SERVICE MANUAL WASHING Washing machines ELECTROLUX HOME PRODUCTS ITALY S.p.A. Spares Operations Italy Corso Lino Zanussi, 30 I - 33080 PORCIA /PN (ITALY) Fax +39 0434 394096 Edition: 2005.11.
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CONTENTS 1 2 3 PURPOSE OF THIS SERVICE MANUAL ................................................................................................. 6 IMPORTANT NOTES................................................................................................................................. 6 WASHING PRINCIPLES ........................................................................................................................... 7 3.1 Washing .............................................................
5.5 Pressure switch ................................................................................................................................ 36 5.5.1 General characteristics.............................................................................................................. 36 5.5.2 Pressure switch hydraulic circuit ............................................................................................... 36 5.5.3 Electrical symbol.......................................................
6.7.3 Front counterweight................................................................................................................... 56 6.8 Drum lifter ......................................................................................................................................... 57 6.9 Access to the pumps/manifolds ........................................................................................................ 58 6.9.1 Drain pump (standard version)..................................
1 PURPOSE OF THIS SERVICE MANUAL The purpose of this Service Manual is to provide Service Engineers, who already have the basic knowledge necessary to repair household washing machines, with information of a general nature regarding the P6000 (Nexus) range of washing machines. More detailed information regarding specific models may be found in the Service Notes and Service Manuals (issued separately) for each specific model or functionality.
3 WASHING PRINCIPLES 3.1 Washing The washing of the fabrics consists of transferring the dirt from the fabrics to the water, and is achieved using the following: detergent mechanical action temperature time The washing operation comprises four phases: 1. Soaking (the fabrics must be completely soaked). 2. Dispersal of the dirt (which must be separated from the fabrics). 3. Suspension of the dirt (once removed from the fabrics, the dirt must not re-deposit, but must be held in suspension). 4.
3.2 Fabrics 3.2.1 Natural and artificial fibres NATURAL FIBRES Wool ANIMAL FIBRES Special wool Silk Cotton Linen CELLULOSE VEGETABLE FIBRES Canapa Hemp Ramie ARTIFICIAL FIBRES Viscosa rayon Cupro rayon Special rayons ARTIFICIAL CHEMICAL FIBRES Rayon and polynosics Acetate rayon Triacetate rayon Polyammide fibres Polyurethane fibres SYNTHETIC CHEMICAL FIBRES Polyureic fibres Polyester fibres Polytechnical fibres 3.2.
3.2.3 International symbols for washing of fabrics Labels marked with the following symbols are affixed to the garments, and provide valuable information relative to their treatment.
3.3 Classification of soiling The dirt in the fabrics consists essentially of: PROTEICN-BASED substances OXIDABLE substances GREASE VARIOUS substances CHEMICAL substances Protein soiling (enzymatic) - sensitive to ENZYMES Blood, Eggs, Chocolate, Grass etc. Oxidable substances - sensitive to BLEACH Wine, Tea, Coffee, Fruit etc. Greasy soiling - sensitive to SURFACE-ACTIVE AGENTS Oil, Butter, Salt etc.
3.6 Water Water is the most important element in the washing process, and is fundamental to the final result. Ideally, the water used for the wash should have the following composition: Clear and transparent, a low level of hardness, absence of manganese, low iron and mineral salt content. The water may contain various substances (mineral and others) in varying quantities: Fe (iron), Mg (manganese), Si (silicon), Na (sodium), Ca (calcium), K (potassium).
3.6.3 Total water hardness Total hardness is the sum of the temporary hardness (caused by calcium and magnesium bicarbonates) and the permanent hardness (caused by sulphates, chlorides and calcium/magnesium nitrates). Hardness expressed in French degrees (°F) represents the quantity of calcium carbonate, in grammes, contained in 100 litres of water. Hardness expressed in German degrees (°D) represents the quantity of calcium oxide, again in grammes per 100 litres of water.
3.7 Detergents Modern detergents are less aggressive than those used in the past, partly for reasons of environmental protection and partly to prevent damaging the fibres. If used correctly, these offer an excellent protective treatment and a high level of washing power. Detergents that contain no phosphates are far more sensitive to the reaction with calcium.
3.7.3 Functions of other components of a detergent 1. ENZYMES: Enzymes are proteins produced by living cells (animal and vegetable) and are able to transform organic materials with a high molecular weight, such as starches, proteins and fats, into more easily soluble products. These integrate with and facilitate the action of the detergent, eliminating protein-based dirt. Their direct action also facilitates the removal of other types of dirt.
3.7.4 Detergent quantities - efficiency of the washing programme according to the load and the water hardness. In order to perform its function completely and correctly, the appropriate quantity of detergent must be used, which depends on the quantity of water that is contained in the tub of the washing machine, the type of washing cycle, the type of fabrics, the type of soiling and the quantity of washing in the drum. Small quantities of detergent will be insufficient for efficient washing.
3.7.5 Washing additives 1. SOFTENER: (Cationic surface-active agent + fragrance): This additive is introduced automatically by the appliance during the final rinse. It softens the surface of the fabric, which thus remains soft to the touch and easier to iron. If used incorrectly before or during the wash, or if introduced too early into the tub by the water fill system, its action is rendered ineffective by the surface-active agents contained in the detergent. 2.
3.8 The function of the water temperature The variety and quality of natural and synthetic fibres which comprise the fabrics, which are sometimes present in percentages that are not declared correctly on the labels, make it necessary in many cases to use a detergent whose washing action is effective at low temperatures. As a result, the consumer today tends to use washing programmes with a maximum temperature of about 60°C, partly due to increasing sensitivity to energy savings.
3.9 Washing machine programmes Pre-wash (not for wool and, in some cases, delicate fabrics) Wash 1st rinse 2nd (3rd) rinse Final rinse (softener) (Rinse-hold) Final spin 2005.11 dmm 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 1. 2. 3. 4. 1. 2. 1. 2. 1. 2.
3.10 Control panel The plastic control panel is secured to the control panel support by anchor tabs and one or more screws. The shape of the control panel depends on the styling, with LCD display, with DISPLAY or without. 2005.
3.11 “JETSYSTEM” washing system In the "Jetsystem" washing system, considering that the removal of the dirt is performed solely by the water that passes through the fibres, the remaining part of the washing solution has been eliminated. In other words, this system is based on the possibility of washing the fabrics using only the water used to wet them; the quantity of water introduced into the appliance is therefore proportional to the type and quantity of the fabrics in the drum.
4 STRUCTURAL CHARACTERISTICS 4.1 “NEXUS” technology These appliances are produced using the NEXUS technology, a patented system consisting of five subassemblies: Base Cabinet Control panel support Washing group Work-top 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Base Damper Rear cabinet Washing group Suspension spring Conveyor Work-top Control panel support Front cabinet Control panel Detergent drawer Door 4.2 1. 2. 3. 4. 5. 6.
4.3 Control panel support 3 2 1. 2. 3. 4. Selector Electronic board Pressure switches Detergent dispenser 4 1 The control panel support (in galvanized sheet metal) is secured by a series of screws to the two cabinet shells. Several components are fitted to the support: electronic board, pushbuttons, switch, capacitor, pressure switches, detergent dispenser and control panel. Also secured to the support are the two suspension springs for the washing group.
4.5 Door Door characteristics: • large 30 cm • angle of aperture 160° and 180° • alignment with front panel • differently-styled surrounds • type of aperture (various handles) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Front surround Door glass Rear surround Hinge Handle Handle spring Pin Latch Latch spring Flange 4.5.1.1 1. 2. 3. 4. 5. Handle assembly Handle Hinge pin Latch Latch spring Handle spring (certain models only) 2005.
4.6 Washing groups The washing group is suspended from the support cross-member by two helical springs. The oscillation of the washing group is absorbed by the two dampers attached to the base. Balancing of the washing group is provided by a front counterweight in cement. 4.6.1 1. 2. 3. 4. 5. Damper Rubber vibration damper Shaft Shaft seals Cylinder Rubber vibration damper 2005.
4.6.2 Washing group in Carboran The tub consists of two half-shells in Carboran, secured together by a series of self-tapping screws. The two counterweights are screwed to the half-shells. The bellows seal is secured to the front half-shell by a metal elastic ring. 1. 2. 3. 4. 5. 6. Front half-shell O-ring Rear half-shell Drum Front counterweight Counterweight anchor screw 7. Bellows seal 8. Ring securing the seal to the tub 9. Ring securing the seal to the cabinet 10. Rear counterweight 11.
4.6.3 Drum The drum consists of a stainless steel casing to which the two flanges are crimped. Three Carboran lifters are pressure-fitted to the internal face of the drum. The drum spider, in aluminium alloy, is secured to the edge of the drum by screws. A brass bushing is pressure-fitted to the drum shaft. 1. 2. 3. 4. 5. 6. 7. Drum casing Flange Drum lifter Drum spider Screws Drum shaft Drum shaft bushing Drum spider 2005.
4.6.4 Drum rotation drive belt These appliances are fitted with elastic drive belts. The motor is mounted in a fixed position, and no regulation is possible. 3 1. Motor pulley 2. Elastic drive belt 3. Drum pulley 2 1 Different types of drive belts, produced by various manufacturers and with different characteristics, are used in production: • • rubber belts (black) plastic belts (yellow) The length marked on the drive belt (1217, 1280 etc.
4.7 Detergent dispenser 4.7.1 Detergent dispenser with multiple-outlet solenoid valve This type of detergent dispenser, in different dimensions, is used in models featuring: • EWM1000 electronic control system • EWM2000EVO electronic control system • EWM3000NEW electronic control system The water is ducted into the detergent compartment by a solenoid valve with one inlet and 2 or 3 outlets. The detergent drawer may consist of 3 or 4 compartments. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
4.7.1.1 • • Principles of operation Water fill to pre-wash compartment (Pre-wash solenoid valve) This version is used in models with three compartments (EWM1000) and 3 or 4 compartments (EWM2000EVO/EWM3000NEW). The detergent contained in compartment "a" is introduced at the beginning of the pre-wash phase. In certain models featuring the "stains" option, compartment "a" may be used (as an alternative) to contain the stain-removal product, which is introduced during the wash phase.
4.8 “NEW JET” circulation circuit 1. Tube between tub and filter body 2. Filter body 3. Drain filter 4. Washer 5. Filter knob 6. Drain pump 7. Pump cover 8. Circulation pump intake tube 9. Circulation pump 10. Pump cover 11. Circulation tube 12. Pressure chamber Drain filter This drain system is self-cleaning: the filter traps only objects of a certain size. The drain tube is used to empty the drain circuit. The pump impeller can be inspected after unscrewing the filter. 2005.
5 ELECTRICAL COMPONENTS 5.1 Suppressor 5.1.1 General characteristics The suppressor is connected to the input of the appliances power line, and prevents radiofrequency disturbance from entering the power circuit. 5.1.2 Electrical symbols 5.1.3 Circuit diagrams 5.1.
5.2 5.2.1 Push-button General characteristics Single-button versions are used. These differ as regards the number and functionality of the contacts: - switch - deviator (single- or two-pole) 5.2.2 Electrical symbol Normally-closed switch Normally-open switch Deviator 5.2.3 Checking for efficiency DOES NOT POWER THE APPLIANCE OR DOES NOT PERFORM THE SPECIFIC FUNCTION: - Use a tester to check for correct closure (or aperture) of the various contacts.
5.3 Instantaneous door safety interlock 5.3.1 General characteristics Certain models with electronic control systems feature an instantaneous door safety interlock. In this case, the door can be opened as soon as the drum comes to a stop. 5.3.2 Operating principle 1. Solenoid protective PTC 2. Solenoid valve 3. Lever mechanism 4. Camme 5. Bi-metal PTC 6. Electrical contacts (main switch) 7.
5.3.2.3 Protective cut-out for solenoid valve A PTC, connected in series to the solenoid valve, serves as a current limiter (i.e. overheating cut-out) in the following cases: → If the triac on the main PCB is short-circuited → If the START/PAUSE button is pressed repeatedly (more than 10 times) 5.3.3 Electrical symbol 5.3.4 Circuit diagram 1. Main switch 2. Solenoid valve 3. PTC protective solenoid valve cut-out 4. Bi-metal PTC 5. Connector 2005.
5.4 Solenoid valve 5.4.1 General characteristics The solenoid valve ducts water through the detergent dispenser, and is controlled electrically by the pressure switch. 1. 2. 3. 4. 5. 6. 7. 8. 1. 9.
5.5 Pressure switch 5.5.1 General characteristics The function of the pressure switch is to determine the quantity of water to be introduced into the tub. In other words: Ö It controls the water fill levels during the washing phases. Ö It acts as an anti-boiling safety device when connected in series to the heating element. Ö It can also act as an anti-overflow safety device if connected in series to the drain pump. Ö It can act as an anti-foam device during the spin phases. 2. 3. 4. 5. 6. 7.
Operating principle Tub empty As there is no water in the tub, there is no pressure on the diaphragm, which thus remains in the lower position due to the counterforce exerted by the spring. In this position, the contact is closed on "empty". 5.5.3 Water flows into the tub When the connection between the tub and the pressure chamber is interrupted by the water, the pressure between the pressure chamber and the internal chamber of the pressure switch increases.
5.6 5.6.1 Analogue (electronic) pressure switch General characteristics The electronic pressure switch is an analogue device whose function is to control the level of water in the tub; it is used in certain models with electronic control systems (EWM2000EVO – EWM3000NEW). The electronic circuit is connected directly to the main PCB. 5.6.2 Operating principle 1. Air intake tube 2. Membrane 3. Coil 4. Electronic circuit (oscillator) 5. Core 6. Spring 7. Calibration spring 8.
5.6.3 Electrical symbol 5.6.4 Circuit diagrams and operating frequency Version for EWM2000EVO EWM3000NEW control system 5.6.5 Checking for efficiency In the event of a fault in the pressure switch, the operation of the appliance is immediately interrupted. Where possible, always read the alarm code. Possible alarm codes caused by faults in the pressure switch: EWM2000-EWM3000NEW: E31, E32,E33, E34, E35 2005.
5.7 5.7.1 Induction (asynchronous) motors General characteristics The function of the motor is to rotate the drum at different speeds: Ö high speed for the spin phases Ö low speed for the wash phases The primary characteristics of these motors is that they do not require a start-up current. Instead, the current in the rotor builds up by induction, hence the name "induction" motor. These motors are also termed "asynchronous" because the speed of rotation is not the same as the synchronization speed. 5.7.
5.8 Commutator motor 5.8.1 General characteristics Commutator motors are fitted to appliances with spin speeds of between 600 and 1,600 rpm. 1. 2. 3. 4. 5. 6. Stator Terminal block Commutator Tachometric generator magnet Tachometric generator coil Brush 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Stator Stator winding Brush Commutator Rotor winding Motor drive shaft Pulley Bearing Tachometric generator coil Magnet Spring 5.8.
5.8.2.1 Control of the speed of the motor Speed control is obtained by using an electronic control system to vary the voltage (V) applied to the motor. The technique used consists of a "phase division" performed by the Triac. A Triac is a bi-directional electronic switch. Closure of the circuit between A1 and A2 (anodes) takes place in the presence of the appropriate signals received by the gate (G). Start-up signals Voltage to motor 5.8.2.
5.8.2.3 Tachometric generator As in all motors powered in series, the speed of the commutator motor depends on the load. In other words, its speed diminishes as the load increases. This makes it necessary to ensure that the power voltage to the motor, and therefore its speed, be constantly controlled by an electronic speed control system.
5.8.4 Circuit diagram P = Motor overload cut-out R = Rotor S = Stator T = Tachometric generator 5.8.5 Checking for efficiency 1. Check the connector blocks (wiring) and check for any bent or detached terminals. 2. Check for traces / residue / deposits of water or detergent and identify their source. 3. Check for any windings / components connected to mass or inadequately earthed using a tester with a minimum scale of 40mW across each terminal and the casing (correct reading is ∞). 4.
5.9 Heating element 5.9.1 General characteristics The heating element that heats the washing water is encapsulated, i.e. inserted into a watertight stainless steel tubular casing. 1. Heating element (1950W) 2. NTC sensor 5.9.1.1 Seal The seal between the tub and the heating element is provided by a seal which expands against the nut. 1. 2. 3. 4. 5. 6. Fixed flange Washer Moving flange Nut Heating element terminals NTC Sensor 5.9.2 Electrical symbol 5.9.
5.10 NTC temperature sensor integrated in the heating element 5.10.1 General characteristics In the electronic models an NTC sensor is used to control the washing temperature. In these sensors, the internal resistance decreases as the temperature increases. This reduction in resistance is detected by the electronic control system which, when the desired temperature is reached, disconnects the heating element. 1. 2. 3. 4.
5.11 Drain pump 5.11.1 General characteristics The function of the drain pump is to discharge the water at the end of each phase of the washing cycle. These centrifugal pumps are actioned by a synchronous motor. 1. Impeller 2. Rotor 3. Stator The rotor consists of a permanent magnet, and may rotate in either direction. The rotor may rotate for approximately 15 minutes without actioning the impeller.
5.12 Circulation pump 5.12.1 General characteristics Jetsystem models are fitted with a synchronous circulation pump which continuously circulates the water from the filter body into the tub through the bellows seal. 5.12.2 Electrical symbol 5.12.3 Checking for efficiency NO RE-CIRCULATION - POOR WASHING RESULTS 1. Check that the impeller is not jammed and check for slippage. 2. Check the resistance of the stator winding, which should be approximately 150/200 Ω.
6 ACCESS TO COMPONENTS 6.1 Work-top a. Remove the two rear screws (1), push the work-top towards the rear of the appliance and detach. 6.1.1 Pressure switch a. Remove the work-top. b. Detach the wiring connectors. c. Press the anchor tabs (2) and pull towards the rear. d. Detach the pressure switch tube. 6.1.2 Suppressor a. Remove the work-top. b. Detach the wiring support from the crosspiece and move downwards (3). c. Remove the suppressor. d. Detach the wiring connectors. 6.1.3 Solenoid valve a.
6.2 Control panel a. Remove the work-top. b. Extract the detergent drawer. (Fig.5) c. Remove the screws that secure the control panel to the control panel support. (Fig.6) d. Remove the lateral (b) screws which secure the control panel to the crosspiece and release the anchor tabs (a) from the support. (Fig.7) e. Release the control panel from the lower right-hand guide and remove. To facilitate its release, unscrew the screw which secures it to the cabinet and lift the control panel support slightly.
6.3.2 Control/display board The way in which these boards are fastened depends on the styling version. To access the board: a. Remove the control panel b. Release the PCB casing from the control panel or remove the screws. For further details, refer to the specific Service Manuals for the various types of electronic control systems. 6.3.3 Electronic pressure switch a. Remove the top. b. Press down the anchor tabs and release the pressure switch from the support. (Fig. 10) c. Detach the connector. d.
6.4.3 Door safety interlock a. Remove the seal from the front panel. (Fig. 12) b. Remove the two screws which secure the door delay device to the front panel. c. Remove the door delay device. (Fig. 13) d. Remove the cover from the door delay device. 13 6.4.4 Bellow seal a. Detach the retaining ring and the seal from the front panel. b. Remove the clamp and pull out the circulation tube. (Fig. 14) c. Remove the seal and the ring by pulling downwards (it is held in position by an elastic ring).
6.5 Rear cabinet shell 18 17 a. Remove the top. b. Remove the screws which secure the cabinet shell to the upper crosspiece. (Fig.17) c. Remove the screw head masking caps and remove the lateral screws which secure the cabinet shell to the base. (Fig.18) d. Detach the wire clamp from the cabinet. (Fig.19) e. Remove the rear screws and slide the cabinet shell away from the base. (Fig.20) 19 N.B.: After removing the rear cabinet shell, special care must be taken when moving the appliance.
6.5.3 Detergent dispenser 25 26 27 a. Remove the rear cabinet shell. b. Unscrew the clamp and detach the tube from the detergent dispenser to the tub. c. Detach the steam venting tube from the tub (if present). d. Extract the detergent drawer. (Fig.25). e. Remove the screw which secures the control panel to the detergent dispenser. (Fig.26) f. Remove the screws which secure the detergent dispenser to the crosspiece. g. Detach the tube(s) from the dispenser to the solenoid valve. h.
6.5.6 Drum pulley a. Remove the rear tub shell. b. Detach the drive belt from the pulley. c. Block the pulley in position and remove the screw. d. Remove the pulley. 30 6.5.7 Pressure chamber a. Remove the rear cabinet shell. b. Loosen the clamps and detach the pressure switch tubes from the pressure chamber. c. Remove the screw. (Fig. 30) d. Use pliers to widen the spring clip and detach the pressure chamber from the tub hose.
6.7.1 Drum shaft bearings If it is necessary to replace the bearings, the engineer may: replace the rear tub shell complete with bearings and sealing ring. replace the bearings and the sealing ring only. 33 In the latter case: a. Remove the tub and the drum from the appliance. b. First remove the external bearing, then the internal bearing with its seal.
6.8 Drum lifter The drum lifter can be removed from the interior for tubs in Carboran of type G23. Removal Insert a screwdriver into the following holes: for G13 tubs, into the fourth hole in the lifter for G10-G11-G12-G18-G19 tubs, into the third hole in the lifter ⇒ for G17 tubs, into the second hole of the lifter b. Bend the drum anchor tabs as shown in the figure (34) c. Pull the drum lifter towards the door of the appliance and detach from the drum (Fig.35) a. ⇒ ⇒ 34 35 a. b. c. d.
6.9 Access to the pumps/manifolds Important! Do not fit the circulation pump in place of the drain pump and vice versa! 6.9.1 Drain pump (standard version) To access the drain pump, it is not necessary to remove the rear cabinet shell. The pump can be accessed from the base. a. Detach the clamps which secure the filter body to the base and raise slightly. (Fig. 37) b. Remove the drain pump. c. Detach the drain hose. d. Detach the wiring connectors.
6.9.3 Circulation pump Access to the pump is from the base of the appliance: a. Remove the two screws which secure the pump to the base. b. Detach the circulation pump assembly from the base. c. Loosen the clamps and detach the hoses from the pump (Fig. 40). d. Detach the cover. e. Detach the wiring connectors. f. Remove the circulation pump assembly. Fig.40 6.9.4 Drain filter body a. Remove the rear cabinet shell. b. Lay the appliance face-down. c. Remove the circulation pump (if present). d.
6.10 Front cabinet shell a. b. c. d. e. f. g. h. i. j. k. l. m. n. Remove the top. Remove the control panel. Remove the door. Detach the bellows seal from the front panel. Remove the two screws which secure the door delay device to the front panel. Remove the rear shell Detach the circulation hose (if present) from the front shell. (Fig.43) Replace the rear shell, leaving a gap of 1-2 cm in order to remove the lateral screws which secure the front shell to the base. (Fig.
