Bosch WFMC3200UC Training Manual
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Bosch WFMC3200UC Training Manual

Bosch WFMC3200UC Training Manual

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WFMC Washer Training Program
WFMC Washer Training Program
WFMC WASHER TRAINING MANUAL
1st Edition/Revision 6 (2/2/04)

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Summary of Contents for Bosch WFMC3200UC

  • Page 1 WFMC Washer Training Program WFMC Washer Training Program WFMC WASHER TRAINING MANUAL 1st Edition/Revision 6 (2/2/04)
  • Page 2 WFMC Washer Training Program WFMC Washer Training Program • Features and Benefits • Features and Benefits • Product Description • Product Description • Warranty • Warranty • Installation • Installation • Operation • Operation • Disassembly • Disassembly • Reassembly •...
  • Page 3 Features and Benefits Features and Benefits • True American sized drum & tub • True American sized drum & tub • Full sized opening • Full sized opening (easier loading and unloading) (easier loading and unloading) • Tilted tub to facilitate door seal draining •...
  • Page 4 Extra Features and Benefits WFMC6400 Extra Features and Benefits WFMC6400 • Continuous cycle notification digital display • Continuous cycle notification digital display • Electronic control • Electronic control • Accurate water level control independent of water • Accurate water level control independent of water pressure pressure •...
  • Page 5 Product Description Product Description • Electronic controls • Electronic controls • Guaranteed temperatures • Guaranteed temperatures • Large capacity & door opening • Large capacity & door opening • UL listed (U.S. & Canada) • UL listed (U.S. & Canada) •...
  • Page 6 The warranties provided by BSH Home Appliances ("Bosch") in this Statement of Warranties apply only to Bosch clothes washers sold to the first using purchaser by Bosch or its authorized dealers, retailers or service centers in the United States or Canada.
  • Page 7 Warranty Warranty Serial # Label Serial # Label The serial # label, located on the front of the washer next to the door hinge, shows necessary warranty information. Serial # label Factory serial # - Can convert • Model # - “WFMC6400UC/01”. factory serial # to FD # for warranty use.
  • Page 8 Installation Installation Reprint of Installation Instructions (1) Reprint of Installation Instructions (1) NOTE: Be sure to follow all national & local codes. 1st Edition/Revision 6 (2/2/04)

  • Page 9: Installation Installation

    Installation Installation Reprint of Installation Instructions (2) Reprint of Installation Instructions (2) HINT: To quickly HINT: To avoid damaging washer, don’t move remove shipping it while the feet (leveling legs) are extended. (transport) bolts, 13mm socket wrench. 1st Edition/Revision 6 (2/2/04)

  • Page 10: Installation Installation

    Installation Installation Reprint of Installation Instructions (3) Reprint of Installation Instructions (3) Cold & hot water HINT: connections are clearly marked on the rear of the washers. HINT: To eliminate possibility of leaking, HINT: Be sure to remove the transport don’t overtighten fittings.
  • Page 11 Operation Operation Fascia Panels Fascia Panels WFMC3200UC WFMC6400UC 1st Edition/Revision 6 (2/2/04)

  • Page 12: Operation Operation

    Operation Operation Controls Controls WFMC3200UC Both have Regular/ Special Wash Cotton, Permanent Cycle Selector Press, Delicates, Hand Digital Buttons Knob Wash, Temperature Display Boost, Rinse Plus & Bleach settings. WFMC6400UC 1st Edition/Revision 6 (2/2/04)
  • Page 13 During the entire fill the washer continually adjusts for the size of the load and determines if more water is needed using an analog pressure switch and a flow meter. 2. Digital Temperature Sensor (WFMC3200UC & WFMC6400UC) The thermostat monitors the temperature of the water and controls the length of time the heating element is on, ensuring the proper temperature for the chosen cycle.
  • Page 14 Sensors (2) 1A/1B. Load & Dynamic Load Sensors Mechanical Pressure Switch - (WFMC3200UC & WFMC6400 UC) measures the water level after the first fill. If the water level is high (like for smaller loads), the pressure increases and the pressure switch does not provide more water.
  • Page 15 Operation Operation Sensors (3) Sensors (3) 1A/1B. Flow Meter Exact monitoring of water inflow. Ensures exact control of water inlet valves so that there is always the right amount of water for wash and rinse cycles. Together with the pressure switch, there is a continuous adjustment of wash time, water and energy in relation to the load size.
  • Page 16 Operation Operation Sensors (4) Sensors (4) 2. Digital Temperature Sensor Both models are equipped with an Electric Heater and Temperature Sensor (NTC) to deliver guaranteed wash temperatures. Compare with competition NOTE: washers which only have heaters in top of the line models. Heater Thermostat (NTC) 1st Edition/Revision 6 (2/2/04)
  • Page 17 Operation Operation Sensors (5) Sensors (5) 3A/3B. Suds & Continuous Suds Sensors Detection during draining out after main wash WFMC6400 immediate additional rinse & cancelling of 1st rinse spin Detection during 1st rinse spin WFMC6400 immediate interuption of spin insertion of one or two additional rinses WFMC3200 reduced agition during additional anti foam rinse Detection during any other rinse spin...
  • Page 18 Operation Operation Sensors (6) Sensors (6) 4. Unbalanced Load Sensor 2-step detection • Accurate measuring of unbalance by deviation of spin speed and slow down time of drum • Infinite adapting of spin speeds • Compensates reducing of spin speeds by prolonging spinning times •...
  • Page 19 Operation Operation Sensors (7) Sensors (7) 4. Unbalanced Load Sensor 2-step detection 1200 1000 max. 15 trials load distribution unbalance Spin speed (rpm) spinning profile good small 1200 (max.) After 4 attempts uneven medium 1000 (reduced) After 7 attempts 800 (low) After 14 attempts none dangerous...
  • Page 20 Operation Operation Cleaning Drain Pump Trap Cleaning Drain Pump Trap Unlike WFK, WFL & WFR washers, drain pumps are maintenance-free. So, larger objects such as coins and paper clips are no longer collected in the drain pump trap. The drain pump trap is only meant to be cleared by servicers.
  • Page 21 Operation – Operation – Preventing Water Collecting in Door Seals Preventing Water Collecting in Door Seals Unlike WFK, WFL & WFR washers, WFMC washers have tilted tubs and flow through tub paddles to help prevent water collecting in door seals and to enhance wash water flowing through clothes.
  • Page 22 Disassembly – Disassembly – Fascia (Control) Panel (1) Fascia (Control) Panel (1) T-20 screws To remove fascia panel to access control module & dispenser, remove (4) T-20 Torx front/side screws and lift panel up. Caps over screws can be removed using fingernails or a sharp knife –...
  • Page 23 Disassembly – Disassembly – Fascia (Control) Panel (2) Fascia (Control) Panel (2) Control modules can be readily removed from fascia panels, but there’s a knack to it – must use the procedure below exactly as shown. Start from left side Pry outer &...
  • Page 24 Disassembly – Disassembly – Top & Rear Panels (1) Top & Rear Panels (1) T-20 screws Removing top panel screws Removing top panel Top panel removed Rear panel removed To remove rear panel to access drive motor and rear of drum, remove (18) T-20 screws.

  • Page 25: Disassembly Drum/Front Panel

    Disassembly – Disassembly – Drum/Front Panel (1) Drum/Front Panel (1) Remove hinge cover screws Remove hinge screws Remove door seal spring Remove door latch screws Carefully remove front shield Removing front shield 1st Edition/Revision 6 (2/2/04)
  • Page 26 Disassembly – Disassembly – Drum/Front Panel (2) Drum/Front Panel (2) T-20 screws Front panel tab T-20 screws Remove top front panel screws Remove bottom front panel screws Note front panel mounting tabs Removing front panel at this point will make HINT: removing front counterweights easier.
  • Page 27 Disassembly – Disassembly – Drum/Front Panel (3) Drum/Front Panel (3) Remove door latch Door latch manual release Top counterweight must be removed 13mm screws Remove counterweight screws Slide out counterweight Note counterweight bushing slots in tub 1st Edition/Revision 6 (2/2/04)
  • Page 28 Disassembly – Disassembly – Drum/Front Panel (4) Drum/Front Panel (4) 13mm screws 13mm screws Remove front counterweight screws Removing counterweight screws Note counterweight screw bushings in tub Remove door seal Disconnect main water inlet hose Disconnecting main water inlet hose 1st Edition/Revision 6 (2/2/04)
  • Page 29 Disassembly – Disassembly – Drum/Front Panel (5) Drum/Front Panel (5) Disconnect dispenser hoses Disconnect water inlet valve hoses Disconnecting hot water valve hose Remove dispenser screws Remove dispenser Disconnect drain hose 1st Edition/Revision 6 (2/2/04)
  • Page 30 Disassembly – Disassembly – Drum/Front Panel (6) Drum/Front Panel (6) Disconnect sump hose clamp Disconnect sump hose Remove Remove drain pump Disconnect sump hose clamp sump NOTE: Old style drain pump shown (not used in production) 1st Edition/Revision 6 (2/2/04)
  • Page 31 Disassembly – Disassembly – Drum/Front Panel (7) Drum/Front Panel (7) NOTE: Old style dampers shown (not used production) Remove belt from tub Disconnect hoses Disconnect dampers Disconnect motor wires Remove drum drive motor Showing drum drive motor mounts 10mm bolts NOTE: Old style dampers shown (not used in production)
  • Page 32 Disassembly – Disassembly – Drum/Front Panel (8) Drum/Front Panel (8) 13mm bolt Remove pulley wheel Remove tub rear spring Remove tub washer Remove tub ground wire Tub ground wire & washer 1st Edition/Revision 6 (2/2/04)
  • Page 33 Disassembly – Disassembly – Drum/Front Panel (9) Drum/Front Panel (9) Remove Disconnect locking Disconnect heater heater wires NTC wires 10mm bolt Unscrew motor Disconnect motor Remove control screws control wire harnesses motor control 1st Edition/Revision 6 (2/2/04)
  • Page 34 Disassembly Disassembly Drum, Outer Drum (Tub) & Dampers (1) Drum, Outer Drum (Tub) & Dampers (1) Outer drum (tub) The tub consists of two durable Polinox plastic shells which are screwed to each other. To remove outer tub: Disconnect wire harnesses (as needed) – wire ties can be cut off, but clips shouldn’t be cut. Remove front panel, rear panel, fascia panel (with detergent dispenser) and top panel.
  • Page 35 Disassembly Disassembly Drum, Outer Drum (Tub) & Dampers (2) Drum, Outer Drum (Tub) & Dampers (2) Rear drum bearings are NOTE: factory press fit into rear outer tubs and cannot be removed or serviced. Bearing and drum shaft Lift drum out of tub Showing drum and tub parts 1st Edition/Revision 6 (2/2/04)
  • Page 36 Disassembly – Disassembly – Drum Drive Motor Drum Drive Motor To remove drum drive motors: • Remove rear panel • Remove rear tub spring Drum drive • Remove drum belt motor • Disconnect wire harnesses • Remove two motor bolts, then pull motor out 10mm bolts toward rear of washer Rear tub...
  • Page 37 Disassembly – Disassembly – Drain Pump Drain Pump To remove drain pumps: • Remove front panel • Loosen and remove hoses • Disconnect wire harness • Carefully slide pump toward rear of washer, then lift it out of washer (taking care to not damage the four rubber feet).
  • Page 38 Disassembly – Disassembly – Water Valves & RFI Filter Water Valves & RFI Filter Water valves HINT: are bent and snapped into place. When removing valves, take care not to break off plastic pieces. Hot water valve Water valves T-20 screws …and that’s all there is to taking Unscrew RFI filter...
  • Page 39 WFMC3200 Wiring Diagram WFMC3200 Wiring Diagram 10ºC (50ºF): 36 – 44kW 20ºC (68ºF): 22.8 – 27.4kW 30ºC (86ºF): 14.8 – 17.5kW 40ºC (104ºF): 9.8 – 11.5kW 50ºC (122ºF): 6.6 – 7.7kW 60ºC (140ºF): 4.6 – 5.3kW 66ºC (151ºF): 3.73 – 4.29kW 73ºC (163ºF): 2.94 –...
  • Page 40 WFMC6400 Wiring Diagram WFMC6400 Wiring Diagram 10ºC (50ºF): 36 – 44kW 20ºC (68ºF): 22.8 – 27.4kW 30ºC (86ºF): 14.8 – 17.5kW 40ºC (104ºF): 9.8 – 11.5kW 50ºC (122ºF): 6.6 – 7.7kW 60ºC (140ºF): 4.6 – 5.3kW 66ºC (151ºF): 3.73 – 4.29kW 73ºC (163ºF): 2.94 –...
  • Page 41 WFMC Service Tips WFMC Service Tips Ratings Ratings • Rated 120VAC, 15A, 60 Hz, 1350W (uses 11A max.). • Heater rated 1000W. • Hot & cold water inputs: 3/4” NPT, 14.5 – 145 psi, 2.2 gal. (8 l)/minute – 5.2 gal (19.8 l)/minute. •...
  • Page 42 WFMC Service Tips – WFMC Service Tips – Infrequently Asked Questions (1) Infrequently Asked Questions (1) • Length of power cord – 6’ (72”) • Net weight – 216 lbs. (98 kg.) • Drum capacity / volume – 3.1 ft (88 l) / 17.6 lbs.
  • Page 43 WFMC Service Tips – WFMC Service Tips – Infrequently Asked Questions (2) Infrequently Asked Questions (2) • Wash temperatures: 155ºF Sanitary, 150ºF Temp. boost, 120ºF – 125ºF Hot, 90ºF – 95ºF Warm, 60ºF – 70ºF Cold. • Door opening – 16” (41 cm) •...
  • Page 44 WFMC Service Tips WFMC Service Tips Drum Drive Motor Drum Drive Motor Unlike previous washers, drum Drum motor resistances: Motor control drive motors are controlled by separate motor controls mounted on the base near the motors (in the right rear of washers). These controls provide motor power &...
  • Page 45 WFMC Service Tips WFMC Service Tips Drain Pump Drain Pump Drain pumps reliably pump water out from washer NOTE: Drain pump motor resistance ranges from 140 – 200Ω. tubs through the drain reservoir and drain hose. Unlike earlier washers, these pumps maintenance free -- access to remove debris is only meant for servicers.
  • Page 46 WFMC Service Tips WFMC Service Tips NTC & Heater NTC & Heater 10ºC (50ºF): 36 – 44kW 20ºC (68ºF): 22.8 – 27.4kW 30ºC (86ºF): 14.8 – 17.5kW 40ºC (104ºF): 9.8 – 11.5kW 50ºC (122ºF): 6.6 – 7.7kW 60ºC (140ºF): 4.6 – 5.3kW 66ºC (151ºF): 3.73 –...
  • Page 47 WFMC Service Tips WFMC Service Tips Door Lock Door Lock To remove the access cover to use the door lock HINT: manual release, insert a pointed object (or tool) into the hole, push in to release the latch and rotate the cover clockwise. Door lock manual release HINT: Can remove fascia panel &...
  • Page 48 WFMC Service Tips WFMC Service Tips – Resetting Door Locks (1) – Resetting Door Locks (1) Occasionally door locks stay locked when doors are opened while they’re locked, preventing doors from closing. Please follow these instructions to reset door locks. Rear view Remove front seal spring...
  • Page 49 WFMC Service Tips WFMC Service Tips – Resetting Door Locks (2) – Resetting Door Locks (2) There are three ways to reset door locks (shown below) – each has advantages & disadvantages: Access past door seal (shown on previous page) – eliminates any chance of cosmetic damage, but requires reattaching door seal spring (which can be tricky).
  • Page 50 WFMC Service Tips WFMC Service Tips – Replacing Door Locks – Replacing Door Locks If door locks don’t hold properly, replace them (as shown below): Acceptable door locks – Those showing “1” on black housing and “1”, “2” or “3” on white carrier (see below).
  • Page 51 WFMC6400 Service Tips WFMC6400 Service Tips Water Flow Meter Water Flow Meter Flow sensor The flow sensor measures the volume of (cold) water flowing into the detergent dispenser. It consists of an impeller wheel with a magnet core and a Hall integrated circuit.
  • Page 52 WFMC6400 Service Tips WFMC6400 Service Tips Mechanical & Mechanical & Analog Pressure Switches Analog Pressure Switches The water level (pressure switch) system consists of a Mechanical Analog mechanical pressure switch and an analog pressure switch. Pressure Pressure Switch Switch Mechanical Pressure Switch The mechanical pressure switch (brown) has (3) switching positions: •...
  • Page 53 WFMC Service Tips WFMC Service Tips Polinox Outer Drum (Tub) Polinox Outer Drum (Tub) POLINOX TUB POLINOX TUB Lifecycle Test 4000 washes = 10 years Highest spin 300 consecutive times (wash-spin, wash-spin, etc. - have tested up to 900 wash-spin cycles) Heat Resistant Up to 130°C (266°F) Stability Dropped from a great height, won’t dent like Stainless Steel...
  • Page 54 WFMC3200 Service Tips WFMC3200 Service Tips – Control Module – Control Module Wire & Terminal Colors Wire & Terminal Colors IMPORTANT: possible to miswire the WH, YE & GN To drain terminals. Make sure pump To water the terminals are in valves right order...
  • Page 55 WFMC6400 Service Tips WFMC6400 Service Tips – Control Module – Control Module Wire & Terminal Colors Wire & Terminal Colors IMPORTANT: possible to miswire the WH, GY & GN To drain terminals. Make sure pump To water the terminals are in valves right order...

  • Page 56: Starting Test Program

    Turn washer, then close WFMC3200UC door. Entering & using WFMC3200 test programs: • To reset, rotate cycle selector knob to Off position. • To enter test program, push and hold Spin Selection and Delay Start buttons at the same time, then rotate cycle selector knob ccw to Permanent Press Cold position.
  • Page 57 WFMC Service Tips WFMC Service Tips Test Program (1B): Starting Test Program (1B): Starting WFMC6400 Test Program WFMC6400 Test Program The WFMC6400 washer test programs self-diagnose problems, including listing the last 8 fault codes from the control module & the last 16 fault codes from the motor control. The tests are easy to use, speeding up and simplifying diagnosing washer issues.
  • Page 58 WFMC Service Tips WFMC Service Tips Test Program (1C): Choosing Tests Test Program (1C): Choosing Tests Understanding WFMC3200 & WFMC6400 test programs: Generating fault codes: Most fault codes are generated by running specific tests. Viewing fault codes: Fault codes are viewed only by running test P1 (WFMC6400) / P:01 (WFMC3200), not during each test.
  • Page 59 WFMC Service Tips WFMC Service Tips Test Program (1D): Displaying Test Program (1D): Displaying Selected Tests Selected Tests Both washers have displays showing what test has been selected. Generates Test # Test WFMC32 Display WFMC64 Display Fault Codes Display fault codes P:01 P1:ERRORS Safety test (don't run)
  • Page 60 WFMC Service Tips WFMC Service Tips Test Program (1E): WFMC64 Text Test Program (1E): WFMC64 Text Displays Displays WFMC6400UC washers have full text displays showing which devices are running at each point during each test. They’re helpful for visually determining whether washers are properly filling, draining &...
  • Page 61 WFMC Service Tips WFMC Service Tips Test Program (2A): Fault Code Displays Test Program (2A): Fault Code Displays Viewing fault codes: • WFMC3200 display alternates between fault code (e.g. E:01) & when fault occurred on in last 8 washes (e.g. C:00) – shows C:00 if fault didn’t occur. •...

  • Page 62: Module Fault Codes

    WFMC Service Tips WFMC Service Tips Test Program (2B): Module Fault Test Program (2B): Module Fault Codes (Test 1) Codes (Test 1) Test P1:ERRORS / P:01 (Viewing control module fault codes) -- Start & end test P1 Last 8 fault codes are (WFMC6400) / (P:01) (WFMC3200) by pushing Start/Pause button.

  • Page 63: Motor Control Fault Codes

    WFMC Service Tips WFMC Service Tips Test Program (2C): Motor Control Test Program (2C): Motor Control Fault Codes (Test 1) Fault Codes (Test 1) Test P1:ERRORS / P:01 (Viewing motor control fault codes) -- Start & end test P1 by Last 16 fault codes are pushing Start/Pause button.
  • Page 64 WFMC Service Tips WFMC Service Tips Test Program (3): Tests 2 & 3 Test Program (3): Tests 2 & 3 Test P2:SAFETY / P:02 (Safety test program) -- Operation WFMC6400 Display Notes Skip this European test. The test ends on its own - stop it by pushing the Starts ccw Filling valve 1 only D M P H...
  • Page 65 WFMC Service Tips WFMC Service Tips Test Program (4): Tests 4 & 5 Test Program (4): Tests 4 & 5 Test P4:MOTOR / P:04 (Motor test program) -- Test P5:VARIANT / P:05 (Model coding) Test 4 turns on motor (wash & spin) and generates fault codes. Skip test 5.
  • Page 66 WFMC Service Tips WFMC Service Tips Test Program (5): Tests 6 & 7 Test Program (5): Tests 6 & 7 Test P6:DISPLAY / P:06 (Display test program) -- Test P7:SELECTOR / P:07 (Selector knob test Test 6 turns on all displays for a visual check. The test ends on program) -- Test 7 turns on the selector knob for a visual check.
  • Page 67 WFMC Service Tips WFMC Service Tips Test Program (6): Tests 8 & 9 Test Program (6): Tests 8 & 9 Test P8:NIVEAU1 (Analog pressure switch test Test P9:NIVEAU2 / P:09 (Mechanical pressure program) -- switch test program) -- The test turns on the analog pressure switch The test turns on the mechanical (WFMC6400 only) and generates fault codes.
  • Page 68 WFMC Service Tips WFMC Service Tips Test Program (7): Tests 11 Test Program (7): Tests 11 Test P11:FLOW (Flow meter test program) -- Test P13:VALVE1 / P:13 (Water inlet valves test test turns on the flow meter (WFMC6400 only) and generates fault program) -- The test turns on all 3 water inlet valves and codes.
  • Page 69 WFMC Service Tips WFMC Service Tips Test Program (8): Tests 14 Test Program (8): Tests 14 Test P14:BUZZER / P:14 (Buzzer test program) -- Test P16:HEATER / P:16 (Heater & NTC test Buzzer sounds when test is run. program) -- The test turns on the heater &...
  • Page 70 WFMC Service Tips WFMC Service Tips Troubleshooting (1) Troubleshooting (1) Symptom Problem Solution Washer won’t start. Electricity is disconnected Make sure washer is connected to an appropriate 120V, 60 Hz or has been turned off. circuit (according to local codes). Turn on electricity. Cycle selector knob or Control module has onboard cycle selector knob.
  • Page 71 WFMC Service Tips WFMC Service Tips Troubleshooting (2) Troubleshooting (2) Symptom Problem Solution Drum won’t rotate. Drum rear bearing Check how drum rotates. If drum wobbles or won’t move, has failed. replace outer tub (containing faulty rear bearings). Motor control has Check voltage at motor connectors when motor is energized.
  • Page 72 WFMC Service Tips WFMC Service Tips Troubleshooting (3) Troubleshooting (3) Symptom Problem Solution Washer overheats. Control module has Check voltage to heater. If voltage is present when heater failed. shouldn’t be on, replace faulty control module. NTC failed. Disconnect NTC and measure resistance at terminals (~ 22.8 – 27.4 kΩ...
  • Page 73 WFMC Service Tips WFMC Service Tips Troubleshooting of Minor Troubleshooting of Minor Faults 1 Faults 1 (Customer Self Help) (Customer Self Help) 1st Edition/Revision 6 (2/2/04)
  • Page 74 WFMC Service Tips WFMC Service Tips Troubleshooting of Minor Troubleshooting of Minor Faults 2 Faults 2 (Customer Self Help) (Customer Self Help) 1st Edition/Revision 6 (2/2/04)
  • Page 75 WFMC Service Tips WFMC Service Tips Customer Cleaning and Customer Cleaning and Maintenance Maintenance 1st Edition/Revision 6 (2/2/04)

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