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MARS 2-PJT Dryer

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Title: 1 Author: win-2 Last modified by: Windows XP Created Date: 3/14/2005 6:02:33 AM Document presentation format: – PowerPoint PPT presentation

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Title: MARS 2-PJT Dryer


1
SAMSUNG Clothes Dryer
MARS 2-PJT Dryer TRAINING MANUAL
MAR. 2007
Digital Appliances Division
2
CONTENTS
  1. Product Introduction
  2. Changed Part List
  3. Instruction of Function
  4. Test Mode Error Check
  5. Reference Information
  6. Disassembly Reassembly

3
1.Product Introduction
1-1. Concept
? Extra-Capacity ? Energy Saving ? Time Saving
? 7.0 cu.ft. ? Energy Saving 3200
Wh/Cycle ? Time Saving Normal Course 44
min
Main Feature
Sub. Feature
? Fuzzy Algorithm ? Easy Reversible Door ?
Ergonomic Design
4
1.Product Introduction
1-2. Specification
Item Item Frontier I (316LEW) Frontier I (316LEW) Frontier I (316LEW) Mars II (203AEW) Mars II (203AEW)
Item Item Frontier I (316LEW) Frontier I (316LEW) Frontier I (316LEW) Silver White
Feature ??(cu.ft. DOE) 7.3 7.3 7.3 7.0 7.0
Feature Power source Electric/Gas Electric/Gas Electric/Gas Electric/Gas Electric/Gas
Feature Drying Cycle 9 9 9 7 7
Feature Heater 5,300 W (22,000Btu/hr) 5,300 W (22,000Btu/hr) 5,300 W (22,000Btu/hr) 5,300 W (22,000Btu/hr) 5,300 W (22,000Btu/hr)
Feature Drying Level 5 5 5 3 3
Feature Temp Select 5 5 5 4 4
Feature Remaining time display Yes Yes Yes Yes Yes
Feature Drum light Yes Yes Yes Yes Yes
Feature Child lock Yes Yes Yes Yes Yes
Feature Reversible Door Yes Yes Yes Yes Yes
Feature Drum material STSS STSS STSS STSS STSS
Feature Window Size 15 inch 15 inch 15 inch 15 inch 15 inch
Feature Size (WxDxH Inch) 27x30x38 27x30x38 27x30x38 27x30x38 27x30x38
Performance Cycle time (AHAM 8lbs) 44 min 44 min 44 min 44 min 44 min
Performance DOE Energy Factor 1.37(kg/Kwh)-Elec 1.2 (Kg/Kwh) Gas 1.37(kg/Kwh)-Elec 1.2 (Kg/Kwh) Gas 1.37(kg/Kwh)-Elec 1.2 (Kg/Kwh) Gas 1.37(kg/Kwh)-Elec 1.2 (Kg/Kwh) Gas 1.37(kg/Kwh)-Elec 1.2 (Kg/Kwh) Gas
Performance Drying Noise 57 dBA 57 dBA 57 dBA 57 dBA 57 dBA
Design Door STSS Chrome Trim STSS Chrome Trim STSS Chrome Trim ABS PP ABS PP
Design Control Panel LED LED LED LED LED
Design Display Color Green Green Green Green Green
5
1.Product Introduction
1-3. Product Dimension
Dimension Inches(cm)
Height 38 (96.5)
Width 27 (68.6)
Depth With Door Open 90 Degrees 49 (124.5)
Depth 30-1/4 (77.0)
6
2.Changed Part List
2-1. Design
Basic(Frontier1) Mars 2

Panel
Display
Door
Frame-Front
7
2.Changed Part List
2-2. Door
Div Basic(Frontier1) Mars 2
Shape
Assy Door Cover Door( Stainless Decoration) Inner D/Safety Cover Door (Silver Color Decoration)
8
2.Changed Part List
2-3. Panel
Div Basic(Frontier1) Mars 2
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.
9
2.Changed Part List
2-4. Frame-Front
Div Basic(Frontier1) Mars 2
Shape
Assy Panel Capacity 7.3 Cu.ft. Capacity 7.0 Cu.ft.
10
2.Changed Part List
2-5. Design
Div Basic(Frontier1) Mars 2
Shape
Assy PCB Sub Display type Progress Bar 88 Seg Function Button 11 Ea Display type Progress LED 88 Seg Function Button 9Ea
11
3.Instruction of Function
3-1. Control Panel
12
3.Instruction of Function
3-1. Control Panel
13
3.Instruction of Function
3-1. Control Panel
14
3.Instruction of Function
3-2. Child Lock
How to Activate Deactivate To 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.
15
3.Instruction of Function
3-3. Rack Dry
How to Mount Drying Rack 1. 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.
16
4. Test Mode Error Check
4-1-1. Continuous Run Mode
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.
17
4. Test Mode Error Check
4-1-2. Special Test Mode
  • 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).

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.)
18
4. Test Mode Error Check
4-1-3. Sensor Bar Touch Data Mode
  • Definition of Sensor Bar Touch Data Mode
  • It is to check the status of Sensor Bar.

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.)
19
4. Test Mode Error Check
4-1-4. Cycle Count Mode
Definition of Cycle Count Mode - It is to bring
up the total number of cycles that User have
carried out.
  • How to Enter
  • Press the Signal button at Service Mode.

20
4. Test Mode Error Check
4-1-5. Software Version Mode
Definition of Software Version Mode - It is to
retrieve its software version.
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"
21
4. Test Mode Error Check
4-1-6. System Check Mode
Power Off State
Dry Level Power
System Check Mode
(Normal User Mode)
Definition of System Check Mode - It is to check
Motor Heater Relays.
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.
22
4. Test Mode Error Check
4-2. Error items and Diagnostic Codes
Display Description Trigger Cause Corrective Action
tS Dryer Thermistor Short Very low resistance - Clogged lint screen. - Restricted vent system. - Check Thermistor resistance.
tO Dryer Thermistor Open Very high resistance - Clogged lint screen. - Restricted vent system. - Check Thermistor resistance.
do Door Open Dryer running with Door open - Close the door and run the dryer. - Loose or open wire terminals in Door S/W.
FE Power Source Frequency Error Abnormal Power Frequency - Power frequency should be normal.
23
4. Test Mode Error Check
4-2. Error items and Diagnostic Codes
Display Description Trigger Cause Corrective Action
dF Door Circuit Failure Invalid state for more than 256 msec - Loose or open wire terminals in Door S/W.
hE Heater Error Invalid heating temperature - Restricted vent system. - Check Thermistor resistance.
bE Button Error Button held down for more than 75secs - Button jammed.
od Excessive Dry More than 240min drying time Drying time is added up too much.   Check Sensor Bars.
Et EEprom Fail Invalid EEprom communication - Replace PCB
24
5.Reference Information
5-1. Troubleshooting
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.
25
5.Reference Information
5-1. Troubleshooting
Problem Possible Cause Corrective Action
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
26
5.Reference Information
5-1. Troubleshooting
Problem Possible Cause Corrective Action
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
27
5.Reference Information
5-1. Troubleshooting
Problem Possible Cause Corrective Action
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.
28
5.Reference Information
5-2. Wiring Diagram
29
5.Reference Information
5-2. Wiring Diagram
30
5.Reference Information
5-3. Component Check
Parts Image Description Value

Thermistor Unplug connector and test from wire insertion side. Pin 2 and Pin 6 of CN6 10 K? _at_ 77 F/25C
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 Infinity Less than 1 ? Infinity Less than 1 ?
Lamp Unplug connectors and test switch terminals.  Check across terminals 80 to 100 ?
Belt Switch Unplug connectors and test switch terminals. Check across terminals switch closed Check across terminals switch open Less than 1 ? Infinity
Gas
Electric
ltRadiant Sensorgt
COM NO NC
31
5.Reference Information
5-3. Component Check
Parts Spec Description Value

Thermostat 1 Thermostat Cut Off 185F/85C, 25A Unplug connector and measure its resistance Less than 1 ?
Thermostat 2 Hi Limit 260F/117C, 25A (Electric) 230F/110C, 25A (Gas) Unplug connector and measure its resistance Less than 1 ?
Thermostat 3 Thermostat Cut Off 320F/160C, 25A Unplug connector and measure its resistance Less than 1 ?
Heater 240V 5300W Unplug connectors and test Heater terminals 10 ?
Thermostat 1
Thermostat3 Thermostat2 Heater
Thermostat2
Electric Dryer
Gas Dryer
32
5.Reference Information
5-3. Component Check
Parts Image Description Value
Radiant Sensor (Gas) Unplug connectors and test sensor terminals. Closed
Sensor Bars Unplug connector and measure its resistance. Pin 4 to Pin 5 of CN6 Infinity dry load 190 ? 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 ? Open
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 ? 1350 ? 1900 ? 1300 ?
33
5.Reference Information
5-4. Main PBA Layout (The Principle Part)
?
?
?
?
?
?
?
?
?
?
Item Part No. Description
? Ry1 Motor Relay
? Ry2 Heater Relay
? PC12 Check for the Frequency Make the Zerocross Door Lock Check
? BD1 It Work to Change the AC to the DC
? IC9 Drop the Voltage
? IC1 Regulation for the 5V
Item Part No. Description
? CE3 Charge the DC LINK (300V)
? IC1 Drive the Relay Supply the Current to the Acting Current
? BZ1 Making a Sound
? Micom Control the Washing Machine
34
5.Reference Information
5-5. Connector Relay Terminal Description (Main
PBA)
CN5 ?Connects to Earth ?Connects to Door
CN2 ?? Connects to Sub Display for the
Communication.
CN1 ?? Connects to Sub Display for the
Communication.
CN3 ?AC1
Relay 1 ?Connects to a Belt Switch of the
Motor ?Connects to AC1
Relay 2 ?Connects to Heater ?Connects to AC1
CN12 ?NC ?Connects to Thermister1 ?NC ?Connects
to Moisture Sensor1 ?Connects to Moisture
Sensor2 ?Connects to Themister2
35
5.Reference Information
5-6. Sub PBA Layout (The Principle Part)
?
?
?
?
?
Item Part NO. Description
1 DSP1 Display the Course
2 IC1 3 Drive the LED Display Supply the Current to the Acting Current
3 ENCODER1 Rotary Switch (For the Selecting a Course)
4 LED KEY Input the Detail Course Display the Resent Course
36
5.Reference Information
5-7. Connector Relay Terminal Description (Sub
PBA)
CN2 ?? Connects to Main PBA for the
Communication.
CN1 ?? Connects to Main PBA for the
Communication.
37
5.Reference Information
5-8. Nomenclature
Model Code for Dealer
BOM Model Code
2
3
A
E
W
/
XAA
0
DV
Code for SEA
Dealer A (All Buyer)
Color W (White) S (Imperial Silver)
Capacity
Power Source - E Electric - G Gas
DV (Dryer Vent Type)
38
5.Reference Information
5-9. Models
Model code SPEC COLOR
DV203AEW 7.0 cu.ft Capacity Electric type 240V/60Hz, Color Wht
DV203AGW 7.0 cu.ft Capacity Gas type 120V/60Hz, Color Wht
DV203AES 7.0 cu.ft Capacity Electric type 240V/60Hz, Color Imperial Silver
DV203AGS 7.0 cu.ft Capacity Gas type 120V/60Hz, Color Imperial Silver
39
5.Reference Information
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.
40
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
1. Unplug the unit. 2.Remove 2 screws from the
tails. 3.Slide back Top Cover and remove it.
Top Cover
Drum Lifter
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.
Control Panel
41
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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 others 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
42
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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.
43
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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
44
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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)
45
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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.
46
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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
47
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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.)
Rear Bulkhead
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.
48
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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)
49
6.Disassembly Reassembly
Move
FIGURE
DESCRIPTION
PART NAME
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.
50
The End
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