LG DLEX8377 Service Manual

LG TRAINING MANUAL

Steam Dryers DLEX8377*M/DLG8388*M

Fall 2008

Published August 2008 by LG Electronics USA Trainng Center

Copyright © 2008 LG Electronics of Alabama, Inc.

Phone Contacts:

Contact	Number		Hours of Operation
Customer Service	(800)	243-0000	24/7 - 365 days a year
Technical Support	(800)	847-7597	7am-7pm Mon-Fri / Sat 8-2 CST
Parts Sales	[phone]		7am-7pm Mon-Sat CST
Training Center	[phone]		8am-5pm Mon-Fri CST

Web Contacts:

Web Site	Address	Description
LG USA	www.lgusa.com	USA sales site
Customer Service	us.lgservice.com	Customer support
GCSC	aic.lgservice.com	Service center support
Customer Service Academy	www.LGCSAcademy.com	Technical training

TRAINING MANUAL	DLEX8377WM

IMPORTANT SAFETY NOTICE

The information in this training manual is intended for use by persons possessing an adequate background in electrical equipment, electronic devices, and mechanical systems. In any attempt to repair a major appliance, personal injury and property damage can result. The manufacturer or seller maintains no liability for the interpretation of this information, nor can it assume any liability in conjunction with its use. When servicing this product, under no circumstances should the original design be modified or altered without permission from LG Electronics. Unauthorized modifications will not only void the warranty, but may lead to property damage or user injury. If wires, screws, clips, straps, nuts, or washers used to complete a ground path are removed for service, they must be returned to their original positions and properly fastened.

CAUTION

To avoid personal injury, disconnect the power before servicing this product. If electrical power is required for diagnosis or test purposes, disconnect the power immediately after performing the necessary checks. Also be aware that many household appliances present a weight hazard. At least two people should be involved in the installation or servicing of such devices. Failure to consider the weight of an appliance could result in physical injury.

ESD NOTICE

Some of the electronic components in appliances are electrostatic discharge (ESD) sensitive. ESD can weaken or damage the electronics in these appliances in a manner that renders them inoperative or reduces the time until their next failure. Connect an ESD wrist strap to a ground connection point or unpainted metal in the appliance. Alternatively, you can touch your finger repeatedly to a ground connection point or unpainted metal in the appliance. Before removing a replacement part from its package, touch the anti-static bag to a ground connection point or unpainted metal in the appliance. Handle the electronic control assembly by its edges only. When repackaging a failed electronic control assembly in an anti-static bag, observe these same precautions.

REGULATORY INFORMATION

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential installation. This equipment generates, uses, and can radiate radio frequency energy, and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna; Increase the separation between the equipment and the receiver; Connect the equipment to an outlet on a different circuit than that to which the receiver is connected; or consult the dealer or an experienced radio/TV technician for help.

DISCLAIMER

The information in this training manual was accurate at the time of publication. Every effort has been made to ensure accuracy. Updates, changes, etc. are available via GCSC and LGCSacademy. The information in this manual is intended for persons with adequate backgrounds in electronics, mechanical, and electronic servicing. The manufacturer and seller are not to be held responsible for any liability incurred from its use.

COMPLIANCE

The responsible party for this device’s compliance is LG Electronics Alabama, Inc.; 201 James Record Road, Huntsville, AL, 35813.

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Contents

Important Notices (The Small Print Page)		1
Contents		2
Introduction		3
LCD Control Panel		4
LED Control Panel		5
Safety Notices		6
Warranty Information		7
Specifications		8
Accessories		9
Drying Rack Installation		9
Stacking Kit Installation		10
Makeup Air		11
Pedestal		12
Remote Laundry Monitor Installation		14
Electrical Connection (Electric Dryer Only)		15
Gas Connection (Gas Dryer Only)		18
Dryer Cycle Chart		19
Steam Cycle Information		20
STEAMFRESH™		20
Reduce Static		20
Easy Iron		20
Display PWB		21
Main Control Board		21
Main Control Board (Photo, with connectors labeled)		22
Schematic (Electric Dryer)		23
Schematic (Gas Dryer)		24
Diagnostic Test Mode		25
Component Testing Procedures		26
Motor Diagram and Schematic		29
Safety Switches		30
Centrifugal Switch		30
Belt Switch		30
Diagnostic Test Procedures		31
Test 1 – AC Electrical Supply		31
Test 2 – Thermistor Test (Power Off)		34
Test 3 – Motor Test		35
Test 4 – Moisture Sensor Test		36
Test 5 – Door Switch Test		37
Test 6 – Heater Switch Test (Electric Dryer Only)		38
Test 7 – Gas Valve Test (Gas Dryer Only)		39
Test 8 – Semiconductor (Sensor) Test		40
	continued on next page Æ
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Contents, continued

Gas Conversion (Natural Gas to Propane)	41
Regulator Conversion	42
Orifice Change	42
Gas Pressure Testing	43
Gas Valve Operation	44
Disassembly and Repair Instructions	45
Top Plate (Cover)	45
Panel Drawer (Water Container)	45
Control Panel	46
Front Cabinet	47
Door Reversal	47
Guide Assembly (for Steam Generation)	48
Steam Generator	49
Steam Generator Troubleshooting	50
Main Components	50
Theory of Operation	50
Thermistor Testing	51
Pump Motor Testing	51
Panel Body and Frame	53
Tub Front (Front Bulkhead)	53
Drum, Belt, and Pulley	54
Drum Lamp	55
Vent Replacement (Side Venting Kit)	56
Additional Venting Information	57
Static Pressure Testing and Vent Kit	58
Filter Assembly and Moisture Sensor	59
Rear Bulkhead	59
Air Duct	59
Rollers	60
Blower Housing	61
Exploded Views	62
Parts List	67
Supplementary Materials	70
Serial Number Identification	70
Ohm’s and Watt’s Laws (Chart and Formulae)	71
Temperature Conversion (Chart and Formulae)	72
Service Bulletins	73

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INTRODUCTION

MAIN CONTROL PANEL

The Steam Dryer is available in two models. The top end model includes an LDC control panel while the next model down has LEDs instead. Both models function similarly. (See photo, next page.)

The LCD control panel includes a display window and an array of option buttons.

The steam feature buttons (REDUCE STATIC and EASY IRON) add these steam features to the end of any of the sensor cycles available.

(See complete explanation on page 20.)

1. Cycle selected

2. Approximate time remaining on cycle

3. Progress indicator (%age complete)

4. Child Lock indicator

5. Sensor cycle indicator

6. Indicators – refer to the option buttons below the window. These buttons allow the user to override the default settings on many cycles.

Error messages are displayed in the LCD window as well.

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INTRODUCTION, continued

MAIN PANEL

New features on the control panel include the STEAM FUNCTION BUTTONS and the ADD WATER warning lamp.

The option buttons are the same on both types of control panel.

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SAFETY

Check the local laws and regulations concerning the installation and connection of gas. In most localities, it is illegal to connect gas piping, re-jet or adjust burners, or repair gasfired equipment unless you are licensed and certified so to do. It is the servicer’s responsibility to comply with all such regulation.

The STEAM GENERATOR operates at a high temperature (hot enough to boil water.) When servicing the steam generator, let it cool before beginning work. Hot water and steam can cause severe burns and injuries.

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WARRANTY

Warranty statements vary by product. Be sure to check the warranty that was included with the product because that is the valid warranty. This statement is generic and for instructional purposes only.

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SPECIFICATIONS

Specifications are subject to change without notice.

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ACCESSORIES

DRYING RACK

STACKING KIT

PEDESTAL

The DRYING RACK is used to dry items that should not be tumbled, like sweaters, tennis shoes, etc. It should be removed and stored when not in use. The rack is included with the dryer. (See installation procedure, below.)

The STACKING KIT is used to stack a dryer on top of a matching washer. (NEVER put a washer on top of a dryer!) The stacking kit should not be used in situation where there is the possibility of excessive vibration and movement of the washer, such as in a mobile home or an upper floor of a frame structure. The stacking kit is available as an optional purchase. (See installation procedure, page 10.)

The PEDESTAL can be used under either the washer or the dryer. It is possible to stack a washer and dryer on a pedestal, but the dryer controls may be difficult to reach and the possibility of vibration and movement is greater. The pedestal is available as an optional purchase. (See installation procedure, pages 12 ~ 13.) Pedestals are available in heights of 7¼” and 13”.

INSTALLATION (RACK)

Open the dryer door.

Put the rack in place.

Select RACK DRY (2nd button on right)

Press START.

Be sure the front of the rack is properly situated in the notches on either side of the filter. The back should rest on the drum and allow the drum to rotate.

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INSTALLATION (Stacking Kit)

WARNING! Do not attempt this alone! At least two people are required to lift the dryer and place it properly on top of the washer. Failure to observe this warning could result in serious physical injury and damage to the appliances.

Place the washer on a solid, even floor. If you plan to use a pedestal, install it now before going any further.

Peel the protective paper from the adhesive tape on the side bracket.

Fit the side bracket firmly to the top plate using the adhesive tape, as shown in the drawing.

Secure the bracket to the top plate using a screw, as shown.

Repeat these steps for the other side.

Level the dryer on a firm solid floor and lock down the adjusters before placing it on top of the washer.

Lift the dryer on top of the washer it toward the front of the washer, as shown.

Slide the dryer all the way back to the stop on the rail.

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INSTALLATION (Stacking Kit) continued

Install the front rail of the stacking kit. Push the front rail back against the stops on the side brackets.

Insert a screw to attach the front rail to the side bracket.

Insert the other screw for the other side.

INSTALLATION (Makeup Air)

Minimum clearances must be observed, particularly if the dryer is installed in a closet or a laundry alcove. The dryer is essentially an air pump moving 150 cfm (cubic feet per minute) and that air must come from somewhere for the dryer to operate properly. Additional air must be supplied to support proper combustion.

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INSTALLATION (Pedestal)

For 27” Pedestals

(Washer, Dryer, and Combo)

Remove the pedestal, installation hardware, and instructions from the shipping container.

Level the pedestal on a solid, flat, level floor. Lock down the rear adjusters, but leave the front ones free for now.

Set the dryer on the pedestal and level it. Level it and lock down all four adjusters on the dryer.

Note which holes are for the washer and which are for the dryer. If you are stacking the appliances, the washer should be on the bottom.

REAR FRONT

Remove the protective paper from the adhesive surface of the bracket.

Be particularly careful, because when this adhesive makes contact, there is no adjustment possible.

NOTE: Some kits include two sets of brackets (curved for the dryer and flat (shown) for the washer.) Use the correct bracket for your application. The curved bracket is for clearance of the exhaust vent when a dryer has been converted to side venting. (See next page.)

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INSTALLATION (Pedestal) continued

Holding the adhesive part of the bracket away from the dryer, insert the screws and get them started.

Press the bracket onto the dryer and tighten the screws.

Press the brackets onto the sides of the dryer and rub the brackets from side to side to ensure the total adhesive area is attached completely.

Tighten all the screws securely.

Lower each leg of the dryer one-fourth turn with the adjusting wrench to put a little pressure between the dryer and pedestal to prevent any motion and rattling.

Push the dryer into place.

Check the level and adjust the front legs of the pedestal as necessary. Then lock down the adjusters.

The pedestal kit includes the mounting plates (with adhesive covered by paper) and the screws to attach the plates.

Remember, some pedestal kits come with two sets of brackets. The flat tops are for washers; the curved tops (shown) are for dryers. Use the correct brackets for your application. The curved bracket is for clearance of the exhaust vent when a dryer has been converted to side venting.

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INSTALLATION (Modem and Monitor)

REMOTE MONITOR

The monitor plugs in to any 120 VAC outlet in the home. It receives its data signal via the power lines.

Be sure the dryer is unplugged.

Remove the modem cover.

Save the cover for future use; in the event you must remove the modem, you can replace the cover.

Attach the modem to the socket with the screws provided.

Plug the monitor’s power cord in an outlet where you can observe it easily. Use the stand or the wall mount bracket.

Press and hold the button until the display shows SET.

The dryer can be operated normally without the modem if the customer does not wish to purchase it as an option.

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ELECTRICAL CONNECTION (Electric Dryer Only)

PIGTAIL INSTALLATION

Install the appropriate power cord for the outlet available. Grounding through the neutral conductor is prohibited in new branch-circuits, mobile homes, recreational vehicles, and where prohibited by local code.

4-wire Connection

The 4-wire receptacle looks like this.

Power cord with spade terminals.

Power cord with ring terminals.

Install a strain relief on the power cord.

Then connect the terminals to the terminal block, matching the wire colors.

A. Ground screw on chassis

B. Green wire from power cord

C. Strain relief

D. Neutral screw on terminal block

E. Terminal block

F. Neutral wire from power cord

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ELECTRICAL CONNECTION (Electric Dryer Only) continued

3-wire Connection

The 3-wire receptacle looks like this.

Power cord with spade terminals.

Power cord with ring terminals.

Install a strain relief on the power cord.

Then connect the terminals to the terminal block, matching the wire colors. Add a wire to connect the chassis ground to neutral.

A. Ground screw on chassis

B. Green wire from power cord

C. Strain relief

D. Neutral screw on terminal block

E. Ground-to-neutral connection

F. Neutral wire from power cord

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ELECTRICAL CONNECTION (Electric Dryer Only) continued

Be sure to tighten all screws firmly, but do not strip them or distort the contact area. You want a secure connection without damage to the connectors.

Be sure to install a strain relief on the power cord.

Replace the terminal block cover by inserting the tabs into the slots and letting them slide down to engage.

Fold it over to the back of the dryer so it covers the access to the terminal block. Be sure no wires are exposed or could touch any metal surface.

Secure the cover with a screw.

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GAS CONNECTION (Gas Dryer Only)

CAUTION! (This warning applies to both natural gas and propane.)

Gas is both flammable and explosive. Use caution when working with gas.

In most locations, installing and connecting gas is restricted to properly trained and licensed persons.

Always inspect joints and connections for a leak with a soapy solution. If you see bubbles, turn the gas off and open a window. If you smell gas, turn off the main valve and open a window.

The gas dryer requires a 120 VAC, single-outlet, dedicated circuit. The cord is installed at the factory and no user-intervention is required.

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DRYER CYCLE CHART

* SENSOR DRY	The dryness level is set by the customer.
** MANUAL DRY	The temperature is set by the customer. The maximum drying time
	for RACK DRY or SPEED DRY is 1 hour 39 minutes.

The default settings can be overridden by the customer in most cases.

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STEAM CYCLE INFORMATION

The steam dryer is designed to provide the power of steam through the introduction of steam into almost every drying cycle.

STEAMFRESH™

The STEAMFRESH™ cycle is a 20-minute cycle that tumbles the clothes in a spray of steam. This cycle is NOT a wash cycle, but is instead designed to refresh clothing that has been packed away, stored, or otherwise wrinkled and less than freshly laundered. The steam cycle will refresh from one to five items during its 20-minute run time. The drum tumbles the clothes while steam sprays through them for the first five minutes. Then the steam continues while the drum tumbles for 2 seconds once each minute. At that point (12 minutes in to the cycle,) the steam generator is turned off and the dryer continues to tumble constantly with the main heater engaged to finish drying the clothes. The main heater is turned off for the last two minutes of the cycle while the drum continues to tumble to allow the clothes to cool.

The MORE TIME and LESS TIME buttons are used to adjust the number of items to be freshened during the STEAMFRESH™ cycle.

The time cannot be adjusted by the user when a sensor dry cycle is engaged.

REDUCE STATIC

The REDUCE STATIC cycle is an add-on to all the regular cycles except AIR DRY or RACK DRY. When REDUCE STATIC is selected, the main heater is turned off two minutes before the end of the cycle and the steam generator is energized for the final two minutes while the drum continues to turn.

EASY IRON

The EASY IRON cycle is an add-on to all the regular cycles except AIR DRY or RACK DRY. When EASY IRON is selected, the main heater is turned off eight minutes before the end of the cycle and the steam generator is energized for the final eight minutes while the drum tumbles for two seconds once a minute.

CHILD LOCK can be engaged only after a cycle has been selected and the START button has been pressed. CHLD LOCK locks ALL controls, including the POWER button. It releases at the end of the cycle or in the event of a power failure.

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DISPLAY PWB

The display board is actually two boards connected by a ribbon cable. One board holds the selector knob and cycle indicator LEDs. The other holds the LCD display and adjustment buttons to override the pre-set cycle selections.

DISPLAY BOARD

The display board includes the LCD display and LEDs that indicate the various cycle and option information. It is made of two boards that are permanently connected by a ribbon cable that is soldered to the board at each end. This makes the boards a single unit. The purpose is to allow the display board to flex to fit inside a curved control panel while maintaining its integrity as a single board.

MAIN CONTROL BOARD

The main board is attached to the back of the display board in the control panel by two screws. Many of the components of the dryer can be tested by removing their connector at the main board.

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MAIN PWB

The main board includes the relays that operate electric heaters and gas valves. The gas and electric models have a different main board.

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SCHEMATIC – ELECTRIC DRYER

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SCHEMATIC – GAS DRYER

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