Fisher & Paykel Smartload DEGX1 User manual

DRYER
Models DEGX1 & DGGX1
517760

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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
Technical Publications
PO Box 58-732, Greenmount, Auckland
78 Springs Road, East Tamaki
New Zealand
Telephone: [phone]
Facsimile: 09 273 0656
Fisher & Paykel Appliances Inc
27 Hubble, Irvine
California, CA92618
USA
Telephone: [phone]
Facsimile: 949 790 8911
COPYRIGHT FISHER & PAYKEL APPLIANCES LTD 2004

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CONTENTS
1 Servicing Requirements .................................................................................................................. 7
1.1 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
1.2 Specialized Tools ................................................................................................................................7
1.2.1 Fisher & Paykel Smart Tool.........................................................................................................7
2 Model Information .......................................................................................................................... 8
2.1 Model Number .....................................................................................................................................8
2.2 Serial Number .....................................................................................................................................8
3 Technical Overview ........................................................................................................................ 9
3.1 Finish ...................................................................................................................................................9
3.2 Electrical Supply..................................................................................................................................9
3.3 Dimensions..........................................................................................................................................9
3.4 Maximum Capacity (Full Load) ...........................................................................................................9
3.5 Principles of Operation ......................................................................................................................10
3.5.1 Electronic Control ......................................................................................................................10
3.5.2 Loading ......................................................................................................................................10
3.5.3 Lid Lock Control.........................................................................................................................10
3.5.4 Lint Filter ....................................................................................................................................11
3.5.5 Airflow ........................................................................................................................................12
3.5.6 Temperature Control .................................................................................................................13
3.5.7 Cool Down .................................................................................................................................13
3.5.8 Drum Parts.................................................................................................................................13
3.5.9 Drum Control. ............................................................................................................................15
3.5.10 Drum Door Control ....................................................................................................................15
3.5.11 Heater Control. ..........................................................................................................................18
3.5.12 Auto Sensing .............................................................................................................................19
3.5.13 Regulator Valve .........................................................................................................................20
3.5.14 Gas Flame Detector ..................................................................................................................21
3.6 Gas Igniter .........................................................................................................................................22
3.7 Gas Regulator Valve .........................................................................................................................22
3.8 Gas Flame Detector ..........................................................................................................................22
3.9 Thermostat Cutout – Automatic Reset (Gas) ....................................................................................22
3.10 Thermostat Cutout – Manual Reset (Gas) ........................................................................................23
3.11 Element Assembly 240V 3.6 KW ......................................................................................................23
3.12 Element Assembly 240V 1.4KW .......................................................................................................23
3.13 Thermostat Cutout – Automatic Reset (Electrical)............................................................................23
3.14 Thermostat Cutout – Manual Reset (Electrical) ................................................................................24
3.15 Motor – 3 Phase 240W......................................................................................................................24
3.16 Exhaust Temperature Sensor Loom .................................................................................................24
3.17 Lid Lock .............................................................................................................................................24
3.18 Motor Control Module........................................................................................................................25
3.19 Sensor Module ..................................................................................................................................25
3.20 Display Module..................................................................................................................................25

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4 Diagnostics ....................................................................................................................................26
4.1 Overview ...........................................................................................................................................26
4.2 Fault Code Summary ........................................................................................................................27
4.3 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
5.1 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 Check the Continuity of the Power Cord (Gas).........................................................................36
5.1.4 Check the Continuity of the Main Harness (Gas)......................................................................36
5.2 Problem - No Heat ............................................................................................................................36
5.2.1 Check All Thermostats (Gas and Electric) ................................................................................36
5.2.2 Check the Elements (Electric Only) ..........................................................................................36
5.2.3 Check Voltage Across Elements (Electric Only) .......................................................................37
5.2.4 Measure the Current Draw for Each Element (Electric Only) ...................................................37
5.2.5 Check the Gas Valve/Regulator (Gas Only) .............................................................................37
5.2.6 Check the Flame Detector (Gas Only) ...................................................................................... 38
5.2.7 Check the Igniter (Gas Only).....................................................................................................38
5.2.8 Check the Exhaust Sensor (Gas and Electric)..........................................................................38
5.2.9 Check Inlet and Outlet Duct Seals ............................................................................................38
5.3 Problem – Drum Does Not Rotate ....................................................................................................38
5.3.1 Check for Fault Code. ...............................................................................................................38
5.3.2 Check the Integrity of the Belt. ..................................................................................................38
5.3.3 Check the Motor Windings. .......................................................................................................39
5.4 Problem - Under Drying/Damp..........................................................................................................39
5.4.1 Possible User Faults .................................................................................................................39
5.4.2 Possible Installation Faults........................................................................................................39
5.4.3 Possible Maintenance Problems...............................................................................................39
5.4.4 Check the Inlet and Outlet Duct Seals ......................................................................................39
5.4.5 Check the Heating Circuits........................................................................................................39
5.4.6 Check the Moisture Sensing Circuit ..........................................................................................39
5.5 Problem - Over Drying ......................................................................................................................40
5.5.1 Check the Moisture Sensing Circuit ..........................................................................................40
6 Service Procedures ........................................................................................................................41
6.1 Removal of Lid ..................................................................................................................................41
6.2 Components in Console Area ...........................................................................................................41
6.3 Removal of Display Module ..............................................................................................................41
6.4 Removal of Top Deck .......................................................................................................................42
6.4.1 If the top deck is to be removed for replacement:.....................................................................42
6.4.2 If the top deck is to be removed to gain access to other components:.....................................42
6.5 Removal of Lid Lock..........................................................................................................................43
6.6 Components Within Cabinet .............................................................................................................43
6.7 Removal of Front Cabinet Brackets ..................................................................................................43
6.8 Removal of Door Grabber Assembly ................................................................................................44
6.9 Removal of Door Grabber Actuator ..................................................................................................44
9.10 Removal of Door Grabber.................................................................................................................45
6.11 Removal of Door Bracket..................................................................................................................46
6.12 Removal of Drum Door .....................................................................................................................46
6.13 Removal of Drum Door Buffers.........................................................................................................47
6.14 Removal of Drum Door Key Bracket.................................................................................................47

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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
6.25 Removal of Inlet Panel Assembly .....................................................................................................52
6.26 Removal of Inlet Duct Seal................................................................................................................52
6.27 Removal of Inlet Bearing Shaft..........................................................................................................53
6.28 Removal of Drum Inlet Bearing .........................................................................................................53
6.29 Removal of Belt .................................................................................................................................54
6.30 Removal of Drum ..............................................................................................................................54
6.31 Removal of Lint Filter Assembly........................................................................................................54
6.32 Removal of Motor ..............................................................................................................................54
6.33 Removal of Fan .................................................................................................................................55
6.34 Removal of Fan Motor Housing ........................................................................................................55
6.35 Removal of Motor Control Module ....................................................................................................56
6.36 Removal of Sensor Module ...............................................................................................................56
6.37 Removal of Gas Igniter (Gas Models)...............................................................................................56
6.38 Removal of Flame Detector (Gas Models)........................................................................................56
6.39 Removal of Thermostats ...................................................................................................................57
6.40 Removal of Gas Regulator Valve, Pipe and Burner Tube (Gas Models) .........................................57
6.41 Removal of Elements (Electric Models) ............................................................................................57
6.42 Removal of Front Foot Bracket Assembly.........................................................................................58
6.43 Removal of Rear Foot Bracket Assembly .........................................................................................58
7 Wiring Diagrams........................................................................................................................... 60
7.1 U.S.A. Model (Electric) ......................................................................................................................60
7.2 U.S.A. Model (Gas) ...........................................................................................................................61
8 Fault Finding Flow Charts ............................................................................................................ 62
8.1 No Power...........................................................................................................................................62
8.2 No Heat (Electric Models) .................................................................................................................63
8.3 No Heat (Gas Models).......................................................................................................................64
8.4 Drum Door Not Opening/Closing ......................................................................................................65
8.5 Drum Does Not Rotate ......................................................................................................................66
8.6 Clothes Take Too Long to Dry ..........................................................................................................67
8.7 Noisy..................................................................................................................................................68

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1 Servicing Requirements
1.1 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.
Ensure the mains power has been disconnected before servicing any part of the dryer. If
the power is required to be on for electrical fault finding, or observing gas flame or
checking operation, then extreme care should be taken not to make contact with electrical
components other than with testing probes. Ensure the dryer is turned off when removing
any electrical component or connection.
1.1.2 Electrostatic Discharge
Electronic components are prone to damage from electrostatic discharges. The electronic
modules in this product contain no user serviceable components and breaking seals to
access internal components of an electronic module may void the product warranty. Avoid
contact with PCB edge connectors when handling electronic modules.
1.1.3 Good Working Practices
Ensure the work areas are kept tidy and free of hazards while servicing the dryer. On
completion of the servicing, ensure the dryer and work areas are left clean and tidy.
1.1.4 Safety Test
On completion of any service carried out to the dryer, all safety tests as required by law
must be carried out.
1.1.5 Sheet Metal Edges
When working around cut sheet metal edges use appropriate gloves or protection to
eliminate the chance of receiving a laceration.
1.1.6 Gas Leakage Test
On completion of any service carried out on a gas dryer, all safety tests as required by law
must be carried out.
1.2 Specialized Tools
1.2.1 Fisher & Paykel Smart Tool
Fisher & Paykel have developed diagnostics software for use in a laptop computer or a
handheld palm computer. With this software, diagnostic data may be downloaded from
the appliance to assist in servicing.
Authorised service centres may download this software from the Fisher & Paykel web site.

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2 Model Information
The product serial plate is located on the upper rear of the cabinet and contains the
following information:
2.1 Model Number
The model number contains the following information:
DEG X 1
Series
Size
Feature Level
Heating Type (E = Electric, G = Gas)
Product Type (Dryer)
2.2 Serial Number
The serial number consists of three letters and six digits and contains the following
information:
Example:
BEN123456
Sequential Serial Number
Manufacturing Plant Code
FISHERPAYKUL Code indicates month of
manufacture
CUMBERLAND Code indicates year of
manufacture
Cumberland Code
Letter C U M B E R L A N D
Year 1234567890
Fisherpaykul Code
Letter F I SHERPAYKUL
Month123456789101112
Manufacturing Plant Code
A Laundry – Australia
F Refrigeration – New Zealand
M Range & Dishwasher
N Laundry – New Zealand
Q Refrigeration - Australia
In the example above, the appliance was manufactured in the fifth month of the fourth year
(2004) at the New Zealand Laundry plant.

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3 Technical Overview
3.1 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
3.2 Electrical Supply
Operating Voltage Maximum Current
USA Electric 220/240V AC 60Hz 24 amps
USA Gas 110/120V AC 60Hz 6 amps
3.3 Dimensions
Height to lid
Open 55½ in - 56¾ in 1410mm – 1440 mm
Closed 37½ in - 38½ in 950 mm – 980 mm
Height to console 40¼ in - 41½ in 1020 mm – 1050 mm
Width 27 in 685 mm
Depth 27½ in 700 mm
Note: Exact height of the SmartLoad™dryer is dependent on how far the feet are inserted
into the base of the dryer.
Weight Packed 152 lbs (69kg)
Unpacked 134 lbs (61kg)
3.4 Maximum Capacity (Full Load)
Drum Volume 6.5 cubic feet (.184 cubic metres)

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3.5 Principles of Operation
1.1.1 Electronic Control
The 120V or 220/240V power supply is connected to
the motor control module which rectifies to DC for
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
heater(s). The motor control module does the actual
control of those devices.
The sensor module is responsible for the overall
control of the dryer, including the input and output of
all other peripherals. The sensor module controls
the lid lock and the drum door actuator, senses the
drum position and speed, measures. the exhaust
duct temperature through the exhaust sensor and
measures the dampness of the clothes load via the
sensor bars.
The algorithm for when the heaters are turned on and off, and also for the speed and
direction of the motor, is implemented within the sensor module, but the switching of the
elements or gas heater, and control of the motor, is done by the motor control module in
response to the commands from the sensor module.
When the mains power is first applied to or restored to the sensor module, the dryer will
endeavour to continue operating from when the power was lost. If mains power was lost
during a drying cycle, it will continue to dry to the same set dryness level, otherwise the
machine will return to have the drum door open and the lid unlocked.
The display module is a “Dumb” module and user interface that passes user settings to the
sensor module and displays information in the form of LED displays transmitted from the
sensor module.
3.5.2 Loading
The dryer always stops with the drum door open. The user places the drying load into the
drum, closes the lid, pushes the Power button, selects the required cycle and presses the
Start/Pause button. The lid will lock, the drum will rotate and the door grabber will slide
the drum door closed. The door grabber will then move clear of the drum.
3.5.3 Lid Lock Control
SmartLoad™has a lock installed in the lid to provide added safety while the dryer is
operating. It ensures that the lid cannot be opened while the drum is rotating.
The lid lock is a mechanism driven by a DC solenoid and prevents the lid being opened
when the drum is rotating. If the lid lock mechanism is not engaged for any reason,
including open circuit or short circuit, a “Locked” is not assumed. If unable to lock after the
user has requested a start, a User Warning will be given.
Sensor Module
Motor Control Module
Display Module

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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.
•When the LID LOCKED LED is not illuminated, the lid is not locked and the lid
can be opened.
•If the LID LOCKED LED is flashing, the lidlock is in the process of locking or
unlocking, (i.e. while the dryer coasts down or Start/Pause has been pressed).
During this stage the lid cannot be opened.
The lid must be closed before the drying cycle can start. If Start/Pause is pressed with
the lid open, the dryer will beep, signalling the lid needs to be closed. Once the lid has
been closed and Start/Pause is pressed, the lidlock will be activated and the cycle
begins.
If the power fails, either from a power cut or having been switched off at the wall, the lid
may be opened. In some circumstances the drum door may not be in the open
position. When the power is restored the dryer will automatically recommence the
drying cycle as long as the lid is shut.
If it is absolutely necessary to remove the load before the power is
restored, follow the steps below:
1. Ensure the dryer is disconnected from the power supply.
2. Open the lid (this will already be unlocked).
3. On the left hand side of the dryer there is a thumb tab that
appears when the drum is not open. Press the thumb tab and
rotate the drum by hand towards the back of the machine.
4. Hold the thumb tab down until the drum door starts opening.
5. Keep rotating the drum until the door is fully open and the drum
comes to a stop.
6. The clothes can now be removed.
7. Close the lid once the clothes have been removed.
8. Re-connect the power supply to the dryer.
The drum door will automatically close and the dryer will resume
normal operation when power is restored.
3.5.4 Lint Filter
Lint laden air passes through the small
holes in the outlet end of the drum (the
small holes around the lint bucket). The
lint removal system is directly behind
these holes. As this air moves through
the holes it is forced through the lint
filter. The fan then
sucks the air down
through the duct
and out the back
of the dryer.
Lint Filter
Lint Filter

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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. That reduces
the possibility of any blockages or hazards caused by the accumulation of lint.
There is a scraper situated on the top of the lint collecting housing which the filter moves
past. Where the lint on the filter builds up, the lint begins to touch the scraper, and is
automatically scraped off. Because the scraper is directly above the lint bucket it falls
straight in.
The scraper helps achieve consistent airflow throughout
the drying cycle by continuously removing any
accumulated lint from the mesh of the filter.
The dryer user manual and lid label instruct the user to
empty the lint bucket before the lint reaches the top of the
transparent part of the bucket. If the lint bucket overflows
due to the user not emptying it, the SmartLoad™ dryer
can clear itself. The user just needs to empty the bucket
and run the dryer on a cycle for approximately 20 minutes.
The dryer will free all the trapped lint and will re-deposit it
back into the lint bucket.
3.5.5 Airflow
An intake grill at the bottom rear of the cabinet provides an entry point for the airflow
through the dryer via four large louvred slots. Additional air is drawn in at the front of the
cabinet under the front panel. A fan on the exhaust side of the drum draws the air over the
heating elements/gas burner located in a combustion chamber, through an inlet duct and
into the drum.
The air exits the drum through a self-cleaning lint filter in the drum outlet duct, then passes
through the fan housing and out the rear exhaust vent situated at the bottom rear of the
cabinet.
Lint
Rear Exhaust Vent
Air Intake Grill
Lower Rear Cabinet Panel
Scraper
Lint

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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. An exhaust temperature sensor is used to monitor the
exhaust temperature. The controller limits the temperature to what is required for the
various cycles.
An auto reset thermostat located on the burner housing also limits the heat into the dryer,
but if it fails to operate, them a manually resetable thermostat also situated on the burner
housing will trip at 318oF (150oC), turning off the heat to protect the clothes.
3.5.7 Cool Down
The dryer enters a cool down period at the end of the cycle. During this period the dryer
continues to run with the heating elements/burner turned off, blowing cool air through the
load to help prevent creasing. If an Auto Sensing cycle has been selected, the cool down
period will continue until the exhaust temperature drops to 95oF (35oC). If a Timed Dry
cycle has been selected, the cool down period will run for the last 5 to10 minutes of the
timed dry period.
3.5.8 Drum Parts.
1. Drum Inlet End: Allows inlet air to pass through. This is how air enters the drum. It
also houses the inlet central bearing assembly, about which the drum rotates.
2. Drum End Outlet: Provides the route for air to exit the drum as well as securing
the lint filter. The outer face has dimples which are collectively referred to as “the
drum tachometer”. The central flange of the drum end outlet is supported and
guided by seven bearing pads which are mounted in the outlet duct.
3. Vanes: Encourage clothes to tumble during the drying cycle.
Cold
Air
Drum
Lint Removal
System
Heater
Hot Air
Belt
Outlet
Belt Tensioner
System
Fan Motor

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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. It also latches the door closed over the end of the
track.
7. Locking Bar: Attached to its ends are the hinge arms. Its function is to hold these
hinges in the correct orientation.
8. Hinge Spring: Springs the hinge arm down to ensure latching when the door is
closed.
There is also a Drum Door Scraper that prevents clothes from being drawn into the gap
between the drum and the door when the door is opening, and a Key Bracket that
prevents the door from closing when the clothes are protruding.
1
2
3
4
5
6
78

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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.
When tumble drying, the drum is tumbled at 47 RPM,
during opening and closing at 5 RPM, and at other
speeds as required and requested from the sensor
module. Feedback on speed is via the drum
tachometer signal, which comes via the sensor
module.
When drying, the drum rotates in the door closing
direction for 4 minutes, after which it coasts to stop
and reverses for 40 seconds, then coasts to stop
before repeating the reversing throughout the drying
and cooling cycle. The reversing of the drum
direction reduces tangling.
During Wrinkle Guard the drum rotates in one direction for 30 seconds, then stops for 5
minutes without opening the drum door, after which it goes in the opposite direction for 30
seconds, then pauses again before turning off. If the user does not remove the clothes
load, the cycle is repeated 255 times, which take approximately 23 hours.
The drum tachometer uses pressed “dimples”, formed directly into the drum end outlet,
spaced every 2 degrees to provide positioning information while also providing speed data.
There is a 15 degree “gap” to provide the reference for absolute position. An infrared
diode and optical receiving transistor provide the reading of the “dimples.” The digital
signal is output to the motor control module, which uses the signal for speed controlling the
drum. The drum position is monitored by the sensor module, which uses the position for
both speed commands and drum door actuator control.
3.5.10 Drum Door Control
The drum door is opened and closed by the door
grabber, which is positioned by an actuator driven
by a small DC brush motor.
A mechanical interlock prohibits the drum door from
latching closed if garments get caught in the door
opening. With the door unable to close, the drum
will stall, which will be sensed by the motor control
module and corrective action will occur.
After Start/Pause is pressed when the dryer is
waiting with the drum door open:
1. The lid will lock.
2. The sensor module assumes the drum door is open at “Home” and rotates the drum at
5 RPM in the drum door close direction. If it is “Home” and the grabber lowered, the
door will close at 78 degrees away from “Home”. Note: If the door is closed and the
grabber lowered, the drum will simply rotate with a slight rubbing noise of the grabber
on the drum.
Belt Tensioner
System
Belt
Three Phase
Motor
Reference
Point
Dimples

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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.
4. At the “Retract Grabber Position”, 142 degrees from “Home”, the sensor module
begins moving away the grabber.
•If a fault is detected during the actuator movement, the operation of the actuator will
be checked. The drum will stop and an attempt will be made at moving the actuator
back to lower the door grabber.
•If a fault is again detected, a maximum of five attempts are made at moving the
grabber, alternating the direction with each attempt, until finally the dryer will display
the relevant fault code and remain in the stationary position with the lid unlocked. If
however the actuator is operated correctly, the grabber is left in the retracted
position.
5. When the grabber is confirmed to have retracted, the drum motor is sped up to 47
RPM and the sensor module will begin or continue the normal drying operation.
When Pause is pressed or the drying is completed:
1. If the drum is rotating in the Close direction, then it will be reversed and the drum
speed will be set at 20 RPM, at which speed the position of the drum is verified using
the tacho “Gap” as its reference. If however the drum was moving in the open
direction, its position may have already being verified at the higher speed, but if not,
will be set to slow down to 20 RPM until the position is verified. If within 40 seconds
the sensor module is unable to verify its position, either because no “Gap” of sufficient
arc has been detected or a correct count for a complete revolution of the drum cannot
be obtained, then a fault code will be displayed.
2. Once the position is known, the drum speed begins to slow to 5 RPM. Provided the
drum speed has reduced to at least 18 RPM when the drum position is 132 degrees
from the extended door grabber position (210 degrees from “Home”), the lowering of
the grabber begins.
3. As the bridges approach the lowered door grabber, wings on each side of the grabber
enter the bridge channels. If the wings do not enter the channels, the grabber will be
unable to open the drum door (refer to the diagram below).
As the drum continues to rotate, the engagement ribs attached to the door grabber
unlatch the drum door hinge arms, lifting them out of the channel slots. The hinge
arms are raised by details on the door grabber to the top face of the bridge channels.
The drum continues to rotate in the opening direction, while the drum door is held
stationary by the door grabber.
Door Grabber is lowered against the Wrapper

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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.
The dryer electronics can determine whether the drum has reached the correct
position by way of the optical sensor attached to the Sensor board, which uses the
dimples on the drum end outlet to determine the drum position.
4. Provided there is no failure in extending the grabber, the drum door will be opened.
However, if a failure is detected in the actuator’s movement, the drum will immediately
stop. The dryer will then attempt to retract the grabber. If the grabber is successfully
retracted, the sequence will repeat from step 1 of this opening sequence. However, if
the actuator fails to successfully move the grabber after repeated attempts, the sensor
module will stop the drum in its closed state and a fault code will be displayed. Five
attempts are made to open the drum door before flagging the fault.
5. The lid lock will be released.
When the power is first switched on or restored after interruption:
In normal circumstances where the previous cycle was completed successfully, when
power is reapplied to the product, the sensor module will assume the door is open and the
machine is at rest. In all other cases it will either continue operating or return to the
“home” position so that the drum door is open and the lid is unlocked. If for some reason
the drum door is not open, then the operator will need to first start, then pause the
machine to return it to its drum open position. When the dryer recommences operation,
the sensor module must allow for the situation where the drum door may be part way
through an opening or closing sequence. In order to do this without the risk of damaging
any of the mechanical parts, the sensor module executes the following sequence:
Engagement Ribs contacting Hinge Arm Hinge Arm and Locking Bar are unlatched by
the Door Grabbe
r
Bridge Channels
Door Partiall
y
O
p
ened Drum is stopped by the Door Grabber

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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” (fully open) position.
3. The sensor module then operates the grabber and leaves it in the retracted position.
4. Provided the grabber was successfully retracted, the drum will continue rotating in the
Close direction; ramp up to full speed, and the dryer will continue its cycle.
3.5.11 Heater Control.
The heaters are controlled in response to the selected drying cycle chosen and also
according to other technical requirements such as reversing and over heating.
In the electric heater models, the heater housing is fitted with two elements that supply
about 5 kW of heat when both are on. There is a 3.6kW and a 1.4kW element that are
used at various times depending on the cycle chosen and the drum/fan direction. For the
gas model, a gas burner is used to provide the heat, and this is turned on for lower duty
times for the Permanent Press and Delicate cycles to apply similar heating as the electric
model.
When drying, the heater is only switched on when the drum is up to speed. Because of
the time it takes for the element to cool down after switching off, the larger element in the
electric model is switched off a few seconds before stopping to reverse, to prevent
excessive heat entering the drum.
The software in the motor control module responds to the switching on and off of the
heater as requested by the sensor module. It also monitors the automatic thermostat on
the heater housing for excessive restriction of airflow, and if detected, will set a User
Warning but continue the drying cycle until the end of the cycle when the warning will
reset. If the User Warning occurs, the drying will take a longer time to complete and the
load will possibly end up a little damp.
Each cycle, Denim through to Delicate, has a temperature limit, as defined in the table
below, as measured in the exhaust air. After switching off at the limit, the temperature has
a hysteresis of 5 degrees below these temperatures when the heat source switches back
on.
Denim Regular Permanent
Press
Delicate
149oF (65oC) 149oF (65oC) 140oF (60oC) 127oF (53oC)
When tumbling the heat source is turned on as shown in the table below:
Electric
Door Close Direction
4 minutes
Door Open Direction
40 seconds
Element 2/3
Heat
Element 1/3 Heat Element 2/3
Heat
Element 1/3
Heat
Denim ON ON OFF ON
Regular ON ON OFF ON
P.Press ON OFF OFF ON
Delicate ON OFF OFF ON
Air Dry OFF OFF OFF OFF

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Gas
Door Close Direction
4 minutes
Door Open Direction
40 seconds
Gas Ignition
delay
Gas Heating
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 No Heat
Note: During heating, if the temperature exceeds the limits for the particular cycle, the
heat is turned off and can significantly reduce the heating time. This is particularly true for
gas dryers which require the 30 second ignition time.
Cycle times can be affected by a number of factors including:
•The cycle chosen
•Load size
•Size of items
•Type of fabric
•Load wetness
•Venting method
•Location of dryer
•Condition of exhaust ducts
•Heat used (electric, natural gas or LPG gas)
•Environmental conditions (temperature, humidity)
The table below shows approximate cycle times (in minutes) for an 8 pound (3.6 kg) load
dried using the regular cycle.
Damp Damp/Dry Dry Dry/Extra Dry Extra Dry
Smartload™Electric 26 36 47 50 50
Smartload™Gas 29 38 47 49 51
3.5.12 Auto Sensing
When wet or damp clothes are loaded into a dryer they are partially saturated with water
which is a relatively good conductor of electricity. In the SmartLoad™ dryer, sensor bars
are used to measure the conductivity. When moisture in the clothes touches across the
sensor bars (located beneath the lint bucket) their conduction is measured. As the clothes
dry they become less conductive and it is this measurement that is used to calculate the
dryness of the clothes load.
Large loads will brush against these moisture sensor bars more frequently than small
loads, and this strike count is used to help determine the dryness of different sized loads.
Different fabrics retain moisture differently; a thick towel containing a lot of moisture will
often conduct the same as a light synthetic garment containing very little. It is this
difference in fabric characteristics plus the initial unknown moisture content that makes the
calculation of dryness reasonably complex.

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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. The pressure regulator is factory set to
maintain 3½ inches of water column (WC) gas pressure at the orifice (0.87kPa). The
regulator is service adjustable. The two solenoid valves are in series such that the gas
flowing through the pressure regulator must pass through both valves to get to the orifice
and burner. At dryer start up, the gas igniter is energised and the first valve is opened.
Once the gas igniter has reached ignition temperature, the gas flame detector operates the
second valve, allowing gas to flow through the orifice and into the burner venturi, and
ignition takes place. The second valve is held open only when a flame or hot ignition is
detected by the gas flame detector.
The orifice is a precisely drilled brass plug screwed into the outlet port of the regulator
valve. The orifice extends into the burner venturi. The combination of regulated pressure
and orifice size provides the proper volume of gas for the heat rating of the burner. The
regulator valve comes from the factory sized and adjusted to deliver heat at the rate of
20,000 BTUs per hour, using natural gas.
While natural gas is most commonly used, the regulator valve is also able to
accommodate the use of LPG. In this case, a LPG conversion kit (part number 395489) is
used to modify the regulator valve to achieve the correct volume of gas flow for LPG.
Gas Pipe Gas Flow
Regulator
and Valves
Orifice Igniter
Flame Detector
Information fed back
to gas flow regulator
and valves from
Combustion
Chamber
Gas Pipe
Gas Flow
Regulator and
Valves
Burner
Venturi
Orifice
Igniter
Igniter
Bracket
Gas Burner Assembly