Service Manual DOC. NO. 438.9228-76/04 EDITION 2010.08.
For parts, service and technical assistance call your local Wascomat dealer Wascomat Customer Support Whether you need spare parts or technical advice to guide you to the source of a malfunction, our nationwide network of authorized dealers are able and ready to serve your needs, or call the Wascomat Customer Service Hotlines listed below. Spare Parts Technical Support 516-371-2000 Before ordering parts, refer to the Wascomat spare parts manual (also available on www.wascomat.
NOTICE TO SERVICE PERSONNEL INSTALLATION Improper installation of Wascomat laundry and wet cleaning equipment can result in personal injury and severe damage to the machine. REFER INSTALLATION TO QUALIFIED PERSONNEL! RISK OF ELECTRIC SHOCK The equipment utilizes high Voltages. Disconnect electric power before servicing. The use of proper service tools and techniques, and the use of proper repair procedures, is essential to the safety of service personnel and equipment users.
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Service Manual EX618 – EX677, SU620 – SU677, W620 –W677 Compass Control WARNING: ALL OPERATING AND MAINTENANCE PROCEDURES SHOWN ON THE NEXT PAGE OF THIS MANUAL MUST BE FOLLOWED DAILY FOR PROPER OPERATION OF YOUR WASCOMAT MACHINE. PLEASE ENTER THE FOLLOWING INFORMATION AS IT APPEARS ON THE MACHINE(S) DATA PLATE(S). MACHINE TYPE OR MODEL MACHINE SERIAL NUMBER(S) ELECTRICAL CHARACTERISTICS:__________ VOLTS,_ ________ PHASE,_________ HZ.
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SAFETY AND WARNINGS SIGNS Replace If Missing Or Illegible One or more of these signs must be affixed on each machine as indicated, when not included as part of the front instruction panel. LOCATED ON THE OPERATING INSTRUCTION SIGN OF THE MACHINE: PRECAUCION CAUTION 1. Do not open washer door until cycle is completed, operating light is off, and wash cylinder has stopped rotating. 2. Do not tamper with the door safety switch or door lock. 1.
II NOTICE TO: OWNERS, OPERATORS AND DEALERS OF WASCOMAT MACHINES IMPROPER INSTALLATION AND INADEQUATE MAINTENANCE, POOR HOUSEKEEPING AND WILLFUL NEGLECT OR BYPASSING OF SAFETY DEVICES MAY RESULT IN SERIOUS ACCIDENTS OR INJURY. TO ASSURE THE SAFETY OF CUSTOMERS AND/OR OPERATORS OF YOUR MACHINE, THE FOLLOWING MAINTENANCE CHECKS MUST BE PERFORMED ON A DAILY BASIS. 1.
Contents Contents Safety precautions...................................................................................... 11 Technical data............................................................................................. 13 Machine presentation ................................................................................ 21 Description............................................................................................. 21 Function......................................................
Contents Drain valve................................................................................................... 95 Description............................................................................................. 95 Function.................................................................................................. 96 Repairs................................................................................................... 97 Detergent compartment....................................
Safety Precautions 11 Safety Precautions The machine is only intended for water-wash use. Do not allow minors to use the machine. Do not hose down the machine with water. The machine's door lock must under no circumstances be bypassed. If the machine develops a fault, this must be reported to the person in charge as soon as possible. This is important both for your safety and that of others.
Technical data 13 Technical data EX618 Innerdrum volume diameter EX625 EX630 EX645 EX660 EX677 litres/ft3 75/2.6 105/3.7 130/4.6 180/6.4 240/8.5 300/10.6 mm/inch 520/20 1/2 595/23 7/16 650/25 9/16 725/28 9/16 795/31 5/16 795/31 5/16 Drum speed wash extraction rpm rpm Heating electricity kW steam hot water G-factor Weight, net kg/lbs 49 1100 49 1025 49 980 44 930 42 890 42 820 5.4/7.5 x x 7.
Technical data 14 Technical data W/SU620 Innerdrum volume diameter W/SU625 W/SU630 W/SU645 W/SU660 W/SU677 85/3.0 105/3.7 130/4.6 180/6.4 250/8.8 330/11.7 litres/ft3 mm/inch 520/20 1/2 595/23 7/16 595/23 7/16 650/25 9/16 725/28 9/16 795/31 5/16 Drum speed wash extraction rpm rpm 49 587/830 49 548/776 49 548/776 44 525/742 44 497/702 42 474/671 Heating electricity kW steam hot water 5.4/7.5 x x 10 x x 7.
Technical data 1 2 3 4 5 6 7 8 9 10 15 Electrical connection Cold water Hot water Hard water (option) Steam connection Drain Liquid detergent supply Control panel Soap box Door opening, EX618: ø 310 mm/12 3/16", EX625: ø 365 mm/14 3/8", EX630: ø 395 mm/15 9/16", EX645, EX660, EX677: ø 435 mm/17 1/8" A B C D E F G H I K L M N O P R S EX618 720 690 1115 355 720 825 45 1030 220 1010 135 910 830 360 100 240 – EX625 830 705 1200 365 740 910 45 1115 220 1095 135 995 9
Technical data 16 in inch A B C D E F G H I K EX618 28 3/8 14 28 3/8 32 1/2 1 3/4 40 9/16 8 11/16 39 3/4 EX625 32 11/16 27 3/4 47 1/4 14 3/8 29 1/8 35 13/16 1 3/4 43 7/8 8 11/16 43 5/16 EX630 35 13/16 30 7/8 52 3/16 17 1/8 32 1/2 40 3/4 4 15/16 49 8 7/16 48 1/4 EX645 38 3/16 34 1/4 55 1/2 18 1/2 37 3/16 44 1/8 4 1/2 52 3/8 9 1/16 50 13/16 EX660 40 3/16 36 56 7/8 19 11/16 37 5/8 45 1/2 3 15/16 53 9/16 8 7/16 51 15/16 EX677 40 3/16 41 3/4 56 7
Technical data 1 2 3 4 5 6 7 8 9 10 17 Electrical connection Cold water Hot water Steam connection Drain Liquid detergent supply Control panel Soap box Water reuse Door opening, W/SU620: ø 310 mm/12 3/16", W/SU625, SU630: ø 365 mm/14 3/8", W630, SU645: ø 395 mm/15 9/16", W645, W/SU660, W/SU677: ø 435 mm/17 1/8" in mm W/SU620 A B C D E F G H I K L M N O P R 660 730 1115 355 765 825 45 1030 215 1010 130 830 385 – 100 225 W/SU625 720 705 1200 365 740 910 45 1115
Technical data 18 in inch A B C D E W/SU620 26 28 3/4 W/SU625 28 3/8 27 3/4 W/SU630 28 3/8 W645 29 1/2 43 7/8 14 47 1/4 14 3/8 31 1/8 47 1/4 34 5/8 52 1/2 SU645 29 1/2 W660 32 11/16 37 5/8 55 1/2 SU660 32 11/16 37 5/8 55 1/2 W677 35 13/16 40 15/16 56 7/8 in inch L 32 11/16 52 1/2 M N F G H I K 30 1/8 32 1/2 1 3/4 40 9/16 8 7/16 39 3/4 29 1/8 35 13/16 1 3/4 40 7/8 8 7/16 43 1/8 14 3/8 32 1/2 35 13/16 1 3/4 40 7/8 8 7/16 43 1/8 17 1/8 36 40
Technical data Frequency of the dynamic force Max floor load at extraction Hz lbs force kN Frequency of the dynamic force Hz 19 EX618 EX625 EX630 EX645 EX660 EX677 18.3 17.1 16.3 15.5 14.8 13.7 417±110 1.9±0.5 560±112 2.5±0.5 703±114 3.1±0.5 944±221 4.2±1.0 1158±221 5.2±1.0 1387±277 6.2±1.2 W620/ SU620 W625/ SU625 W630/ SU630 W645/ SU645 W660/ SU660 W677/ SU677 9.3/13.8 8.7/12.9 8.7/12.9 8.3/12.3 7.9/11.7 7.5/11.
Machine presentation Machine presentation 21 1 Description General 1 The machines covered in this service manual include the following models: Drum volume Model name litres/ft 3 75/2.6 EX618 85/3.0 W/SU620 105/3.7 EX625, W/SU625 130/4.6 EX630, W/SU630 180/6.4 EX645, W/SU645 240/8.5 EX660 250/8.8 W/SU660 300/10.6 EX677 330/11.7 W/SU677 The machines feature an electronic programme unit with fixed washing programmes that may be changed using optional accessories.
Machine presentation 22 Function General 2 This section presents a general overview of the functions of the machine. Most functions are then presented in detailed in separate chapters later on in this service manual. The machine is freely suspended, which means the outer drum and motor are mounted on a supporting ”cradle” that rests on four shock absorbers for dampening the imbalance in the machine. The washer drum (inner drum) is belt driven by a motor.
Machine presentation 23 2 1 2 3 4 5 18 17 16 6 15 7 14 13 8 12 9 11 10 1. Detergent drawer 10. Shock absorber (not SU- and W-model) 2. Water inlet valves 11. Avloppsventil 3, Power supply 12. Support 4. I/O-board 13. Door 5. Rear electrical module 14. Door lock 6. Motor control 15. Program knob 7. Outer drum 16. Display 8. Coil spring (not SU- and W-model) 17. Control panel 9. Motor 18.
Machine presentation 24 Program unit 3 3 The control panel contains a program knob and a display. The panel can also be equipped with two preset buttons. Program unit The control panel and display are used by: • the user to select the machine’s fixed wash programs, to select up to two options for each wash program and for information on the wash process and any fault indicators. • service personnel for navigation and control of the program unit’s service program.
Machine presentation Motor and motor control 5 6 5 25 1 The washer drum (inner drum) is belt driven by a frequency controlled motor. The motor is located on a motor shelf under the outer drum and has been arranged with a belt tensioner. Motor control is microprocessor controlled and can control the acceleration of the drum, its rpm and its retardation very precisely. Motor control communicates with the program unit through a serial interface.
Machine presentation 26 Door lock 7 8 The door lock is electromechanical with twin safety breakers. The lock is bi-stable, i.e. the lock must be given an active signal from the program unit to lock as well as unlock the door. 7 1 A separate circuit integrated in the program unit checks and controls the locking and unlocking of the door through a lock module. The circuit has separate controls that the drum is empty and that it is stationary.
Machine presentation Heating 9 27 9 1 Electric heating heats the washing water with three elements accessible from the front of the machine. The machine’s heating system is described more thoroughly in the section Heating. Water connections 9 The machine can have one, two, three or four water inlet valves depending on the machine size and customer requirements. In this unit there are also eight connections for an external detergent feeder.
Machine presentation 28 Detergent compartment 11 11 The detergent compartment has four compartments for prewash, main wash, rinse and bleaching agent/liquid detergent. 1 The machine’s detergent compartment is described more thoroughly in the section Detergent compartment. Drain valve 11 The valve is a diaphragm valve that is opened and closed through water pressure. The control valve is mounted by the water valves. The machine’s drain valve is described more thoroughly in the section Drain valve.
Program unit Program unit 29 1 Description The program unit is electronic and comprises a circuit board containing microprocessor, program memory, current regulating circuits, temperature and level control, etc. 1 The program unit receives its power from a separate voltage unit. 2 The program unit receives information from the temperature sensor, door lock and level switches. There is also a serial interface to the motor control.
Program unit 30 Inputs and outputs The program unit board has the following inputs and outputs: 3 Board connector Con 1 Con 2 Con 3 Con 4 Con 5 Con 6 Con 7 Con 8 Con 9 Con 10 Con 11 Con 12 Con 13 Con 14 Con 15 Con 16 Con 17 Con 18 Con 19 Con 20 Con 21 Con 22 3 Function Input from temperature sensor (Temp) Databus (D-bus) Databus (D-bus) Tacho Communication, motor control unit (M-com) Connection for software/service download (P-load) Input, Level sensors (level) Serial communication (RS 232) Input, Em
Program unit 31 Menu tree The machine software is constructed with menus that are structured according to the menu tree below. The menus become available when the machine is in service mode, see under the heading ”Engaging service mode”. SERVICE ACTIVATE OUTPUTS SHOW INPUTS ARTICLE NUMBER SHOW DLCU COM. RESET DLCU SHOW MCU COM. RESET MCU SHOW SINGLE SHOW COM.
Program unit 32 Activating service mode Service mode is activated by using one of the following alternative: 1 Alt. 1 Alt. 1 Service switch on the CPU board under the top cover on the front of the machine. Alt. 2 Service switch on the I/O board at the rear of the machine to the right of the electrical connection. Alt. 3 Service switch on the CPU card will be activated via a link arm which can be accessed from the front below the top front panel. (On machines with coin counting only.
Program unit Only for WB4130H, WB4180H 33 1 Service mode is activated by using one of the following alternative: Alt. 1 Alt. 1 Service switch on the I/O board at the rear of the machine to the right of the electrical connection. Alt. 2 Service switch on CPU card under left hand side of the top cover. 1 6578 Press the service button about 2 sec. 6580 Alt.
Program unit Only for WDX630cc/co, WDX655cc/co 1 Alt. 1 Alt. 1 Service switch on the CPU board under the top cover on the front of the machine. Service mode is activated by using one of the following alternative: Alt. 2 Service switch on the CPU card will be activated via a link arm which can be accessed from the front below the top front panel. 1 Press the service button about 2 sec. 6582 A Alt.
Program unit 2 The machine software will now switch to its service mode. The display lists the submenus available in this mode. 35 2 MAIN MENU 01.00.00.00 SERVICE PARAMETER PROG STATISTICS CONFIG 1 CONFIG 2 This service manual describes the functions and programming instructions for the following submenus: • • • • SERVICE CONFIG 1 ACTIVATE WASH PROGR. I/O ADDRESS For submenus not presented in this document, please refer to the programming manual.
Program unit 36 Service program 4 The service program is used to facilitate troubleshooting the machine. Using this program you can: MAIN MENU 01.00.00.00 SERVICE PARAMETER PROGR.
Program unit ACTIVATE OUTPUTS 6 Select the ACTIVATE OUTPUTS row and press the knob. The display now shows the functions (outputs) that can be activated. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 7 DOOR NORMAL DRAIN DRAIN A-D COLD WATER HOT WATER HARD WATER TANK 1-4 WATER HEAT 1 HEAT 2 HEAT 3 POWDER DETERGENT LIQUID DETERGENT INTERLOCK MOTOR PROGRAM RUN MACHINE FREE DRUM CW DRUM CCW DISTRIBUTION LOW EXTRACT MEDIUM EXTRACT HIGH EXTRACT TURBO EXTRACT CLUTCH START CAP.
Program unit 38 SHOW INPUTS 8 9 Select the SHOW INPUTS row and press the knob. The display now shows the sensor signals (inputs) that can be activated. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • COUNT 1 DOOR LOCK DOOR CLOSED START BUTTON CPU SERVICE BUTTON PRICE PROGRAMMING PRICE REDUCTION FREE WASH COIN 1 COIN 2 EMERGENCY STOP ALTER.
Program unit ARTICLE NUMBER 10 11 Select the ARTICLE NUMBER row and press the knob. You can now choose on the display to show the article numbers for the program units, I/O boards, motor control or DLCU fitted in the machine. Select the unit for which to show the article number. SHOW DLCU Com. 12 13 Select the SHOW DLCU COM. row and press the knob. The display shows the status of the communication to and from the DLCU board. For detailed information, see next page.
Program unit 40 Communication CPU-DLCU showed in the service program From DLCU (first data byte) bit 7 bit 6 0 Always 1 Always 0 bit 5 DLCU detects unlock command from CPU bit 4 bit 3 bit 2 DLCU detects no rotation DLCU detects motor stop from CPU DLCU detects no water in drum DLCU detects motor run from CPU DLCU DLCU detects wa- have ter in drum generated unlocking pulse DLCU DLCU detects lock detects command rotation from CPU 1 bit 1 DLCU have not generated unlocking bit 0 DLCU have not
Program unit SHOW MCU Com. 15 16 Select the SHOW MCU COM. row and press the knob. The display shows the status of the communication to and from the frequency control such as actual speed and set speed values. For detailed information, see next page. 41 15 *SERVICE* 01.06.00.00 RESET DLCU SHOW MCU COM. RESET MCU SHOW SINGLE SHOW COM.PORTS WEIGHT CALIBRATION 6204 RESET MCU 17 Reset frequency control from the error code by selecting the RESET MCU row and pressing the knob.
Program unit 42 Motor status showed in the service program From MCU (first data byte) bit 7 1 Indicate a trip state with no automatic restart bit 6 Reset trip state bit 5 Writing, reading to uP/ EEPROM bit 4 Weight mode bit 3 bit 2 Unbalance mode Serial control mode bit 1 bit 0 Always 0 Always 0 bit 1 bit 0 From MCU (second data byte) bit 7 bit 6 bit 5 bit 4 bit 3 bit 2 0 No short circuit indication DC-bus Interlock voltage OK OK Motor following 1 First short circuit indication
Program unit WEIGHT CALIBRATION 18 Select the WEIGHT CALIBRATION row and press the knob. • Operate the machine with an empty drum. • After weight calibration, the weight deviation will be shown in a hexadecimal format on the bottom line of the display. • The drum will go faster and slower a number of times during weight calibration. This is normal. Weight calibration will take a few minutes. • When exiting weight calibration after it is complete, you will have the option of saving the calibration value.
Program unit 44 MEASURE UNBALANCE 22 23 Select the MEASURE UNBALANCE row and press the knob. Put in a known unbalance weight. A corresponding weight must be shown in the display once imbalance measurement has taken place. 22 *SERVICE* 01.12.00.00 MEASURE WEIGHT MEASURE UNBALANCE DISPLAY TEST EXIT Confirm that measurement is to be performed with YES or return to the previous menu with NO. This function is used to check that the machine is measuring unbalance correctly.
Program unit Config 1 26 The configuration 1 menu contains all the functions and parameters that service personnel can change without a password. MAIN MENU 04.00.00.00 STATISTICS CONFIG 1 CONFIG 2 ADJUST DISPLAY RESET TO FACTORY ACTIVATE WASH PROGR. Engage the machine’s service mode. 26 45 Select the CONFIG 1 row in the main menu and press the knob. All the available parameters will now be displayed. The table below gives the deerror value on the right.
Program unit 27 Select the desired function/parameter and press the knob. 28 To engage and disengage functions, turn the knob to select YES or NO and then press the knob. 29 To adjust the value, set the value and press the knob. The arrow in each menu shows the column to be adjusted. 27 CONFIG 1 04.01.00.00 PAUSE PERMITTED RAPID ADVANCE NEW PROG. SELECT SHOW TIME SHOW TEMP • Turn the knob clockwise to set the desired number between 0 and 9.
Program unit PAUSE PERMITTED Select whether it should be possible to pause during an on-going wash program. Yes = A pause is allowed during a wash program. No = A pause is not allowed during a wash program. RAPID ADVANCE Select whether is should be possible to rapid advance forward or backward through the wash program while it is in progress. Yes = It is allowed to rapid advance through a wash program. No = It is not allowed to rapid advance through a wash program.
Program unit 48 NEW PROG. SELECT Select whether to allow switching to another wash program while one is in progress without first stepping rapidly through to the end of the current program before switching. Will only work if PAUS is allowed. Yes = Switching to a new wash program is allowed. No = Switching to a new wash program is not allowed. SHOW TIME Select whether the calculated remaining program time is to be shown on the display window while the program is in progress.
Program unit SHOW TEMP Select whether the current water temperature is to be shown on the display window while a wash program is in progress. This function cannot be shown on the display at the same time as the SHOW IS LEVEL function, only one of the functions can be shown at one time. Yes = The water temperature is shown. No = No temperature is displayed in the display window. SHOW IS LEVEL Select whether the current water level is to be shown on the display window while a wash program is in progress.
Program unit 50 TEMP cONTRol water Select whether the machine is to control and adjust the water temperature by opening and closing the main valves for hot and cold water during filling. Yes =Control of main valves during filling. - Alt.1: Hot and cold water valves both open. If the set water temperature is exceeded, the hot water valve will be shut automatically. - Alt. 2: Only hot water valve open.
Program unit AUTO START paid Select whether the machine is to be able to start automatically, when full price has been paid, for the chosen wash program. Yes =Automatic start engaged. NOTE! If the signal for blocking the start button is engaged, it also applies to the blocking signal for the automatic starting func tion. No = The automatic start function is disengaged. AUTO PROG.
Program unit 52 SHOW prog. counter Select whether the contents of the machine’s counter of completed wash programs should be shown in the display window while a wash program is in progress or outside the wash program without going into service mode. The counter is shown on the display after pressing the control knob twice in quick succession. Yes = The contents of the program counter can be displayed if a time has been set for the function SHOW.STAT.DOUBLECLI.
Program unit AUTO PROG SELECT Choose whether wash programme 1 should be selected automatically and displayed in start position as soon as the door is opened/closed or coins are inserted in the coin slot. Yes = Automatic programme selection takes place. No = Automatic programme selection off MEASURE WEIGHT Select whether the count weight function should be activated. Note that the function cannot be activated for wash programs that are programmed for no weight count. Yes = Count weight activated.
Program unit 54 second LANGUAGE (coin) Select one of the available languages to be shown as second language. Note that this function is only available on machines equipped with the coin interface software, where the user menu in the display is presented with two languages. language timeout SEC. (ahl/opl) Specify with the knob the time after which an unused machine should return to the set language. The time is given in steps of 1 second; 0 - 2550 seconds. sec.
Program unit MAX FiLL time, SEC. Specify with the knob the maximum time (in seconds, 0 - 2550) it should take to fill the machine with water to the programmed level. If the water has not reached the correct level within the set time, the ”NO WATER” error message will appear on the display. 6. WATER IN DRUM Select if the error code shall be active or not. For an explanation of the error code, see section "Error codes". 7. DRUM OVERFILLED Select if the error code shall be active or not.
Program unit 56 show weight time, SEC. Used for machines with weight count. Once weighing has been carried out, the weight obtained is displayed over the specified time. MAXDIFf, wash time MIN Specify with the knob the maximum time deviation for the total time of the wash program. If this is exceeded in comparison with the total time when the same wash program was last used, the stored total time shall only be adjusted with the limit time. Note that this applies to both positive and negative time.
Program unit DECIMAL IN price (ahl/opl) On machines with coin counter, the price can be displayed with or without colon (0:00 or 000). Yes = The colon is displayed. No = The colon is not displayed. flush delay, LIQ. SEC. Delay time before flushing of detergent after water filling is ended. The time is given in steps of 1 second in the range 0 -255 seconds. flush on, LIQ. SEC. Rinse times for rinsing detergent after the drum has been filled with water and flush delay has gone.
Program unit 58 DISPLAY STATIST. SEC. Indicate using the knob how long the statistics for COINS – HOUR COUNTER – PROGRAM COUNTER are to be displayed when the power to the machine is switched on. The time is given in steps of 1 second in the range 0 -255 seconds. SHOW STAT. DOUBLECLI. Indicate using the knob how long the statistics for COINS – HOUR COUNTER– PROGRAM COUNTER are to be displayed following rapidly pressing the knob twice. The time is given in steps of 1 second in the range 0 -255 seconds.
Program unit QUICK START BUTTON 1 and 2 (COIN) Select if the two buttons, available on the Compass timer, shall be used as quick start buttons or as option buttons. Yes = The button is set to quick start. No = The button is set to option button. NOTE! Only in GEN6COINOP software and Freescale microprocessor S12. VOLUME Set the volume on the voice guidance board (if the machine is equipped with voice guidance). A value between 0 and 255 can be used where 0 will turn the voice guidance off vgb. welc.
Program unit 60 Activate wash program The ACTIVATE WASH PROGR. menu is used to specify the wash programs in the program library that are to be made available to the user and in which order the wash programs are to be presented in the display. 31 32 Engage service mode and select the ACTIVATE WASH PROGR. row in the main menu. Press in the knob. All the wash programs contained in the installed program library are now shown.
I/O modules 61 I/O modules General Washing machines may be equipped with either one or two I/O modules: • I/O module 1 controls internal machine functions and is always installed in the machine prior to delivery. It controls outputs to water valves, waste discharge and heating. • I/O module 2 is installed as an optional extra, controlling the external functions of the machine, i.e. inputs from payment and booking systems and outputs to detergent pumps.
I/O modules Function options via the service program 1 Engage service mode, highlight the SERVICE line in the main menu and press the knob. 1 MAIN MENU 01.00.00.00 SERVICE PARAMETER PROGR. STATISTICS CONFIG 1 CONFIG 2 ADJUST DISPLAY The display will now show the different submenus in the service program. 2 3 4 Highlight the ARTICLE NUMBER line and press the knob. You can now choose to view the article numbers of program devices, I/O modules, motor control or DLCUs installed in the machine.
I/O modules Function options via program designation 5 The parameter software installed in a machine’s program device on delivery is specified on 2 plates, one located on the inside of the door and one by the machine's electrical connection.
I/O modules 64 Function options for Type 1 and Type 2 I/O modules Function options, I/O module Type 1 A B C D E Waste Waste Waste Waste Waste Heating Heating Heating Heating Heating 3 Hot water 3 Hot water – 1 Hot water 1 Hot water 3 Cold water 4 Cold water 4 Cold water 5 Cold water 1 Cold water Function options, I/O module Type 2 A B C D E F G External slot meter Start block Start block Price reduction PC 5 Start block Heat switch Price programming Start/Pause
I/O modules Replacement of I/O module I/O modules 1 and 2 are installed in the same way, but are located in different parts of the machine. The following illustration only shows how to replace I/O module 2, but the same procedure also applies to I/O module 1. 65 8 I/O module 2 is located on the rear PCB and accessible once the protective plate is removed. 8 • Remove the electrical connections on the module. 9 • Using a screwdriver, undo the lock screw holding the module in position.
I/O modules 66 External connections to I/O module type 2 12 1=N 2=L 4 = Earth Connection of external dosing equipment 1 A 2 3 4 The external dosing equipment power supply must never be connected to the machine's incoming terminal block. Machines fitted with connectors 12 6 9 • Connect the pump assembly to connections A and B on the washing machine. Connect the signal cable to B and the power supply to A.
I/O modules 67 Outputs 14 15 14 • External power supply (e.g. 24V DC) for pumps is to be connected to 9 and 10. If the internal power supply (from the washing machine) is to be used, it may be taken from 1 (N) and connected to 9 and from 2 (L) and connected to 10. The outputs may be loaded with max 0.5 A.
I/O modules 68 16 • Connection 8 may be connected if there is to be a pause in the wash program, e.g. while detergent is being dosed. The figure shows an example of engaging a 24V pause signal. The wash program will pause for as long as the pause signal remains active (high). 16 24 V 6266 17 • If connection 7 is connected, an error message will be shown in the display if any of the chemical tanks are empty. However, the wash program will continue.
I/O modules 69 Circuit diagram of function options for I/O module type 2 The wiring diagram for I/O module type 2 may be one of the following variants: 22A, 22B, 22C, 22D, 22E, 22F or 22G.
I/O modules 70
I/O modules 71 22C
I/O modules 72 22D
I/O modules 73 22E 6315 • Heating pause: By connecting a signal to connec
I/O modules 74 22F 5 6 1 2 1 2 3 4 5 RE101 Output 6 NO Output 6 NC RE102 RE103 Output 5 RE104 Output 4 Output 3 Output 2 Output 1 Input 4 Input 3 4 RE105 PTD5 3 6 Con 107 1 2 Con 115 2 Input 2 Input 1 RE106 1 Con 109 Con 110 Con 108 2 Com. Com.
• The gas heating unit must be connected to connections 17, 18 and 19.
I/O modules 76 Addressing I/O modules After replacing an I/O module or in instances where a second module has been added to a washing machine, the new I/O module must be addressed in order to activate its function options. The function options of the module are controlled by the parameter software loaded on the relevant program device. 18 MAIN MENU 08.00.00.00 RESET TO FACTORY ACTIVATE WASH PROGR. QUICK START BUTTONS I/O ADDRESS PRICE PROGRAMMING EXIT • Engage the machine's service mode.
Door and door lock Door and door lock Description 1 77 1 1 The door locks consists of the following: • Door lock, which contains - An actuator that locks the door lock and also has two built-in micro switches, S4a and S4b. The actuator is bi-stable, i.e., it has two stable positions: locked door and unlocked door. The actuator must receive a pulse to lock and unlock the door lock. S4a and S4b are both closed when the door is locked. - A micro switch S3 that is closed when the door is closed.
Door and door lock 78 Function The door lock locks the door When the door is closed (closed door lock switch S3), the programme unit may request door locking by applying a voltage of 200-240 V on the door lock controller A31 input X92. 2 The following check is made by the A31 card prior to locking of the door: • No water in drum - input "level" from level guard B2 is closed = 0 V • Drum not turning - pulse frequency on input "Tacho" from rotation sensor B3 less than 0.4 Hz.
Door and door lock 79 The door lock unlocks the door The programme unit requests door unlocking by applying 0 V on input X92 of the door lock controller. 3 The following check is made prior to unlocking of the door: • No water in drum - input "Level" from level guard B2 is closed = 0 V • Drum not turning - pulse frequency on input "Tacho" from rotation sensor B3 is less than 0.4 Hz.
Door and door lock 80 Repairs 4 Repair work on the machine should only be done by specially trained personnel. Emergency opening of door lock 4 1. Take down power from the machine by turning the main power switch to the 0 position. 2. Remove the front cover or top cover. When replacing the door lock, it is recommended to remove the front cover. 3. Press down the emergency opening button.
Door and door lock Replacing the door lock 1. Take down power from the machine by turning the main power switch to the 0 position. 2. Remove the front cover alt. side pole. 3. Remove the door (two screws in each hinge). 4. Remove the front panel. 5. Remove the door lock (three holding screws). 6. Verify the strap positions on the cable for the lock. Cut the necessary straps to undo the cables leading to the lock. 7. Undo the connectors. 8. Replace the door lock. 9. Reconnect the new (door) lock. 10.
Motor and motor control Motor and motor control Warnings DANGER Be careful when measuring the electric components in the motor control. All components have a potential difference of approx. 300 V in relation to protective earth and neutral. When the green LED on the motor control card is lit, the components carry dangerous voltages. The motor control lose all voltage about 10-30 seconds after the voltage has been disconnected and the motor has stopped.
Motor and motor control 84 Description 1 Motor 1 The motor is fitted in a bridge carrier under the outer drum. It drives the washing drum using a drive belt. The motor is frequency-regulated and is controlled by a microcomputer control. The various speeds for normal operation, distribution speeds and extraction as well as acceleration/ retardation can be controlled with a high degree of precision.
Motor and motor control Motor control 2 85 2 The motor control unit is microcomputer controlled and is situated under the top cover of the machine, right above the outer drum. Motor control U1 The unit consists of a PCB (mother board) fitted on a heat sink that does double-duty as part of the housing. The cable harness is directly connected to the PCB, voltage supply input and the voltage supply to the motor using connectors; the other cables are connected with flat connectors to the PCB.
Motor and motor control 86 Function DANGER Be careful when measuring the electric components in the motor control. All components have a potential difference of approx. 300 V in relation to protective earth and neutral. When the green LED on the motor control card is lit, the components carry dangerous voltages. The motor control lose all voltage about 10-30 seconds after the voltage has been disconnected and the motor has stopped.
Motor and motor control The motor control is also able to deliver the various instantaneous and output values during constant speed, acceleration and retardation. These values are used to calculate the weight of the loaded laundry and to detect any load imbalances. A separate unbalance switch can also be connected to the motor control.
Motor and motor control 88 Inputs and outputs 4 4 X301: Serial communication Handles communication between the motor control and the programme unit. Using a special interface, it is possible to connect a PC for testing the motor control. X301 X302 Card No. Function X 301:1 X 301:2 X 301:3 X 301:4 Tacho signal Gnd Txd Rxd 6657 X302: Lock sequence input Detects when the door is locked or unlocked. The motor cannot start until the door has been locked.
Motor and motor control X311: Voltage supply 89 6 Input voltage, single phase or rectified three-phase 6 min: 200V-15% max: 240V+10% X312: AC supply to motor and input from the motor thermal protector The motor is fed with alternating current with varying frequency that is proportional to the motor speed. EX618-EX630 Card No. X 312:1 X 312:2 X 312:3 Function AC supply to motor, phase 1 AC supply to motor, phase 2 AC supply to motor, phase 3 EX645-EX677 Card No.
Motor and motor control 90 LED indications Two LEDs, one yellow and one green, indicate status and any errors on the motor controller and motor. The table below shows the blinking patterns of the various error codes. 7 7 Green LED LED blinking pattern Cause OK blink (brief pause every 5 seconds) Microcomputor in motor control unit not working, voltage is on. approx. 5 seconds Current limiter of motor control has switched on.
Motor and motor control Repairs 91 8 Mounting bolt Repair work on the machine should only be done by specially trained personnel. Spacer Motor replacement Disassembly 1. Take down power from the machine. 2. Remove the rear cover. 3. Undo the bracket for the drain hose connector from the lower rear piece, then remove the rear cover. Motor cable 4. Undo the ground connection from the motor. 8 5. Remove the drive belt by pulling the belt towards you while rotating the drum by hand.
Motor and motor control 92 Adjustments 9 Drive belt tension The drive belt is pre-tensioned upon delivery from the factory.
Motor and motor control 10 11 To adjust drive belt tension: first undo the motor retaining screw (A) by using two cap keys. When undoing screw (A) use one cap key as holder-on on the screw's nut. Press down the motor by using a screw driver in order to tension the belt. Tighten the retaining screw and check the tension according to table. 93 10 Inspection of the drive belt tension is an important part of general maintenance.
Drain valve Drain valve 95 1 EX – model Description 1 The drain valve is situated on a flange at the bottom of the outer drum and can be accessed from the front after removing the front cover. The drain valve consists of the following principal parts: • Lower part with rubber diaphragm. • Piston and cylinder. • Pressure plate and recoil springs. Drain valve 6562 • Rubber diaphragm with drain connection. • Upper part with connection for outer drum.
Drain valve 96 Function 2 The drain valve uses the water pressure in the cold-water inlet to close the valve. A feed hose is connected between the water inlet and the control valve. When the control valve operates (drain valve should be closed), the control valve opens the water pressure onto the feed hose, which is connected to the lower part of the drain valve. When the lower part is filled with water, the lower part diaphragm pushes up the piston.
Drain valve Repairs 97 3 1 Repair work on the machine should only be done by specially trained personnel. 2 3 Disassembly 4 5 6 For repair works on the drain valve, there is a risk that water still left in the machine may flood onto the floor. Be sure to dry up any spilled water since it may cause people to slip and hurt themselves. 7 8 9 101772 1. Take down power from the machine. 2. Remove the front cover. 3 3. Disconnect the drain hose from upper part of the valve. 4.
Drain valve 98 Assembling 5 6 5 1. Connect the pressure hose to the lower part of the valve. Verify that the hose is not bent or pinched. 1 2. Fit the rubber bellows onto the sleeve coupling. 2 3. Hook the valve onto the bolts and turn the valve into position. Secure the 4 retaining bolts of the valve. 3 4 4. Secure the hose clamp at the connection of the rubber bellows on the sleeve coupling. 5 5. Connect the drain hose to the upper part of the valve. 6 6.
Detergent compartment Detergent compartment 1 Description Detergent compartment The detergent compartment of the machine is designed for use with powder and liquid detergent. The compartment is divided into four subcompartments as follows: 1 99 • Compartment 1 - For pre wash with powder or liquid detergent. 2 • Compartment 2 - For main wash with detergent powder. • Compartment 3 - Rinse. • Compartment 4 - Main wash with liquid detergent or, bleaching-agent.
Heating Heating 101 1 Description Contactor Electric heating 1 The heating system of the machine consists of: • Three heating elements for heating the water in the drum. • A temperature sensor to detect the water temperature in the drum. • One or two heating contactors for switch-on/ switch-off of the heating elements. The heating elements and the temperature sensor are situated at the bottom of the outer drum close to the edge. They can be accessed front the front after the front plate is removed.
Heating 102 Function 2 Electric heating 2 2 1 The three heating elements in the machine are connected to separate phases and are switched on and using one or two heating contactors, K.21 and K22 (two contactors are used for higher heating power). The heating contactors are controlled by the programme unit A1, output (X36:7). 5 The programme unit receives information on the water temperature in the machine through an analogue signal from the temperature sensor situated in the outer drum.
Heating Repairs Repair work on the machine should only be done by specially trained personnel. 103 4 Heating element Replacing the heating elements Wen replacing the heating elements, there is a risk that water still left in the machine may flood onto the floor. Be sure to dry up any spilled water since it may cause people to slip and hurt themselves. 1. Take down power from the machine. 2. Remove the front cover. 3. Make a note of how the heating elements are connected. 4 4.
Abbreviations Abbreviations Abbreviation Explanation DLCU Door lock control unit MCU Motor control unit RMC Residual moisture control MIS Management information system CBT Central payment system SCU Scale unit SW Software DMIS Detergent management system EMIS External management information system CW Clock-wise CCW Counter clock-wise A/D SCU Analog/digital scale unit 105
Preventive maintenance Preventive maintenance To maintain correct and proper functioning and to prevent interruption of service, the following maintenance scheme should be adhered to. The maintenance interval should be adapted to how frequently the machine is used. Daily • Check the door and door lock: - Let the door remain open and try starting the machine. The machine should not start. - Close the door, start the machine and try opening the door.
Preventive maintenance - Verify that all internal hoses do not leak. - Inspect the drive belt. Adjust the tension or replace if necessary. - Check that water does not leak onto the floor. - If the heating time is unusually long, check the heating elements. If the water is very hard, check whether there are lime deposits on the heating elements. Decalcify the elements if necessary. Adapt the amount of deliming agent to the manufacturer’s guidelines.
Troubleshooting Troubleshooting General information on troubleshooting The troubleshooting section is used to trace errors in the machine to a defective component or unit. There is a memory in the program unit that will save the selected program for approx. 3-5 minutes in the case of power cuts. The machine will restart automatically if the power is turned on again within this time. Safety regulations Troubleshooting may only be carried out by authorised personnel.
Troubleshooting 110 Errors with error code An error in the program or in the machine is indicated on the display by an error message comprising an error code and a descriptive text. 1 1 ERROR 001 NO WATER Error code 6204 Error code The following is a brief description of all error codes. The following pages describe error codes, possible causes and corrective measures for each code.
Troubleshooting Error code (from CPU) Text message 012 Program failure 013 No motor comm. 014 Level adjust. 015 Emergency stop 016 Timeout heating 017 Door lock 018 Start not allowed 019 Master comm. 020 I/O MCU Interlock 021 I/O Communication 022 Oil 023 No I/O addressed 024 Checksum from DLCU 027 Level offset 028 CPU/DLCU low level 029 Error code (from MCU) Dryer comm.
Troubleshooting 112 Only for WDX630cc/co, WDX655cc/co Error code (from Dryer program unit) Text message 073 Short temp input sensor 074 short temp outp. sensor 075 Fan motor too hot 076 Drum motor too hot 077 External error 078 Machine overheated 079 Filter lid open 080 Incorrect programming 081 Drying error RMC program 082 Drying error Autostop PR. 083 Drying error Time program 084 No gas flame detec. 085 No vacuum detected 086 Short in vacuum sens.
Troubleshooting Alt. 1 Service mode is activated by using one of the following alternative: 2 Activating service mode 113 Alt. 1 Service switch on the CPU board under the top cover on the front of the machine. Alt. 2 Service switch on the I/O board at the rear of the machine to the right of the electrical connection. Alt.
Troubleshooting 114 Only for WB4130H, WB4180H 2 Service mode is activated by using one of the following alternative: Alt. 1 Alt. 1 Service switch on the I/O board at the rear of the machine to the right of the electrical connection. Alt. 2 Service switch on CPU card under left hand side of the top cover. 2 6578 Press the service button about 2 sec. 6580 Alt.
Troubleshooting Only for WDX630cc/co, WDX655cc/co 115 2 Alt. 1 Alt. 1 Service switch on the CPU board under the top cover on the front of the machine. Service mode is activated by using one of the following alternative: Alt. 2 Service switch on the CPU card will be activated via a link arm which can be accessed from the front below the top front panel. 2 Press the service button about 2 sec. 6582 A Alt.
Troubleshooting 116 3 The machine software will now switch to its service mode. The display lists the submenus available in this mode. 3 MAIN MENU 01.00.00.00 SERVICE PARAMETER PROG STATISTICS CONFIG 1 CONFIG 2 This service manual describes the functions and programming instructions for the following submenus: • • • • SERVICE CONFIG 1 ACTIVATE WASH PROGR. I/O ADDRESS For submenus not presented in this document, please refer to the programming manual.
Troubleshooting Description of error codes and causes Error codes from CPU Error code 01, NO WATER This error code is generated by the CPU board. When filling with water, the level specified by the wash program must be attained within a certain time. This time is normally set to 10 minutes but can vary depending on the type of machine and the software. If the filling time eceeds the maximum allowed filling time, error code 01 will be displayed.
Troubleshooting 118 Error code 04, NTC LOW TEMP This error code is generated by the CPU board. This error code is displayed if the temperature around the NTC sensor is below approx. -9°C. A low temperature means the resistance in the sensor is too high, above approx. 23.7 kohm. This can be because the machine has been standing outdoors, an open circuit in the sensor, a break in the cable to the sensor, etc.
Troubleshooting Error code 07, OVERFILLED This error code is generated by the CPU board. The error code arises if the drum has been filled with water above a predetermined level during an on-going wash program. It can be caused by a blocked level hose, drops of water in the level tube, defective filler valve, defective electronic filler control, etc. Action: • Blow through the level hose and check that it is not blocked and does not contain any water.
Troubleshooting 120 Error code 09, KLIXON This error code is generated by the CPU board. The error code means that the temperature in the motor has been so high that the klixon breaker in the motor has been triggered. It can be caused by overloading the motor due to an overloaded drum, low rpm for long periods, defective klixon breaker in motor, short in cable between motor and CPU board, etc. Error code 09, DRUM OVERFILLED (only in coin operated machines) This error code is generated by the CPU board.
Troubleshooting Error code 11, UNB. ON AT PROG. START This error code is generated by the CPU board. The error code means that the mechanical imbalance breaker, if existing, is already active when the wash program starts. It can be caused by a defective imbalance breaker, mechanical problem making the imbalance breaker always active, short in the edge connection or cables, etc. Error code 12, PROGRAMME FAILURE This error code is generated by the CPU board.
Troubleshooting 122 Error code 15, EMERGENCY STOP This error code is generated by the CPU board. The error code arises if the emergency stop switch has been activated on the machine. The cause can be inadvertent activation of the emergency stop, defective emergency stop switch, incorrect or shorted cable, etc. Error code 16, TIMEOUT HEATING This error code is generated by the CPU board. The error code is based on degrees/minutes. A check is made during water filling.
Troubleshooting Error code 20, I/O MCU INTERLOCK This error code is generated by the CPU board. The program controller has read from the motor control or I/O board that the interlock is not active. The reason for interlock failure can be a problem with the hatch lock, damaged motor supply cables or the I/O board with interlock voltage etc. The most probable error source is the I/O board. The display will also show which I/O board is missing interlock or if it is the motor control that has no interlock.
Troubleshooting 124 Error code 23, NO I/O ADDRESSED The error code means that there is no I/O board addressed in the system at all. Action: • (Requires password) Readdress the existing I/O board from the service menu. Error code 24, CHECKSUM FROM DLCU This error code is generated by the CPU board. The program unit has detected an error in the internal communication in the DLCU-processor. Action: • Replace the CPU board. Error code 27, LEVEL OFFSET This error code is generated by the CPU board.
Troubleshooting Error code 28, CPU/DLCU LOW LEVELS The DLCU contains a mechanical level monitor which ensures that there is no water in the machine when the lock opens. To ensure that the level monitor functions correctly, the mechanical level monitor is compared with a nominal value generated by the CPU, which is compared with the electronic level check.
Troubleshooting 126 Error codes from MCU Error code 31, HEAT SINK TOO HOT This error code is generated by the motor control. There is a temperature sensor (NTC) mounted on the motor control cooling flange next to the power transistors in the output stage. If the temperature of the cooling flange gets too high (> 90°C) the error code will be set to protect the transistors. The cause of high cooling flange temperature can be e.g. a stiff drum in combination with intensive use and high ambient temperature.
Troubleshooting Error code 32, MOTOR TOO HOT This error code is generated by the motor control. Each time the motor is started from stationary, the motor control will first measure the resistance between two phases in the motor. The motor control processor governs the output transistors so that a DC current flows between two phases in the motor winding.
Troubleshooting 128 Error code 33, NO INTERLOCK This error code is generated by the motor control. The motor control must be powered with 230V/50 or 60 Hz on the interlock input in order to drive the motor. This signal is a confirmation that the door is closed and locked. Motor control receives its commands to rotate the drum from the timer via a serial communication link between the motor control and timer.
Troubleshooting Error code 35, MOTOR SHORT CIRCUIT This error code is generated by the motor control. The motor control reads the power consumption of the motor continuously. If the current for some reason gets too high (= exceeds a certain limit), the motor control will cut the current to the motor. After the motor has stopped (= tachometer indicates stationary motor), the motor control will attempt to restart it.
Troubleshooting 130 Error code 36, INTERLOCK HARDWARE This error code is generated by the motor control. The motor control must be powered with 230V/50 or 60 Hz on the interlock input in order to drive the motor. The interlock circuits in the motor control have been split into two channels so that a component error in motor control cannot give a false confirmation that the door is locked. These two channels are checked against each other.
Troubleshooting Error code 38, HIGH DC VOLTAGE This error code is generated by the motor control unit. The motor control unit constantly measures the voltage over the mains input. If the voltage is too high (= exceeds a certain limit), the motor control unit will shut off the current to the motor. Once the motor has stopped (= the tacho sensor indicates that the motor is stationary), the motor control unit checks to see whether the input voltage is still high.
Troubleshooting Error code 42, NO PARAMET. SET IN MCU This error code is generated by the motor control unit. The motor controller (MCU) (inverter) contains several different parameter sets for different motors. During power up the timer checks that the correct parameter set digit is written into the MCU. If not, the timer will write down the parameter set digit defined in fixed config.
Troubleshooting Error code 45, MOTOR NOT FOLLOWING This error code is generated by the motor control. The motor control must always receive information on the rotation of the motor from the tacho sensor in order to rotate. If the tacho sensor is not working, the motor can rotate for max. 10 seconds during the starting process. After this period, the ”MOTOR NOT FOLLOWING” error code will be activated.
Troubleshooting 134 Error codes from DLCU Error code 51, CHECKSUM FROM CPU DLCU has detected an error in the internal communication between DLCU and CPU. The DLCU processor will reset itself when the error has disappeared. CPU reads the error message when the program starts and finishes and generates an error code, the error message is ignored between these two occasions. Reason: Strong interference from surrounding equipment etc. can cause error codes. Action: Re-set the error codes.
Troubleshooting Error code 52, CHARGE CIRCUIT DLCU contains an arming circuit that is charged when the door lock coil is to be activated. For safety reasons, this arming circuit must be discharged when the door lock coil is not to be activated. If the arming circuit for operating the door lock is charged when it is not supposed to be, an error message will be sent to the CPU processor. If the error ceases, the message will not be sent to the CPU.
Troubleshooting 136 Error code 54, TACHO, NO SET SIGNAL DLCU counts the tacho pulses from the motor in order to guarantee that the drum is stationary when the door is opened. To ensure that the signal from the tacho generator is working correctly, DLCU compares the tacho signal to a digital bit value from the CPU processor, which is due to the CPU having activated the motor.
Troubleshooting Error code 56, SET SPEED DOOR OPEN DLCU counts the tacho pulses from the motor in order to guarantee that the drum is stationary when the door is opened. To ensure that the signal from the tacho generator is working correctly, DLCU compares the tacho signal to a digital bit value from the CPU processor, which is due to the CPU having activated the motor. If the digital bit value is on when the door lock is unlocked, an error message will be sent to CPU.
Troubleshooting 138 Error code 60, ACTUATOR CIRCUIT The DLCU processor controls the door lock actuator coil. The DLCU processor checks continuously that the coil is engaged. DLCU can detect a break in the circuit (>50 kohm) (DLCU cannot detect a short in the circuit). If there is a break in the actuator circuit, CPU will be notified; the error message will disappear if the error ceases.
Troubleshooting Only for WDX630cc/co, WDX655cc/co Error codes from DRYER PROGRAM UNIT For more information see Service Manual for Selecta II Error code 73, SHORT TEMP INPUT SENSOR The thermistor element measuring the air inlet temperature to the drum, or the wiring to the sensor has shorted. (E 03 in the Service Manual for Selecta II). Error code 74, SHORT TEMP OUTP. SENSOR The thermistor element measuring the air outlet temperature from the drum, or the wiring to the sensor has shorted.
Troubleshooting Error code 80, INCORRECT PROGRAMMING Programming error/incorrect or missing parameter. (E 10 in the Service Manual for Selecta II). Error code 81, DRYING ERROR RMC PROGRAM Maximum allowable RMC time exceeded (non-coin operated models only). (E 11 in the Service Manual for Selecta II). Error code 82, DRYING ERROR AUTOSTOP PR. Maximum allowable Autostop time exceeded (non-coin operated models only). (E 12 in the Service Manual for Selecta II).
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