignition in LOW fire.

C. The burner will first light in LOW fire.

If HIGH FIRE switch is enabled, the unit will switch to HIGH fire.

D. If any of the devices discussed in step A open, the gas circuit is disabled, the unit goes into lockout, and the burner lockout light is lit.

Before resetting, inspect the unit to determine the cause and take corrective action.

3.3 –Adjusting HIGHFIRE (Winter Mode) Gas Pressure

Tools Required:

Straight Screwdriver

Step 1:

Verify gas is turned on to the unit.
Incoming gas pressure should be between 8.5” WC and 28” WC.
Open gas enclosure lid.

Step 2:

Remove the cap from the gas regulator with the screwdriver.
Under the cap is the adjuster for regulating how much gas pressure is applied during HIGH fire (circled in red below).
The adjuster is a screw. Turning it inward raises the pressure. Backing it out lowers the pressure.
Turn the heated dryer on in high fire mode.
With the unit on, adjust the screw until the gas gauge reads steady at 3.5” W.C.
Install the regulator cap on the regulator.

Figure 9–High Fire Regulator Adjustment

3.4–Adjusting LOW FIRE (Summer Mode) Gas Pressure

Tools Required:

Straight Screwdriver

Step 1:

Verify gas is turned on to the unit
Incoming gas pressure should be between 8.5” W.C. and 28” W.C
Open gas enclosure lid

Step 2:

The modulating gas actuator (P-HYD-2172) controls the LOW fire (Summer mode)
The modulating gas actuator can be removed from the gas valve.
Turn on the heated dryer and place the unit in high fire mode
With unit in high fire, adjust the safety stop. This sets the low fire gas pressure position. See Figure 11 & 12.
After the safety stop has been moved, turn the unit into low fire. Wait until gas pressure has stabilized. Ideal low fire gas pressure is 1.0” W.C.
It may take a few tries to get the low fire position to 1.0” W.C. Repeat the above steps until this pressure has been established.

Figure 10–Modulating Gas Actuator (P-HYD-2172)

Figure 11–Safety Stop is circled in red. Stop can be removed without any tools. Safety Stop snaps onto actuator.

Figure 12–to adjust the Safety Stop, during HIGH fire operation, move the stop to a new position along the arc. DO NOT remove the actuator from the valve during HIGH fire operation. The black level will rest against the stop during LOW fire operation.

Section 4: Spare Parts

4.1 –Spare Parts List

Description	Tommy PN	Manufacturer PN
Modulating valve	P-HYD-2171	SV-1.0NN
Modulating valve actuator	P-HYD-2172	ACT-10.0
Regulating valve w/ red spring	P-HD-1000	RV61-1IN
Pressure Gauge 0-30” WC	P-HD-1001	030DGT
Propeller (CW)	P-HD-1002	MS-23-1/2-11.5XHD
Motor 3.0 HP 460/3 PREM TEFC	P-HD-1003	00318ET3E182T-W22
Motor Contactor	P-HD-1004	LC1K0610B7
Overload Relay	P-HD-1005	LR2K0312
Burner on Relay –CR3, CR12	P-HD-1006	RU4S-A24
Relay Base	P-HD-1007	SU4S-21L
Air Flow Switch –Blue Spring	P-HD-1008	JD-2
High Temp Limit Switch	P-HD-1010	A19ADB-38C
Flame Safeguard	P-HD-1011	35-605201-005
Primary Fuses	P-HD-1022	KLDR01.6
T1 Transformer –100VA	P-HD-1012	9070T100D19
Air Circulation Guard –27” dia	P-HD-1019	2ATB9
Ind. Light –24V AMB w/ 30” WL	NA	1813-X-20-20320
Ind. Light –24V RED w/ 30” WL	NA	1813-X-20-20310
High Fire ON/OFF switch	NA	90-0003
Circuit Breaker –24V	P-HD-1018	UMBW-1C1-4
Pressure Gauge -6” to +10” WC	P-HD-1013	LPG4-D9022N
Midco HMA-2A Section –18” Tee	P-HD-1014	1080810
Midco Inlet Flange –1-1/2” w/ Pilot	P-HD-1015	1030250
Midco Blank Plate	P-HD-1016	1120255
Midco Brute Pilot Spark & Flame Rod (single unit)	P-HD-1009	1200350
ASCO RedHat 1” 2-Way Normally Closed Gas Solenoid Valve (12VDC)	P-HD-1020	8214G251
Heated Dryer Gas Gauge Assembly	P-HD-1021	Gas Gauge Assembly

Section 5: Troubleshooting

5.1 -Common Issues

Issue	Possible Cause	Possible Remedy
A. Burner Not Operating	See problems "B" through "D". High Temp Limit Switch flipped. Gas is turned off to the unit Failed Air Flow Switch. Loose Wiring Connection at the air flow switch. Failed Control Transformer. Failed or malfunctioning main gas valve(s). Airflow to low, low airflow switch is open.	See problems "B" through "D". Check and/or replace. Verify the gas valve is turned on. Check and/or replace. Check and tighten. Check and/or replace. Check and/or replace. Check for reason of insufficient airflow and correct.
B. Power Failure	Disconnect not turned on. Blown fuse. Main to unit disconnect is not on.	Turn to disconnect. Check and/or replace. Turn on power at main.
C. Motor Not Operating	Disconnect is not turned on. Blown fuses. Main to unit disconnect is not on. Failed motor. Loose wiring to the motor. Motor is overloaded. improper supply voltage. Motor overheated.	Turn to disconnect. Check and replace. Turn on power at main. Check and/or replace. Check and/or replace. Check for proper speed. Check and correct. Check firing rate of unit.
D. Fan Not Operating	See problems "B" and "C". Bearings seized.	See problems "B" and "C" Check and/or replace
E. Flame Will Not Light	Inadequate signal to the safeguard control. Loose wires from the flame sensor. Dirty flame rod. Moisture on flame rod leads. Defective flame rod. Defective flame safeguard controller. short in the flame sensor leads.	Check micro-Amps or VDC from flame sensor. Check and correct. Clean and/or replace. Check and dry leads. Use di-electric grease inside boot. Check and/or replace. Check and/or replace. Check and/or replace.
F. Unable to Achieve High Fire	Low gas supply pressure.	Check and adjust.
G. Unable to Achieve Low Fire	Modulating controls are improperly set. Faulty amplifier or modulating gas valve.	Consult Fenwal 35-605201-005 Manual. Contact vendor. Check and/or replace.
H. No Gas Flow	Manual gas valve(s) closed. See problem "A".	Open manual gas valve(s). See Problem “A”.
I. Unable to Achieve Desired Discharge Temperature	Improper gas supply pressure. Faulty amplifier or proportioning motor.	Check and correct. Consult Fenwal 35-605201-005 Manual. Contact vendor.

Tommy Heated Dryer Support Guide UPDATED.pdf
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Operator Manual: Tommy Heated Dryer