Fisher & Paykel smartload DEGX1 Service Manual
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Fisher & Paykel smartload DEGX1 Service Manual

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DRYER
Models DEGX1 & DGGX1
517760

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Summary of Contents for Fisher & Paykel smartload DEGX1

  • Page 1 DRYER Models DEGX1 & DGGX1 517760...
  • Page 3 MANUAL 517760 - DATE OF ISSUE JULY 2004 The specifications and servicing procedures outlined in this manual are subject to change without notice. The latest version is indicated by the reprint date and replaces any earlier editions. Fisher & Paykel Appliances Ltd Fisher &...

  • Page 4: Table Of Contents

    CONTENTS 1 Servicing Requirements ........................7 Health & Safety............................7 1.1.1 Electrical Safety ...........................7 1.1.2 Electrostatic Discharge........................7 1.1.3 Good Working Practices......................7 1.1.4 Safety Test...........................7 1.1.5 Sheet Metal Edges ........................7 1.1.6 Gas Leakage Test ........................7 Specialized Tools ..........................7 1.2.1 Fisher & Paykel Smart Tool......................7 2 Model Information ..........................
  • Page 5 4 Diagnostics ............................26 Overview ............................26 Fault Code Summary ........................27 Diagnostic Mode ..........................34 4.3.1 Entering the Diagnostic Mode ....................34 4.3.2 Entering the Data Download Mode ...................34 4.3.3 Entering the Showroom Mode....................34 5 Fault Diagnostics ...........................35 Problem - No Power..........................35 5.1.1 Check the Continuity of the Power Cord (Electric)..............35 5.1.2 Check the Continuity of the Main Harness (Electric) ..............35 5.1.3...
  • Page 6 6.15 Removal of Drum Door Scraper......................47 6.16 Removal of Drum and Chassis Assembly..................48 6.17 Removal of Outlet Panel Assembly....................48 6.18 Removal of Outlet Duct Assembly ....................49 6.19 Removal of Outlet Duct Bearings......................49 6.20 Removal of Outlet Duct Seal ......................49 6.21 Removal of Exhaust Sensor......................50 6.22 Removal of Lint Collector Housing....................50 6.23 Removal of Conductivity Contacts ....................50 6.24 Removal of Belt Tensioner ........................51...

  • Page 7: Servicing Requirements

    Servicing Requirements Health & Safety ™ Note: When servicing the SmartLoad electronic dryer, health and safety issues must be considered at all times. Specific safety issues are listed below to remind service people of the health and safety issues. 1.1.1 Electrical Safety WARNING! TO AVOID ELECTRIC SHOCK! Do not attempt to service this dryer without suitable training and qualifications.

  • Page 8: Model Information

    Model Information The product serial plate is located on the upper rear of the cabinet and contains the following information: Model Number The model number contains the following information: D E G X 1 Series Size Feature Level Heating Type (E = Electric, G = Gas) Product Type (Dryer) Serial Number The serial number consists of three letters and six digits and contains the following...

  • Page 9: Technical Overview

    Technical Overview Finish Cabinet: Pre-paint (Polyester) Touch-Up Paint: White #503086 Lid: ABS Co-injected, one piece Console: ABS with Polycarbonate insert for control panel Drum: Stainless steel grade 430T Top Deck: Polypropylene Electrical Supply Operating Voltage Maximum Current USA Electric 220/240V AC 60Hz 24 amps USA Gas 110/120V AC 60Hz...

  • Page 10: Principles Of Operation

    Principles of Operation 1.1.1 Electronic Control The 120V or 220/240V power supply is connected to Sensor Module the motor control module which rectifies to DC for Display Module use by its own controller and peripherals, and also for the sensor module. The motor control module has an optically isolated serial communications port to the sensor module from which it receives commands for operating the drum motor and the...

  • Page 11: Lint Filter

    The LID LOCKED LED (above the Start/Pause button) comes on when the lid is locked to tell the user when they cannot open the lid. • When the LID LOCKED LED is illuminated, the lid is locked and the lid cannot be opened.

  • Page 12: Airflow

    The lint filter in the SmartLoad™ dryer is circular and is positioned next to the drum. When the drum rotates the lint filter rotates with it. The filter is made of very fine 200-micron mesh. All clothes dryers produce potentially flammable lint. Use of a fine mesh enables a lint filter to catch more lint from the air before it reaches the exhaust ducting.

  • Page 13: Temperature Control

    Belt Lint Removal System Hot Air Drum Belt Tensioner System Motor Cold Heater Outlet 3.5.6 Temperature Control The user can select either a dryness level that they require or a timed drying period. Auto sensing of the clothes load dryness level is achieved by touch sensors that sense the moisture content of the load.
  • Page 14 4. Drum Door: Slides back along grooves in the bridge to provide access into the drum. 5. Door Bracket: Secures and seals the drum in the closed position and houses components for latching the door. 6. Hinge Arm: Part of the door assembly, which is contacted by the door grabber for opening and closing the door.

  • Page 15: Drum Control

    3.5.9 Drum Control. The drum is coupled to a three phase induction motor by way of a pulley on the motor shaft, which drives via a “V” belt and belt tensioner system. The motor control module controls the motor by generating the three phases from a high voltage rectified DC rail.
  • Page 16 3. If the motor stalls after the drum has moved at least 42 degrees, a “Clothes Jammed” fault will be internally flagged and the drum will reverse and the door will open before trying to close again. After three unsuccessful attempts, the drum door will open, the lid will be unlocked and the relevant User Warning will occur.
  • Page 17 Bridge Channels Hinge Arm and Locking Bar are unlatched by Engagement Ribs contacting Hinge Arm the Door Grabber As the drum reaches the fully opened position, details on the drum bridges hit the door grabber, causing the motor to stall and the drum to stop. The drum is now in a fully opened position, where the user can load or unload garments from the dryer.

  • Page 18: Heater Control

    1. Moves the drum in the open direction to check if the user has manually opened the drum door, and if found so, will stop and assume the normal off position. 2. If not “Home”, moves the drum so as to close the door, moving as far as would normally be required to close the door from the “Home”...

  • Page 19: Auto Sensing

    Door Close Direction Door Open Direction 4 minutes 40 seconds Gas Ignition Gas Heating delay Denim 30 seconds 3 minutes 30 seconds No Heat Regular 30 seconds 2 minutes 30 seconds P.Press 30 seconds 2 minutes 30 seconds Delicate 30 seconds 2 minutes 30 seconds Air Dry No Heat...

  • Page 20: Regulator Valve

    3.5.13 Regulator Valve In a gas dryer, the regulator valve forms part of the gas control system and performs the function of regulating the gas pressure into the burner venturi and turning the gas flow on and off. The regulator valve consists of two solenoid shut-off valves, a gas pressure regulator and a gas orifice assembled into a single cast body.

  • Page 21: Gas Flame Detector

    3.5.14 Gas Flame Detector The gas flame detector is an essential safety device that forms part of the control system for the gas burner. It consists of a thermostatically operated single-pole, single-throw, normally closed bimetallic switch that is sensitive to radiant energy. The function of the gas flame detector is to detect when the gas igniter has reached an appropriate temperature to ignite the incoming gas/air mixture, and then energise the secondary valve in the regulator assembly, releasing the gas into the burner venturi.

  • Page 22: Gas Igniter

    Gas Igniter Part Number 395188 Cold Resistance 40 - 200 Ohms Typical Temperature 2399°F (1315°C) @ 120V Minimum Temperature 1805°F (985°C) @ 80V Maximum Temperature 3092°F (1700°C) @ 132V Gas Regulator Valve Combination gas pressure regulator and dual automatic gas valve. Part Number 395369 Voltage Rated...

  • Page 23: Thermostat Cutout - Manual Reset (Gas)

    3.10 Thermostat Cutout – Manual Reset (Gas) Part Number 395191 Type SPST Trip Temperature F (145 3.11 Element Assembly 240V 3.6 KW Two sets of Nichrome wire elements linked in parallel between Mica plates. A ceramic insulator is used to support the element assembly in the housing.

  • Page 24: Thermostat Cutout - Manual Reset (Electrical)

    3.14 Thermostat Cutout – Manual Reset (Electrical) Part Number 395155 Type SPST 30 Amps/240 Volts AC F ± 11 C ± 6 Trip Temperature (100 3.15 Motor – 3 Phase 240W Part Number 395378 Voltage Rated 190 Volts AC 85 Hz Power 240 Watts Current...

  • Page 25: Motor Control Module

    3.18 Motor Control Module Part Number 395400 (Electric models) 395401 (Gas models) 3.19 Sensor Module Part Number 395394 3.20 Display Module Part Number 395124 - 25 -...

  • Page 26: Diagnostics

    Diagnostics Overview If a fault occurs that prevents correct operation of the dryer, and is detected by the controllers, the dryer is stopped, the display shows a fault code and the beeper is continuously turned on and off. Pressing the Power button will stop the beeper but leave the fault code displayed to help the service technician diagnose the problem.

  • Page 27: Fault Code Summary

    Fault Code Summary The following are the fault codes that may be displayed. The remedy section of each fault is the suggested sequence of repair or replacement. If the first suggestion does not remedy the fault, check the next on the list. Fault Code 1 Communications Error.
  • Page 28 Fault Code 4 Invalid Option Link Read. The motor control module heat source option link read is invalid. Remedy: Replace the motor control module. (Refer to Section 6.35) Fault Code 6 Door Jammed - User Warning. The door is unable to close due to either clothes catching or an excessive closing load.
  • Page 29 Fault Code 8 Exhaust Sensor Over Temperature. The exhaust sensor measures over temperature (fire detection, element short circuit or low resistance). Remedy: (1) Check the integrity of the sensor circuit checking particularly for short circuits. Approximate resistances (+ 10%) at various temperatures are;...
  • Page 30 Fault Code 12 Lid Lock Switching Device Failure. Remedy: Check that there are no short circuits in the lid lock circuit which may have caused the failure in the sensor module. The resistance of the lid lock should be between 50 and 100 ohms. If the circuit is correct, replace the sensor module.
  • Page 31 Fault Code 20 Door Actuator Stalled. Remedy: As per fault code 21. Fault Code 21 Door Actuator Required Excess Voltage. Remedy: (1) Ensure there is no weight placed on the lid of the product (e.g. clothes basket). If so, remove the weight and retest. (2) Inspect the installation, making sure that the cabinet sits evenly on the floor.
  • Page 32 Fault Code 22 Door Actuator Open Circuit. Remedy: (1) Check that the actuator wiring is plugged into the sensor module and is not open circuit. If faulty, replace. (2) Replace the sensor module. (Refer to Section 6.36) Fault Code 23 Door Actuator Movement Interrupted By Low Voltage.
  • Page 33 Fault Code 29 Brown-Out Data Retrieval Error. Remedy: (1) If the fault occurs every time the dryer is turned on, replace the sensor module. (Refer to Section 6.36) (2) Replace the motor control module. (Refer to Section 6.35) Fault Code 30 Lid Lock unable to Lock - User Warning.

  • Page 34: Diagnostic Mode

    Diagnostic Mode 4.3.1 Entering the Diagnostic Mode Turn the power supply to the dryer on. Press and hold the Auto Dry down button, then press the Power button. The dryer is now in level 0 of the diagnostic mode. After initial entry into the diagnostic mode, the Start/Pause button operates the dryer as normal.

  • Page 35: Fault Diagnostics

    Fault Diagnostics Problem - No Power The following checks are based on there being the correct supply voltage at the outlet and the power cord is fastened securely to the dryer’s terminal block. WARNING: The power must be turned off and the dryer disconnected from the supply outlet to carry out the following checks.

  • Page 36: Check The Continuity Of The Power Cord (Gas)

    5.1.3 Check the Continuity of the Power Cord (Gas) Follow instructions for removal of the drum and chassis assembly. (Refer to Section 6.16) Pass the main power cord through the exhaust duct. Disconnect the 3 way in-line connector that is clipped to the motor controller.

  • Page 37: Check Voltage Across Elements (Electric Only)

    5.2.3 Check Voltage Across Elements (Electric Only) WARNING: Because the power must be on to carry out the following checks extreme care must be taken as death or electrical shock can occur. Refit the top deck and reconnect the machine to power supply. Start the dryer (Note: If there is no wet load in the dryer, the controller will turn the heat off after a short space of time.) With the dryer running on a regular cycle in the closing direction, and with the...

  • Page 38: Check The Flame Detector (Gas Only)

    5.2.6 Check the Flame Detector (Gas Only) The flame detector is much like a thermostat, although it is sensitive to radiant heat whereas a thermostat relies more on conduction/convection to get hot. However they are both essentially just switches. Therefore when it is cold the sensor should be closed circuit (near zero resistance) and when the sensor is sufficiently hot the switch will open (open circuit).

  • Page 39: Check The Motor Windings

    5.3.3 Check the Motor Windings. Remove the cover of the motor control module. (Refer to Section6.35) Unplug the motor harness from the motor control module. Check the resistance of the motor windings at the plug end of the motor harness. Resistance should be 9.6 ohms across any two terminals of the plug. If the motor resistances are correct, replace the motor control module.

  • Page 40: Problem - Over Drying

    Problem - Over Drying 5.5.1 Check the Moisture Sensing Circuit Check that the machine is correctly earthed. Check that the conductivity contacts are connected correctly. With the power disconnected from the dryer, use a suitable high impedance meter on a high ohms range to measure the resistance between the conductivity contacts. It should be 6.4 megohms (+1 megohm).

  • Page 41: Service Procedures

    Service Procedures ™ In order to service components of the SmartLoad dryer, certain procedures must be followed. These procedures are set out below. Servicing Note To avoid stripping screws, do not overtighten when re-assembling parts. If using a power screw driver have the torque setting on low. Take extra care not to damage wire terminals on removal as some of these have release clips.

  • Page 42: Removal Of Top Deck

    Removal of Top Deck 6.4.1 If the top deck is to be removed for replacement: Follow instructions for removal of the console. (Refer to Section 6.2) Disconnect the wiring harness from the display module. Carefully remove the two lid buffers from the front side top of the deck by levering upwards, taking care not to damage the top deck.

  • Page 43: Removal Of Lid Lock

    Removal of Lid Lock Follow instructions for removal of the top deck. (Refer to Section 6.4.2) Remove the screw securing the lid lock to the underside of the top deck, move the front downwards and slide out. Reassembly Refit in reverse manner. Components Within Cabinet Follow instructions for removal of the top deck.

  • Page 44: Removal Of Door Grabber Assembly

    Removal of Door Grabber Assembly Follow general servicing instructions for components within the cabinet. (Refer to Section 6.6) Close the drum door completely. Disconnect the wiring from the door grabber actuator at the sensor module. Push the tabs in on the rear of the left and right hand grabber housings and lift the Push Tabs assembly upwards and outwards.

  • Page 45: Removal Of Door Grabber

    Reassembly Refit in reverse manner. Ensure that the wiring to the actuator motor is clipped under the hooks and is in the slots in the cover. With the actuator clipped into the grabber housing, ensure that the actuator linkage is located correctly.

  • Page 46: Removal Of Door Bracket

    6.11 Removal of Door Bracket Follow general servicing instructions for components within the cabinet. (Refer to Section 6.6) If the drum door is closed, push down on the tabs on each side of the drum and slide the drum door partially open.

  • Page 47: Removal Of Drum Door Buffers

    6.13 Removal of Drum Door Buffers Follow general servicing instructions for components within the cabinet. (Refer to Section 6.6) Remove the door grabber assembly. (Refer to Section 6.8) Slide the drum door open. Unclip the drum door buffer and remove from underneath the drum door by pushing on the tab.

  • Page 48: Removal Of Drum And Chassis Assembly

    6.16 Removal of Drum and Chassis Assembly Follow general servicing instructions for components within the cabinet. (Refer to Section 6.6) Follow instructions for removal of the door grabber assembly. (Refer to Section 6.8) Remove the lid from the motor control module by pushing the clip on lid, lifting the front of the lid and sliding forward.

  • Page 49: Removal Of Outlet Duct Assembly

    6.18 Removal of Outlet Duct Assembly Follow instructions for removal of the outlet panel assembly. (Refer to Section 6.17) Remove the wiring loom plugs from the sensor module assembly. Remove the sensor module assembly from the outlet chassis panel. (Refer to Section 6.36) Lay the outlet panel assembly down with the outlet chassis panel uppermost.

  • Page 50: Removal Of Exhaust Sensor

    6.21 Removal of Exhaust Sensor Follow instructions for removal of the outlet duct Sensor Pocket assembly. (Refer to Section 6.18) Unclip the wiring loom and exhaust sensor harness Harness from the collector housing bracket. Clip Unclip the exhaust sensor from the pocket in the collector housing bracket by pushing it forward, then down.

  • Page 51: Removal Of Belt Tensioner

    6.24 Removal of Belt Tensioner Follow instructions for removal of the drum and chassis assembly. (Refer to Section 6.16) Remove the belt tensioner assembly by pushing against the spring tension and unclipping from the rear chassis beam. Push Belt Tensioner A screwdriver can be used to unclip it by putting the blade through the slot and levering against the beam.

  • Page 52: Removal Of Inlet Panel Assembly

    6.25 Removal of Inlet Panel Assembly Follow instructions for removal of the drum and chassis assembly. (Refer to Section 6.16) Manually open the drum door. Remove the drum inlet bearing. (Refer to Section 6.28) Lay the assembly on its left hand side. Remove the belt tensioner.

  • Page 53: Removal Of Inlet Bearing Shaft

    6.27 Removal of Inlet Bearing Shaft Follow instructions for removal of the inlet panel assembly. (Refer to Section 6.25) With a deep bore 22mm ( ”) socket, unscrew the inlet bearing shaft and remove. Reassembly Refit in reverse manner. Before refitting the inlet bearing shaft, ensure that the inlet bearing spacer is in position on the bolt between the inlet duct front panel and the inlet duct back panel.

  • Page 54: Removal Of Belt

    6.29 Removal of Belt Follow instructions for removal of the belt tensioner. (Refer to Section 6.24) Remove the outlet panel assembly. (Refer to Section 6.17) Remove the belt from the motor pulley. Remove the belt from around the drum. Reassembly Refit in reverse manner.

  • Page 55: Removal Of Fan

    6.33 Removal of Fan Follow instructions for removal of the motor. (Refer to Section 6.32) Remove the circlip securing the fan to the motor shaft. While sitting in a chair, place feet on top of the base of the fan and pull upwards on the motor. This will pull the motor shaft out of the spline in the fan.

  • Page 56: Removal Of Motor Control Module

    6.35 Removal of Motor Control Module Follow general servicing instructions for components within the cabinet. (Refer to Section 6.6) Remove the screw securing the front of the module to the base panel. Push in the tab below this screw and lift the front of the module upwards.

  • Page 57: Removal Of Thermostats

    6.39 Removal of Thermostats Follow general servicing instructions components within the cabinet. (Refer to Section 6.6) Remove the push on connectors from the appropriate thermostat terminal. Remove the screw securing the thermostat to the combustion housing and lift the thermostat clear. Reassembly Refit in reverse manner.

  • Page 58: Removal Of Front Foot Bracket Assembly

    6.42 Removal of Front Foot Bracket Assembly Follow instructions for removal of the drum and chassis assembly. (Refer to Section 6.16) Lay the cabinet on its side on a protective surface, with the foot bracket to be removed uppermost. With a screwdriver, push inwards on the rear tab of the foot bracket.
  • Page 59 Push the tab on the foot adjusting guide. Push the rear of the guide through the base panel and lift clear. Push the foot upwards to clear the top of the foot adjusting guide. Slide the foot sideways to remove it from the strap. Draw the strap back through the housing.

  • Page 60: Wiring Diagrams

    Wiring Diagrams U.S.A. Model (Electric) - 60 -...

  • Page 61: Model (Gas)

    U.S.A. Model (Gas) - 61 -...

  • Page 62: Fault Finding Flow Charts

    Fault Finding Flow Charts No Power Is there Arrange repair of power to the supply etc. as supply necessary outlet? Is the power cord fitted Refit correctly correctly? Is there Check as per continuity of Section 5.1.1 the power (Electric) or 5.1.3 cord? (Gas) Is there...

  • Page 63: No Heat (Electric Models)

    No Heat (Electric Models) Is a fault Refer to Section code displayed? Check as per Section 5.2.1 thermostats Repair/replace as necessary Check as per Are element Section 5.2.2 Replace motor resistances Repair/replace as control module necessary Are the Fit new inlet duct Is the inlet elements Check as per...

  • Page 64: No Heat (Gas Models)

    No Heat (Gas Models) Is a fault Refer to Section Replace sensor code module displayed? Is the inlet Fit new inlet duct Is the gas seal. Refer Section duct seal Reinstate supply supply OK? 6.26 Has the Is the outlet Reset thermostat.

  • Page 65: Drum Door Not Opening/Closing

    Drum Door Not Opening/Closing Is a fault Refer to Section code displayed? Are jockey pulleys free & Rectify fault belt aligned Check manual operation of Rectify fault drum door for jamming etc. Is actuator Repair as operating necessary Is drum inlet Is cabinet Replace bearing.

  • Page 66: Drum Does Not Rotate

    Drum Does Not Rotate Is a fault Refer to Section code displayed? Are the jockey Refit/repair as pulleys free & necessary belt aligned Are motor winding Refer to Section resistances 5.3.3 correct? Is continuity of harness to Repair/replace motor OK? Replace motor control module - 66 -...

  • Page 67: Clothes Take Too Long To Dry

    Clothes Take Too Long to Dry Are the inlet Is a fault grill & burner code Clean Refer to Section inlet grill free displayed? of lint? Are the Has the Clean and/or conductivity correct cycle Advise customer to reconnect correctly. contacts clean and been chosen use correct cycle...

  • Page 68: Noisy

    Noisy Are jockey Is ducting pulleys free & Repair Rectify fault damaged? belt aligned Are drum Are motor or Tighten vanes Rectify fault vanes tight? fan loose? Is there Fit new inlet duct excessive lint Is the inlet seal. Refer Section build up on Clean duct seal...
  • Page 69 Notes - 69 -...

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