Electrolux SAHARA User manual

DRYERS
Condense / Heat Pump Tumble Dryers - DISASSEMBLY
Publication number: 599 796-724
EN
Edition: 08/2019 - Rev.0.2
© ELECTROLUX HOME PRODUCTS
Customer Care - EMEA
Training and Operations Support
Technical Support

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PRECAUTION
1PRECAUTION
Information
“Safety”
All the work to be performed inside the appliance requires
specific skills and knowledge and may only be carried out
by qualified and authorised Service Engineers
Due to the safety precautions it is forbidden to repair
basements filled up with Propane R290. Only a replacement
of the whole basement is permitted.
This platform is not fitted with an ON/OFF switch. Before you
access internal components, take the plug out of the socket
to disconnect the power supply.
Some of the components in the mechanical part could
cause injuries, so wear suitable protection and proceed with
caution
Always empty all the water from the condensation tank
before laying the appliance on its side.
If the appliance has to be placed on its side for
maintenance or another reason, lie it on its left side, to avoid
the risk of any residual water falling onto the main circuit
board.
Document Revisions
Revision
Date
Description
0.0
03/2016
Document creation
0.1
03/2017
Added: Steam generator tank with cover;
POne control panel and board; plastic “SAN”
door; POne kick plate panel
0.2
08/2019
Added: Safety information; spare parts for
Propane; Optiflow basement R290
2PURPOSE OF THIS MANUAL
The purpose of this Service Manual is to provide Service Engineers who
are already familiar with the repair procedures with information
regarding: Condense / Heat Pump Tumble dryers
based on SAHARA and OPTIFLOW structures
fitted with EDR10, EDR11,EDR12,EDR14 EU,EDR16 electronic control
systems.
The manual deals with the following topics:
oDrying circuit.
oTechnical and functional characteristics
oAccess

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CONTENTS
3CONTENTS
1PRECAUTION 1
2PURPOSE OF THIS MANUAL 1
3CONTENTS 2
4OPERATING PRINCIPLE 3
5FUNCTIONAL PARTS 10
6ELECTRICAL EQUIPMENT 13
7DRYER 23
8HOUSING 25
9DISASSEMBLY 26

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OPERATING PRINCIPLE
4OPERATING PRINCIPLE
4.1 OPERATING PRINCIPLE
Condense drying system
Heat Pump drying system
100% Energy
consumption
Water
pump
Condenser
100%
Energy
input
Water tank
Air flow
Cooling air
Heating
element
of which
50% Energy
is recovered
Water
pump
Condenser
(Heat generator)
Expansion
valve
Evaporator
(Heat exchanger)
60%
Energy
input
Water tank
Air flow
Refrigerant
flow
Compressor

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OPERATING PRINCIPLE
4.2 CONDENSE DRYERS - DRYING CIRCUIT
There are two air groups inside the appliance:
•One hot one closed in on itself inside the appliance;
•One open cold one, for the circulation of ambient air through the condenser.
The first air group, which is hot and closed in on itself, circulates inside the appliance:
The fan (1) pushes air inside the heat exchanger (5), and from this via the heater unit (2), the air
heats up and via a conveyor enters inside the drum passing through the holes in the back panel.
The warm dry air moves through the laundry moving in the drum removing the dampness and
transforming it into warm damp air; this exits from the front part of the drum through the fluff filter
(3) and the lower filter (4), and is then channelled through the conduit to the fan (1); from here it is
pushed inside the heat exchanger (5) where dampness is condensed. When this comes out, we
have dry air and the cycle continues as described above.
The second air group, the one circulating ambient air through the condenser:
The fan (6) takes in ambient air through an air inlet in the back panel, pushing it into the heat
exchanger (5), and cooling it. The air comes out on the opposite side of the exchanger,
dispersing inside the appliance and coming out of the slots in the kick plate.
The two air groups, the damp hot one and the cold one cross over in the heat exchanger (5),
producing heat exchange and, therefore, condensation of the humidity.
The condensation water that forms inside the exchanger is collected in a trap (7) where there is a
float (9) that informs the circuit board that water is present, so the circuit board powers a pump
(11) which conducts the water from the trap (7) to the tank (8).
The tank was designed to collect the condensation water of a complete cycle with a full load, so
approximately 5.5 litres.
If for any reason the tank is filled beyond its capacity, any overflowing water is collected by the
tank support and channelled along a pipe (not shown in the diagram) back inside the trap (7),
moving the float (9) up, and thus activating the micro switch (10). The electronic control unit
makes 7 attempts to empty the trap in specific amount of time, after which the electronic control
unit recognizes the problem and cuts off the electricity supply to the appliance and lights a LED
to inform the user that the tank is full.
Operating principle
1.
Hot air fan
2.
Heater unit
3.
Fluff filter
4.
Fluff filter
5.
Heat exchanger
6.
Cold air fan
7.
Condensation collection tray
8.
Condensation collection tank
9.
Float device
10.
Micro switch
11.
Condensation water suction pump

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OPERATING PRINCIPLE
4.3 HEAT PUMP DRYERS - DRYING CIRCUIT
Operating principle
Operating principle with auxiliary condenser
Operating principle with steam generator
1.
Evaporator
2.
Condenser
3.
Drum
4.
Condensation collection tray
5.
Condensation collection tank
6.
Compressor
7.
Air circulation fan
8.
Capillary tube
9.
NTC sensor
10.
Compressor cooling fan
11.
Condensation water suction pump
12.
Auxiliary condenser
5
11
4
6
10
3
7
2
1
9
8

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OPERATING PRINCIPLE
The cycle of the tumble dryer heat pump consists in evaporating, compressing, condensing and expanding the refrigerant.
By pressing the START/PAUSE button the drying cycle begins, the gas in the circuit is conveyed by the compressor (6) to the condenser (2), where at the
outlet the circulation pipe known as capillary (8) narrows. This capillary slows down the release of gas and ensures that the pressure inside the condenser
(2) increases bringing the gas to a liquid status and a pressure level of around 27 bar.
This rise in pressure subsequently increases the temperature of the gas that is now liquid inside the condenser (2) reaching around 53°C.
The air circulated by the fan (7) passes through this condenser (2) overheating before entering the drum (3) where the washing is located.
The evaporator (1) is located at the capillary outlet (8) with the gas circulation pipe being larger than the capillary which thus expands the hot, liquid gas
coming from the condenser (2).
This gas expansion means that the gas in its liquid state once again becomes a gaseous state causing the gas itself to cool and subsequently cooling the
entire evaporator, bringing it to a temperature of around 20°C.
The, by now hot air is circulated by the fan (6) and passes through the washing in the drum (3) absorbing humidity and reaches the evaporator (1) humid
and hot. The latter which is now at a lower temperature thanks to the expansion of the gas ensures that all the humidity in the circulating air condenses.
The condensed water created is collected in a tray (4) and conveyed via a pump to the tank (5) located above the drum.
At this point, the air is now cold and dry and goes through the condenser (2) again, once again overheating before entering the drum (3) and the gas now
cooled in the evaporator (1) returns to the compressor where it will once again be compressed and sent into the condenser (2) re-starting the cycle.
The entire gas evaporating and compressing system is kept in balance by a NTC (9) located at the entrance to the capillary (8). This collaboration with the
main circuit board ensures that if the outgoing temperature from the condenser surpasses a certain level a fan (10) located in front of the compressor starts
working and lowers the temperature.
In the models with auxiliary condenser, the operating principle remains the same and the only single variant is in the auxiliary condenser positioned in
series to the main condenser. This ensures that the whole system is better balanced, thus increasing performance.

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OPERATING PRINCIPLE
4.4 STEAM GENERATOR PRINCIPLE
These appliances are fitted with a steam generator comprising a pulse-powered miniature boiler
(6) and a pump (5) which is necessary to fill the boiler.
If you wish to use the IRON AID programmes, you first need to fill the tank (1) with distilled water
through the filling inlet up to the MAX level of approximately 0.9 litres, or if a drying cycle has
already been carried out, it is filled automatically through the condensation water filling pump.
This allows the float (3) to move away from the magnetic sensor (2) and therefore cancel the
alarm shown on the display.
As soon the drying cycle has ended, the membrane pump (5), which also acts as a non-return
steam valve, begins to draw water through the pipe and pump it into the boiler (6). The water
that has heated turns into steam and travels up the pipe, and it is then introduced into the drum
through the nozzle (7).
The quantity of steam that can be selected using this button varies the amount of time for which
the pump and boiler remain in operation.
STEAM GENERATOR TANK
- Version with cover 1. Tank fixing points
2. Overflow outlet
3. Water outlet towards the
boiler
4. Water inlet connector from
the condensation trap
5. Water filling assembly and
tank connector
6. Lint filter
7. Float with magnet
8. LED light and level sensor
board
9. Sensor cover
Operating principle
1.
Distilled water tray
2.
Level sensor
3.
Float
4.
Manual fill tank
5.
Membrane pump
6.
Boiler
7.
Steam outlet nozzle
6
2
1
3
4
8
5
7
1
9
6
1
5
7
4
2
3

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OPERATING PRINCIPLE
4.5 WATER CIRCUIT – CONDENSE / HEAT PUMP
The condensation water that forms inside the exchanger is
collected in a trap.
There is a float (5) inside this trap that informs the circuit board
that there is water. This powers a pump (1) which conveys the
water through the red pipe (2) from the trap to the tank
inserted in the tank support (4).
The tank was designed to receive the condensation water of a
complete cycle at full load, approximately 5.5 litres.
If, for whatever reason, the tank fills up beyond its capacity,
the overflowing water is collected by the support tank and via
the transparent pipe (3), is re-conveyed inside the trap
pushing the float (5) upwards and this activates the micro-
switch. The electronic makes 7 attempts to empty the trap
within a set time, after which the electronic control recognises
the problem and disconnects the power supply to the
appliance and lights up a LED informing the user that the tank
is full.
Condense
Heat Pump
1. Pump immersed in the trap.
2. Tank water drain pipe (red).
3. Water overflow drain pipe (transparent).
4. Tank support.
5. Level sensor.
4
2
3
1
5
1
4
2
3

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OPERATING PRINCIPLE
4.6 WATER CIRCUIT – HEAT PUMP WITH STEAM GENERATOR
The condensation water that forms inside the exchanger is
collected in a trap.
There is a float inside this trap that informs the circuit board
that there is water. This powers a pump which conveys the
water along a pipe (1) from the trap to the main tank; at one
point the water from the pump comes to a fork and so one
part is shunted along the pipe (2) to the collection tank
necessary for the steam generator (3).
Before entering this tank, the water is filtered by the filter
present in the manual water filling assembly (7).
The excess water obtained when the drying cycle has not
ended yet and the steam generator tank is full is channelled
along the overflow pipe (4) towards the trap and from there,
the pump recycles it. The main tank was designed to collect
the condensation water of a complete cycle with a full load, so
approximately 5.5 litres.
If for some reason the tank fills up beyond its capacity, the
overflowing water is collected by the tank support and is re-
conveyed inside the trap along the transparent pipe (12),
pushing the float upwards and thus activating the microswitch.
The electronics make 7 attempts to empty the trap within a set
time, after which if the float has not dropped the electronic
control recognises the problem and disconnects the power
supply to the appliance and lights up a LED informing the user
that the tank is full.
If you are using a cycle that uses steam, the water inside the
transparent tank (3) reaches the pump (8) along the pipe (6);
this pump, which also acts as a pulse powered non-return
valve, conveys the water to the boiler (9) where it turns into steam and travels along the pipe (10) and the nozzle (11) to the inside of the drum.
Heat Pump with Steam Generator
1. Condensation water filling pump from
the pump to the main tank.
2. Fork in the pipe originating from the
pump towards the main tank and the
steam generator tank.
3. Steam generator tank (transparent).
4. Overflow pipe.
5. Level sensor and LED lights.
6. Steam generator system water filling
pipe.
7. Manual water filling assembly and
filter.
8. Steam generator pump.
9. Steam generator boiler.
10. Steam pipe.
11. Steam outlet nozzle in the drum.
12. Main tank overflow pipe.
9
1
2
3
4
5
6
7
11
10
12
8