MARS 2-PJT Dryer TRAINING MANUAL MAR. 2007 SAMSUNG Clothes Dryer Digital Appliances Division.

MARS 2-PJT DryerTRAINING MANUAL

MAR. 2007

SAMSUNG Clothes Dryer

Digital Appliances Division

1.1. Product IntroductionProduct Introduction

2.2. Changed Part ListChanged Part List

3.3. Instruction of FunctionInstruction of Function

4.4. Test Mode & Error CheckTest Mode & Error Check

5.5. Reference InformationReference Information

6.6. Disassembly & ReassemblyDisassembly & Reassembly

CONTENTS

1-1. Concept

1.Product Introduction

7.0 cu.ft. Energy Saving [3200 Wh/Cycle] Time Saving [Normal Course: 44 min]

MainFeature

Sub.Feature

Fuzzy Algorithm

Easy Reversible Door

Ergonomic Design

Extra-Capacity

Energy Saving

Time Saving

1-2. Specification


ItemFrontier I(316LEW)

Mars II (203AEW)

Silver White

Feature

용량 (cu.ft. DOE) 7.3 7.3 7.0 7.0

Power source Electric/Gas Electric/Gas Electric/Gas Electric/GasDrying Cycle 9 9 7 7

Heater5,300 W

(22,000Btu/hr)5,300 W

(22,000Btu/hr)5,300 W

(22,000Btu/hr)5,300 W

(22,000Btu/hr)Drying Level 5 5 3 3

Temp Select 5 5 4 4

Remaining time display Yes Yes Yes Yes

Drum light Yes Yes Yes Yes

Child lock Yes Yes Yes Yes

Reversible Door Yes Yes Yes Yes

Drum material STSS STSS STSS STSS

Window Size 15 inch 15 inch 15 inch 15 inch

Size (WxDxH : Inch) 27x30x38 27x30x38 27x30x38 27x30x38

Performance

Cycle time (AHAM 8lbs)

44 min 44 min 44 min 44 min

DOE Energy Factor1.37(kg/Kwh)-Elec1.2 (Kg/Kwh) Gas

1.37(kg/Kwh)-Elec1.2 (Kg/Kwh) Gas

Drying Noise 57 dBA 57 dBA 57 dBA 57 dBA

Design

Door STSS +Chrome Trim ABS + PP

Control Panel LED LED

Display Color Green Green


1-3. Product Dimension

DimensionInches(cm)

Height38”

(96.5)

Width27”

(68.6)

Depth With Door Open 90 Degrees

49”

(124.5)

Depth30-1/4”

(77.0)

Basic(Frontier1) Mars 2

Panel

Door

Display

2.Changed Part List

2-1. Design

Frame-Front

Div Basic(Frontier1) Mars 2

Shape

Assy

Door

•Cover Door( Stainless Decoration)•Inner D/Safety

•Cover Door (Silver Color Decoration)

2.Changed Part List

2-2. Door


Shape

Assy

Panel

•Separated Jog Dial & Power Button •All buttons are constructed by

separated parts.

•Separated Jog Dial & Power Button,

Start /Pause Button•All buttons are constructed by

separated parts.

2.Changed Part List

2-3. Panel


Shape

Assy

Panel

•Capacity : 7.3 Cu.ft. •Capacity : 7.0 Cu.ft.

2.Changed Part List

2-4. Frame-Front


Shape

Assy

PCB

Sub

•Display type : Progress Bar +88 Seg•Function Button : 11 Ea

•Display type : Progress LED +88 Seg•Function Button : 9Ea

2.Changed Part List

2-5. Design

3-1. Control Panel

3.Instruction of Function

How to Activate & DeactivateTo activate Child Lock, press the Time and Signal buttons at the same time for 3sec.To cancel it, repeat the above.

Description:1. It can be set up during the power-on or the operation.2. With this function activated, all buttons except for the Power button are to be uncontrollable.3. The Child Lock lamp will light up.

Notice:1. When the power goes out and comes back again, the Child Lock function will keep being activated.2. Just in case there are no buttons operating, except for the Power button, with its power back, check “Child Lock Lamp”, please.

3-2. Child Lock


3-3. Rack Dry


How to Mount Drying Rack1. Open the door.

2. Mount Drying Rack in tumbler by engaging the two rear tails into the two recessed areas in the back wall.

3. Place the front tail of Drying Rack on top of the lint filter.

4. Place items to dry on the rack, giving enough space between them to give more air contact.

5. Close the door.

6. Use Time Dry. Select time based on the conditions of items such as their water contents and fabric styles.

Start the dryer. It may be necessary to reset the timer if a longer drying time is needed.

SUGGESTED ITEMS SUGGESTED TEMP. SETTINGS

Washable sweaters

(block to shape; lay flat on rack)Heat (Low/Extra Low)

Stuffed toys

(cotton or polyester fiber filled)Heat (Low/Extra Low)

Stuffed toys

(foam or rubber filled)Air Fluff

Foam rubber pillows Air Fluff

Sneakers Fluff or Heat

WARNING – Drying foam rubber, plastic or rubber with a heat setting may cause damage to

the item and could lead to a fire. So, use Air Fluff only.

4. Test Mode & Error Check

Continuous Run Mode:

1. Press Dry Level + Signal for 3 sec during Power On State (normal user mode).

2. Once in Continuous Run Mode, “cc” and the remaining time will blink in the 7-Segment.

3. The previous cycle will restart during Continuous Run Mode until the mode is deactivated.

4. During Continuous Run Mode, press Dry Level + Signal for 3 seconds to go back to normal user mode. “cc” will go off and the remaining time will keep blinking.

4-1-1. Continuous Run Mode

Power On State(Normal User Mode)

Continuous Run ModeDry Level + Signal

3Sec

4-1-2. Special Test Mode


How to Enter:- To enter Service Mode , press Temp + Signal for 3 seconds, or until it sends out a beeping sound 3 times. (same for all Frontier models.)

Definition of Special Test Mode (Service Mode):- Dryer should be on to activate Service Mode. - With the activation of Service Mode, it will display 0 (Default Special Test Mode).

4-1-3. Sensor Bar Touch Data Mode


How to Enter:- Press Temp + Signal for 3 seconds during the drying process (same for all Frontier models.)

When there are wet items being dried, data will add up (from 0 to 1200 and repeating)as the wet clothes touch the sensor bars.

It is to check the moisture sensor bars (if it does not change with wet clothes inside, check the sensor bars.)

Definition of Sensor Bar Touch Data Mode:- It is to check the status of Sensor Bar.

4-1-4. Cycle Count Mode


How to Enter:- Press the Signal button at Service Mode.

Definition of Cycle Count Mode:- It is to bring up the total number of cycles that User have carried out.

4-1-5. Software Version Mode


How to Enter:- At Special Test Mode, press Temp until it sends out a beeping sound (same for all Frontier models.) ex) In case of "U105", U0 means major version "v1“ 05 means minor version "05"

Definition of Software Version Mode:- It is to retrieve its software version.


How to Enter System Check Mode:1. With the unit off, press Dry Level + Power. 2. " t2 " will light up. 3. Press Start/Pause. Then, it will work in the following order. Motor(CW) Relay On → Heater Relay On → Heater Relay Off → Motor(CW) Relay Off (Repeating)

Caution! Do not give it too much testing time. It would over-burden the Main PCB.

4-1-6. System Check Mode

Power Off State(Normal User Mode)

System Check ModeDry Level + Power

Definition of System Check Mode:- It is to check Motor & Heater Relays.

4-2. Error items and Diagnostic Codes


Display Description Trigger Cause & Corrective Action

tS Dryer Thermistor ShortVery low

resistance

- Clogged lint screen.- Restricted vent system.- Check Thermistor resistance.

tO Dryer Thermistor OpenVery high resistance

- Clogged lint screen.- Restricted vent system.- Check Thermistor resistance.

do Door OpenDryer running

with Door open- Close the door and run the dryer.- Loose or open wire terminals in Door S/W.

FEPower Source

Frequency ErrorAbnormal Power

Frequency- Power frequency should be normal.

4-2. Error items and Diagnostic Codes


Display Description Trigger Cause & Corrective Action

dF Door Circuit FailureInvalid state for more

than 256 msec- Loose or open wire terminals in Door S/W.

hE Heater ErrorInvalid heating temperature

- Restricted vent system.- Check Thermistor resistance.

bE Button ErrorButton held down for

more than 75secs- Button jammed.

od Excessive DryMore than 240min

drying time-Drying time is added up too much. -Check Sensor Bars.

Et EEprom FailInvalid EEprom communication

- Replace PCB

Problem Possible Cause & Corrective Action

Will Not Start or Run

• All connectors are plugged in correctly.

• Dryer is plugged into the power outlet.

• Check if house fuses or circuit breaker is blown.

• Check if the door is closed properly (if it is open, “do” will light up).

• Check if the rotary selector dial works well.

• Check if Control Board is good.

• Check if the belt is cut off or Belt Cut-off switch is initiated.

• Check if Drive Motor is spinning properly.

• Check motor winding resistance: 2.88ohms between pin #3 and 4, 3.5ohms between pin #4 and 5.

Motor runs/ tumbler will not turn• Check if the belt is cut off.

• Check if Idler Tension Spring is fatigued and get relaxed, pressing Belt S/W.

• Check if Idler Pulley is jammed or stuck.

Runs a few minutes and then stops

• Lint built-up around Drive Motor.

• Insufficient power.

• Blower Impeller stuck in Blower Housing.

5-1. Troubleshooting

5.Reference Information


Blown Fuses

Tripped Circuit Breaker

(Electric Model)

• The amperage readings are at 240 volts. One line will be 24 amps and the other

line will be 21amps. The neutral line will be at 3 amps. If the above amperages

are present, then the house wiring, fuse box or circuit breaker could be

suspicious (faulty).

• Shorted heating element to housing.

• Incorrect wiring or wire-short to ground.

• Drive motor winding shorted to ground.

Blown Fuses

Tripped Circuit Breaker

(Gas Model)

• During ignition, the dryer will draw 7 amps. With the burner ON, the dryer will

draw 4.5 amps. If the dryer is drawing amperages roughly about, then the house

wiring, fuse box or circuit breaker could be suspicious (faulty).

• Igniter harness loose and shorted to base.

• Incorrect wiring or wire shorted to ground.

• Drive motor winding shorting to ground.

No Heating (Motor Spinning)

• Defective Heater (Open Circuit).

• Hi-Limit trips easily or is open.

• Regulating thermostat trips easily or is open.

• Membrane Switch (Open – Centrifugal S/W).

• Check Thermistor.

• Check Sensor Bars






Will Not Dry Gas Model

Poor Gas Ignition

When the dryer is operated on a heat setting, the igniter should be energized and burner shall fire within 45 seconds at 120 VAC. The failure of a component in this system will usually be indicated by one of three symptoms:

The igniter does not glow.

If the igniter does not heat up, remove power and using an ohmmeter, check the following:

• Open Radiant Sensor (Flame Sensor)

• Open Igniter

• Shorted Booster Coil

• Open wiring

• Bad Motor Switch (Centrifugal S/W, Neutral supply)

• No power from control ( L1 supply)

No gas ignition with the igniter glowing.

If the igniter heats up but the main burner flame is not ignited, remove power and using an ohmmeter, check the following:

• Open Secondary Coil

• Open Holding Coil

• Open wire harness

• Stuck Radiant Sensor (Stuck closed)

It dies after the ignition (gas).

If a normal ignition takes place and after a short while the flame goes out, check for the following:

• Radiant sensor contacts opening prematurely.

• Weak gas valve coil may get open when being stressed by higher Temps.

• Weak Hi-Limit

• Poor venting

• Bad drum rubber seal


Insufficient Drying

Too much wrinkle

Rough texture

Long drying time

• Clean Lint Filter.

• Remove any restriction in the exhaust system.

• Too long Exhaust Pipe (extended) or too many elbows.

• Insufficient air-intake.

• Incorrect tumbler speed due to the slipping of Tumbler Belt.

• Remove any restriction in Blower Impeller.

• Overloaded Dryer.

• Set the selection according to labels on the clothes.

• Clothes containing too much water.

Noise/Vibration

• Thumping - Check for loose tumbler baffle, worn or misaligned rear tumbler rollers, eccentric tumbler or stepped weld-seam on tumbler.

• Ticking - Check for loose wire harness or any restriction in Blower Wheel.

• Scraping - Check if front or rear bulkhead Felt Seal is out of position or Tumbler Front Bearing is worn out.

• Roaring - Check if Blower Wheel rubs on Blower Housing, or Motor Bearing is worn out.

• Popping/Squealing - Check for belt slipping.



5-2. Wiring Diagram


5-3. Component Check


Parts Image Description Value

ThermistorUnplug connector and test from wire insertion side.Pin #2 and Pin #6 of CN6 10 KΩ @ 77° F/25°C

Door Switch

Unplug connectors and test switch terminals. Door open terminals COM to NC Door open terminals COM to NO Door closed terminals COM to NC Door closed terminals COM to NO

InfinityLess than 1 ΩInfinityLess than 1 Ω

LampUnplug connectors and test switch terminals. Check across terminals 80 to 100 Ω

Belt SwitchUnplug connectors and test switch terminals. Check across terminals switch closed Check across terminals switch open

Less than 1 ΩInfinity

COMNONC

[Gas] [Electric]<Radiant Sensor>



Parts Spec Description Value

Thermostat 1Thermostat Cut Off

185°F/85°C, 25AUnplug connector and measure its resistance Less than 1 Ω

Thermostat 2

Hi Limit260°F/117°C, 25A

(Electric)230°F/110°C, 25A

(Gas)

Unplug connector and measure its resistance Less than 1 Ω

Thermostat 3Thermostat Cut Off

320°F/160°C, 25AUnplug connector and measure its resistance Less than 1 Ω

Heater 240V 5300W Unplug connectors and test Heater terminals 10 Ω

Thermostat 1 Thermostat3 Thermostat2 Heater

Electric Dryer Gas Dryer

Thermostat2



Parts Image Description Value

Radiant Sensor(Gas)

Unplug connectors and test sensor terminals. Closed

Sensor BarsUnplug connector and measure its resistance.Pin #4 to Pin # 5 of CN6

Infinity dry load 190 Ω ± 10% wet load

Motor

Unplug harness connector and test motor circuits. Pin #4 and Pin #5 (Windings) Pin #1 and Pin #2 (Centrifugal switch)

Refer to 5-2 wiring for differences between Electric & Gas

2 ΩOpen

Gas Valve

Unplug connectors and test valve terminals(its numbering is from the front terminal.) Check across terminals #1 and #3 (Booster Coil).Check across terminals #1 and #2 (Holding Coil).Check across terminals #2 and #3 (Both coils in series). Check across terminals #4 and #5 (Secondary Coil).

550 Ω1350 Ω 1900 Ω1300 Ω

5-4. Main PBA Layout (The Principle Part)


Item Part No.

Description

① Ry1 Motor Relay

② Ry2 Heater Relay

③ PC1~2 Check for the FrequencyMake the ZerocrossDoor Lock Check

④ BD1 It Work to Change the AC to the DC

⑤ IC9 Drop the Voltage

⑥ IC1 Regulation for the 5V

Item Part No. Description

⑦ CE3 Charge the DC LINK (300V)

⑧ IC1 Drive the Relay Supply the Current to the Acting Current

⑨ BZ1 Making a Sound

⑩ Micom Control the Washing Machine

①

②

③

④⑤

⑥

⑦

⑧

⑨

⑩

5-5. Connector & Relay Terminal Description (Main PBA)


CN5①Connects to Earth②Connects to Door

CN5①Connects to Earth②Connects to Door

CN2①~ Connects to Sub Display⑬ for the Communication.

CN2①~ Connects to Sub Display⑬ for the Communication.

CN12①NC②Connects to Thermister1 ③NC④Connects to Moisture Sensor1⑤Connects to Moisture Sensor2⑥Connects to Themister2

CN12①NC②Connects to Thermister1 ③NC④Connects to Moisture Sensor1⑤Connects to Moisture Sensor2⑥Connects to Themister2

CN3①AC1

CN3①AC1

Relay 1①Connects to a Belt Switch of the Motor②Connects to AC1

Relay 1①Connects to a Belt Switch of the Motor②Connects to AC1

CN1①~ Connects to Sub Display⑫ for the Communication.

CN1①~ Connects to Sub Display⑫ for the Communication.

Relay 2①Connects to Heater ②Connects to AC1

Relay 2①Connects to Heater ②Connects to AC1


5-6. Sub PBA Layout (The Principle Part)

①

③

②

④

④

Item Part NO. Description

1 DSP1 Display the Course

2 IC1 ~ 3Drive the LED & DisplaySupply the Current to the Acting Current

3 ENCODER1 Rotary Switch (For the Selecting a Course)

4 LED & KEYInput the Detail CourseDisplay the Resent Course

5-7. Connector & Relay Terminal Description (Sub PBA)


CN2①~ Connects to Main PBA⑬ for the Communication.

CN2①~ Connects to Main PBA⑬ for the Communication.

CN1①~ Connects to Main PBA⑫ for the Communication.

CN1①~ Connects to Main PBA⑫ for the Communication.

5-8. Nomenclature


2 3 A E W / XAA0

Code for SEA

DV

BOM Model Code

DV

(Dryer Vent Type)

Power Source

- E : Electric

- G : Gas

Color

W (White)

S (Imperial Silver)

Dealer

A (All Buyer)

Capacity

Model Code for Dealer

5-9. Models


Model code SPEC COLOR

DV203AEW7.0 cu.ft CapacityElectric type240V/60Hz, Color : Wht

DV203AGW7.0 cu.ft CapacityGas type120V/60Hz, Color : Wht

DV203AES7.0 cu.ft CapacityElectric type240V/60Hz, Color : Imperial Silver

DV203AGS7.0 cu.ft CapacityGas type120V/60Hz, Color : Imperial Silver

5-10. Q & A


Q. What does it mean when chasing light appear in the display?

A. The chasing lights appear in the display when Wrinkle Prevent is selected. This lets you know that the dryer is tumbling intermittently for 95 minutes with room temperature air after the cycle is complete to reducing wrinkling. The load is dry and can be removed at any time during Wrinkle Prevent.

Q. Why is the estimated drying time so long?

A. The initial estimated drying time will be longer because the dryer has not yet detected the amount of moisture in the load. After the dryer has been running for several minutes, a more accurate estimate will be displayed. Remember, the times are estimated. The actual drying time may be longer or shorter, depending on the load.

Q. My dryer seems to run longer than I expect. Why?

A. The dryer automatically senses the dryness level of load. Be careful to avoid overloading your dryer. For best drying results, avoid mixing heavy and lightweight items in the same load.

Move

Drum Lifter

Control Panel

1. Unplug the unit.2.Remove 2 screws from the tails.3.Slide back Top Cover and

remove it.

Top Cover

FIGUREDESCRIPTIONPART NAME

6.Disassembly & Reassembly

1.Unplug the unit.2.Remove Top Cover.3.Remove four screws from the Drum.

1.Unplug the unit.2.Remove Top Cover.3.Remove two screws from the PCB case.4.Unplug all connectors.5.Remove four screws fixing Control Panel to the unit.6.Remove it from the unit.

Move

1.Unplug the unit.2.Remove two screws from Door Lock Guide.3.Remove two screws from Door Hinge.4.Assemble Door Lock Guide and Door Assy to each other’s location. 5.Remove screws along the perimeter of Door Inner Panel.6.Remove Inner Panel.7.Remove Gasket to separate Inner Door Glass.8.Remove the outer window by pushing it outward.9.Insert screwdriver into the slot and lever up Door Latch.

Door Reversal / Disassembly



Move

Front Panel Removal



1.Unplug the unit.2.Remove Top Cover.3.Remove Control Panel.4.Remove five screws fixing Front Panel to the unit.5.Pull Front Panel forward and disconnect the Interior

Light harness.7.Lift the Front Panel out of the three tabs on the bottom and remove it from the unit.

Move

Front Bulkhead



1.Unplug the unit.2.Remove Top Cover.3.Remove Control Panel.4.Remove Front Panel.5.Remove five screws fixing the Control Panel support.6.Disconnect the Interior Light harness.7.Disconnect Moisture Sensor wiring harness.8.Remove the four Bulkhead retaining screws.9.Lift and remove Bulkhead from the frame.

Moisture Sensor & Incandescent Lamp

1.Unplug the unit.

2.Remove Top Cover.

3.Remove Control Panel.

4.Remove Front Panel.

5.Remove fixing screws to

disengage Moisture Sensor

& Incandescent Lamp

Move

Drum



1. After the above knock-down to Front Bulkhead, do the

following.2. Flip up Idler Pulley and slip out Belt from it.3.Grasp Drum with one hand and Belt with the other, and take out Drum.

* Carefully spread the cabinet as needed to get extra clearance. But, take care not to deform the cabinet.

1.After the knock-down to Rear Bulkhead, do the following. 2.Remove Roller Keeper and nut.

Rear Roller

(After removing

Rear Bulkhead)

Move

Motor/Blower

Assembly (1)



1.After the knock-down to Drum, do the following. 2.Remove the two screws securing Blower Intake Panel to Blower Housing. 3.Remove Blower Intake panel.4.Remove the blower securing screw under the Thermistor.5.Removed the screw at the bottom of Blower Housing.6.Plug out all the connectors.7.Remove two screws securing the motor bracket to the base.

Move

Motor/Blower

Assembly (2)



8.Remove the assy block by disengaging it from its retaining hooks at the bottom.9.Lock Blower Wheel with a screwdriver and remove the 14mm nut securing the blower wheel to the shaft. 10.Remove Blower Wheel.11.Remove the three screws securing the blower housing to the motor bracket.12.Use a flat-head screwdriver to lever out the motor retention clamps.13.Remove Motor from the unit

Move

1.After the knock-down to Motor/ Blower Assy, do the following. 2.Shut off gas supply.3.Disconnect gas pipe.4.Remove all the connectors.5.Remove two screws (one at the front and the other one at the back) securing Burner to Frame.NOTE: The Igniter Bar is fragile. So, take care when removing Burner Assy.6.Remove the two screws attaching the housing to Burner Bracket. 7.Remove Burner Assy from the unit.

Burner

(For Electric Dryer, refer to Page54.)



1.After the knock-down to Drum, do the following. 2.Remove 7 screws at the back of the unit.3.Lift Rear Bulkhead up and take it out of its retaining slots.

Rear Bulkhead

Move

1.After the knock-down to Rear Bulkhead, do the following. 2.Remove 4 screws securing Vent Duct Assy to the unit.3.Remove the screw securing Vent Duct to the bracket.

Vent Duct



Remove each securing screws to remove each of the sensors.

For differences between Gas and Electric, refer to 5-3. Component Check.

Sensors

(Thermostat,

Thermistor,

Radiant/Flame)

Move

Heater Assembly



1.After the knock-down to Motor/ Blower Assy, do the following.2.Remove the screw (red) securing Heater Assembly.3.Slide it out of its guide at the back.4.Plug out all the terminals.

The End

MARS 2-PJT Dryer TRAINING MANUAL MAR. 2007 SAMSUNG Clothes Dryer Digital Appliances Division.

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Transcript of MARS 2-PJT Dryer TRAINING MANUAL MAR. 2007 SAMSUNG Clothes Dryer Digital Appliances Division.