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Troubleshooting

53

13 Troubleshooting

13.1 General

The troubleshooting section is used to trace errors in the machine to a defective component or unit.

There is a memory in the CPU that will save the selected program for 10 minutes in the case
of power failure.

The machine will restart in pause mode if the power is turned on again within this time. For very
short power failure (less than 10 seconds) the machine will restart automatically.

Safety regulations

Troubleshooting may only be carried out by authorised personnel.

Take care during all work on the machine while the power is on.

Take care when measuring the motor control system since all components have a potential difference of
approximately 300V in relation to protective earth and neutral.The components will contain dangerous
voltages when the green LED on the motor control board is on. The motor control system will remain live for
30-60 seconds after cutting the power to the machine and the motor has stopped running.

Measurements

For information on measuring points, components and voltages, please refer to the electric
schematic supplied with the machine.

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Summary of Contents for W555H

Page 1: ...Service Manual Washer extractor W555H Type W 55 H 438 9038 40 EN Service manual in original language 2012 02 24 ...

Page 2: ......

Page 3: ...of reed switch 30 11 Control panel 31 11 1 Program unit 31 11 1 1 Description 31 11 1 2 Connections 32 11 1 3 Replacement of program unit 33 11 2 Control knob 37 11 2 1 Replacement of control knob 37 12 I O modules 40 12 1 General 40 12 2 Replacement of I O module 41 12 3 External connections to I O module type 2 45 12 4 Circuit diagram of function options for I O module type 2 46 12 4 1 External ...

Page 4: ... WASHER 57 DRUM MOTOR COMMON 61 DRUM MOTOR MCU 62 INTERNAL COM 67 INTERNAL COM I O 68 INTERNAL COM I O TYPE 6 70 EXTERNAL COM PAYMENT 71 EXTERNAL COM CMIS 72 14 Maintenance 73 14 1 Inspect the interior of the machine 73 The manufacturer reserves the right to make changes to design and component specifications ...

Page 5: ...physical or mental capacity or lack of experience and knowledge Such people must be instructed in the use of the machine by a person who has responsibility for their safety Minors must be supervised to ensure that they do not play with the machine DO NOT MODIFY THIS APPLIANCE All external equipment which is connected to the machine must be CE EMC approved and connected using an approved shielded c...

Page 6: ... 6 E I J B H 6 B H 7 K fig 6733A 1 Operating panel 2 Door opening 255 mm 3 Detergent container 4 Cold water 5 Hot water 6 Drain valve 7 Drain pump 8 Electrical connection A B C D E F G H mm 595 680 850 875 305 660 80 195 60 I J K mm 90 80 650 C Adjustable height 25 mm ...

Page 7: ...traction Marine model rpm 1300 G factor max 530 G factor max Marine model 425 Heating Electricity kW 4 4 Heating Hot water x Frequency of the dynamic force Hz 24 2 Floor load at max extraction kN 1 2 0 3 2 3 Connections Water valves DN BSP 20 3 4 Capacity at 300 kPa l min 17 Drain valve outer mm 50 Draining capacity l min 160 2 4 Sound levels Sound power level IEC 60704 2 4 Wash dB A 59 Extraction...

Page 8: ...g 7608 1 Door 2 Motor 3 Heating unit 4 Drum 5 Detergent container 6 Control panel with program unit 7 I O modules 8 Drain Drain pump After a repair has been made Whenever a repair has been made a function check must be performed before the machine can be used again ...

Page 9: ...wash and start a program Check that the drum rotates normally and that there are no unusual noises Check that there are no leaks in water supply drain connections Check that water passes through the detergent container Check that the door cannot be opened during a program Ready to use If all tests are OK the machine is now ready to be used If some of the tests failed or deficiencies or errors are ...

Page 10: ... 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 A micro switch that is closed when the door is closed An emergency opening button that can be used to open the door lock in an emergency fig 500236 Replacement of door lock Disconnect the power to the machine Demount the front panel fig 6215B ...

Page 11: ...ock 11 Demount the door Demount the trim panel Disconnect the door lock cables and demount the door lock fig 7578 Mount the new door lock and connect the cables Mount the trim panel Mount the door and the front panel ...

Page 12: ... can be opened by pressing the emergency opening button To access the emergency opening button remove the front panel The emergency opening button can be reached between the left side panel and the trim panel If not accessible remove also the trim panel fig 7577 ...

Page 13: ...the speed of the motor at any given point but also the acceleration or deceleration rate at which the motor is to achieve the speed required The motor control unit constantly feeds information on current status both normal status and on any abnormalities arising back to the program control unit board The motor control unit can also supply data on the different torque and effect of the motor at con...

Page 14: ...14 Motor and motor control 6 2 Replacement of motor Disconnect the power to the machine Demount the rear panel Disconnect the motor cable and unscrew the earth screw Remove the belt fig 7580 ...

Page 15: ...otor Start with the bolt to left and then the bolt to the right Fasten the belt Make sure the belt is in position Check the belt tension with a frequency meter or similar The frequency shall be 70 Hz 5 Adjust if necessary with the right screw in the slotted hole Connect the motor cable and refit the earth screw Mount the rear panel ...

Page 16: ...16 Heating 7 Heating 7 1 Replacement of heating element Disconnect the power to the machine Demount the rear panel Remove the belt A A fig 7579 Disconnect the connectors to the heating element fig 7583 ...

Page 17: ... release the flange Remove the heating element and insert the new heating element fig 7584 Push on the middle of the heating element to get the flange in position Fasten the bolt Use tightening torque 6 Nm Reconnect the connectors to the heating element use the electric schematic supplied with the machine ...

Page 18: ...o the machine Demount the top panel the front and back panels Demount the door Demount the trim panel Demount the door lock and the rotation guard Cut the cable ties and disconnect the level sensor motor cable and earth cable at the back of the machine fig 7572A ...

Page 19: ...fer to the spare parts list Demount the air hose and the hose from the detergent compartment on top of the drum Remove the belt Disconnect the connectors to the heating elements Loosen the bolt to the heating element and gently push on the middle of the heating element to release the flange Remove all heating elements fig 7591 ...

Page 20: ...20 Drum Disconnect the inlet hose and the vent hose from the drum Unscrew the screws to the side panels and lift of the cabinet to release the drum package fig 7573 ...

Page 21: ...Drum 21 Demount the counter weight by loosening the tension strap fig 7574 Loosen the tensioner holding the drum and remove the drum fig 7575 ...

Page 22: ...requency meter or similar The frequency shall be 70 Hz 5 Adjust if necessary Remount the cabinet Connect the inlet hose and the vent hose to the drum Remount the level sensor motor cable and earth cable at the back of the machine Remount the door lock and the rotation guard Fasten the cables with cable ties in the same position as before Remount the trim panel and the door Remount the top panel th...

Page 23: ...the back panel Remove the belt A and put the new belt in position Check the belt tension with a frequency meter or similar The frequency shall be 70 Hz 5 Adjust if necessary with the right screw in the slotted hole A fig 7579 Remount the back panel Connect the power to the machine ...

Page 24: ...t opens and lets water into the supply line 3 which is connected to the drain valve The water presses up a rubber membrane 4 and a plunger 5 with a pressure plate 6 which closes the valve s rubber membrane 7 When the control valve shuts off water pressure to the drain valve the springs 8 pull back the plunger The return water passes the control valve and runs out into the drain via the return hose...

Page 25: ...nipple for water supply A Remove the nut but leave the bolt B in place securing the drain valve to the right hand side of the saddle Remove the bolts C securing the drain valve on the left hand side of the saddle Pull down the left side of the drain valve a little and then lift the drain valve off from the right hand bolt Demount the drain valve from the hose D C D A B fig 2407 ...

Page 26: ...eft hand side of the saddle Tighten the bolt B Mount the hose for water supply A Mount the hose from the drum D on the drain valve The rubber edge on the hose shall be pulled down over the valve cover Check that the hose edge snaps into place over the lower edge of the cover Mount the trim panel the door and the front panel ...

Page 27: ...en the door to the drain pump and pull out the hose Remove the plug A to empty the drain into for example a baking plate or similar A fig 7388 Demount the hoses to the drain pump Demount the plastic plugs holding the pump in position and remove the drain pump fig 7498 21 Mount the new drain pump and fasten the plastic plugs Remount the hoses and make sure the connections are tight Refit the plug A...

Page 28: ...ater connections into the detergent container are fitted with dispersers which mix the detergent thoroughly with water and flush the compartments clean From the bottom of the detergent container the water is flushed down into the drum fig 500234 22 ...

Page 29: ...ent container Remove the detergent container from the machine and replace with the new one fig 7212B 23 10 2 Replacement of siphon Remove the detergent container from the machine and remove the siphon to be replaced Mount the new siphon A fig 7212C 24 ...

Page 30: ... to the machine Demount the top panel Disconnect the cable from the program unit Remove the reed switch by pulling it out a bit and down from its position Mount the new reed switch and make sure it is in position Connect the cable in the same position as before 1 2 fig 7605 25 ...

Page 31: ... microprocessor program memory serial interface to the motor control I O boards etc The program unit receives its power from a separate power supply unit fig 7582 26 The program unit receives information from the I O boards about inputs like temperature sensor level sensor door status and outputs like drum water valves drain and heat control ...

Page 32: ...ometer COIN Coin meter coin 1 coin 2 blocking EMERG INP 1 Input reed switch detergent box FREE INP 2 Free program key switch Input RS 232 Serial communication ENC Control knob pulses USB TYPE B Connection for software service download PIN CONNECTOR Panel sign connector LEVEL Level control DO Digital output OUTP Output DOOR IN Door lock P BUS Power bus TEMP Temp sensor IN fig W00284 27 ...

Page 33: ...anel Demount the control knob Insert a screwdriver in the upper hole fig 7491 28 Gently push the screwdriver inwards and turn the control knob counter clockwise until the screwdriver goes further in fig 7492 29 Continue turning a quarter of a turn until it is possible to remove the control knob fig 7493 30 ...

Page 34: ... lower hole and press gently Turn the cover ring counter clockwise until it is possible to remove the cover ring fig 7490 31 Demount the program unit Demount the cover to the CPU and disconnect the cables Loosen the screws holding the program unit onto the panel and demount the program unit fig 7606 32 ...

Page 35: ...the control knob unit on the program unit Fasten the screw Mount the program unit with the CPU part Mount the program unit on the control panel and make sure that the guide pins are in position Fasten the screws to the panel A fig 7511 34 Connect the cables and remount the cover to the CPU Mount the cover ring and the control knob Mount the cover ring and rotate it clockwise until it is in positio...

Page 36: ...device is pointing downwards Insert the screwdriver and press the locking device fig 7494 35 Mount the control knob on the inner knob Continue to press with the screwdriver and turn the control knob clockwise until it stops when it is in position fig 7495A 36 ...

Page 37: ...to the machine Insert a screwdriver in the upper hole fig 7491 37 Gently push the screwdriver inwards and turn the control knob counter clockwise until the screwdriver goes further in fig 7492 38 Continue turning a quarter of a turn until it is possible to remove the control knob fig 7493 39 ...

Page 38: ...ss gently Turn the cover ring counter clockwise until it is possible to remove the cover ring fig 7490 40 Mount the new cover ring and rotate it clockwise until it is in position Rotate the inner knob until the locking device is pointing downwards Insert the screwdriver and press the locking device fig 7494 41 ...

Page 39: ...Control panel 39 Mount the new control knob on the inner knob Continue to press with the screwdriver and turn the control knob clockwise until it stops when it is in position fig 7495A 42 ...

Page 40: ...t is working properly In case of a fault and on marine models the machine will use the previous system with tachometer signal from motor to detect out of balance I O module type 2 is installed as an option It controls the external functions like detergent dosing systems and inputs from payment and booking systems etc The functionality of I O module inputs and outputs is depending on the parameter ...

Page 41: ... If the machine has I O module type 2 it is located on I O module type 1 11 or 3 The illustration shows replacement of I O module type 1 Disconnect the power to the machine Demount the top panel fig 7609 44 Remove the electrical connections on the module Note the position of the connections Remove the module by pulling it out towards the front of the machine fig 7610 45 ...

Page 42: ... the electrical connections in the same way as before If both I O module type 1 11 or 3 and I O module type 2 is to be replaced it is recommended to fit the modules together before mounting in the machine 1 2 3 fig 7611 46 Remount the top panel Connect the power to the machine ...

Page 43: ...electrical connections on the module Note the position of the connections Loosen the screw a bit and remove the I O module by lifting it upwards fig 7607 47 Insert the new module and make sure it is in position Connect the electrical connections in the same way as before Fasten the screw and remount the cover Remount the top panel Connect the power to the machine ...

Page 44: ...t the front panel Demount the door Demount the trim panel Disconnect the cable and demount I O module type 6 fig 500266 48 Mount the new module and make sure it is in position Connect the cable Mount the trim panel the door and the front panel Connect the power to the machine ...

Page 45: ...l may be 5 24V DC AC or 100 240V AC At 5 24V the signal reference must be connected to 3 and at 100 240V to 4 Note Do not mix potentials on the inputs Connecting excessive voltage 24V to connection 3 may damage the I O modules 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 fig 6236 49 ...

Page 46: ...ions for I O module type 2 12 4 1 External coin meter Central payment 2A The signal received from external coin meters must be a pulse In order to program set prices the signal initiating the price programming procedure must be active high fig 6606A 50 ...

Page 47: ...t system must transmit a start pulse to the machine The start pulse can be either 230V or 24V In order to receive a feedback signal once the machine has started 230V or 24V must be connected to connection 19 The feedback signal on connection 18 remains active high during the entire program fig 6316A 51 ...

Page 48: ... once permission has been granted to start the machine The signal must remain active high until the machine starts A feedback signal will be present on connection 18 and remain active high whilst the machine door is closed but the program has not started The feedback signal is powered by 230V or 24V from connection 19 fig 6313A 52 ...

Page 49: ...with the coin program package By maintaining an active high signal on connection 5 Price red the price of the program can be reduced This function has a number of uses including providing reductions during a specific period of the day Whilst the signal remains active high the price of the program is reduced by the percentage entered in the price programming menu fig 6314A 53 ...

Page 50: ...ls and inputs for pause signals and empty signal 2E Heating pause By connecting a signal to connection 6 you can pause operation of the machine whilst it heats up The machine will pause for as long as the pause signal remains active high fig 6315A 54 ...

Page 51: ...6 RE106 RE105 RE104 RE103 RE102 Con 107 1 2 3 RE101 Inp Con 115 Function I O s PTD5 Type of I O card 5V Start permitted Central booking payment EBS PCB Camping 230V 0V 24V 24V Start permitted Central booking payment EBS PCB Camping Neutral Line Com 24V Com 100 240V Blocking of start Heating pause Liq det empty Temporary pause Common outputs Power for outputs Common Liquid det sign 1 Liquid det sig...

Page 52: ... of uses including providing reductions during a specific period of the day Whilst the signal remains active high the price of the wash program is reduced by the percentage entered in the price programming menu 1 P U M P D R A IN 1 H O T 1 C O L D 1 CPU 2 3 1 2 3 4 1 2 3 4 D R A IN P BUS P BUS 1 2 3 3 In p u t P ric e re d u c tio n 1 C o m 5 2 4 V A C D C 2 C o m 1 0 0 2 4 0 V A C fig 6636 56 ...

Page 53: ...oubleshooting may only be carried out by authorised personnel Take care during all work on the machine while the power is on Take care when measuring the motor control system since all components have a potential difference of approximately 300V in relation to protective earth and neutral The components will contain dangerous voltages when the green LED on the motor control board is on The motor c...

Page 54: ...ollowed by a description of each error code Error code Text Major Minor 11 REAL TIME CLOCK OUT OF ORDER MAIN COMMON 10 13 INITIALIZING FAILED Error code Text Major Minor 1 NO WATER 2 DOOR OPEN 3 DOOR LOCK FAIL 4 WATER LOW TEMP 5 WATER HIGH TEMP 6 WATER IN MACHINE 8 NO HEATING 9 DRUM OVERFILLED 10 DRUM NOT DRAINED 16 TIMEOUT HEATING 17 DOOR LOCK 27 LEVEL OFFSET 28 WATER LEVEL HIGH DLCU LEVEL LOW MA...

Page 55: ...ext Major Minor 1 I O BOARD MISHMASH 20 I O INTERLOCK INTERNAL COM 40 21 I O COMMUNICATION Error code Text Major Minor 1 CHARGE CIRCUIT 2 SET SIGNAL NO TACHO INTERNAL COM I O 41 3 ACTUATOR CIRCUIT Error code Text Major Minor 1 INTERNAL ERROR 2 POSITION TEST INTERNAL COM I O TYPE 6 42 3 EXTRACT TEST Error code Text Major Minor EXTERNAL COM PAYMENT 51 22 NO CBT COMMUNICATION Error code Text Major Mi...

Page 56: ...mmunication with the internal real time clock in the CPU or if the data sent to from the real time clock is incorrect The error can only be removed by turning of the power to the machine for 30 seconds 10 13 INITIALIZATION FAILED The CPU has an internal time limit for initialization of the system The error code is activated if 15 seconds has expired during start up and the hardware still is not in...

Page 57: ...doesn t lock within a certain time after program start this error code will be displayed This error code will also be displayed if the door switch for locked door signals that the door has been unlocked during an on going program This can be caused by for example a bad or defective door lock loose cable to door lock problem with door lock edge connection 11 4 WATER LOW TEMP This error code is disp...

Page 58: ...is 90 scale units 11 9 DRUM OVERFILLED This error code will be displayed if the drum has been filled with water above a pre determined level during an on going program This error code can be caused by for example 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 an...

Page 59: ...ot blocked and does not contain any water Check in the service program that the level control is working correctly 11 28 WATER LEVEL HIGH DLCU LEVEL LOW The DLCU on I O type 10 contains a mechanical level guard which ensures that there is no water in the machine when the lock opens To ensure that the level guard functions correctly the mechanical level guard is compared with a nominal value genera...

Page 60: ...ter level in the drum must be below the nominal value measured by the electronic level control Cause The level control can be damaged Cross talk in the level control electrical system Leakage in the level controls air hoses Incorrect nominal value possibly caused by a error in the electronic level control Action Check the level control function Switch on level 40 mm switch off level 15 mm Wg Check...

Page 61: ...rt up Action Check that there is power reaching the MCU Check the fuses in the Protection Cable If one of the components in the Protection Cable is damaged the cable must be replaced Check that the indicator LED on the MCU is on The LED can be seen by looking down by the MCU edge connections Check that the communication cable between the CPU board and the MCU is intact and not damaged Measure also...

Page 62: ...s in the motor winding The actuation of the transistors is a measure of the voltage applied to the winding and the resistance can be calculated using the current and voltage values The resistance can then be converted to a temperature since the winding resistance at 20 C and the temperature coefficient are known If the average value of the four latest temperature readings is higher than the maximu...

Page 63: ... 1 in the second byte under Motor Status in the service program the bits are numbered from 0 to 7 where bit 0 is on the far right If bit 1 in the second byte is 1 then the lock is open while a 0 indicates that the lock is closed Replace the defective part 21 5 MOTOR SHORT CIRCIUT This error code is generated by the MCU The MCU reads the power consumption of the motor continuously If the current fo...

Page 64: ...ode being activated can be attributed to an error in the interlock circuits in motor control Action Replace MCU 21 7 LOW DC VOLTAGE This error code is generated by the MCU The MCU constantly measures the voltage over the mains input If the voltage is too low falls below a certain limit the MCU will shut off the current to the motor Once the motor has stopped the tacho sensor indicates that the mot...

Page 65: ... RPM number of short tacho interruptions during wash rpm TACHO CUT OUT HIGH RPM number of short tacho interruptions during extraction rpm Action Check the tacho cables if there are many registrations in the TACHO CUT OUT registers 21 15 MOTOR NOT FOLLOW This error code is generated by the MCU The MCU must always receive information on the rotation of the motor from the tacho sensor in order to rot...

Page 66: ...nit has read from the MCU 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 ...

Page 67: ...0 21 I O COMMUNICATION The error code is activated if the CPU no longer communicate with one or more I O boards There is an internal data bus between the different I O boards in the machine with information about inputs outputs etc that the CPU use to control the machine The error code is activated if the CPU has lost communication with one or more I O boards The error will also be activated if th...

Page 68: ...gital bit value is present an error message will be generated to CPU The error message is filtered in such a way that the digital bit value should have been on for 2 seconds if this is the case a check is made that the pulses from the tacho sensor are present when the digital bit value ceases Internally the DLCU will automatically clear an error if it disappears during program run CPU reads the er...

Page 69: ...Troubleshooting 69 Action If the error returns after a reset and is not caused by a error in the hatch lock or the cables for the hatch lock change the I O board 10 ...

Page 70: ...INTERNAL ERROR Reading of A D values out of range 42 2 POSITION TEST Position value out of range Check that I O module type 6 is still in correct position 42 3 EXTRACT TEST I O module type 6 is not able to read any or too low values during extraction ...

Page 71: ...ial communication to machine Serial communication with payment system interrupted Check network cable between machine and payment system Check that payment system is operational To reset machine to working state without repairing payment system use Reset CBT communication in service mode Requires password ...

Page 72: ... ERROR Communication between machine and network computer has been interrupted Check network cable between machine and network Check that CMIS on network computer is operational The machine can be operated but statistics could be affected and data could be lost ...

Page 73: ...k that water does not leak onto the floor Inspect the belt Adjust the tension or replace if necessary 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 Never switch on the heating elements when...

Page 74: ...lastpage Electrolux Laundry Systems Sweden AB 341 80 Ljungby Sweden www electrolux com laundrysystems Share more of our thinking at www electrolux com ...

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