SMART DRIVE ELECTRONIC WASHING MACHINE PHASE 1 to 5 – 230v This service manual supersedes all previous Smartdrive 230v service manuals. This manual incorporates all technical bulletins for Smartdrive up to January 2000. Information on IW and IWECO is available in Appendix E. Fisher & Paykel Ltd, Laundry Division. 78 Springs Road, East Tamaki, PO Box 58-732, Greenmount, Auckland. NZ Phone 0064 9 273 0640, Fax 0064 9 273 0649. Fisher & Paykel Customer Services Pty Ltd. ACN.
PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE 5 PHASE 1 GW Model ‘xx0’ PHASE 2 GW Model ‘xx1’ PHASE 3 GW Green & yellow PHASE 4 GW Blue & yellow. PHASE 5 (early) GW MW, LW & AW are different colours. PHASE 5 (late) GW MW, LW & AW are different colours. PHASE 5 IW Bottom right button is ‘Specials’ PHASE 5 IWECO Size 6 & 7 have recirculation fitted.
WHAT PHASE, SIZE & MODEL IS YOUR SMARTDRIVE? PHASE YEAR PHASE 1 1991-93 FRONT PANEL MODEL NUMBERS COLOURS Grey Background GW500, GW600, GW700, MW050, MW060, GW650, MW070 PHASE 2 1993-95 Grey Background PHASE 3 1995-96 White Background with yellow and green buttons PHASE 4 1996-98 White Background (Series 8) with yellow and blue buttons PHASE 5 1998-2001 Various colours. (Series 9 & Series 10) DISPLAY TYPE * AW, LW MW GW IW * ** IDENTIFIER No cycle buttons 4 cycle buttons. Favourite button.
TABLE OF CONTENTS SMART DRIVE ELECTRONIC WASHING MACHINE PHASE 1 to 5 – 230v ..................................1 WHAT PHASE, SIZE & MODEL IS YOUR SMARTDRIVE? .........................................................3 TABLE OF CONTENTS .........................................................................................................................1 1.0 INTRODUCTION .............................................................................................................................1 1.
8.5 RECYCLE..................................................................................................................................33 9.0 SIZE SETTING MODE – Phase 4 and 5 only ...............................................................................35 10.0 USER WARNINGS ..................................................................................................................36 10.1 Insufficient Hot Water (Hot Water LED flashing) ......................................................
1.0 INTRODUCTION 1.1 HOW TO SERVICE SMARTDRIVE IF SMARTDRIVE HAS NO POWER - SEE SECTION 6.1 Power off at the mains socket. Wait 2 minutes. Power on. IF SMARTDRIVE IS DISPLAYING A FAULT - SEE SECTION 11.0 This may be identifiable by an unusual combination of LEDs displayed on the wash progress LEDs. Smartdrive will be making a continuous sound of beeping repeating once every second and will be PAUSED. Phase 1-3 Only press spin buttons until the SPIN HOLD and SPIN SLOW LEDs are on.
1.2 SMARTDRIVE SERVICING – Quick Reference Guide! • • • • • • • • • • • • • • • • • • • • • • • • Smartdrive is not isolated. Even low voltage (5v and 15v) are live! During normal operation only one LED should be flashing. This is the leftmost wash progress LED when Smartdrive is Paused. The product has a diagnostic mode which allows the fault information to be displayed. Diagnostic mode level 3, indicates last fault.
2.0 SPECIFICATIONS Dimensions Height to closed Lid Height to open Lid Width Depth Inlet hose length Dry weight Packed Dry weight unpacked Wash Load AS2040 High Water Capacity Compact (5kg) 900mm-930mm 1280m-1310mm 560mm 560mm 1100mm 48Kg 43Kg 5.0-5.5Kg 63-68L Finish Cabinet Inner Bowl Lid, Console, Outer Bowl, Agitator Touch Panel Medium (6kg) 900mm-930mm 1305mm-1335mm 600mm 600mm 1100mm 52Kg 46Kg 6.0-6.5Kg 76-82L Large(7kg) 900mm-930mm 1350mm-1380mm 650mm 650mm 1100mm 58Kg 51Kg 7.0-7.
3.0 INSTALLATION REMOVING BOWL PACKER AND ACCESSORIES Remove the outer packaging. Leave Smartdrive standing upright. Lift the lid and remove the bowl packer. Remove hoses and accessories. REMOVING TRANSIT RESTRAINT Rotate the agitator anti-clockwise for 3 revolutions. (This unscrews the transit restraint from the base of Smartdrive.) The wash bowl will then be free to move from side to side. Remove the bottom cardboard packer.
LEVELLING SMARTDRIVE It is IMPORTANT to level Smartdrive to ensure even spin performance. Fit the 4 rubber inserts into the feet on the base of Smartdrive. Move Smartdrive to its final position. (a minimum clearance of 20mm each side of Smartdrive for ease of installation.) Adjust the feet so that Smartdrive is level and cannot rock. To check if Smartdrive is level look into Smartdrive bowl and make sure it sits slightly forward of centre. FINALLY Turn on the water and check all hose connections for leaks.
4.
4.1 Electronics Systems Smartdrive electronics consists of 4 mains parts: - a) Motor, (b) Motor Controller Module, (c) Display Module and (d) Rotor Position Sensor. The interconnections are shown in the block diagrams below:- Wiring diagram for Phase 1. NB. Phase 1 (spare) uses a motor controller similar to Phase 2-4. Wiring diagram for Phase 2-4. NB. Most of phase 2 did not have a reed switch, a white wire loop was connected in place of the blue & black wire.
PHASE 5 WIRING DIAGRAM - 8 -
4.2 Motor The motor is a 3 phase, 42 pole, DC brushless motor, commutation is achieved electronically. The Motor consists of a STATOR (stationary part) and ROTOR (rotating part). The Rotor Position Sensor controls the speed and position of the motor. The STATOR has a 'star point' connection, and motor terminals. The Star point connects the 3 windings to a common point. The DIRECT DRIVE motor has eliminated the need for gearboxes, pulleys and belts.
4.3 Motor Controller Module This module contains the circuitry needed to control the water valves, pump and the motor. It also recieves signals from the rotor position sensor, pressure sensor and the display module. The Motor Controller Module and Display Module are continuously communicating. The Motor Controller Module supplies the Display Module with 15v (11v min 17v max). The two Modules are connected together with a 3 way harness, (Phase 1-4), or a 4 way harness, (phase 5).
4.4 • • • • • • • • • • • • • • Display Module The Display Module contains a microprocessor whose function is to take the inputs from the front panel and send the appropriate command to the Motor Controller Module. It also controls the output to the display LEDs and beeper. Test the Display LEDs. Power on at the wall. This illuminates all LEDs for 2 seconds. Check the operation of all the switches and check the appropriate LED lights. If not all LEDs illuminate check that the LEDs are not bent.
4.5 Water Valves The electronics control the water valves so that a constant water temperature is achieved in the bowl irrespective of the temperatures and pressures of the household hot and cold water systems. To achieve accurate water temperatures a proportional water valve is used on the cold water inlet. Unlike conventional water valves which are either fully on or fully off, the proportional water valve can be controlled so that it can turn on at any water flow rate between fully on and fully off.
4.6 Rotor Position Sensor One of the inputs that the Motor Controller Module needs in order to determine which switches to turn on, is the position of the Rotor. This information is supplied by the Rotor Position Sensor (RPS). On the RPS there are three Hall Sensors. These detect the magnetic field of the individual magnets in the Rotor. As the motor turns, the position of a group of magnets is detected. There are 5 wires on the RPS, 2 for power supply and 3 signal wires.
4.7 Pump The drain pump motor is coupled directly to the base of the outer bowl. This eliminates bowl to pump hoses and the accompanying seals, clips etc. The pump housing is an integral part of the outer bowl. The pump is accessible by removing the inspection hatch on the front of Smartdrive, (Phase 1 to 4 only). It is also accessible from the top by removing the agitator and inner bowl. Phase 5 uses the pump as part of the power supply.
4.8 Inner and Outer Bowls The outer bowl is the assembly to which all the motor, pump system, suspension rods, etc are mounted. Within the outer bowl is the inner bowl and the agitator. During spin, the agitator and inner bowl have to be coupled together and turn as a single unit. In agitate the agitator and inner bowl are free to rotate independently. In Smartdrive the inner bowl is free to move in a vertical direction. The position of the inner bowl is determined by the water level.
Detection Of Inner Bowl Float Off Point – Bowl Check During fill the inner bowl will rotate to ensure that the clothes are evenly saturated with water. When the chosen water level is reached, and before the agitate cycle is started, Smartdrive will carry out inner bowl float checks, (bowl check). The inner bowl will stop and commence a number of small agitate type actions. During this action Smartdrive determines if the inner bowl has floated.
4.9 Lid Switch and Out of Balance Switch Lid Switch If the lid is raised, the lid switch operates and stops the cycle when Smartdrive is stirring during fill or Smartdrive is spinning, (braking). The motor should stop within 10 seconds, all the energy from the motor is dumped into the brake resistor (Phase 1-4) or the pump (phase 5). It is important to understand that it can be a worthwhile test to open the lid at 1000 RPM, this will exercise the braking circuitry in the Motor Controller.
4.10 • • • • Water Temperature Sensing Phase 1-4 uses a thermistor for sensing the water temperature. It is located within the Motor Controller. User can adjust the warm temperature by going into the Option Adjustment Mode. Phase 5 GW uses a thermistor for sensing the water temperature. It is located in the mixing chamber. This is a replaceable item and has a resistance of 10k ohms @ 25oC. 12.5k ohms @ 20oC. Phase 5 MW is not fitted with a thermistor.
5.0 SMARTDRIVE INFORMATION This information is provided to the user in the ‘Use and Care Manual’. It is included here for completeness. The user warning information and some information on Option Adjustment mode is also in this manual. 5.1 Favourite cycle (GW only) – All Phases The user may have a particular combination of wash cycle settings that are frequently used, i.e. Nappy wash, small load of Gym gear, cold water wash etc. It is possible to programme this favourite setting into the memory. 1.
5.3 Delay Start (GW only) – Phase 2 to 5 only Select your wash cycle and options to suit the clothes load, by pressing the appropriate buttons then press the DELAY START button: • • • • Once for 1 hour Twice for 6 hours (phase 2-4) 3 hours (phase 5). Three times for 9 hour delay Four times to cancel and return Smartdrive to normal operation. Smartdrive will now automatically start after the appropriate delay time. The flashing of the wash progress LED will stop when the DELAY START is selected. 5.
AMOUNT OF WATER USED IN THE WATER SAVER RINSE MODEL SHOWER RINSE SPRAY & DEEP RINSE Large 60 litres 115 litres Medium 50 litres 105 litres Compact 40 litres 90 litres Please note, these are approximate figures for high water level. The Time Saver or Soak option can be used with the Water Saver option, push the wash options button until both options have been selected. NB. Water Saver is only available on the Regular and Heavy Duty cycles.
5.7 Wash Performance Information – All Phases Creasing Creasing can be caused by Over loading Smartdrive or the dryer. Permanent Press or Delicate cycles have been designed to minimise creasing, they use a lower spin speed. Do not leave wet clothes to sit in the washer or laundry basket. Soiling Soiling is the result of insufficient detergent for the load. White clothes are better washed separately. Separate light and heavily soiled items, as clothes can pick up soil from dirty wash water.
6.0 SMARTDRIVE PROBLEMS 6.1 If Smartdrive Appears To Have No Power If the module appears to be dead / no power then check the following:• • • • • • • • Is the external mains plug switched on and live? Are all plugs connected into the Motor Controller? Phase 4 Only. Check that the product is not "asleep". There is a mode in the motor controller where it can shut down in the event of a transient on the mains. This can be caused by the thermal trip on the pump, i.e. pump block.
6.3 • • • • • • Check inlet hoses are not leaking. Check drain hose is inserted correctly, and that the drain is not blocked. Check water valves are not jammed on, or dripping when off. Has the pressure pipe been connected when the bowl contained water? The pressure pipe must be connected when the bowl is empty, otherwise flooding may occur on the next cycle. Alternatively Smartdrive may get Fault Code 11. Often caused by Smartdrive leaking or over sudsing. See section 6.4.
• • • • • Check the 2 balance rings in the inner bowl contain water. Check weights. Check for noisy suspension rods. Phase 1 was noisy during Stir. If the inner bowl or agitator is noisy check for obstruction. Check the spline drive is clean. If there is a grating sound check the single stainless steel washer beneath the spline drive. If the motor is abnormally noisy. Some early phase 5 rotors were noisy and replacement may rectify this. Chipped or cracked rotor magnets are unlikely to affect the noise.
6.8 Siphoning Typically this occurs when the Standpipe height is too low. The minimum is 850mm from the floor, this is 90mm ABOVE the drain hose outlet on Smartdrive. With a very low standpipe and a very high water level this could result in water pouring down the standpipe prior to Smartdrive completing fill and resulting in no water in bowl during agitate. This could result in fault code 36 or 38.
7.0 OPTION ADJUSTMENT MODE Smartdrive can be adjusted to operate under a number of different conditions OPTION ADJUSTMENT MODE may be used to customise Smartdrive. Some of this information is available to the user in the ‘Use and Care Manual’. For IW see Appendix E.
Method of Setting the Wash Temperature 1. Select the OPTION ADJUSTMENT MODE by pressing and holding the START/PAUSE button, then pressing the POWER button. 2. Use WASH TEMPERATURE buttons and LEDs to select the temperature setting to be adjusted, i.e. Cold, Cold/Warm, Warm, Warm/Hot, Hot. 3. Use the ADVANCE button and WASH PROGRESS LEDs to increase or decrease the temperature. Each time the ADVANCE button is pressed, the WASH PROGRESS LEDs will advance one position to the right.
FIRST RINSE OPTION (2) FIRST RINSE OPTION (3) Spin only. Does not give as good a suds removal as Option (1) but uses less water than Option (3) Deep Rinse. Gives better suds removal but increases water usage. The first rinse is always followed by a final deep rinse and spin. Method of selecting RINSE OPTIONS 1. Select the OPTION ADJUSTMENT MODE by pressing and holding the START/PAUSE button, then pressing the POWER button. 2. Press the SPIN SPEED buttons to select Rinse options. Hold LED ON OPTION (1).
7.4 Adjusting the Volume of Water Used in the Water Saver Option (GW only) – Phase 3 to 5 You can increase or decrease the volume of water added during the shower rinse on the Water Saver option. Enter the Option Adjustment Mode. Use the WATER LEVEL buttons to select the volume of water you wish to be used in the shower rinse HIGH WATER LED ON MED WATER LED ON LOW WATER LED ON more water Default set water volume less water Press POWER to return to normal mode. 7.
8.0 DIAGNOSTIC MODE Allows the following status information to be Allows control of the following:Pump determined: Last Fault. Hot Water Valve Lid switch status. Cold Water Valve Out of Balance switch status. Restart Size. Recycle Additional information Hot Bowl Flag For IW information see Appendix E. 8.1 WHAT WAS THE LAST FAULT? To enter Diagnostic Mode turn the power on at the power point and off at the console. Press and hold the WASH TEMPERATURE DOWN then press the POWER button.
8.2 TEST LID, OUT OF BALANCE, & SIZE SWITCHES To enter Diagnostic Mode turn the power on at the power point and off at the console. Press and hold the WASH TEMPERATURE DOWN then press the POWER button. Smartdrive will give 2 short beeps. Phase 3 Only press ADVANCE button once. Phase 4 & 5 Only press the SPIN SPEED UP button until the MEDIUM SPIN LED is on, (Diagnostic mode level 4). The state of the lid is determined by the 12 minute (Phase 2-5) or 9 minute (Phase 1-2) wash LED. FIRST RINSE LED = 5- 5.
8.4 RESTART If a problem occurs in Smartdrive, it will try to correct the problem and retry. Smartdrive will rectify any problems of a temporary nature. If there is a continuous problem Smartdrive will retry several times. This process may take up to 10 minutes depending on the type of problem. If Smartdrive still cannot resolve the problem, the fault code is displayed and Smartdrive will beep continuously. RESTART ON is the default state. This forces Smartdrive to retry when a problem occurs.
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9.0 SIZE SETTING MODE – Phase 4 and 5 only Phase 1-3 sizes are determined by 2 switches on the display and protrusions on the console. When replacing Display or Motor Controller enter Option Adjustment mode to set these sizes in EEPROM. To check the size setting on Phase 1-3 use DIAGNOSTIC mode. See section 8.2. Size setting mode is required for Phase 1 spare (426518 Motor Controller and 426433 Display). For IW see service manual Appendix E..
10.0 USER WARNINGS There are a number of warnings which are generally caused by the user or poor installation. These warnings should be corrected by the user. Smartdrive signals user warnings by flashing LEDs and a rippling set of 5 beeps repeated every 6 seconds. This is the same tone that is heard when Smartdrive is first plugged into the mains power. Some warnings are indicated by the wash progress LEDs flashing and no user warning tone, (Restart or Recycle mode).
10.3 No Water (Both Hot and Cold Water LEDs flashing) This warning is indicated by the cold and hot water LEDs flashing. Smartdrive will also be making a rippling set of 5 beeps repeated every 6 seconds and the product will be paused. 1. Check that the taps are turned on. 2. Check that the inlet hoses are connected. 3. Check that the flow rate is not too low. The product requires a minimum flow rate of 3 litres per minute. Check that the filters on the inlet hose are not blocked.
10.6 Suds (First Rinse LED is flashing or Final Spin LED is flashing) This warning is indicated by a rinse or spin LED flashing. Smartdrive will also be making a 'rippling sound of 5 beeps repeating every 6 seconds' and the product will be paused. Too much Detergent has been used and Smartdrive has a suds build up. 1. This is generally caused by too much detergent. Wait for suds to dissolve then rinse clothes using a deep rinse. 2.
10.8 Demonstration Mode (All LEDs flashing in patterns) This feature is designed for in store demonstration purposes. Smartdrive can draw attention to itself with a selection of flashing LEDs. In this mode Smartdrive cannot be started. To Select DEMONSTRATION MODE press and hold the ADVANCE button, then press the POWER button. During the DEMONSTRATION display the LEDs will alternate between all on, LEDs flashing, and all LEDs off.
11.
SMARTDRIVE PHASES 1 to 5 FAULT DESCRIPTIONS When Smartdrive detects a fault it stops. Smartdrive beeps continuously, once per second, and displays a fault code in binary using the 8 wash progress LEDs. The possible fault codes are listed in numeric order with their associated service procedure. The fault code binary value as represented by the Wash progress light condition is shown in brackets, e.g. Fault code 9 (00001001) “Size setting Error”.
5. (00000101) Phase 1 – Communications Fault The Display Module has had difficulty communicating with the Motor Controller. Primary Source - Display Module Action – Turn off at the wall and on again after 5 seconds and try again. If still faulty, then: 1. Check connections of the 12 way harness for bad contacts , corrosion etc 2. Check for moisture in the console area. Dry out if necessary 3. If still faulty, then replace Display Module 4. If still faulty, then replace Motor Controller.
Phase 4 to 5 The Display size switch setting does not match that stored in memory. Action - Reselect the size of Smartdrive by using the SIZE SETTING MODE. Push and hold the water temp up button, then press the power button to enter SIZE SETTING MODE. Three LEDs are used to identify size. The cold water temperature LED identifies 5kg. The low water level LED identifies 6kg. The hold spin speed LED identifies 7kg. If the product has not been setup before all 3 LEDs will be on.
11. (00001011) Phase 1 to 5 - Pressure Sensor Fault While measuring the water level the Motor Controller has detected a negative pressure. Reconnecting the pressure tube to the pressure sensor while the bowl contains water can cause this. Primary Source – Pressure Tube. Action - Check bowl is fully pumped out. Remove pressure tube from pressure sensor, clear pressure tube of any water and reconnect tube. Secondary Source - Motor Controller. (Display Module Phase 1). Action - Replace the Motor Controller.
14. (00001110) Phase 1 - Pump Connection Fault The Display Module has detected that the pump is not on when it should be. Primary Source - Pump Action 1. The pump is fitted with a thermal cut out device. Check if this device has been activated. If the device is activated wait until pump cools down before restarting. Check for any pump blockage and check condition of pump (pump seizure). 2. Check for open circuit pump windings. Check the resistance of the pump. 3.
32. (00100000) Phase 1 - Pump Circuit Error The Display Module has detected that the pump is on when it is off. Primary Source - Display Module Action 1. Check for moisture in the console area. 2. Replace the Display Module. 33. (00100001) Phase 1 - Water Valve Fault The Module has detected a water valve fault. Primary Source - Water Valve connection Action - Check that both valves are connected up properly. Secondary Source - Water Valve coil faulty Action 1. Check the valve coils are not open circuit.
36. (00100100) Phase 1 to 5 - Water Leak Fault The Motor Controller has needed to top up the water level more than 4 times during agitate. This is excessive as normally only one or two top ups are required to replace the air that has escaped from a full load during agitate. The most likely cause is that Smartdrive is siphoning. The other alternative is that Smartdrive has developed a leak. Primary Source - Pump System Action - Check the height of the drain hose outlet. 850mm min. 1200mm max.
The Motor Controller has recorded a water level of empty while it is agitating. The water level must have been greater than empty for Smartdrive the enter the agitate mode initially. The most likely cause of this fault is that the pressure transducer hose has been severed or fallen off during agitate. Alternatively the pressure transducer may be faulty. Primary Source - Mechanical Action - Check that the pressure tube is intact and has not been cut. Secondary Source - Motor Controller.
41. (00101001) Phase 1 to 5 - Temperature Sensor Fault The resistance of the Thermistor is outside the normal limits, the fault is probably due to a short circuit in the Sensor line. Primary Source - Thermistor (Phase 5), Motor Controller (Phase 1 to 4) Action Phase 1 1. Check connections of the 12 way harness 2. Check for moisture in the console area 3. Replace Display Module 4. Replace Display Module. If new Display corrects fault then re-fit original Motor Controller.
44. (00101100) Phase 2 to 5 - Water in Bowl During Spin The Display has sensed a water level in the bowl during spin. This may be caused by a slow pump out rate due to pump hose or pump partial blockage. Primary Source - Pump System Action 1. Check that the pump hose is not squashed or kinked. 2. Check the length of the drain hose and try to reduce the length if excessively long. A 1 metre extension hose of the same diameter fitted to the existing hose is the maximum allowable length. 3.
47. (00101111) Phase 2 to 3 - Bowl Dis-engaged Fault While carrying out a bowl check, the Motor Controller has found that the bowl is not engaged even though the pressure sensor indicates that the bowl is empty. The Motor Controller continues to check for 2 minutes. During this time the module has not been able to determine a valid bowl status and so displays this fault. This fault differs from fault 40 in that a valid bowl status could not be determined.
50. (00110010) Phase 2 to 5 - Hot Valve Fault The Motor Controller has measured a voltage from the valve diagnostic circuit that indicates that the hot valve is faulty. The most likely cause is that the valve harness has not been connected correctly. Primary Source - Wiring Action - Check valve harnesses are correctly fastened to valves. Secondary Source - Water Valves Action - Check valve coils are not faulty ( open circuit ).
53. (00110011) Phase 2 to 5 - Rotor Position Sensor Fault The Motor Controller has attempted a motor step test and has found that the motor has not stepped to the correct position. It has detected that the motor is connected and that the Motor Controller drive is operational. The Rotor Position Sensor signal sensing system is at fault.
56. (00111000) Phase 4 to 5 - Bowl Check Fault While carrying out a bowl check Smartdrive has not been able to determine a valid bowl status and so the Display flags this fault. This fault differs from fault 40 in that a valid bowl status could not be determined. The first two areas to check are the clutch and the pressure tube. Primary Source - Mechanical Action 1. Check that there are no clothes or other foreign objects preventing the clutch from reengaging. 2.
61. (00111101) Phase 4 - Motor Controller Fault The Motor Controller has been attempting to perform an internal EEPROM write. Prior to writing the Motor Controller has tested the 15 Volt supply and found that it is below the safety level for writing EEPROM and has reported this to the display. This may be due to mains transients at the time of write or due to a faulty Motor Controller. Primary Source - Motor Controller Action - Replace Motor Controller 62.
104. (01101000) Phase 2 to 5 - Comms. Error Refer to Fault code 105 for action. 105. (01101001) Phase 2 to 5 - Comms. Error Time-out These faults are reported when the Display module detects an error in the communications between the Display module and the Motor Controller. NB. If the product is an IW, check that the motor controller is not 426520. If it is replace with a compatible part. This is incompatible and will give a fault code 105 at the start of agitate.
identify size, cold water temperature LED identifies 5kg, the low water level LED identifies 6kg, the hold spin speed LED identifies 7kg. If the product has not been setup before all 3 LEDs will be on. To set the size for 5kg push the wash temp up button. To set the size for 6kg push the water level up button. To set the size for 7kg push the spin speed up button. Set Model to LW, MW or GW.
Secondary Source - Rotor Position Sensor Action - If the harness seems to be correct, check the Rotor Position Sensor for loose, damaged, or faulty components. Tertiary Source - Motor Controller Action - The Motor Controller motor sensing circuitry may be faulty. Replace Motor Controller. 131. (10000011) Phase 1 to 5 - Repetitive Rotor Position Sensor Error The Motor Controller has found an error in the pattern received from the Rotor Position Sensor.
136. (10001000) Phase 1 to 5 - Motor Stall The Motor Controller has been unable to start the motor rotating and signals the Display module with motor stall error. Possible causes of this fault are: Faulty motor harness, faulty or jammed motor, seized bearings or seals, faulty Motor Controller, faulty Rotor Position Sensor or harness. Primary Source - Wiring Action - Measure/check the motor harness, connectors and motor for discontinuity.
160. (10100000) Phase 1 to 5 - Bowl Engaged During Agitate The bowl has re-engaged itself during agitate. Possible causes for this are a leak in the air bell, bowl is over-loaded with clothes, the clutch has jammed or is fouled with a foreign object. Primary Source - Mechanical Action 1. Make sure the bowl is not overloaded with too many clothes. 2. Check that the rotating bowl assembly is not jammed to the agitator with any foreign object that may be caught under the agitator skirt. 3.
164. (10100100) Phase 4 to 5 - Brake Function Time-out Fault This fault indicates that the Motor Controller has been attempting to brake for 20 seconds. All spin loads should come to rest within 10 seconds something must have gone wrong during the brake to prevent the bowl stopping in time. Primary Source - Wiring Action - Measure/check the motor harness, connectors and motor for discontinuity. This can be done by taking a resistance measurement between phases of the motor harness at the Motor Controller.
12.0 MECHANICAL SERVICE SECTION 12.1 COMPLETE DISASSEMBLY CAUTION: Ensure power and water supplies are disconnected before servicing. There is still mains power within the console when on/off switch in the `off' position. 1. 2. Isolate from the power supply. To remove the lid, open it to the upright position and lift it clear. An anti-static wrist strap must be used when handling electronic modules. Clip the strap to the earth terminal at the rear of the top deck.
PHASE 2 TOPDECK SHOWING WIRING CONNECTIONS 4. Disconnect the pressure tube from the pressure sensor. 5. Disconnect display module plug, the motor/pump harness plug and Rotor Position Sensor plug. Remove the pump earth lead and mains cable earth lead from the Motor Controller Module. Remove the plugs from the back of the mains cable clamp, undo the 2 screws holding the clamp and remove the clamp from the console feed the mains cable earth wire through the cable clamp opening.
7. Unclip the bias spring from the front left suspension rod. Unclip the neck ring from the top of the outer bowl. 8. Remove the fabric softener dispenser, unscrew the agitator retaining nut and remove the agitator. 9. The inner bowl may now be lifted clear. (If the inner bowl is not easy to lift clear, then remove the three spline retaining screws and remove the driven spline. Then pull the drive spline off the shaft and lift out the inner bowl).
14. Lay the cabinet on its back, on protective material, and slide the outer bowl assembly out, but note that approximately 1 litre of water must be removed from the pump sump before laying the cabinet on its back. 15. 16. 17. 18. 19. - 65 - To remove the pump, release the locking tab. Turn the pump anti-clockwise, lift it clear and remove the electrical connections. Remove the two screws securing the wiring duct to the outer bowl base. Remove the drain hose clamp.
12.2 ASSEMBLY GUIDELINES Assembly is the reverse of disassembly. The following points are worth noting. Drain Hose Outlet Elbow. Refit to the base. NB: Ensure the lugs on the elbow are located underneath the pump bracket. Clamp into position. Pump. Turn the pump clockwise when refitting it into the bayonet fixture. Check that the locking tab has clicked into place. Wiring. Fit the wiring harness into all the securing clips. Check that the harness assembly is secured to the suspension rod, (photo).
12.3 MOTOR ASSEMBLY & DISASSEMBLY 1. Remove the rotor by using a 16mm or 5/8" socket. Lift the rotor clear, and place in a plastic bag. The rotor has strong magnets and can attract metal objects. If any foreign objects are caught in the rotor area these may cause the magnets to wear and create a fine black powder which will permeate through the whole appliance. 2. Unscrew the 4 bolts securing the stator to the outer bowl using a 3/8" socket. 3. Lift the stator clear of the shaft, turn over.
12.4 PUMP BLOCKAGE Pump Block error is fault code 37. This is one of the most likely problems encountered in Smartdrive. See section 11.0 for more information on fault code 37. Drain the Bowl. This can either be done using the pump or emptying the bowl manually. If there is a service hatch (Phase 1-4). Remove the front inspection panel by inserting a screw driver into the slot and turn anticlockwise 1/8 of a turn. Pull outwards and remove. Flick Starting the pump.
12.5 SHAFT & BEARING REMOVAL 1. Fit the spline tool over the shaft. Remove the 1 1/4"AF shaft retaining nut securing the shaft. 2. Lay the outer bowl on its side before removal of the shaft. This ensures that the shaft does not fall directly onto the floor. NB: The shaft can only be removed towards the inside of the outer bowl. Remove the shaft. If the shaft is difficult to remove, use a puller and a mandrel.
12.6 SHAFT & BEARING ASSEMBLY 1. The bearings must be inserted separately with the inner bearing fitted first and pulled down with the bearing tool onto the shoulder in the bearing housing. IMPORTANT: There must be no gap between the bearing outer race and the shoulder of the aluminium extrusion. Remove the insertion tool at this point and check that the inner bearing is fully home. 2. Fit the bearing spacer and press in the outer bearing using the bearing tool.
3. 4. 5. Ease the shaft through the bearings from inside the outer bowl. Take care the shaft is fitted with the threaded retaining nut section facing downwards in the direction of the base. Fit the shaft retention nut. Use the spline tool and spanner to tighten the shaft retention nut. Invert the outer bowl. Take care not to damage the shaft or flooring. Fit the assembly thimble sleeve onto the shaft before fitting the seal.
Appendix A: 128 64 32 16 Binary Decoding Chart – 8 Bits (0-255) 8 4 2 1 8 WASH PROGRESS LEDs short wash ΟΟΟΟΟ ΟΟΟΟ✹ ΟΟΟΟ✹ ΟΟΟ✹ ΟΟΟ✹Ο ΟΟΟ✹✹ ΟΟΟ✹✹ ΟΟ✹ ΟΟ✹ΟΟ ΟΟ✹ ΟΟ✹Ο✹ ΟΟ✹✹ ΟΟ✹✹Ο ✹✹Ο ΟΟ✹✹✹ ΟΟ✹✹✹ Ο✹ΟΟΟ Ο✹ΟΟ✹ ΟΟ✹ Ο✹Ο✹Ο Ο✹Ο✹✹ Ο✹✹ΟΟ ✹✹ΟΟ Ο✹✹Ο ✹✹Ο✹ Ο✹✹✹Ο ✹✹✹Ο Ο✹✹✹✹ ✹ΟΟΟΟ ✹ΟΟΟ✹ ΟΟΟ✹ ✹ΟΟ✹ ΟΟ✹Ο ✹ΟΟ✹✹ ΟΟ✹✹ ✹Ο✹ΟΟ ✹Ο✹Ο✹ ✹Ο✹✹Ο ✹✹Ο ✹Ο✹✹✹ ✹✹ΟΟΟ ✹✹ΟΟΟ ✹✹ΟΟ ✹✹ΟΟ✹ ΟΟ✹ ✹✹Ο ✹✹Ο✹Ο ✹✹Ο ✹✹Ο✹✹ ✹✹✹ΟΟ ✹✹✹ΟΟ ✹✹✹Ο ✹✹✹Ο✹ ✹✹✹✹Ο ✹✹✹✹Ο ✹✹✹✹✹ rinse ΟΟΟ ΟΟ✹ ΟΟ✹ 0 1 8 9 16 17 24 25 32 33 40 41 48 49 56 57 64 65 72 73 80 81 88 89 96
Appendix B: Technical Bulletins These are extracts from previous technical bulletins. WM011 ALTERNATIVE SPARE PARTS FOR PHASE 1 MOTOR CONTROLLER – June 1999 – Phase 1 only Fisher &Paykel is no longer able to obtain some electronic components to continue the manufacture of the current Motor Controllers, part number 425243P. We have therefore introduced a redesigned Motor Controller Module and Display Module.
WIRING CONNECTIONS WATER VALVES ROTOR POSITION SENSOR DISPLAY PRESSURE SENSOR PUMP MOTOR OOB HARNESS PUMP EARTH End view of 426418P Motor Controller Module wiring connections. WM013 PUMP HOOD KIT – January 2000 – Phases 2 to 5 Changes have been made to the pump hood, cap and the impeller to decrease the possibility of small pieces of grit and lint blocking the pump. When servicing a blocked pump on Smartdrive, the new pump hood kit, Part Number 479188P, should be fitted.
WM51 DIAGNOSTIC FLOW CHART – Sept 1992– Phase 1 only This is a flow chart for original Phase 1 Smartdrive Motor Controllers and Displays. These are fitted with a slow blow 32mm 6A fuse. Use this flow chart when there is no power to the display module and Smartdrive is powered on.
WM65 BIB DEFLECTOR – April 1994– Phase 1 only Fisher & Paykel have introduced a new bib deflector with 3 vertical fins to replace the early Phase 1 deflector part number 425768. It is recommended that whenever a phase 1 Smartdrive is serviced the new bib part number 425968 be fitted. This replacement deflector is designed to drain the water from the inlet nozzle prior to Smartdrive entering the last spin.
WM80 CONDENSATION KIT – May 1996 – Phase 2 & 3 only A condensation kit is available to reduce build up in the console area and around the electronics is available as part number 472976. This kit must be fitted to all Phase 2 & 3 Smartdrive where the display module has failed due to condensation or there is condensation present in the console area. Common symptoms caused by condensation in the display module are:1. Start/Pause button hard to push or not working. 2.
Appendix C: Smarttool Smarttool is an Application which is run on a PC or a Casiopea Palm-Top. This application may be used with the following Fisher & Paykel products :• • • Smartdrive. Phase 1-5. Washing Machine. ActiveSmart. Refrigerator. DishDrawer. Dishwasher. The fault information is downloaded from the products front panel LEDs via a light pen. For a PC this is part no. 425930D The PC connection is made to a serial port via a DB9 connector. The Casiopea, part no.
Appendix D: Tools for Servicing Smartdrive SERVICE TOOL KIT PART NUMBER 502009 502009 Bearing Puller Kit. This kit is shown above and is used for insertion and extraction of bearings. The extraction washer is available separately. 502034 Rotor Puller Adapter. This tool is used to extract the rotor when the plastic nut is broken. 502105 Rotor Position Sensor. This will connect directly to the RPS or Phase 1 Motor Controller. It requires a 9 volt battery to operate.
Appendix E: E.1 • • • • • • • • • • • • • • IW SMARTDRIVE SERVICING IW Quick Reference Guide The Intuitive Washer can display the most recent user warning and fault. The Intuitive Washer uses the motor to detect the fabric type. The Intuitive Washer uses the same motor, bowl and wrapper as Phase 5 Smartdrive. Two types, Intuitive Washer (IW) without recirculation and Intuitive Eco (IWECO) with recirculation. The display clearly identifies this at power up. IW ECO.
E.3 INTRODUCTION to IW This Service Supplement contains specifications, size setting and diagnostic mode. The first Intuitive Washer(IW) was introduced in Phase 5 Smartdrive in 1999. Three models were released, IW509, IW609 and IW709. These products were upgraded in 2000 to include recirculation, these products are called Intuitive ECO. These products were IWC09 (non recirc), IWM10, IW710, IWL10 and IW810.
recirculation will not work. It is important not to mix the different coloured modules as they are not compatible and Smartdrive will not work. It will normally display a fault code and beep if the modules have been mismatched. Delay start is 1 to 9 hours, (IW) or 18 hours (IWECO) in increments of 1 hour. WATER TEMPERATURE SENSING The thermistor for sensing the water temperature in Smartdrive is located in the inlet chamber and is available as a separate spare part, part number 479164P.
RECIRCULATING VALVE PUMP The pump is the same as Phase 5. The pump forms part of the power supply. If it not connected Smartdrive will appear to have no power. The pump resistance is 33 ohms. E.4 OPTION ADJUSTMENT MODE for IW In Option Adjustment Mode the following adjustments may be made: The fill level selected by Auto Water Level. The type of rinse. The temperature of the wash. The spin speed for Creasables. The recovery routine selected when a load goes out of balance.
AUTO WATER - Auto Water Level Adjustment The water level that Smartdrive fills to on auto water level may be adjusted. Select AUTO WATER. Use the MORE or LESS buttons to decrease or increase the fill level. NB: If there is not enough water for the load, check by pausing Smartdrive and pushing the clothes down to see how much spare water is at the bottom of the bowl. Clothes often float and Smartdrive can sensethe water under the clothes.
E.5 DIAGNOSTIC MODE for IW DIAGNOSTIC MODE incorporates tests for the pump, diverter valve, water valves, and also the data display mode. To enter DIAGNOSTIC MODE, turn the power on at the power point and off at the console. Press and hold the ‘SPECIALs’ / ’LifeCycles’ button and then the POWER button. Smartdrive will give 2 short beeps and the LCD screen will go blank. NB: Make sure that the buttons are released after the beeps, or Smartdrive will take itself out of diagnostic mode.
FAULT STATUS The Fault Status screen will display the fault code for the current or last fault that has occurred in Smartdrive. It will also display how many cycles ago the fault occurred and at what part of the cycle. The fault code can be checked in Section 11 to identify the repairs that may be necessary. Fault Status Fault code: 130 5 cycles ago at progress SPIN DRAIN PUMP TEST When in diagnostic mode, the FABRIC CARE button turns the drain pump on or off.
RECYCLE In the Control Option mode, similar to setting the RESTART. Push the button beside the word RECYCLE to toggle on and off Recycle. At the end of servicing, Smartdrive may require an extended test where it can be left to complete a number of wash cycles. By turning on RECYCLE Smartdrive will continuously repeat the selected wash cycle until RECYCLE is turned off.