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Electrolux ZANUSSI TCE7124W Service Manual
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Electrolux ZANUSSI TCE7124W Service Manual

Electrolux ZANUSSI TCE7124W Service Manual

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 ELECTROLUX ZANUSSI S.p.A.
Spares Operations Italy
Corso Lino Zanussi,30
I - 33080 PORCIA /PN (ITALY)
Fax +39 0434 394096
Edition: 2002-07-30
SOI/DT 2002-07 dmm
Publication No.
599 35 38-32
EN
SERVICE MANUAL
DRYER
P54
(CONDENSER NEXUS 4)
ELECTROMECHANICAL
ELECTRONIC
TANK IN LOWER
SECTION
Production:
ZP - Porcia (IT)
DRYERS
599 35 38-32

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Summary of Contents for Electrolux ZANUSSI TCE7124W

  • Page 1 SERVICE MANUAL DRYERS DRYER  ELECTROLUX ZANUSSI S.p.A. Publication No. (CONDENSER NEXUS 4) Spares Operations Italy Corso Lino Zanussi,30 ELECTROMECHANICAL I - 33080 PORCIA /PN (ITALY) 599 35 38-32 ELECTRONIC Fax +39 0434 394096 TANK IN LOWER SECTION Edition: 2002-07-30...
  • Page 2 SOI/DT 2002-07 dmm 2/55 599 35 38-32...
  • Page 3 CONTENTS INTRODUCTION..........................5 Installation ............................ 5 Use............................... 5 Purpose of this service manual ..................... 5 Safety............................5 AIR CIRCULATION SYSTEM INSIDE THE DRYER WITH TANK IN LOWER SECTION....... 6 CONSTRUCTIVE CHARACTERISTICS ....................7 DRUM ..............................8 4.1.1 Drum for electromechanical dryer ................... 8 4.1.2 Drum for conductimetric electronic dryer .................
  • Page 4 16.4.1 Heater unit..........................39 16.5 ACCESS FROM THE SIDE PANEL.................... 40 16.5.1 Floating microswitch ......................41 16.5.2 Float............................. 41 16.5.3 Drop tray ..........................42 16.5.4 Door lock..........................42 ACCESS FROM THE RIGHT PANEL ....................43 16.5.5 Capacitor..........................43 16.5.6 Front scroll cover (warm air circulation)................. 43 16.5.7 Back scroll cover (cold air circulation) ...................
  • Page 5 1 INTRODUCTION The special feature of a condenser dryer is that it is not necessary to connect an exhaust duct to vent the warm air to the exterior. Instead, the humidity is removed from the wash load by a specially-designed heat exchanger in which two air circuits interact: the warm, humid air which circulates inside the appliance and the cold air drawn in from the surrounding ambient.
  • Page 6 2 AIR CIRCULATION SYSTEM INSIDE THE DRYER WITH TANK IN LOWER SECTION There are two air circuits inside the dryer: - the first is a warm-air circuit, which is sealed within the appliance - the second is an open cold-air circuit, which circulates air from the ambient through certain sections of the appliance) In the first warm-air circuit, the air circulates inside the appliance: The fan (1), ducts the air through a heat exchanger (5), and then to the heater unit (2), 2).
  • Page 7 3 CONSTRUCTIVE CHARACTERISTICS 1 - Work top 11 – Rear panel 2 – Control panel support 12 – Crossbar 3 – Front panel 13 – Side panel 4 – Fluff filter 14 – Duct 5 – Fluff filter support 15 – Front panel 6 –...
  • Page 8 4 DRUM 4.1.1 Drum for electromechanical dryer 1 – Front flange 2 – Drum housing 3 – Back flange 4 – Drum lifters General features: Parts 1, 2 and 3 are connected by crimping. The plastic lifters are fitted with screws. The various elements which make up the drum may be in sheet steel (AISI 430), galvanized steel or a mix of zinc and steel.
  • Page 9 AIR SEALS AND DRUM SUPPORTS 5.1 Front air seal 1 – Back seal (fixed to the rear panel) 2 – Drum 3 – Rear panel 5.2 Rear drum support 4 – Anti-clutching washer 5 – Fixing ring (Benzing) 6 – Rear panel 7 –...
  • Page 10 7 SAFETY DEVICES This dryer is provided with 2 safety devices in order to make the dryer safe for the user: One safety is inside the door lock (see par. 8.8 page15) One safety is in the heat exchanger box (when the door is open to check the heat exchanger, a microswitch is actioned and switches off the dryer).
  • Page 11 8 MAIN ELECTRIC COMPONENTS 8.1 Junction box with integrated interference suppressor A = Interference suppressor components L = Phase N = Neutral The suppressor is connected to the input of the dryer's power line, and is designed to prevent radio disturbance in the mains circuit.
  • Page 12 8.4 Time switch General features: The time switch is a time-device that controls the various phases which make up a drying cycle. It consists of two sectors: - The first one, for drying resistant fabrics (Linen, Cotton ect.) lasts max. 150 minutes with 10 minutes of cooling, with the two heating elements of the heater unit switched on.
  • Page 13 8.5 Heater unit 1 - Filament heating element 2 - Ceramic supports 3 - Sheet metal casing 4 - Safety thermostat N.C. (automatic reset) 5 - Safety thermostat N.C. General features: The heater unit consists of two wire heating elements with different powers. The heating elements are fitted to ceramic supports, and the entire assembly is contained in a sheet metal casing.
  • Page 14 8.6 Cycling thermostat ° 1 - Terminal of 110 N.C. safety thermostat ° 2 - Terminal of 82 N.C. automatic reset functional thermostat 3 - Bimetal 4 - Contact C - Terminal not used General features: The thermostats regulate and control the air temperature inside the appliance. They are bimetal, with fixed temperature values.
  • Page 15 8.8 Door lock 8.8.1 Dryer with electromechanical control General features: An electromechanical device is used as door lock, which powers the appliance after the closure of the door and the pressure of the start button. It is provided with child safety and in case of need the door can be opened pushing it from the inside. Key wiring diagram: A –...
  • Page 16 2 - By closing the door, the catch E rotates pin F. This movement frees lever G and the button of the diverter A changes position closing the contacts 1-3. Start button (H) can perform its function. 3 – By pushing start button (H) placed in the front panel, the coil (M) is powered, which actions the slider (I). This moves the lever (L) thus modifying the position of the deviator (B) and closing contacts 4-6.
  • Page 17 8.8.2 Dryer with electronic control This type of door lock differs from the previous because it has only one microswitch, that actioned from the door catch. The functioning is the same to that described in paragraph 1and 2 for the electromechanical version.
  • Page 18 9 DRYER WITH ELECTRONIC CONTROL 9.1 Electrical components 9.1.1 NTC-Sensor The NTC sensor is fitted to the flange of the wash load aperture, inside the drum. The sensor consists of a resistor (whose resistance varies with the temperature) contained in a metallic capsule; the surface of the capsule is an integral part of the interior of the drum.
  • Page 19 9.1.2 Programme selector The programme selector can be a 12-16 position commutator (depending on the version); each position corresponds to a binary code which determines the drying cycle. 9.1.2.1 16-position programme selector (some versions) 9.1.2.2 12-position programme selector (some versions) SOI/DT 2002-07 dmm 19/55 599 35 38-32...
  • Page 20 9.1.3 Conduct metric sensor The conduct metric 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 conduct metric sensor switches on four minutes after the start of the automatic programme.
  • Page 21 9.1.4 Power board 1 = Display socket Kp1 = Line 2 = Programme selector = Motor 3 = Humidity sensor NTC = Temperature sensor 4 = Tank switch = Pilot lamp 5 = Electronic board = Pump b1 = Line switch RL1 = Relay b2 = Microbox (heat exchanger) RL2 = Relay...
  • Page 22 9.1.5 Power supply to loads The figure above represents a simplified version of the power supply circuit to the heater unit via relays RL3 and RL4; relays RL2 and RL1 power the motor and determine the direction of rotation of the motor. SOI/DT 2002-07 dmm 22/55 599 35 38-32...
  • Page 23 10 THE PHASES OF A DRYING CYCLE DRYING X duration for automatic programmes, while for the timer-controlled cycles the duration is determined by the time set with the selector. COOLING 10-minute duration. ANTI-CREASE 30 minutes duration. Timer-controlled drying cycles end with a cooling phase. 10.1 DRYNG Phase During this phase the corresponding LED remains lit, the heating unit and the drum rotation motor are powered.
  • Page 24 PHASE 1 = No loads powered. PHASE 2 = Clockwise rotation of motor. PHASE 3 = No loads powered. PHASE 4 = Counter-clockwise rotation of motor. PHASE 5 = Counter-clockwise rotation of motor + 1400W branch of heating element ON. PHASE 6 = Counter-clockwise rotation of motor and both branches of heating element ON.
  • Page 25 11 ELECTRONIC CONTROL SYSTEM: TIMING SEQUENCE * During the initial 30 minutes, the duration of the counter-clockwise drum rotation phases is 180 seconds. Thereafter, the duration of these phases increases to 240 seconds. SOI/DT 2002-07 dmm 25/55 599 35 38-32...
  • Page 26 12 TEST CYCLE FOR 12-16 POSITION SELECTOR PROGRAMME CARRY OUT THE TEST CYCLE WHENEVER THE POWER BOARD IS REPLACED The test cycle must be performed to check the following: - that the electronic board has been installed correctly - that the main functions of the dryer are performed correctly BEFORE STARTING THE TEST CYCLE, CHECK THE CODE ON THE LABEL AFFIXED TO THE BOARD (for board no.
  • Page 27 13 ALARMS 13.1 Alarm conditions during the test cycle The test cycle is interrupted after activating the loads; LED lights and the buzzer sounds. - Check that the tank is empty. - Check the wiring between contacts H6.3 and H6.4 and the float microswitch. - Check the float microswitch.
  • Page 28 If the microprocessor identifies one of the conditions listed above, operation of the dryer is interrupted; the LEDs continue to flash in order to warn the user of the malfunction. If the error is eliminated, the dryer returns to normal operation when the programme selector knob is turned to RESET and the drying cycle is re-selected.
  • Page 29 14 AUTOMATIC CYCLES SYMBOLS AND SETTINGS 14.1.1 With 16-position selector The symbols are shown on the control panel in the figure below, which represents a full configuration. The control panel consists of three buttons, six LEDs, a programme selector, an ON/OFF pilot lamp, a switch and a door opening button.
  • Page 30 PROGRAMME DESCRIPTIONS COTTON EXTRA DRY Clothes with a relative final humidity between –6% and -0% can be dried by setting this cycle. Both branches of the heater unit are switched on; the maximum drying time is three hours. The maximum temperature reached is 85°. If the half-power key is selected (the branch with less power of the heating unit is not selected) the maximum temperature reached is 80°.
  • Page 31 BABY By setting this programme a relative humidity between -3% and +3% can be reached, same characteristics of the COTTON CUPBOARD DRY, the software adds a fixed time (of 25 minutes). Only one branch of the heater unit is switched on (the 1400W one), the maximum dry time is 3 hours, the maximum temperature reached in this cycle is 55°.
  • Page 32 2. SWITCH 3. REDUCED TEMPERATURE KEY The dryer has a heater unit that consists of two heating elements, and according to the versions there are two kind of power. Pressing the key once, the electronic control excludes the low-powered branch of the heater unit controlling the opening of RL4 and at the same time Led D1 lights to indicate that the function has been selected;...
  • Page 33 14.1.2 With 12-position selector The symbols are shown on the control panel in the figure below, which represents a full configuration. The control panel consists of three buttons, six LEDs, a programme selector, an ON/OFF pilot lamp and a switch. All the functions are described below: 1.
  • Page 34 PROGRAMME DESCRIPTIONS COTTON EXTRA DRY Clothes with a relative final humidity between –6% and -0% can be dried by setting this cycle. Both branches of the heater unit are switched on; the maximum drying time is three hours. The maximum temperature reached is 85°. If the half-power key is selected (the branch with less power of the heating unit is not selected) the maximum temperature reached is 80°.
  • Page 35 30’ By selecting this programme the drying is timed, both branches of the heater unit are switched on, conduct metric sensors is disabled, the temperature inside the drum reaches a maximum value of 85° and is checked by the NTC sensor. If the half-power key is selected (the branch with less power of the heating unit is not selected) the maximum temperature reached is 80°.
  • Page 36 LED D6 (END OF CYCLE) It flashes when the dryer is in the ANTI-CREASE phase together with Led D5. It flashes only when the drying cycle has completed together with Led D5. LED D6 (FULL TANK) It flashes only when the tank is full. 15 SUMMARY TABLES OF LEDS OPERATION Leds D1 and D2 light when the options are selected, respectively;...
  • Page 37 16 SERVICING IF AN ELECTRIC SCREWER IS USED, PAY ATTENTION NOT TO TIGHTEN THE SCREWS TOO MUCH 16.1 Door To remove the door, remove the screws which secure it to the hinge. 16.1.1 Fluff filter fitted to door - Lift upwards and clean after each cycle. 16.1.2 Felt filter support - Remove the two screws that fit the felt filter to the inner door.
  • Page 38 After removing the worktop, the positions of the following components can be seen. 1 – Timer 2 – Pushbuttons 16.3.1 Control support - Remove the tank and the screws that fit it to the front part. 16.3.2 Control panel - Remove the screws that fit the control panel (indicated by the arrows). - Release all the hooks that fit it to the control support (pay attention not to break them, because the plastic hardens) 16.3.3 Timer...
  • Page 39 16.4 ACCESS FROM THE REAR PANEL 16.4.1 Heater unit - Remove the screws (1) which secure the rear panel cover (in plastic) in the central part and release the hooks (2) which secure it externally. Remove the outer screws which secure the rear panel cover. Remove the left panel (seeing the appliance from the front).
  • Page 40 The junction box of the heater is inserted into the micro support and it is fixed by a hook. - Use a screwdriver to move the hook and extract the junction box; remove the clamps the fix the wiring to the base and extract the wiring. - Remove the two screws that fit the heater to the rear panel paying attention to the right screw of the heater which fixes a baffle.
  • Page 41 - Remove the screw (1) which secures the support micro and use a screwdriver for the two hooks which secure it to the sump. - Lift them simultaneously and unthread the micro support towards outside. 16.5.1 Floating microswitch Putting upside down the support you can access the floating microswitch. 16.5.2 Float Inside the sump there is the float.
  • Page 42 To extract it rotate the float 90° clockwise as shown. - Lift it up, rotate it towards outside and extract it. To reinsert the float, repeat the same operations backwards. While reassembling the pump, the float and the tank microswitch, repeat the same operations backwards, paying attention that when the micro support is remounted it is necessary to use a screwdriver in the fissure (indicated by the arrow), to lift the micro lever and lean it over the float (if...
  • Page 43 ACCESS FROM THE RIGHT PANEL To the start-up capacitor To the fan of the warm air circulation To the fan of the cold air circulation To the drum rotation motor To the belt tensioner To the belt tensioner spring - Remove the worktop (as previously described). - Remove the right panel, unscrewing the screw which secures it to the crossbar.
  • Page 44 16.5.7 Back scroll cover (cold air circulation) - Remove the screw and release it from the three hooks (two upper and one lower side) which fit the scroll to the base and remove it. 16.5.8 Drum rotation motor After removing the covers from the two scrolls you can access the drum rotation motor.
  • Page 45 16.6 ACCESS FROM THE FRONT PANEL 16.6.1 Front flap - Remove the screws which secure it to the front panel. - To remove the gasket it is sufficient to extract it from its seat. - To remount the flap in its seat, pay attention to insert the hooks in their proper seats and then fasten the fixing screws.
  • Page 46 16.8 ACCESS FROM THE REAR PANEL - To the drive belt - To the drum - To the duct - To the duct rollers - To the front and rear seals To remove the rear panel: - Remove the worktop - Remove the right and left side panels - Remove the plastic protection - Remove the rear panel cover...
  • Page 47 17 SERVICING: ELECTRONIC DRYERS 17.1 Access from the worktop - Electronic control - Programme selector - Display board - Front brush 17.1.1 Electronic control - Unscrew the screw which fits the electronic control to the crossbar, move it towards the rear panel so that the hook which fixes it to the side panel can be extracted.
  • Page 48 18 REVERSING THE DOOR Proceed as follows: - Remove the screws which secure the hinges to the cabinet (1) and remove the door. - Remove the screws which secure the hinge covers (2) and fit them on the opposite side (i.e. to the positions where the hinges were previously fitted (1).
  • Page 49 ELECTROMECHANICAL VERSION - Insert the wiring inside the hook (3). - Put upside down the door lock, fit it to the opposite side where the front hole cover was inserted and secure it to the cabinet (5), paying attention not to squash the wiring between the door lock and the front panel.
  • Page 50 - Position the door in the opposite side of the dryer and screw the hinges into position (10). - Position the left and right side panels (fit the fixing screws to their original positions otherwise the earth ground continuity will be interrupted. - Position the worktop.
  • Page 51 19 FINAL TESTING OF DOOR CLOSING: In order to check that the door closes correctly (i.e. in compliance with safety standards) after reversing, proceed as follows: -Make a loop (1) using string, wire etc. - Loop the string around the door latch and close the door. Check the door opening safety system: - Connect the dynamometer (2).
  • Page 52 20 WIRING DIAGRAMS ELECTROMECHANICAL VERSION Anti-interference filter Mains-on light Cool button Motor Box switch Motor Capacitor Door safety interlock Overheat protection thermostat Earth ON/OFF button Heating elements Start button Junction box Thermostat Water level switch Timer motor Low temperature button Water reservoir ind.
  • Page 53 ELECTRONIC VERSION Anti-interference filter Mains-on light Box switch Motor Door safety interlock Motor Capacitor Earth Overheat protection thermostat Heating elements Start button Junction box Thermostat Level switch Timer motor Low temperature button Water reservoir ind.lamp. SOI/DT 2002-07 dmm 53/55 599 35 38-32...
  • Page 54 ELECTRONIC VERSION Anti-interference filter Mains-on light Box exchanger Motor Display p.c.b. Motor Capacitor Door safety interlock ON/OFF button Earth Overheat protection thermostat Heating elements Power p.c.b. Junction box Programme selection Mains-on light Thermostat SOI/DT 2002-07 dmm 54/55 599 35 38-32...
  • Page 55 SOI/DT 2002-07 dmm 55/55 599 35 38-32...