Electrolux W4400H Service Manual Download

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Troubleshooting

5950

X11

UNDER VOLTAGE

The motor controller indicates the DC level is
too low.

If the power is on, be very careful when

working on the machine.

Switch off the machine for at least 0 seconds
to ensure the motor controller has been comple-
tely reset. Then try to start the machine again. If
the error returns, troubleshoot as follows:

1. Verify the voltage supply (230/400 V) to the motor
controller at the contactor X311.

Voltage too low

Voltage OK

The motor controller is
probably defective.

2. Inspect the power supply (230/400 V) at the main
power switch Q1 on the machine.

Voltage too low

Voltage OK

Defective cabling

Troubleshoot the mains.

Summary of Contents for W4400H

Page 1: ...Service Manual W4400H W3600H W3850H W31100H Clarus Control 438 9206 51 06 22 ...

Page 2: ......

Page 3: ...A2 76 I O cards 77 Control system transformer T10 83 The service program 84 To select the Service Program function 85 To control the machine functions 87 I O card inputs 88 Settings 1 89 To select the SETTINGS 1 function 90 Password 91 Variables under SETTINGS 1 93 Settings 2 114 To select the SETTINGS 2 function 115 Variables under SETTINGS 1 116 To replace the CPU board 142 To replace an I O boa...

Page 4: ...pment Optional equipment 173 Description 173 Safety rules 173 After a power cut 173 Water level reduction 174 Actual weight display 174 Resetting the weighing equipment 174 Calibrating the weighing equipment 175 Checking accurancy of weighing equipment display 175 If the weighing equipment has a fault 175 The dead load selector 176 To replace a load cell 177 To replace the scale unit 178 Component...

Page 5: ...uld the machine malfunction please report the fault to the technician responsible for the machine All external equipment which is connected to the machine must be CE EMC approved and connected using an approved shielded cable Emergency stop If the machine for some reason has to be stopped press emergency stop button When necessary measures have been taken the emergency button can be reset by pulli...

Page 6: ... ...

Page 7: ...800 50 800 6 6 6 6 1 8 1 8 1 8 1 8 500 700 500 700 500 700 500 700 20 20 20 20 Water valves connection DN BSP recommended water pressure valve open kPa Functioning limits for water valve kPa Capacity at 300 kPa l min Drain valve outer Ø mm Draining capacity l min Steam valve connection DN BSP rec steam pressure kPa operating range of steam valve kPa Compressed air connection DN BSP rec air pressur...

Page 8: ... 12 0 11 1 16 0 75 15 9 6 4 22 7 3 24 7 3 Frequency of the dynamic force Hz Max floor load at extraction kN Technical data 5 5 6 6 7 6 8 Sound levels Airborne sound level dB A re 2x10 5 Pa With insulation Motor Power consumption kW 65 76 73 73 70 70 70 70 ...

Page 9: ...0H W31100H U V W3600H A B C D E F G H I K L M N O P R S T U V 1390 1600 2015 970 200 1850 270 660 525 425 860 1565 420 430 2200 1120 2180 955 275 275 Technical data Dimensions 1 Control panel 2 Door opening ø 700 3 Soap supply injector powder optional 4 Cold water connection 5 Hot water connection 6 Third water connection optional 7 Steam connection 8 Drain 9 Electrical connection 10 Compressed ai...

Page 10: ... G H I K 9 4 5 6 12 The movement when tilting 9 B A E C 1 2 3 D Front Right side 9 only W3600H Rear side G 7 only W3600H 7 only W3850H W31100H U V Technical data 1 Control panel 2 Door opening ø 700 3 Soap supply injector powder optional 4 Cold water connection 5 Hot water connection 6 Third water connection optional 7 Steam connection 8 Drain 9 Electrical connection 10 Compressed air 11 External ...

Page 11: ...V 3 AC 5 5 16 400 V 3 AC 5 5 16 415 V 3 AC 5 5 16 440 V 3 AC 5 5 16 480 V 3 AC 5 5 16 230 400 V 3 AC 38 100 63 240 V 3 AC 38 100 346 V 3 AC 38 80 380 V 3 AC 38 63 400 V 3 AC 38 63 415 V 3 AC 38 63 440 V 3 AC 38 63 480 V 3 AC 38 50 Heating Voltage Total Fuse alternative alternative kW A No heating or Steam heating Electrical heated ...

Page 12: ...16 440 V 3 AC 4 0 16 480 V 3 AC 4 0 16 230 V 3 AC 38 100 230 V 3 AC 56 160 240 V 3 AC 38 100 240 V 3 AC 56 160 380 V 3 AC 38 63 380 V 3 AC 56 100 400 V 3 AC 38 63 400 V 3 AC 56 100 415 V 3 AC 38 63 415 V 3 AC 56 100 440 V 3 AC 38 63 440 V 3 AC 56 80 480 V 3 AC 56 80 Heating Voltage Total Fuse alternative alternative kW A No heating or Steam heating Electrical heated ...

Page 13: ... 6 7 16 480 V 3 AC 6 7 16 Heating Voltage Total Fuse alternative alternative kW A No heating or Steam heating W31100H 200 V 3 AC 5 3 35 230 V 3 AC 5 3 25 240 V 3 AC 5 3 20 380 V 3 AC 5 3 16 400 V 3 AC 5 3 16 415 V 3 AC 5 3 16 440 V 3 AC 5 3 16 480 V 3 AC 5 3 16 Heating Voltage Total Fuse alternative alternative kW A No heating or Steam heating ...

Page 14: ...14 ...

Page 15: ...e union between the inner drum and the outer drum at the back has two heavy duty bearings and is sealed with three radial seals 1 Motor wash action and extraction Shock absorbers Detergent dispenser option Door and door lock Spring suspension Water inlet valves Connection points external liquid supply Compressed air connection Inlet valves water and steam Drum Frame Venting 6072 5724 Control unit ...

Page 16: ...ration and deceleration to be controlled with high precision The drain valve is a diaphragm valve which is operated by compressed air The door is locked when the program starts The machine is supplied complete with a microprocessor based control unit The electrical components are in the automatic control unit on the machine rear The machine exterior is made up of Front panels of stainless steel Ba...

Page 17: ...door lock is working normally Check that the door does not leak Clean the door sealing disk of detergent residue If the machine has an automatic dispenser clean this including scoops of detergent residue Check that the drain valve is not leaking and that it opens and closes normally Check the compressed air regulator A If necessary empty separated water Every third month Ensure that the external s...

Page 18: ...18 ...

Page 19: ... Prior to commencing troubleshooting pay close attention to the precautions in section 1 If the power is on be very careful when working on the the machine DANGER Be very careful when measuring the motor controller since all com ponents have a potential difference of about 300 V compared to Ground and Neutral When the green LED is lit all components are powered with dange rous voltage When the pow...

Page 20: ...ror indication Error indications can be reset in two different ways By pressing START the error may be tempo rarily reset The machine then continuous the programme that was already started If the error code remains the error will come back at once By pressing athe error is reset and the started programme is cancelled Error codes A brief summary of all error codes and the pos sible cause for each e...

Page 21: ...s function is switched off N instead the drain valve will open for a short time and discharge some of the water This is described under the function DRAIN TIME WHEN OVERFILL i e DRAIN TIME AFTER OVER FILLING earlier in this section MACHINE OVER FILLED 08 ERROR NO HEAT The temperature has not increased by the number of degrees specified in the function MIN TEMPERATURE INCREASE see back in this sect...

Page 22: ...put ru 20 is below the value 5 which is a condition for locking the door When the door is locked the timer again command running at 0 Hz and this time the apparent current and the output voltage shall have a value above 5 21 ERROR I O COMMUNICATION Communication between the CPU board and one of the I O boards interrupted or disturbed I O COMMUNICATION 22 ERROR LOW OIL LEVEL In machines with an oil...

Page 23: ...G Check that all the fuses for the three fases are OK 34 Short circuit between motor windings or to earth OVER CURRENT Check the isolation to ground for motor cable and motor 36 Electronics too hot OVERHEAT Check the ambient temp Check if the drum is running smoothly 38 Power module too hot OVERHEAT PM Check the ambient temp Check if the drum is running smoothly 39 Motor thermal protection has tri...

Page 24: ...ht GO TO THE MENU Press SELECT Press SELECT The service program The service program makes fault finding on the machine easier as it allows you to control the vari ous machine functions individually water filling detergent flushing motor rotation clockwise and counterclockwise motor action distribution and extraction drain door lock heating buzzer You can also check which input signals to the PCU a...

Page 25: ... PROGRAM COUNTER IN CLS CLEAR WASH PROGRAM COUNTER IN SMC SCALE ADJUSTMENTS CALIB OF LEVEL SENSOR EXIT SELECT SELECT Not for FOM71 CLS Prevention of unauthorised access A button on the CPU circuit board has to be pres sed to gain access to the service program to prevent its unauthorised or inadvertent use The CPU circuit board is located behind the control panel Two screws have to be undone to ope...

Page 26: ...ETERGENT 11 28 LIQUID DETERGENT 12 29 LIQUID DETERGENT 13 33 MOTOR CLOCKWISE 34 MOTOR COUNTERCLOCKWISE 35 DISTRIBUTION 36 LOW EXTRACT 37 MEDIUM EXTRACT 38 HIGH EXTRACT 39 TURBO EXTRACT 40 NORMAL DRAIN 41 DRAIN BLOCKING 42 RECYCLE DRAIN A 43 RECYCLE DRAIN B 44 RECYCLE DRAIN C 45 RECYCLE DRAIN D 49 OIL PULS 51 DOOR LOCK 55 HEAT 56 HEAT 2 AS STANDARD 64 BUZZER EXIT To activate the various machine fun...

Page 27: ...o back to the previous display I O card inputs I O BOARD 2 CHANGE HEATING SYSTEM REPEAT RINSE Press 2 When the programme unit has two I O cards 1 2 3 4 5 6 7 8 9 0 Press any key to go back to the previous display It is now possible to verify the various input signals from I O card 2 To end the service programme End the service programme by pressing a SERVICE PROGRAM LEVEL 2 TEMP 22 C SPEED 0 DRAIN...

Page 28: ...asurement that X3 1 2 at A11 is 16 V If not troubleshoot the voltage supply circuit verify that the green LEDs on the programme unit card and the I O card blink quickly verify the fuses F11 and F12 T 1 25 A in the rear control unit Replace burnt out fuses 1 Perform a communication test using the test box Refer to the manual Instructions for Clarus Communication Tests OK LED on test box Defective L...

Page 29: ...easure the voltage 230 V at the water valve No voltage Voltage OK The valve is probably defective Verify and remedy 3 Depending on the valve measure the supply voltage 230 V of the water valve at switch X9 on I O card 1 A11 The relay functions can also be verified using the LEDs on I O card 1 No voltage Voltage OK Defective cables between the communication card A11 and the water valve or defective...

Page 30: ...ed bent blocked and has not come lose from the T joint drum programme unit card A1 or level guard B2 Level hose OK Defective level hose Fit the hose correctly or replace it Level detector on programme unit card A1 probably defective Enter the service programme and verify that the level indication is stable Blow into the level hose and check the level indication increases Check the level system for...

Page 31: ...efective contact 2 Exit the programme using a Enter the service programme unlock the door if it is locked Verify voltage supply is present between X5 4 5 when the door is closed No voltage Voltage present but black square does not light I O card 1 A11 probably defective 3 Verify voltage is present between X5 3 5 Voltage present No voltage Troubleshoot the cabling for the voltage supply between the...

Page 32: ...t function Incorrect function Replace S3 5 Inspect the cabling between X5 and S3 using an ohm meter Cabling OK Incorrect cabling Remedy or replace the cables Inspect the mechanical function of the door lock Replace any defective components or replace the door lock Switch cam Microswitch S3 Lock solenoid and microswitch S4 Lock pin Lock plate ...

Page 33: ...e is voltage between X5 2 6 when the door lock is engaged No voltage Voltage present but black square does not light I O card 1 A11 probably defective 3 Verify that there is voltage supply between X5 1 5 when the door lock is switched on Voltage present No voltage Troubleshoot the cabling for the voltage supply between the main power switch Q1 and X6 4 Is the lock command present Measure X 92 on t...

Page 34: ...20 5844 21 5592 22 5353 23 5124 Resistance OK Incorrect resistance The temperature sensor is probably defective 2 Exit the programme using a Enter the service programme and read the temperature the display window shows 0 C Short circuit inputs 1 and 2 on card switch X1 Verify that the display window shows 100 C Yes No Incorrect temperature sensing on the programme unit card Replace the card Incorr...

Page 35: ...21 5592 22 5353 23 5124 Resistance OK Incorrect resistance The temperature sensor is probably defective 2 Reset the connection on the sensor and exit the programme using a Enter the service programme and read the temperature Disconnect one of the inputs 1 and 2 on card switch X1 Verify that the display window shows 0 C Yes No Incorrect temperature sensing on the programme unit card Incorrect cabli...

Page 36: ...water in the drum Water in drum No water in drum 2 Enter the service program and record the actual level value Disconnect the level hose from the programme unit card A1 Level value does Level value falls not change The level hose is probably blocked by fluff or due to incorrect installation Verify and clean or replace the hose Level detector on programme unit card A1 is defective Verify the operat...

Page 37: ...s locked i e poured in continuously 1 Visually inspect Is there too much water in the machine No Yes Exit the programme and drain the machine 2 Exit the programme using a Enter the service programme and record the actual level value Undo the level hose from the programme unit and verify whether the level falls No Yes Inspect the level system hoses nipples and air box 3 Inspect whether the level in...

Page 38: ...ry careful when working on the machine Try to restart the machine i e reset the error code by pressing START If the error returns first make sure that the programme module is not incorrectly pro grammed the heat supply is intact the steam boiler is operating the drain does not leak 1 Exit the programme using a Enter the service programme and fill up water to above the safety le vel 5 10 cm above t...

Page 39: ...the error code by pressing START If the error returns first verify these items Is the drain is blocked by fluff or foam Are the the level hose and air box blocked blow into the level hose Verify the operation of the drain using the service programme Is the drain in the room capable of receiving the water from the machine ...

Page 40: ... working on the machine Try to restart the machine i e reset the error code by pressing START If the error returns troubleshoot as follows Verify the mechanical function of the imbalance switch the resistance between the imbalance switch and the cabling If the error remains there is probably an internal error in the motor controller ...

Page 41: ...ion between the programme unit and the motor controller has been interrupted or interfered If the power is on be very careful when working on the machine Try to restart the machine i e reset the error code by pressing START If the error returns ...

Page 42: ...the factory If the calibration values are missing or outside the limits an error is generator at programme start The programme can however be started by pressing START once more In this case the standard values are used and the level swill not be as exact Carry out programming anew and make sure the calibration values are within the allowed limits ...

Page 43: ...be indicated The same error will also be indicated if the weight transfered from the scale to the timer at the beginning of a water filling periode is above a certain li mit set in the configuration system of the machine To correct the problem try to first zerocalibrate the scale and then reset the scale in the service mode If the error remains please contact service ...

Page 44: ...ed If the power is on be very careful when working on the machine Find out the reason for the emergency stop button having been pressed Take the necessary measures Reset the emergency stop button by turning it counter clockwise Restart the machine by pressing START or a ...

Page 45: ...very careful when working on the machine Try to restart the machine i e reset the error code by pressing START If the error returns troubleshoot as follows 1 Undo the card connection X5 on I O card 1 A11 Error message returns No error message Troubleshoot the door lock actuator and the cabling for electric or mechanical short circuit I O card A11 probably defective Switch cam Microswitch S3 Lock s...

Page 46: ...bleshooting START NOT ALLOWED The network does not allow start of the washing programme Try to reset the error code If the error remains contact the responsible person for the network and have the error fixed ...

Page 47: ...rror code by pressing START If the error returns troubleshoot as follows Verify that the cable between the network and X7 on programme unit card A1 is connected If the cable is properly connected contact the person responsible for the network Note This error code will disappear by itself after se veral programme starts In case communication has been interrupted intentionally the machine can be ope...

Page 48: ...controller has been comple tely reset Then try to start the machine again If the error returns troubleshoot as follows 1 Measure the interlock signal on the motor controller XA2 16 interlock 24V and XA2 22 GND No signal Signal OK Troubleshoot the motor controller 2 Measure the signal on the I O card 1 interlock bus A11 X10 No signal Signal OK Troubleshoot the cabling between the motor controller a...

Page 49: ...machine Try to restart the machine i e reset the error code by pressing START If the error returns troubleshoot as follows 1 Perform a communication test using the test box Refer to the manual Instructions for Clarus Communication Tests OK LED on test box Defective LEDs on test box Troubleshoot according to the manual Instructions for Clarus Communication Tests The motor controller or cabling for ...

Page 50: ...50 Troubleshooting LOW OIL LEVEL Low oil level in the oil container Applies only to machines with oil lubrication Fill up with oil and restart the machine Verify for any leaks ...

Page 51: ...nt that monitors received mains signals in terms of voltage levels loss of phase etc If this input goes high the error message is displayed Find out the reason for the error indication by inspecting the mains monito ring equipment For more on this troubleshooting refer to the manual supplied with the mains monitoring equipment in use ...

Page 52: ...hen the drum is empty Does the level indication exceed the set limit value Yes No 2 Try to restart a washing programme again No error code Error remains The level hose is probably blocked Replace or clean the level hose Temporary error 3 Undo the level hose from the programme unit card A1 Does the level indication still exceed the set limit value Yes No The level hose is probably blocked Replace o...

Page 53: ...led by the pressure sensor system the pressure sensor system must be calibrated The pressure sen sor system for water filling can be calibrated in the service mode It is possible to use the machine in weight mode filling water on weight without calibrating the water pressure sensor system ...

Page 54: ...54 Troubleshooting NO SCALE CONNECTED Communication between the timer and the scale is not working Check the wire between the timer and the scale If still not working please contact service ...

Page 55: ...or Switch off the machine for at least 30 seconds to ensure the motor con troller has been completely reset Then try to start the machine again If the error returns troubleshoot as follows 1 Verify that the drum and motor operate smoothly Drum motor OK Heavy operation of the drum motor Defective bearings in drum or motor or there is an object between the outer and inner drum Inspect and remedy 2 E...

Page 56: ...m and motor operate smoothly Drum motor OK Heavy operation of the drum motor Defective bearings in drum or motor or there is an object between the outer and inner drum Inspect and remedy 2 Wait for at least 10 minutes to allow the motor to cool down Then switch on the machine again Enter the service programme and run the motor at low washing revolutions Verify whether the error indication immediat...

Page 57: ...itch Undo the contactor at X3 on the motor Use an ohmmeter to measure the resistance towards the motor Measure between 1 2 1 3 and 2 3 Correct resistance should be W4400H W3600H W3850H W31100H cold motor 0 84 ohm 0 68 ohm 0 48 ohm hot motor 1 13 ohm 0 9 ohm 0 6 ohm Correct resistance One of the resistance values is incorrect The motor is probably defective Troubleshoot the cabling between the moto...

Page 58: ... the resistance towards the motor Measure between 1 2 1 3 and 2 3 Correct resistance should be W4400H W3600H W3850H W31100H cold motor 0 84 ohm 0 68 ohm 0 48 ohm hot motor 1 13 ohm 0 9 ohm 0 6 ohm Correct resistance One of the resistance values is incorrect The motor is probably defective 2 Inspect the cabling from X312 on the motor controller to X3 on the motor Use an ohmmeter and measure the fiv...

Page 59: ...in MCU receiving circuitry for lock acknowledgement signal The test of the MCU interlock circuits proceeds in the following way Before the locking of the door lock a speed command is sent from the timer to the MCU 0 Hz Then the timer checks that the value of the apparent current ru 15 and output ru 20 is below the value 5 which is a condition for locking the door When the door is locked the timer ...

Page 60: ...e the motor controller has been comple tely reset Then try to start the machine again If the error returns troubleshoot as follows 1 Verify the voltage supply 230 400 V to the motor controller at the contactor X311 Voltage too low Voltage OK The motor controller is probably defective 2 Inspect the power supply 230 400 V at the main power switch Q1 on the machine Voltage too low Voltage OK Defectiv...

Page 61: ... the motor controller has been completely reset Then try to start the machine again If the error returns troubleshoot as follows 1 Verify the voltage supply 230 400 V to the motor controller at the contactor X311 Voltage too high Voltage OK The motor controller is probably defective 2 Inspect the power supply 230 400 V at the main power switch Q1 on the machine Voltage too high Voltage OK Defectiv...

Page 62: ...troller has been completely reset Then try to start the machine again If the error returns troubleshoot as follows 1 Verify the voltage supply 400 V to the motor controller at the contactor X311 Large voltage fluctuations Voltage OK The motor controller is probably defective 2 Inspect the power supply 230 400 V at the main power switch Q1 on the machine Large voltage fluctuations Voltage OK Defect...

Page 63: ...By disconnected the flat cable from the display card pressing a key and the measuring the resistance between the outputs that should close it is possible to determine correct operation of any one key The table below shows the outputs that need to be closed for each key Key Outputs that should close 1 2 7 2 2 6 3 2 5 4 3 7 5 3 6 6 3 5 7 4 7 8 4 6 9 4 5 0 5 8 A 6 8 B 1 2 C 1 3 D 7 8 ...

Page 64: ...64 ...

Page 65: ...upply to I O board CPU board display unit and control unit door lock K11 Motor interlock K12 Motor fan relay K21 24 Heating relay K36 Relay oil lubrication M23 Fan motor controller M24 Fan door Q1 Main switch isolating switch R1 Brake resistance T1 Transformer for adaptation of feed voltage for control unit and control equipment T10 Transformer power supply I O board CPU board and display unit U1 ...

Page 66: ...Z1 R1 Z2 T10 Q1 T1 U1 M23 F31 K21 K22 K23 K24 M20 E20 M24 F11 F12 A11 A12 A13 X149 X148 X146 X145 X144 X143 X142 K11 K36 K12 X111 X110 X105 X106 X112 X103 X101 X104 X102 X100 B41 B42 Y6 Y41B Y42B Y51 Y1 Y41A Y42A Y2 Control unit ...

Page 67: ...rogram in progress signal External detergent supply External buzzer flashlight 6069 Recycling Interlock motor control 6071 6068 6068 X110 X105 X106 X112 X114 X103 X102 X101 X100 100 X144 2 X144 1 X143 1 X143 2 K12 K13 X144 2 X144 2 X144 1 X144 1 X146 X145 X149 X147 X148 1 2 1 2 3 4 7 5 6 8 9 10 1 2 3 4 1 2 1 2 3 4 7 5 6 8 9 10 1 2 3 4 1 2 1 2 1 2 3 4 7 5 6 14 8 910111213 1 2 3 4 7 5 6 14 8 9101112...

Page 68: ...common neutral Water recycling outputs X145 1 Drain 1 Y1 2 Pump 1 3 Stop drain Y1b 4 Drain 2 Y2 normally open 5 Drain 2 Y2 normally closed 6 Drain 3 7 Drain 4 8 Tank 1 water valve Y44 9 Tank 2 water valve Y54 10 Common neutral Connectors X100 Connector 37 pole CPU board X101 Connector 14 pole door lock X102 Connector 14 pole control unit and sensor s for tilt function optional equipment X103 Conne...

Page 69: ... A200 1 CPU circuit board 2 X200 Connector 37 pole operator unit 3 X201 Connector 4 pole sensor s thermostat 4 A200 3 Card reader 5 A200 2 Display circuit board 6 S2 Connection terminals 7 X202 Connector 4 pole weighing equipment 8 X7 DMIS CMIS optional equipment ...

Page 70: ... interfaces The CPU board has its own level switch and inputs from temperature sen sors I O boards The I O boards receive information from the CPU board concerning the outputs which are to be controlled The I O boards can control the follo wing functions I O board 1 door lock water valves cold and hot water flush 1 drain 1 detergent dispensing 1 4 external detergent dispensing 1 4 and heating rela...

Page 71: ...vel sensing Motor control unit Display unit CPU board Emergency stop System voltage I O board 1 I O board 2 Outputs and inputs to and from various washer extractor func tions Control unit door lock Door lock Temperature sensing Level sensing I O board 3 Tilting Tilting functions ...

Page 72: ...72 ...

Page 73: ...ction and drain valve On the input connection blocks it is possible to connect signals for control of e g the detergent supply The cards also have inputs for emergency stop and door lock ACK 6060 M1 Temp 1 Door lock controller A31 Motor controller U1 Level guard B2 Door lock A41 Programme unit A1 Transformer T10 Water valves Drain valves Level guard Emergency stop I O card 1 A11 I O card 2 A12 Dis...

Page 74: ...tor controller To obtain information about the various operations of the washing machi ne the following inputs are used The CPU card has inputs for e g temperature sensors The CPU card receives information from the I O card inputs about door locking state and any external switches e g Start Stop and Pause The CPU card has a pressure sensor to which a hose for measuring the water level in the drum ...

Page 75: ...shorted to confirm changes made in Configuration 1 and 2 Card Switch Function X1 Input from water temperature sensor X2 not used X3 not used X4 Output to motor controller X5 1 3 Serial communication with I O card 1 X5 4 5 Voltage supply from I O card 1 X6 1 5 Serial communication with display card X6 6 7 Voltage supply to display card X7 PC communication X8 Motor communication reserved X9 Scale co...

Page 76: ...ric display window The display card also detects which buttons are pressed on the con trol panel and sends these signals to the CPU card Card switch Function X1 Not used X2 Communication with card reader for memory cards X3 Not used X4 Not used X5 Connection from front key board X6 1 2 Voltage supply from CPU card X6 3 7 Serial communication with CPU card X3 X2 X1 X6 Flat cable for keypad Connecti...

Page 77: ...al switches e g Start Stop and Pause Signals on these inputs are passed on to the CPU card The outputs control water valves detergent supply drain and hea ting The voltage supply to the CPU and I O cards takes place via I O card 1 A11 which feeds voltage to both the CPU card A1 and a possible I O card 2 A12 Note that if the programme unit uses two cards and one needs to be replaced special program...

Page 78: ... 230 V direct supply neutral X10 1 Interlock signal to motor controller phase Supply to relays from I O 1 phase 2 Interlock signal to motor controller neutral Supply to relays from I O 1 neutral X11 1 Supply to relays from I O 2 phase 2 Supply to relays from I O 2 neutral X12 1 To X13 supply to relays 11 14 phase To X13 supply to relays 11 14 phase 2 To X13 supply to relays 11 14 neutral To X13 su...

Page 79: ...elay K21 2 Neutral X9 1 9 Hot water inlet Y25 2 8 Powder 5 Y22 3 10 Powder 4 Y14 24 4 7 Cold water inlet Y15 5 6 Powder 3 Y13 6 5 Powder 2 Y12 7 4 Powder 1 Y11 8 N common neutral X14 1 14 Signal 4 external detergent pump 2 12 Signal 3 external detergent pump 3 13 Signal 2 external detergent pump 4 11 Signal 1 external detergent pump 5 N common neutral I O card 3 A13 Function Outputs X9 1 Phase K42...

Page 80: ...2 Cold hard water Y35 Flushing detergent dispenser 2 N neutral 3 2 X8 1 3 2 Neutral X9 1 9 Inlet C Y65 2 8 Inlet B Y55 3 10 Inlet A Y45 4 7 Drain C Y4 5 6 Drain B Y3 6 5 Drain A Y2 8 N common neutral X14 1 14 Signal 8 external detergent pump 2 12 Signal 7 external detergent pump 3 13 Signal 6 external detergent pump 4 11 Signal 5 external detergent pump ...

Page 81: ... Door lock micro switch S4 N No 3 4 1 Door lock position micro switch S3 N 5 6 2 Door lock micro switch S4 Phase X15 1 4 External start stop signal phase 2 4 External start stop signal neutral 3 3 External pause signal phase 4 3 External pause signal neutral X16 1 2 Emergency stop S2 3 4 External service switch 5 6 Oil level 7 8 ...

Page 82: ... 1 4 2 4 3 3 4 3 X16 1 2 3 4 5 6 7 8 I O card I O card 3 A13 Connection block No Opto coupler Function Inputs X5 1 Neutral S44A No 2 Neutral S44A COM 3 Neutral S44A COM 4 1 2 Neutral COM 5 1 Phase 6 2 Phase S44B COM X15 1 4 Neutral 2 4 Phase K41 COM 3 3 Neutral 4 3 Phase K42 COM X16 1 2 K46 3 4 K47 5 6 K44 7 8 K45 ...

Page 83: ...e feed for the CPU board I O boards and display board The transformer supplies 12 V on its secondary side and can be adapted to suit any of four different primary voltages by moving a bridge The transformer should normally be connected for a primary voltage of 230 V Adaptation for different power supply voltages takes place at transformer T1 ...

Page 84: ...GENT POWDER 5 17 LIQUID DETERGENT 1 18 LIQUID DETERGENT 2 19 LIQUID DETERGENT 3 20 LIQUID DETERGENT 4 21 LIQUID DETERGENT 5 22 LIQUID DETERGENT 6 23 LIQUID DETERGENT 7 24 LIQUID DETERGENT 8 33 MOTOR CLOCKWISE 34 MOTOR COUNTERCLOCKWISE 35 DISTRIBUTION These signals can be read I O BOARD 1 EMERGENCY STOP TEMPORARY PAUSE OIL REMOTE START SERVICE PHASE CHECK DOOR LOCKED DOOR CLOSED I O BOARD 2 CHANGE ...

Page 85: ...splayed Press repeatedly Press to highlight GO TO THE MENU Press SELECT Press SELECT The service program The service program makes fault finding on the machine easier as it allows you to control the vari ous machine functions individually water filling detergent flushing motor rotation clockwise and counterclockwise motor action distribution and extraction drain door lock heating buzzer You can al...

Page 86: ...OUNTER CLEAR WASH PROGRAM COUNTER IN CLS CLEAR WASH PROGRAM COUNTER IN SMC SCALE ADJUSTMENTS CALIB OF LEVEL SENSOR EXIT SELECT SELECT Prevention of unauthorised access A button on the CPU circuit board has to be pres sed to gain access to the service program to prevent its unauthorised or inadvertent use The CPU circuit board is located behind the control panel Two screws have to be undone to open...

Page 87: ...RGENT 11 28 LIQUID DETERGENT 12 29 LIQUID DETERGENT 13 33 MOTOR CLOCKWISE 34 MOTOR COUNTERCLOCKWISE 35 DISTRIBUTION 36 LOW EXTRACT 37 MEDIUM EXTRACT 38 HIGH EXTRACT 39 TURBO EXTRACT 40 NORMAL DRAIN 41 DRAIN BLOCKING 42 RECYCLE DRAIN A 43 RECYCLE DRAIN B 44 RECYCLE DRAIN C 45 RECYCLE DRAIN D 46 FLASHING LIGHT 51 DOOR LOCK 55 HEAT 56 HEAT 2 AS STANDARD 64 BUZZER EXIT To control the machine functions...

Page 88: ...k to the previous display It is now possible to verify the various input signals from I O card 2 Now you can check the various input signals from I O board 1 A black square in front of the name indicates that the input is active Press any key to go back to the previous display SERVICE PROGRAM LEVEL 2 TEMP 22 C SPEED 0 DRAIN CLOSED YES EMERGENCY STOP DOOR LOCKED TEMPORARY PAUSE DOOR CLOSED OIL REMO...

Page 89: ...TURE DISPLAY ACTUAL SPEED MACHINE NOT HEATED TEMPERATURE CONTROL OF WATER TEMPERATURE IN C REPEAT PROGR MODE QUESTION LOCKED STANDARD WASH PROGRAMS LEVEL QUICK COOL DOWN LEVEL UNBALANCE LEVEL LOW LEVEL MEDIUM LEVEL HIGH MIDDEL TEMPERATURE COOL DOWN DEFAULT MOTOR ON TIME DEFAULT MOTOR OFF TIME FLUSH DELAY TIME FLUSH ON TIME BUZZER ON BUTTON MAX FILLING TIME MAX HEATING TIME SHOW WEIGHT TIMEOUT PC5 ...

Page 90: ...ENU Press SELECT Press twice to highlight SETTINGS 1 Press SELECT MENU MAKE A CHOICE WASH PROGRAM LIBRARY PROGRAMMING MODE SETTINGS 1 MEMORY CARD SERVICE MODE STATISTICS WASH PROGRAM LIBRARY PROGRAMMING MODE SETTINGS 1 MEMORY CARD SERVICE MODE STATISTICS MANUAL MODE SETTINGS 2 EXIT SELECT SELECT RUN A WASH PROGRAM GO TO THE MENU MAKE YOUR CHOICE WITH OR AND PRESS SELECT WEIGHT KG 000 0 ...

Page 91: ...NTER YOUR PASSWORD 0 ENTER NEW PASSWORD Use the numeric keys to enter your four digit pass word Press SELECT To enter a password the first time Password protection or not It is for you to decide whether or not the functions SETTINGS 1 and PROGRAMMING will be pass word protected Please note that if you do decide to implement password protection for either of them then access to both these functions...

Page 92: ...s been entered the display will show and SELECT SELECT PLEASE ENTER YOUR PASSWORD 0 ENTER NEW PASSWORD Enter your four digit pass word Press SELECT To change the password To remove the password protection 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 Press Enter four noughts 0000 SELECT PLEASE ENTER YOUR PASSWORD 0 ENTER NEW PASSWORD SELECT Enter your four digit pass word Press SELECT SETTINGS 1 SETTING...

Page 93: ...1 To do this you have to use a strap to short circuit two terminals on the CPU board see section headed To conclude making changes in variables under SETTINGS 1 Your changes can affect program operation If you have answered any of the first 11 variables in the menu with N No and later during pro gram operation you attempt to activate one of these a message equivalent to FUNCTION NOT ALLOWED will a...

Page 94: ...DJUST SPIN SPEED ALLOWED Y DISPLAY REMAINING TIME Y DISPLAY ACTUAL TEMPERATURE Y DISPLAY ACTUAL SPEED Y MACHINE NOT HEATED N Y N Answer Yes Y or No N Press PROGRAM STEP MAIN WASH 1 STEP TIME 720 SEC SET TEMPERATURE 85 C ACTUAL TEMPERATURE 21 C REMAINING TIME 70 MIN DRUM SPEED 48 RPM RAPID ADVANCE SHOW WEIGHT 991 NORMAL 95 C SELECT PROGRAM STEP MAIN WASH 1 STEP TIME 720 SEC SET TEMPERATURE 85 C ACT...

Page 95: ...Y DISPLAY ACTUAL TEMPERATURE Y DISPLAY ACTUAL SPEED Y MACHINE NOT HEATED N Y N Answer Yes Y or No N Press b If you answer Yes Y Menu line showing current weight will be dis played If you answer No N Menu line showing current weight will not be displayed RUN A WASH PROGRAM GO TO THE MENU MAKE YOUR CHOICE WITH OR AND PRESS SELECT WEIGHT KG 013 5 SELECT TAR Menu line show ing actual weight For machin...

Page 96: ...N Y N For machines with weight measurement installed only Answer Yes Y or No N Press b Y N Answer Yes Y or No N Press ADJUST TIME ALLOWED Y ADJUST TEMPERATURE ALLOWED Y RAPID ADVANCE ALLOWED Y SHOW WEIGHT ALLOWED Y WATER REDUCTION NOT ALLOWED Y MANUAL FUNCTIONS ALLOWED Y PAUSE ALLOWED Y FREE TEXT ALLOWED Y CHANGE WASH PROGRAM ALLOWED Y AUTO RESTART ALLOWED Y ADJUST SPIN SPEED ALLOWED Y DISPLAY REM...

Page 97: ...e allowed PROGRAM STEP MAIN WASH 1 NORMAL PROGRAM FOR NORMALLY SOILED LOADS MANUAL FUNCTIONS TEXT SELECT 991 NORMAL 95 C STD Example of free text entered when the program is created If you answer Yes Y Display of free text will be allowed If you answer No N Display of free text will not be allowed Answer Yes Y or No N Press Answer Yes Y or No N Press If you answer Yes Y The use of the pause functi...

Page 98: ...rogram operation PROGRAM STEP MAIN WASH 1 STEP TIME 720 SEC SET TEMPERATURE 85 C ACTUAL TEMPERATURE 21 C REMAINING TIME 70 MIN DRUM SPEED 48 RPM TEXT SELECT NEW WASH PROGRAM SELECT 991 NORMAL 95 C STD If you answer Yes Y Changing to a different wash program allowed If you answer No N Changing to a different wash program not al lowed Automatic restart allowed Here you determine whether automatic re...

Page 99: ...ft Here you determine whether the time the program has left to run will be displayed during the pro gram This function will not work until the second time the program is run Before that the line will be blank even if you have inserted Y Yes here The time displayed will be based on the average of the last five times the program was used PROGRAM STEP MAIN WASH 1 STEP TIME 720 SEC SET TEMPERATURE 85 ...

Page 100: ...be displayed If you answer Yes Y Actual drum speed will be displayed If you answer No N Actual drum speed will not be displayed Answer Yes Y or No N Press Answer Yes Y or No N Press MANUAL FUNCTIONS ALLOWED Y FREE TEXT ALLOWED Y CHANGE WASH PROGRAM ALLOWED Y AUTO RESTART ALLOWED Y ADJUST SPIN SPEED ALLOWED Y DISPLAY REMAINING TIME Y DISPLAY ACTUAL TEMPERATURE Y DISPLAY ACTUAL SPEED Y MACHINE NOT H...

Page 101: ...t the water to the set temperature before the count down of the wash sequence begins The temperature values will be shown on the display if you have allowed their display Temperature control of water Here you determine whether the machine will monitor and adjust the water temperature during fil ling by opening and closing the cold and hot water valves If you answer Yes Y This function will be acti...

Page 102: ...ermine whether you or the user will be given the chance to select either Standard or Ad vanced mode for each new program module you are programming if you start programming in Standard mode If you answer Yes Y You can select either Standard or Advanced mode for each new program module you pro gram If you answer No N All modules must be programmed using either Standard mode or Advanced mode consist...

Page 103: ...GRAMS N LEVEL QUICK COOL DOWN 175 LEVEL UNBALANCE 0 LEVEL LOW 135 LEVEL MEDIUM 150 LEVEL HIGH 175 MIDDLE TEMPERATURE COOL DOWN70 C DEFAULT MOTOR ON TIME 0 12 DEFAULT MOTOR OFF TIME 0 03 FLUSH DELAY TIME 0 06 Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press No access to standard programs Here you determine whether the user ...

Page 104: ...OW 135 LEVEL MEDIUM 150 LEVEL HIGH 175 MIDDLE TEMPERATURE COOL DOWN70 C DEFAULT MOTOR ON TIME 0 12 DEFAULT MOTOR OFF TIME 0 03 FLUSH DELAY TIME 0 06 FLUSH ON TIME 0 10 Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press Low Medium High levels Here you determine the water levels which are to correspond to L low M medium and H ...

Page 105: ...ool down sequence is divided into two stages 1 wash temperature to middle temperature Throughout this stage the machine will monitor the cool down rate to ensure it does not exceed the cool down rate set 4 C per minute when the machine leaves the factory If the rate set is exceeded no water will be added until the mean value is acceptable again 2 middle temperature to final temperature The rate of...

Page 106: ... on Key click on Here you determine whether or not there will be an audible click or beep each time a key on the PCU control panel is pressed If you answer Yes Y Click beep for each key press If you answer No N No click or beep audible when keys pressed Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press Answer Yes Y or No N ...

Page 107: ...ESS 0 LEVEL IN MM ACTIVE Y START SLOW FILLING HG 10 OFFSET LEVEL HG 2 READY Maximum filling time Here you determine the maximum time to be al lowed for filling the machine with water to the level set If the correct level has not been reached within this time the error message NO WATER will appear on the display Maximum heating time Here you determine the maximum time to be allo wed to heat the wat...

Page 108: ...ER TIMEOUT AT END Y BUZZER TIMEOUT AT PAUS Y ERROR OVERFILLED Y PASSWORD ACTIVE Y CMIS ADDRESS 0 LEVEL IN MM ACTIVE Y START SLOW FILLING HG 10 OFFSET LEVEL HG 2 READY Y N Show weight timeout Here you determine the length of time the weight will be displayed before the normal display is restored Weight display mode PC5 Power Control Here you determine whether input X15 on I O PCB 1 external pause s...

Page 109: ...AM STEP MAIN WASH 1 STEP TIME 720 SEC SET TEMPERATURE 85 C ACTUAL TEMPERATURE 21 C REMAINING TIME 70 MIN DRUM SPEED 48 RPM RAPID ADVANCE PAUSE 991 NORMAL 95 C S When the service technician has serviced the machine this counter is reset When the time on the counter exceeds the pro grammed interval S is displayed in the lower left corner of the display indicating the need for Service Answer Yes Y or...

Page 110: ...PAUS 0 10 1 2 3 4 5 6 7 8 9 0 Buzzer length at pause Here you determine for how long the buzzer should sound at a programmed pause unless it is not turned off manually When programming a washing programme it is possible to select whether or not to pause and sound the buzzer for each washing module before that module starts The buzzer is switched off by pressing a function button on the control pan...

Page 111: ...d according to the explanations CMIS ADDRESS 0 CMIS address Here you can give the machine a unique address when connected to the CMIS system 0 inactive Allowed values 1 127 LEVEL IN MM ACTIVE Y Level in mm active Y es Pressure sensor system for water filling active N o Water filling will be made on weight ...

Page 112: ...detergent valve 3 will be used to finalize the washer filling Detergent valve 3 will be opened given value before the final level is reached OFFSET LEVEL HG Y Offset level hg Gives value will be subtracted from programing water level before water filling starts Only when filling on weight ...

Page 113: ...ap bet ween X7 1 2 is intact and in place Press SELECT and try again SELECT FLUSH DELAY TIME 0 06 FLUSH ON TIME 0 10 BUZZER ON BUTTON Y MAX FILLING TIME 10 00 MAX HEATING TIME 10 00 READY SETTINGS 1 SELECT OK LOADED DO NOT FORGET TO REMOVE STRAP SETTINGS 1 SELECT SELECT SELECT VERIFICATION ERROR CHECK THE STRAP PRESS SELECT TO TRY AGAIN SETTINGS 1 Prevention of unauthorised access A button on the ...

Page 114: ...XTRACT ACCELERATION START EXTRACT ACCELERATION EXTRACT RETARDATION MAX SPEED DURING FILLING MAX LEVEL OFFS FOR AUT CALIB TIME AT DISTRIBUTION SPEED 2 NUMBER OF REDIST LOW 1 UNB NUMBER OF REDIST LOW 2 UNB NUMBER OF REDIST MEDIUM UNB NUMBER OF REDIST HIGH UNB NUMBER OF REDIST EXTREME UNB DRAIN TIME AT PROGR START DRAIN TIME AT PROGR END READY HEATING RELAY ON IF NOT HEATED TEMPERATURE INCREASE ALLOW...

Page 115: ... change via SET TINGS 2 belong to a category which if they are changed carelessly or incorrectly could jeopardise the machine s safety system s or its reliability For this reason SETTINGS 2 is protected by a code password system Every time you access SETTINGS 2 you have to obtain a new password from the supplier The system works like this When you open SETTINGS 2 you will see an eight digit code T...

Page 116: ...RATION 40 EXTRACT RETARDATION 50 MAX SPEED DURING FILLING 100 MAX LEVEL OFFS FOR AUT CALIB TIME AT DISTRIBUTION SPEED 2 NUMBER OF REDIST LOW 1 UNB NUMBER OF REDIST LOW 2 UNB NUMBER OF REDIST MEDIUM UNB NUMBER OF REDIST HIGH UNB NUMBER OF REDIST EXTREME UNB DRAIN TIME AT PROG START DRAIN TIME AT PROG END READY Variables under SETTINGS 2 When the top line of a menu is highlighted you have the option...

Page 117: ...URE STEP IN COOL DOWN 4 C DEFAULT LOW EXTRACT TIME 00 00 DEFAULT MEDIUM EXTRACT TIME 00 00 DEFAULT HIGH EXTRACT TIME 00 00 DEFAULT DRAIN TIME 00 00 DEFAULT DISTR TIME 00 00 DO UNBALANCE MEASUREMENT N DRAIN OPEN DELAY 0 13 START EXTRACT TIME 00 30 Temperature increase allowed Here you determine whether or not it will be pos sible for the user during a wash program to adjust the wash temperature to ...

Page 118: ...er remains in the outer drum If the water has not fallen to this level before the drain time has ended the message NOT DRAI NED will appear on the display For information on the levels used for the various machines see the manual Programming PCS Program Control Unit Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press Level fo...

Page 119: ...RT EXTRACT TIME 00 30 1 2 3 4 5 6 7 8 9 0 Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press HEATING RELAY ON IF NOT HEATED Y TEMPERATURE INCREASE ALLOWED Y LEVEL EMPTY 90 LEVEL OVERFILL 200 PAUSE TEST LEVEL 0 PAUSE TEST TEMPERATURE 18 C DEFAULT TEMPERATURE HYSTERIS 4 C TEMPERATURE STEP IN COOL DOWN 4 C DEFAULT LOW EXTRACT T...

Page 120: ... cool down is not monitored during this stage The valve opens and shuts as you have programmed it to do Temp Time Middle temperature Final temperature Temperature monitoring HEATING RELAY ON IF NOT HEATED Y TEMPERATURE INCREASE ALLOWED Y LEVEL EMPTY 90 LEVEL OVERFILL 200 PAUSE TEST LEVEL 0 PAUSE TEST TEMPERATURE 18 C DEFAULT TEMPERATURE HYSTERIS 4 C TEMPERATURE STEP IN COOL DOWN 4 C DEFAULT LOW EX...

Page 121: ...alues for re start after unbalance Here you determine the drain time and distribu tion time the machine will use if it cannot find the time parameters it requires e g during manual operation of the drain in a washer extractor with a suspended drum Unbalance measurement Here you determine whether the machine will cal culate unbalance before it accelerates to extraction speed Drum unbalance can only...

Page 122: ... point 2 only or a combi nation of 1 and 2 according to the way you program 1 Drain time The drain will be open The motor may be at a standstill on gentle action or normal action 2 Distribution time The drain will be open The motor runs at dist ribution speed During this time the wash load will be distributed evenly around the walls of the inner drum You can program this time here Start extract ti...

Page 123: ...ater to give the motor time to slow down This function is useful if the motor is not a frequen cy controlled one Another function intended primarily for frequency controlled motors which continuously report motor speed to the PCU is called MAX SPEED DURING FILLING SETTINGS 2 described later in this section This function allows you to specify a speed which the motor must drop below before water fil...

Page 124: ...TART EXTRACT TIME 00 30 ROLLOUT TIME 00 01 PAY PER WASH ALARM 0 LOCK TEST DELAY 0 10 DRAIN TIME WHEN OVERFILL 0 05 OIL LUBRICATION HOURS 100 PULSE TIME OIL LUBR SEC 0 01 AMOUNT OF I O MODULES 1 3 3 Pay per wash This question is for special installations with pay systems How to use it is described in the docu mentation supplied with these systems Press ...

Page 125: ...ould be made of the lock s microswitch When the machine commands that the door be locked the door lock is activated The lock actua tes a microswitch which signals whether or not the door is really locked Note that the machine always begins its wash sequence immediately after the door has been locked and that the time you program here will not affect that If when this check is made the microswitch ...

Page 126: ...open for the time programmed and the level will then be checked If the level is still too high the drain valve will open again and so on Over filling can occur if a water valve is faulty or if you have over filled the machine manually Also under SETTINGS 2 there are two functions which influence the way the machine reacts to over filling ERROR OVER FILLED If you answer Y Yes if the drum becomes ov...

Page 127: ...MPERATURE INCREASE 5 C DOOR OPEN DELAY FOR MOTOR LOST 1 00 ERROR NO WATER Y 1 2 3 4 5 6 7 8 9 0 Oil lubrication Here you determine the lubrication interval and pulse time for the oil lubrication systems used on larger washer extractors Number of I O circuit boards Here you specify how many I O circuit boards the PCU has Different types of washer extractor may be equip ped with one two or three I O...

Page 128: ...7 8 9 0 Timeout drain at program start If water in machine at wash program start and level not lower than emty level within given value an error will be indicated Delay clear door text Here you determine how long the text WAITING FOR DOOR TO UNLOCK will remain visible if for some reason the door is not unlocked at the right time When a wash program has ended the text above will be displayed until ...

Page 129: ...mber of degrees you have specified above The function ERROR NO HEAT SETTINGS 2 If you answer Y Yes If the temperature has not increased by the number of degrees you program here over the time which is specified in MAXIMUM HEATING TIME the error message NO HEATING will ap pear on the display If you answer N No Monitoring of heating will be switched off and no error message will be displayed Timeout...

Page 130: ...ith frequency control the MCU loses control of braking at the end of extraction In machines with frequency controlled motors it is the MCU which ensures that the motor and drum are braked smoothly after extraction speed If anything should go wrong at this stage so that the MCU loses control of the braking process colloquially referred to as motor lost the MCU will inform the PCU If the program has...

Page 131: ... HOT 33 The motor has received a start command from the PCU without receiving an interlock signal from the door lock The MCU receiving circuitry for the interlock signal is not faulty NO INTERLOCK 35 Short circuit between motor windings or to earth MOTOR SHORTNING 36 Fault in MCU receiving circuitry for lock acknowledgement signal INTERLOCK HARDWARE 37 DC voltage too low LOW DC VOLTAGE 38 DC volta...

Page 132: ... if the machine has detected a fault error and is dis playing an error message This must give enough time for the water to empty and drum speed to be reduced Please note that the water will not be emptied as a result of all types of error In the case of the HIGH TEMPERATURE error for example the door will remain locked even though the time you have programmed has elapsed One reason for this is to ...

Page 133: ...ure Here you determine the highest temperature the user may alter the wash temperature to manually by using to move to the line for SET TEM PERATURE then entering a new wash tempera ture PROGRAM STEP MAIN WASH 1 STEP TIME 720 SEC SET TEMPERATURE 85 C ACTUAL TEMPERATURE 21 C REMAINING TIME 70 MIN DRUM SPEED 48 RPM RAPID ADVANCE PAUSE SELECT 991 NORMAL 95 C The function above will be available only ...

Page 134: ...URE FOR ERROR 9 C MAX ADJUST TEMPERATURE 97 C MAXIMUM EXTRACT SPEED 825 DEFAULT WASH SPEED 48 DISTRIBUTION SPEED 1 90 DISTRIBUTION SPEED 2 DEFAULT LOW EXTRACT RPM 550 DEFAULT MEDIUM EXTRACT RPM 700 DEFAULT HIGH EXTRACT RPM 900 START EXTRACT SPEED 1000 DEFAULT WASH ACCELERATION 20 1 2 3 4 5 6 7 8 9 0 Default wash speed Here you determine the wash speed the machine will use at any time when it canno...

Page 135: ... 40 START EXTRACT ACCELERATION 40 EXTRACT RETARDATION 50 1 2 3 4 5 6 7 8 9 0 Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press low medium high Time Start extract speed i e Initial extraction speed Here you determine the speed of initial extraction When you are creating a wash program you can determine under Main data whethe...

Page 136: ...lue If you make a mistake while entering digits Press ERASE When you have finished Press Distribution acceleration Here you determine the acceleration rate rpm se cond the machine will use to reach distribution speed and to decelerate after distribution speed respectively This value is not programmable when you create a wash program Instead the machine always uses the value you set here START EXTR...

Page 137: ... Press Start extract acceleration i e Acceleration rate for initial extraction Here you determine the acceleration rate rpm se cond which the machine will use to reach its initial extraction speed This value is not programmable when you create a wash program Instead the machine always uses the value you set here There are two other functions affecting initial extraction which can be programmed und...

Page 138: ... This function is useful for frequency controlled motors Another function intended primarily for motors without frequency control is called ROLLOUT TIME accessed via SETTINGS 2 described earlier in this section ROLLOUT TIME allows you to specify a time period which must elapse before water filling starts If these functions are combined you must ensure that the rollout time will have ended before w...

Page 139: ...to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press Drain time at progr start Drain time at program start after that the level is below level empty START EXTRACT SPEED 1000 DEFAULT WASH ACCELERATION 20 DISTRIBUTION ACCELERATION 9 RETARDATION ACCEL EXTRACT ACCELERATION 40 START EXTRACT ACCELERATION 40 EXTRACT RETARDATION 50 MAX SPEED DURING FILLIN...

Page 140: ...DIST LOW 1 UNB NUMBER OF REDIST LOW 2 UNB NUMBER OF REDIST MEDIUM UNB NUMBER OF REDIST HIGH UNB NUMBER OF REDIST EXTREME UNB DRAIN TIME AT PROGR START DRAIN TIME AT PROGR END READY 1 2 3 4 5 6 7 8 9 0 Use the numeric keys to enter the value If you make a mistake while entering digits Press ERASE When you have finished Press ...

Page 141: ...strap between terminals X7 1 2 on the CPU circuit board Press SELECT SELECT SELECT VERIFICATION ERROR CHECK THE STRAP PRESS SELECT TO TRY AGAIN SETTINGS 2 The display illustrated left will appear if you fail to insert the strap to short circuit termi nals X7 1 2 Check that the strap bet ween X7 1 2 is intact and in place Press SELECT and try again Prevention of unauthorised access A button on the ...

Page 142: ... from the supplier 5 A special program called CMM G3000 Certus Maintenance Manager used for converting and dowloading the files onto the new CPU board This program can also be ordered from the supplier Instructions 1 Order the right software for your CPU board from the supplier You must state the type and serial number of the machine to obtain the correct version of the program If you do not have ...

Page 143: ...ation that downloading is working OK is that the two LED s at the lower left corner Red Tx and Yellow Rx are flashing within one minute The computer will now process and adapt the five files for downloading onto the CPU board This will take a minute or so 8 When downloading is finished the PC screen will tell you that the software is OK 9 Switch off the machine s main power switch Remove the cable...

Page 144: ...C The program is called CMM G3000 and can be used for numbering the I O boards correctly amongst other things This program can be ordered from the supp lier Instructions 1 Order a copy of the program CMM G3000 if you do not have it already Programs can be supplied on diskette or via E mail 2 If you have not already installed it install the program CMM G3000 on your computer 3 Switch off the machin...

Page 145: ...e menu is shown 9 Click I O board address 10 Click I O board to be configured Press the button on I O board 1 A confirmation will be shown on the PC screen 11 Continue in this fashion for other new and unprogrammed I O boards if present 12 When ready disconnect the cable between the PC and the CPU board I O board Pushbutton for programming ...

Page 146: ...146 ...

Page 147: ...and a switch arm mounted on the outer frame plus a sensor mounted on the inner frame The sensor is U shaped and is secured by two screws If the inner frame and therefore the sensor mo ves beyond a certain limit the sensor will actua te the microswitch via the switch arm When this happens the extraction relay is switched out The PCU switches over to wash speed and water filling takes place After th...

Page 148: ... follows release the screws securing the sensor and move the sensor sideways release the screws holding the microswitch mounting plate and move the mounting plate up or down If the imbalance switch is being triggered repeatedly Unsuitable wash loads The imbalance switch is wrongly adjusted refer to section above The dampers are in poor condition see under heading Frame High water level not program...

Page 149: ...nd unlock the door lock S4a and S4b are both closed when the door is locked micro switch S3 that is closed when the door is closed an emergency opening arm that can be used to open the door lock in an emergen cy Door lock control A31 that is situated in the front control unit of the machine This card controls the door lock function and whether the drum is empty and not rotating It locks and unlock...

Page 150: ...t checks that there is no water in the drum and that the drum is at a standstill After that the door lock control unit locks the door lock by activating the solenoid to make the lock pin enter a slot in the lock plate When the lock pin is fully home in this slot swit ches S4A and S4B both close Only now when S3 S4A and S4B are all closed will the outputs on the I O boards which control the machine...

Page 151: ...an 0 4 Hz When the above conditions are met the card A31 outputs a positive pulse on output X96 to the door lock actuator which then locks the door The micro switches S4a and S4b in the actuator are closed when the door is locked These micro switches feed voltage to The output relays on I O card 1 The relays govern the machine s drain and water valves as well as heater switch on Interlock signal f...

Page 152: ...n 0 4 Hz When the above conditions are met the door lock controller outputs an negative pulse on output 96 to the door lock actuator which then unlocks the door Micro switches S4a and S4b now interrupt the actuator and the I O card 1 relays lose all voltage to prevent the motor from starting no interlock signal on motor controller input X302 The drain and water valves of the machine are now disabl...

Page 153: ...m is not rotating LEDs blinking No error The door is locked and there is water in the machine LED s blinking double time No error The drum is rotating LEDs Error state A B C Level guard B2 indicates water in drum when the door lock is open input X93 not closed Motor control indicates that motor is operating when door lock is open input X94 closed No signal from rotation sensor B3 frequency input X...

Page 154: ...a I O card 1 Lock door Prior to the door lock controller locking the door output X96 a check is made of any water left in the drum input X96 closed and whether the drum is not rotating input X94 open Input voltage Function 200 240 V DC Programme unit requests door locking 0 V Programme unit requests door opening Door lock control A31 X90 X91 1 2 1 2 200 240 V Voltage supply to A1 Level guard B2 Mo...

Page 155: ...hen door is locked The input signal from X94 is compared with the signal from the rotation sensor B3 input X95 If the motor is operating but the rotation sensor does not provide a signal error code is shown If the rotation sensor indicates motor operation when the motor is not operating error code is shown Input voltage Function 5 V DC Motor not operating input open 0 V Motor operating input close...

Page 156: ...or locking DC 0 V on input X93 no water in drum DC 5 V on input X94 motor not activated 0 4 Hz on input X95 drum not rotating No error code present Unlocks the door lock when the following condi tions are met DC 0 V on input X92 programme unit request door opening DC 0 V on input X93 no water in drum DC 5 V on input X94 motor not activated 0 4 Hz on input X95 drum not rotating No error code presen...

Page 157: ...ponents have a potential difference of approx 300 V in relation to protective earth and neutral When the red 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 ...

Page 158: ...d and is con trolled by microcomputer control The vari ous speeds for normal operation distribution speeds and extraction as well as acceleration retardation can be controlled with a high degree of precision The motor winding is protected against overlo ads using a thermal overheating protector that is automatically reset 6058 1 102358 OP W3850H W3400H W4400H W3600H ...

Page 159: ...144 2 X144 1 X144 1 X146 X145 X149 X147 X148 1 2 1 2 3 4 7 5 6 8 9 10 1 2 3 4 1 2 1 2 3 4 7 5 6 8 9 10 1 2 3 4 1 2 1 2 1 2 3 4 7 5 6 14 8 910111213 1 2 3 4 7 5 6 14 8 910111213 X142 2 X142 1 150 H O 2 S40 EL 100 X144 2 X144 1 X143 1 X143 2 K11 K36 X144 2 X144 2 X144 1 X144 1 X146 X145 X149 X147 X148 1 2 1 2 3 4 7 5 6 8 9 10 1 2 3 4 1 2 1 2 3 4 7 5 6 8 9 10 1 2 3 4 1 2 1 2 1 2 3 4 7 5 6 14 8 910111...

Page 160: ...communicates with the programme unit via a serial two way interface With the help of the motor control the programme unit can control not only the instantaneous motor rpm but also with high precision the acceleration and retardation of the motor in order to reach the target rpm The motor control continuously replies with information to the pro gramme unit PCB regarding the current operating state ...

Page 161: ...the weight of the loaded laundry and to detect any load imbalances A separate imbalance breaker can also be connected to the motor control The safety system of the machine includes double detection of the door lock Both the programme unit and motor control use different switches to detect proper door locking The motor cannot start unless both switches verify the door is locked ...

Page 162: ...10 mm 23 mm 23 mm F 20N 90N 75N 75N To check the belt tension or to reset it after repla cing components which affect the tension follow the instructions in the illustrations Checking the belt tension is important and should always be included in regular mainte nance and servicing routines 6058 5 102358 OP W3850H W3400H W4400H W3600H ...

Page 163: ...gised Hoses and the control valve are not blocked Check by undoing the supply line at the drain valve and then activating the control valve The rubber diaphragm is in good condition The piston is operating correctly The drain valve will not open Check that The piston is operating correctly The non return flow control valve is open At low air pressures the flow control valve opens more The drain va...

Page 164: ...164 ...

Page 165: ... for all compart ments in the detergent dispenser connected to cold water If the water pressure is low 1 bar the cleaning effect may be less satis factory For this reason where the pressure is low the water flushing times should be increased for best results Do not open the cover when the water valves are flushing water through the detergent dispenser Take care when adding laundry products Powder ...

Page 166: ...166 ...

Page 167: ...tilt both forwards and back wards Insert the two cylinder units from the side of the machine underneath the machine frame If there is vinyl floor covering on the floor To protect the floor from wear a sheet of stain less steel should be laid beneath each cylinder unit For machines with forward tilt only Insert the cylinder unit from the side of the machine underneath the rear section of the machin...

Page 168: ... two pneumatic position sensors on two of the machine feet at left hand front and right hand rear diagonally opposed The position sensors are to be fitted using the inner two fastening bolts of the feet mounted on the corner posts just installed Fit the four corner posts one for each corner of the machine using the bolts which secure the machine feet to the floor Adjust the clearance between the u...

Page 169: ...he table below These li nes do not need to be fastened to the frame but can be laid on the floor underneath the machine The air lines are marked as follows ID marking Connect to 1 Rear air bellows 2 Front air bellows 3 Rear pressure sensor connection 1 4 Rear pressure sensor connection 2 5 Front pressure sensor connection 1 6 Front pressure sensor connection 2 Note that the tubes for the pressure ...

Page 170: ...al equipment 9 9 6049 For machines with forward tilt only The compressed air line to be connected to the air bellows is supplied bundled on the machine rear Connect this line to the connection nipple on the top of the bellows ...

Page 171: ...he entire tilt movement If the switch is released the tilt movement will halt and the machine will stop in its position The bottom switch on the control unit rotates the drum either clockwise or anticlockwise Check that the machine cannot tilt in the opposite direction until it has returned to its normal position after an earlier tilt Check for any possible leaks from compres sed air lines or from...

Page 172: ...ion and fasten the side panel strips Fit the two counterweights to the front panel strip The bolt heads should be at the bottom Hang the front panel strip on the two sleeves you fitted to the side strips Protective plates are mounted on the front and rear Counterweights Sleeve ...

Page 173: ...adjusted automatically according to the actual weight of the load i e the water level is reduced during washing if the machine does not have a full load The consumption of water and energy can thus be reduced Safety rules The weighing equipment is a precision measur ing device and must be treated as such Never spray water directly onto the load cells and scale unit The load cells are vulnerable to...

Page 174: ...splay mode Normal display mode is resumed If a new program number is entered using the numeric keys If a is pressed Automatically after the time set via Settings 1 under Time for weight display While a wash program is running you can switch to weight display mode by selecting Show weight see the section Show weight under Machine operation The weight shown on the display will always be the net weig...

Page 175: ...pment does not show the real weight of this object you will need to follow the Zero calibration procedure a function in the Clarus softwa re Follow the instructions under Zero calibration in the Machine opera tion section of the manual If this is unsuccessful the weighing equipment will have to be recalibrated using the Calibrate the scale function as described under Machine operation If the weigh...

Page 176: ...lls are subjected before any load is pla ced in the wash drum The dead load selector is set before the machine leaves the factory and its setting should not normally be changed For this machine the selector should be set to 1000 1400 kg for W4400H 2100 2550 kg for W3850H W31100H and 1200 1600 kg for W3600H If calibration of the weighing equipment should fail one possible cause can be that this sel...

Page 177: ...e to remove risk of injury and machine damage Machines with tilt function Remove nut bolt A and remove the wheel Remove nut B Use a socket wrench to remove the bolt Disconnect the load cell cable at the scale unit and remove the strap Remove nuts and bolts C Remove the faulty load cell and fit the new assembly is reverse of dis assembly Install the new load cell as indicated by arrow on side of lo...

Page 178: ... its mounting plate Install the new scale unit assembly in reverse order of disassembly Check that the dead load selector is set to 1000 1400 kg for W4400H 2100 2550 kg for W3850H W31100H and 1200 1600 kg for W3600H Calibrate the weighing equipment see Calibrate the scale under Machine operation Connectors load cells Dead load selector Scale unit Connector power supply Connector CPU communication ...

Page 179: ...quipment Optional equipment 22 A90 B90 93 6050 22 X411 X410 X402 X401 X413 X412 A90 Scale unit B90 93 Load cells Connectors X401 Voltage feed X402 Communication with CPU board X410 413 Load cells Component locations ...

Page 180: ...t to 1000 1400 kg for W4400H 2100 2550 kg for W3850H W31100H and 1200 1600 kg for W3600H If it is not set it correctly and calibrate the weig hing equipment according to Calibrate the scale under Machine operation If the weight displayed is 999 9 try following the Zero calibration procedure described under Zero calibration in the Machine ope ration chapter Remove the side panels and check that the...

Page 181: ...the four screws on the scale unit cover Check that the four load cell cables are connected to the scale unit Measure the voltage at the connectors on the weight totalling board between terminal 2 and 3 for each load cell The normal value for an unladen machine is approx 3 5 mV DC A value different from this indicates that the load cell is faulty Replace the faulty load cell s as described under To...

Page 182: ...ing normally apart from the absence of weight parameter display try replacing the scale unit as described under To replace the scale unit If you suspect that the weighing equipment is not displaying accurate weight value Probable cause Probably a faulty load cell Fault finding procedure Place an object of known weight at one corner on top of the washer extractor Check the weight shown on the displ...

Page 183: ...calibrating the weighing equipment the calibration switch may be incorrectly set or an incorrect calibration weight may have been used for calibration Check that the calibration switch is set correctly It should normally be set to NORM During calibration the switch should be set to CAL The calibration weight should be between 40 and 400 kg If relevant necessary calibrate the weighing equipment or ...

Page 184: ...PU communication power supply and load cells are connected Check that these cables are all in good condition If any cable is faulty replace it Information in display in service program Weighing equipment not connected Probable cause CPU board not communicating with scale unit Fault finding procedure Check that the connectors for CPU communication power supply and load cells are connected on the sc...

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