SERVICE MANUAL DRYERS Condenser dryer with electronic control system ELECTROLUX ZANUSSI S.p.A. Spares Operations Italy Corso Lino Zanussi, 30 I - 33080 PORCIA /PN (ITALY) Fax +39 0434 394096 Publication no.
SOI/DT 2003-12 dmm 2/50 599 36 20-08
TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 Purpose of this Manual..................................................................................................................... 5 IMPORTANT................................................................................................................................... 5 2.1 Safety ........................................................................................................................................ 5 2.2 Installation...................
10 ALARMS.................................................................................................................................... 27 10.1 Displaying the alarms to the user ............................................................................................... 27 10.1.1 Alarm display during normal operation ................................................................................ 27 10.2 Reading the alarm codes........................................................................
1 Purpose of this Manual The purpose of this Service Manual is to provide service engineers who already have the basic knowledge necessary to repair dryers with information concerning condenser dryers with electronic control systems (mod. EDR1000NEW) produced in the factory in Porcia (Italy). The EDR1000NEW control system features a single PCB that incorporates the power and display functions and a maximum of 13 LEDs and 5 switches.
3 GENERAL CHARACTERISTICS The EDR1000NEW control system consists of a single PCB which incorporates three functions: power, control and display. This PCB is fitted to conductimetric condenser dryers (i.e. those in which the steam is condensed inside the appliance). The PCB is inserted into a plastic casing, which is attached to the rear side of the control panel support. The PCB is available in two basic versions: one with four pushbuttons, the other with five. Dimensions of appliance Power supply No.
4.1 Four-pushbutton control panel The control panel - as well as the four pushbuttons - features ten LEDs and a programme selector. The options can be selected only after selecting a drying programme using the selector. In this situation, the phase LEDs light and LED L4 (start/pause) flashes. When an option is selected, the corresponding LED lights. The functions of the pushbuttons and the LEDs depend on the configuration code of the appliance; the configuration used in most models is shown below.
4.3 Description of pushbuttons and LEDs 4.3.1 "NO BUZZER" pushbutton This option can be selected only when the dryer is in "selection" mode (set-up). Press this pushbutton to disactivate the buzzer function. The LED lights to indicate this selection. To re-activate the buzzer function, press the pushbutton again; the LED will switch off. Even when the buzzer function is disactivated, the buzzer will continue to signal alarm conditions and warnings.
4.3.6 "CYCLE PHASE" LEDs § Drying: lights during programme selection and when the dryer is performing the DRYING cycle. § Cooling: lights during programme selection if the programme selected includes a COOLING phase, and also when the dryer is performing the COOLING cycle. § Anti-crease / End of cycle: lights during programme selection if the programme selected includes an ANTI-CREASE phase; it also lights while the dryer is performing the ANTI-CREASE phase and at the END of the CYCLE. 4.3.
4.5 Options The table below lists the possible options for the drying programmes, their compatibility with other options and with the various cycles, and when they can be selected or modified. Compatibility with programmes Compatibility with options Phases in which selection / modification is possible SOI/DT 2003-12 dmm EXTRA-DRY CUPBOARD-DRY (EXTRA) CUPBOARD DRY (NORMAL) COTTON SLIGHTLY DAMP IRON-READY MACHINE IRONING EXTRA-DRY SYNTHETIC CUPBOARD DRY IRON READY 90 min. TIME 60 min. 30 min.
4.6 Adjusting the level of conductivity The conductivity of the water used to wash the fabrics varies from zone to zone. The conductimetric sensor is calibrated to a standard value: any major variations in the level of conductivity may affect the final drying result (i.e. the washing may be too dry or too humid): These variations are more noticeable in the "slightly damp" or "iron-ready" cycles; the "cupboard dry cycles are almost entirely unaffected by variations in conductivity.
4.7 Description of operation 4.7.1 Selection phase When the selector is turned from OFF to a drying programme, the LEDs corresponding to the phases of the programme light, and the START/PAUSE LED begins to flash. During this phase ("selection" or "set-up" phase) the various options can be entered, and the corresponding LEDs will light. The drying cycle commences as soon as the START/PAUSE pushbutton is pressed.
4.7.4 Operation in DELAYED START mode This function is possible only on appliances with five-button control panels. The delay time option is configurable; therefore, certain dryers can be set to 1-2-3 hours, some to 2-4-6 hours, the others to 3-6-9 hours. The delay time must be entered before pressing START/PAUSE. To select this option, press DELAYED START as follows: when pressed once, the LED corresponding to the maximum delay time lights.
5 DEMO mode This is a demonstration function that can be used by the retailer to demonstrate the operation of the appliance to customers. The duration is about five minutes. When the appliance is in DEMO mode, the heating elements are not powered and the various phases are of abbreviated duration; the washing inside the drum is not controlled in any way. 5.1 1. 2. 3. 4. 5. 6. 5.2 § Selecting DEMO mode The appliance must be switched off. Press START/PAUSE and any of the option buttons simultaneously.
6 STRUCTURAL AND FUNCTIONAL CHARACTERISTICS 6.
6.
6.3 Drum 1 – Front flange 2 – Drum housing 3 – Rear flange 4 – Drum lifters 5 - Plastic band The drum consists of two half-shells (front and rear) which are joined together by a wide plastic band (5). Separation of the drum into two parts allows the conductimetric sensor to determine the conductivity of the washing inside the drum. Parts 1, 2 and 3 are connected by crimping. The plastic lifters are secured by screws to the internal wall of the drum.
6.5 Hydraulic circuit (versions with canister in upper section) 1 – Pump immersed in the sump 2 – Water fill hose to canister (Red) 3 – Overflow drain hose (Transparent) 4 – Canister The condensation water is ducted from the sump (1) to the tank (4) by the pump immersed in the sump via the hose (2). When the canister is full the overflow is collected in the canister support and ducted to the sump through the hose (3). 6.
7 ELECTRICAL COMPONENTS 7.1 Electronic board The electronic board is housed inside a plastic casing and secured behind the control panel support. The board is available in two basic versions: one with four pushbuttons, the other with five. 1. 2. 3. 4. 5. 6. 7.1.
7.1.2 General structure of board memory The system features an EEPROM, positioned externally to the microprocessor, which memorizes the configuration data, the description of the cycle, the status of the appliance in case of a power failure, and the alarms. Power Failure and machine status µP External asynchronous serial port ROM RAM Internal synchronous serial port EEPROM (external to the µP) Configuration of the appliance Description of the cycle 7.1.
7.2 Conductimetric sensor The conductimetric sensor consists of an electronic circuit (positioned inside the power board) and a section located externally to the board which consists of the wiring, two brushes (sensors positioned in contact with the tub shells) and the two tub shells themselves. The first brush positioned in contact with the front tub shell is fitted to a hinged support on the duct, and is connected by the wiring to the electronic circuit.
7.4 Heater unit 1234- Filament heating element Ceramic supports Sheet metal casing TH1 Safety thermostat (automatic reset) 5 - TH2 Safety thermostat The heater unit consists of two wire heating elements with different powers. The two heating elements are fitted to ceramic supports, and the entire assembly is housed in a sheet metal casing. Two safety thermostats (normally closed) are positioned to one side of the casing.
7.6 Motor 1 – Fan (inclined blades for cold air circulation) 2 – Belt tensioner 3 – Motor 4 – Fan (straight blades for warm air circulation) The motor group consists of a belt tensioner (2), two fan blades (1 and 4) for circulating cold and warm air respectively, fitted to the motor shaft using bolts, and a single-phase asynchronous motor (3) featuring an overheating safety cut-out.
8 ELECTRICAL CIRCUIT 1. 2. 3. 4. 5. 6. 8.1 Suppressor Door interlock microswitch Drum light (certain models only) Heater unit Drum rotation motor Pump 7. 8. 9. 10. 11. 12. Main switch (incorporated in selector) Floating microswitch Heat exchanger microswitch NTC Conductimetric sensor Electronic board Electrical operation The circuit diagram shows all the components of the dryer and their connections to the electronic board.
9 DIAGNOSTICS SYSTEM In diagnostics mode, it is possible to check the operation of the appliance and to read the alarm codes. 9.1 1. 2. 3. 4. 9.2 Access to diagnostics The appliance must be switched OFF. Press START/PAUSE and any one of the option buttons simultaneously. Holding these two buttons down, switch the appliance ON by turning the programme selector knob one position clockwise. Continue to hold down the buttons until the LEDs begin to flash and the buzzer sounds (about 5 seconds).
Selector position Components activated Operating conditions Function checked 1 Ø All the LEDs light in sequence. Ø When a button is pressed, the corresponding LED Always activated. lights and the buzzer sounds. Operation of the user interface. 2 Ø For models with the canister in the lower section: If the floating switch is closed (canister full), the phase/warning LEDs flash; if the switch is open, they remain lit. Ø Canister fill pump: (models with canister in upper section) with switch closed.
10 ALARMS 10.1 Displaying the alarms to the user Operation of the alarms is configurable according to the model. Some or all of the alarms may be displayed to the user. Normally, all alarms except E44, E52, E63, E94, EB2 are displayed to the user. When an alarm condition occurs, the drying cycle may be interrupted or paused; in some cases, for the sake of safety, a forced cooling cycle is performed.
10.2 Reading the alarm codes To read the last alarm code memorized in the EEPROM of the electronic board, proceed as follows: • • Access diagnostics mode (see paragraph 9.1) Turn the programme selector knob clockwise eleventh position. to the 10.2.1 Displaying the alarm code The alarm code is displayed by a repeated sequence of flashing of the ANTI-CREASE/END OF CYCLE LED (0.4 seconds on, 0.4 seconds off, with a pause of 2.5 seconds between sequences).
10.3 Rapid reading of the alarm codes The last alarm code memorized can be displayed even if the appliance is in normal operating mode (e.g. while the drying programme is being performed): ð Press START/PAUSE and any one of the option buttons simultaneously for at least two seconds. The LEDs switch off, then display the flashing sequence that identifies the alarm code. ð The alarm sequence continues to flash as long as the two buttons are held down. ð The reading system is as described in paragraph 10.2.1.
10.6 Table of alarms Alarm Description E00 E21 E22 E31 No alarm E32 Conductimetric sensor signal frequency too low. E41 E51 Power triac of door opening coil faulty. Triac "sensing" circuit for powering the door opening coil faulty Incongruency of the “sensing” signal of the door interlock Motor power triac short-circuited. E52 Intervention of motor overheating safety cut-out. E53 Motor triac "sensing" circuit faulty. E54 Motor inoperational.
Alarm Description E92 Error in the communication between electronic board and control/display board Incongruency in the communication between the electronic board and the display board. E93 Error in the configuration of the appliance. E94 Error in the configuration of the drying cycle. E95 Communication error between microprocessor and EEPROM. Incongruency between selector and cycles E91 E97 Possible fault Wiring faulty. Electronic board faulty. Control/display board faulty.
11 NO ACCESS TO DIAGNOSTICS PROGRAMME 11.1 No LEDs on the electronic board light NO Power cable and connection OK? Replace or repair the power cable and perform the diagnostics programme YES NO Does the suppressor (incorporated in the main terminal block) function correctly? Replace the terminal block + suppressor and perform the diagnostics programme. YES Remove the connector from the main terminal block and connector J8 of the electronic board.
12 TABLES OF DRYING CYCLES The tables contain a description of the main drying cycles of EDR1000new/EDR2000 electronic boards without any options selected. In some cycles, the "degree of humidity" variable is indicated: this function is not featured on the EDR1000new board, and should not thus be taken into consideration 12.1 Key ð ð ð ð ð ð Phase : indicates the various phases of the selected drying programme.
As shown in the diagram below: Motor Heating elements Ø D1 is the delay time before the heater unit is switched on after commencement of direct motor rotation. Ø D2 is the interval between the moment at which the heater unit switches off and the moment at which the motor is paused before reversing the direction of rotation. Ø D3 is the delay time after which the heater unit switches on with respect to commencement of reverse rotation of the motor.
12.
12.
12.6 BABY cycle (No options selected) Phase Drying 1 If selected humidity is "+" Drying 2 If selected humidity is "++" If selected humidity is Cooling "-" All other cycles Pump Anti-crease End of cycle Degree of humidity Maximum time Temp.
13 ACCESSIBILITY OF COMPONENTS If an electric screwdriver is used, ensure that the screws are not tightened excessively! 13.1 Door a. To remove the door, remove the screws which secure it to the hinge. 13.1.1 Fluff filter fitted inside door a. Lift out and clean at the end of each cycle. 13.1.2 Fluff filter support a. Remove the two screws which secure the fluff filter support to the inner door. 13.1.3 Lower fluff filter a. E Remove by lifting from its seat. 13.1.
13.2.2 Control panel support assembly a. b. c. b-d In models with the canister in the upper section: remove the canister and remove the screws which secure the control panel to the canister support. Remove the screws which secure the control panel support to the cabinet. Lift and tilt the control panel support assembly, and remove from the cabinet. d-e 13.2.3 Control panel d. e. f. g. h. Remove the screws which secure the control panel support and the control panel to the cabinet.
13.2.7 Canister container (models with canister in upper section) a. b. Remove the screws which secure the canister container to the control panel and to the rear panel. Detach all the anchor tabs which secure it to the control panel support. 13.3 Removal of the cover and rear panel gives access to: 13.3.1 Heater unit a. Remove the screws (1) which secure the plastic rear panel cover (in the centre of the panel) and release the anchor tabs (2) from around the external perimeter. b.
13.4 Removal of the left-hand side panel gives access to: a. b. The floating microswitch The float The pump (models with canister in upper section) The door interlock Remove the work top. Remove the screws which secure the side panel and remove the panel (see above). In the rear section of the base, the sump contains the pump (models with canister in upper section), the floating microswitch and the float. c c.
13.4.2 Float g g. h. i. h i The float is located inside the sump. To remove the float, turn it 90° clockwise as shown in the figure. Lift the float and rotate outwards, and remove the float. To replace the float, repeat this procedure in reverse sequence. 13.4.3 Pump (models with canister in upper section) The pump, which ducts the water from the sump to the canister (in the upper section) is located next to the sump containing the float. j.
13.5 Door interlock a. Remove the two screws which secure the interlock to the front panel and remove the interlock. 13.6 Removal of the right-hand side panel gives access to: - The motor capacitor The hot air circulation fan The cold air circulation fan The drum rotation motor The drive belt tensioner The belt tensioner spring The NTC sensor a. b. Remove the work top (see above). Remove the screws which secure the right-hand side panel to the crossmember and remove the panel.
13.6.3 Rear air duct cover (hot air circulation) i. j. Remove the motor wiring from the anchor securing the wiring to the duct cover. Remove the three screws which secure it to the base and remove. i 13.6.4 Rear air duct cover (cold air circulation) k. Remove the screw and detach the duct cover from the three anchor tabs (two upper lateral tabs, one lower tab) which secure it to the base, and remove. k 13.6.5 Drum rotation motor l.
13.7 Removal of the front panel gives access to: 13.7.1 The front panel a. b. c. Remove the screws which secure the panel to the front panel. Pull the sealing ring from its seat. To access the aperture button, remove the screws from inside the panel and release the three upper anchor tabs. a d. e. When replacing the panel in its housing, first ensure that the three anchor tabs are correctly positioned in their seats, and only then tighten the screws.
13.9 Removal of the rear panel gives access to: - The rear brush The drive belt The drum The air duct The idle pulley The front and rear seals 13.9.1 Rear brush (conductimetric sensor) a. Remove the screw which secures the drum spindle cover. b. Rotate the drum cover until it is released from the anchor in the lower section. c. The brush is located inside the protective cover. a -b 13.9.2 Rear panel a. Remove the work top b. Remove the left- and right-hand side panels. c.
13.9.6 Duct rollers a. Remove the work top b. Remove the rear panel cover c. Remove the rear panel d. Remove the drum e. Remove the screws which secure them to the duct (2) 13.9.7 Front and rear seals a. Remove the work top. b. Remove the rear panel cover. c. Remove the rear panel. d. Remove the drum. e. The rear seal can be simply pulled away from the ring fitted to the rear panel. f. Slide the front seal (1) from its seat. Notes for replacement of the rear drum seal 1. 2.
14 REVERSIBILITY OF THE DOOR fig. A Proceed as follows: 1. 2. 3. 4. 5. 6. 7. Remove the screws which secure the hinges to the cabinet (fig.A.1). Remove the door. Remove the screws which secure the hinge hole masking plates (fig.A-2) and fit the plates to the holes to which the hinges were previously fitted (fig.A-1). Remove the canister. Remove the work top. Remove the left- and right-hand panels. Remove the front panel hole cap (fig.A-4).
fig. F 18. Remove the hinges by removing the hinge screws (fig.F6). 19. Remove the hinge hole masking caps (fig.F-7). 20. Remove the masking cap from door latch hole (fig.F-8). 21. Remove the door latch (fig.F-9). fig. G 22. 23. 24. 25. Press the hinge hole masking caps into position (fig.G-7). Insert the latch hole masking cap (fig.G-8). Fit the door latch (fig.G-9). Screw the hinges into position (fig.G-6) fig. H 26.
15 FINAL TESTING OF DOOR CLOSURE In order to check that the door closes correctly (i.e. in compliance with safety standards) after reversing, proceed as follows: a. b. Make a loop using string, wire etc. (1). Loop the string around the door latch and close the door. Check the door aperture safety system as follows: c. d. Connect the dynamometer (2) to the loop. Pull the instrument in a direction perpendicular to the plane of the door.
