Fisher & Paykel SMARTDRIVE Service Manual
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Fisher & Paykel SMARTDRIVE Service Manual

Fisher & Paykel SMARTDRIVE Service Manual

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Service Manual

SMARTDRIVE
Electronic Washer
421827

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Summary of Contents for Fisher & Paykel SMARTDRIVE

  • Page 1: Service Manual

    Service Manual SMARTDRIVE Electronic Washer 421827...
  • Page 2 421827 May 2011 The specifications and servicing procedures outlined in this manual are subject to change without notice. The latest version is indicated by the reprint date and replaces any earlier editions. - Fisher & Paykel Appliances Ltd Fisher & Paykel Customer Services Pty Fisher &...
  • Page 3 421827 FISHER & PAYKEL ELECTRONIC WASHING MACHINES Covering the following Models New Zealand Australia & New Zealand Rest of World Model Model Model MW613 92144 MW513 92145 WA55T56MW 94145 HK MW613 92112 MW513 92103 93177 94177 HK WA55T56G WA75T56GW WA55T56G 92109 WA70T60G 92146...

  • Page 4: Table Of Contents

    421827 CONTENTS HEALTH & SAFETY ........................6 SPECIFICATIONS ........................7 Dimensions ........................7 Maximum Capacity (Full Load) ..................7 Water Consumption .......................7 Water Fill Temperature (Approximate Factory Settings)..........7 Wash Motor........................7 Pump Motor ........................8 Water Valves........................8 Diverter Valve ........................8 Thermistor........................8 2.10 Cabinet........................... 8 2.11 Lid ..........................
  • Page 5 421827 DETAILED FAULT CODES....................43 Fault Descriptions ......................43 SERVICE PROCEDURES ..................... 54 Removal of Lid......................54 Components in Console Area..................54 Removal of Display Module QuickSmart, WashSmart, MW, GW & WA....54 Removal of Display Module FabricSmart IW ............... 55 Removal of Water Valves ....................

  • Page 6: Health & Safety

    421827 HEALTH & SAFETY When servicing the Designer series Range Hood, health & Safety issues must be considered at all times. Specific safety issues are listed below with the appropriate icon. Electrical Safety Ensure the mains power has been disconnected before servicing the washer.

  • Page 7: Specifications

    421827 SPECIFICATIONS Dimensions Compact Washer Medium Washer Large Washer Height to lid Open 1320mm – 1350 mm 1360mm – 1390 mm 1410mm – 1440mm Closed 950 mm – 980 mm 950 mm – 980 mm 950mm – 980mm Height to console 1010 mm –...

  • Page 8: Pump Motor

    421827 Pump Motor Part Number Voltage Frequency Resistance Type 420324P 230V AC 50Hz 33Ω +/- 8% @ 20 Selni 421820P 230V AC 50Hz 93Ω +/- 8% @ 20 Hanning Note: Thermal cut-out fitted Water Valves Supply Mode of Operation Voltage Resistance Flow Rate Cold...

  • Page 9: Inner Bowl

    These bumps are designed to improve wash performance by increasing load turnover and movement. Note: The inner bowl is backwardly compatible with all SmartDrive machines. Inner Bowl Weight Large 10.48kg +/- 275g Medium 8.37kg +/- 225g...

  • Page 10: Control Panel Fabricsmart- (Iw)

    2.23 Control Panel QuickSmart– (MW) 2.24 Important Screw / Bolt Torque Settings Below are the important screw torque settings for SmartDrive™ washers. These settings must be adhered to. For all other screws and bolts that are not listed, we recommended that they are tightened sufficiently without being over-tightened.

  • Page 11: Technical Overview

    421827 TECHNICAL OVERVIEW This Service Manual contains information on the Product Specifications, Diagnostic Mode, Detailed Fault Codes and the complete disassembly and assembly instructions for the washing machine. Electronics 3.1.1 Motor Control Module The Motor Control microprocessor performs a wide variety of tasks. Primarily it controls the electronic switching hardware to control the three phase currents in the Smart Drive DC motor.

  • Page 12: Stand By Mode

    421827 3.1.2 Display Module The Display Module provides the link between the washing machine electronics and the user. Input on wash type, water level, spin speed, start/stop and wash cycle time is given by the user via the display push buttons. IW Display Feedback on selection is given to the user by LCD liquid crystal displays or Light Emitting...

  • Page 13: Water Temperature Sensing

    421827 Water Temperature Sensing WashSmart, GW, WA & FabricSmart, IW Machines The thermistor for sensing water temperature is located in the back of the outlet elbow on the valve assembly, and is connected directly to the Motor Control Module. For details on the wash temperature adjustment Refer to the Use &...
  • Page 14 4. The Wash Progress lights show the temperature adjustment possible. When the first progress light is on, the machine will fill with cold tap water only. Press ADVANCE to select the second  light and the SmartDrive will control the temperature to approximately 20°C. Each following light equals approximately a 1°C temperature rise.

  • Page 15: Water Valves

    421827 3.4.4 Wash Temperature Adjustment (FabricSmart, IW Only) 1. Turn machine on at the wall and touch the POWER button. 2. Touch the Lifestyles/Options button noting that OPTIONS highlight, and then use the Scroll arrows to highlight Temperature. Touch the Select button to enter.

  • Page 16: Diverter Valve (Fabricsmart, Iw Only)

    421827 Diverter Valve (FabricSmart, IW Only) The Diverter Valve is situated at the bottom of the outer bowl beside the Pump. It consist of a wax solenoid which heats up and moves a flapper to close off the drain enabling the water to be diverted back into the inner bowl, with the pump running.

  • Page 17: Mw613

    421827 High GW712 (50mm) GW612 (50mm) MW612 (50mm) GW512 (60mm) MW512 (60mm) Medium High GW712 (114mm) GW612 (110mm) GW512 (115mm) Medium GW712 (177mm) GW612 (175mm) MW612 (175mm) GW512 (180mm) MW512 (180mm) Medium Low GW712 (251mm) GW612 (250mm) GW512 (255mm) GW712 (304mm) GW612 (305mm)

  • Page 18: Motor

    421827 Motor 3.8.1 Stator The stator used is not interchangeable with any previous phase or series of machine. This stator has 36 poles with the windings being Aluminium and is Identified by the printed marking AL 60 190T it looks the same as a copper Stator but is 19.5 per winding. Stator (36 Poles) Curved pole tips Testing the Stator...
  • Page 19 421827 Testing the Stator After removing the Stator, it can now be tested. Test points are: R (Red) / B (Blue) B (Blue) / Y (Yellow) Y (Yellow) / R (Red) The value should be approx. 39 +/- 10% Ω 39.0 across any of the two windings.

  • Page 20: Pumps

    421827 Pumps Blocked Pump Detection This is achieved by monitoring the water level during drain. If the water level has not dropped by approximately 3mm within a predetermined time period (approximately 9-10 minutes), then the product will report a pump fault. 3.9.1 Selni The pump is coupled directly to the outer bowl.

  • Page 21: Inner Bowl And Outer Bowl

    421827 When the lid lock is activated on the FabricSmart, IW machine the LCD screen will display a symbol of a padlock. If the lid is left open, the machine will be unable to lock the lid and the cycle will be halted. The machine will play a tune with the words “Please Close The Lid”...

  • Page 22: Agitator

    421827 3.11.1 Detection of Inner Bowl Float off Point – Bowl Check During fill the inner bowl will rotate to ensure that the clothes are evenly saturated with water. When the chosen water level is reached, and before the agitate cycle is started, the machine will carry out inner bowl float checks (bowl check).

  • Page 23: Lint Removal System

    421827 the surface of the water inwards and then push them downwards. The bottom fins then push the clothes towards the outside of the bowl again and back up to the surface. The agitator also features guides on the side to help the user choose the correct water level for each load size.

  • Page 24: Fabric Softener Dispensing

    421827 3.14 Fabric Softener Dispensing TYPE: It is recommended that softener sheets should be used in the dryer rather than using liquid softener in the washing machine. Liquid softener has been known to produce a waxy build-up inside washing machines, called Scrud. We do however; provide a fabric softener dispenser for those who prefer liquids.

  • Page 25: Size Setting Mode

    Motor Controller and or FabricSmart, IW Display Module is fitted to the machine. Failure to do this will result in the machine faulting with fault code 9. The size setting of the SmartDrive may be checked in the size setting mode. QuickSmart, WashSmart, MW, GW & WA Size setting Accessing size setting mode is the best way to check the set size of the machine.

  • Page 26: Fabricsmart Iw Size Setting

    421827 FabricSmart IW Size setting To set the size, turn the mains on at the supply point and off at the console. Press and hold the Lifestyles/Options and the Left Arrow button until the size setting screen is displayed. This will present the option of Medium or Large in the LCD screen.

  • Page 27: Water Valve Test

    421827 5.1.3 Water Valve Test The water valves can be activated in diagnostic mode by pushing WASH TEMPERATURE UP button to activate the Hot Valve and WASH TEMPERATURE DOWN button to activate the Cold valve. Pressing each button once will activate the valve. To de-activate the valve press the same button again.

  • Page 28: Fabricsmart, Iw (Intuitive)

    421827 2. Press the WATER LEVEL UP button so that the Medium water level LED is lit. 3. Press the POWER button to turn the display off (the 3 rightmost wash progress LEDs will be flashing). 4. Press the POWER button to turn the machine on. The machine can now be tested on any cycle.
  • Page 29 421827 5.2.1 Service Screen Upon entering the service screen, one of the following will appear in the LCD display.  Warning Status / Fault Status  Machine Status To scroll between these use either scroll arrow or . 5.2.2 Warning Status / Fault Status Screen Warning Status Fault Status This screen displays the last USER WARNING...
  • Page 30 421827 5.2.3 Machine Status Screen In the top half of the screen it displays the following information. Size is the size of machine, (650mm = Large) HVDC is for on line testing in the factory. WL displays the water level in mm. Temp is the actual temp of the water entering the bowl.

  • Page 31: Control Screen

    421827 5.2.4 Diverter Valve Test The recirculation valve can be activated while in diagnostics, machine status mode, by highlighting with the Scroll arrows DIVERTER option and turning it on with the Select button. The displayed state will change from “Off” to “Heating.” Then by highlighting with the Scroll arrows COLD option and turning the cold water valve “On”...
  • Page 32 421827 To identify that the RESTART feature has been activated, refer to the Restart / Recycle table. (Refer to Section 5.3.4) 5.3.3 Recycle Feature At the end of servicing, the machine may require an extended test where the machine can be left to complete a number of wash cycles.

  • Page 33: Data Download

    421827 Data Download To activate the data download, enter the diagnostic mode with the power on at the supply point press and hold the Lifestyles/Options and Select buttons. Keep the buttons pressed for at least 2 seconds, after which time two beeps will sound. Then press the Start/Pause button.

  • Page 34: User Warnings Quicksmart Washsmart Mw, Gw & Wa

    421827 5.5.1 Settings Adjustment Mode To access the settings menu  Touch the Lifestyles/Options button, OPTIONS will be highlighted, Scroll with the arrows or highlighting SETTINGS and select . The SETTINGS menu will then be displayed.  Scroll and select the option you wish to adjust. ...

  • Page 35: Out Of Balance

    421827 5.6.2 Cold Water Temperature LED Flashing (Insufficient Cold Water) Possible causes: 1. Check that the cold water is connected and that the tap is turned on. 2. Check that the flow rate is not too low. The product requires a minimum flow rate of 3 litres per minute.
  • Page 36 421827 5.6.7 Lid Lock LED Flashing This warning is generated if the electronics have detected that the lid has not been closed. 1. Check that the tang on the lid is not bent or broken. 2. If the lid is closed and the tang is ok, replace the lid-lock assembly. 5.6.8 Demonstration Mode (All LEDs flashing in patterns) This feature is designed for in store demonstration purposes.

  • Page 37: Diagnostic Table Quicksmart, Washsmart, Mw, Gw & Wa Models

    421827 Diagnostic Table QuickSmart, WashSmart, MW, GW & WA Models To use this table, firstly enter Diagnostic Mode (Refer to Section 5.1). The different levels of information can be extracted by using the Spin Speed up and down buttons. Diagnostic Spin Speed LEDs Diagnostic Info Displayed Level...
  • Page 38 421827 Diagnostic Mode 5: Cycle Count at Last Fault (Low Byte). Diagnostic Mode 6: Cycle Count at Last Fault (High Byte). The number of Wash Cycles since the last fault is displayed on the Wash Progress LEDs. The low byte refers to binary* numbers from 1 through to 128. The high byte refers to numbers from 256 though to 32768.

  • Page 39: Voltage Readings From The Controller

    421827 Voltage Readings from the Controller 1. Water Valves 6. Lid lock Varies between 13 – 22V DC Pulses up to 30V when locking, when Note: Accurate voltages can only be locked, sits at approx 10V DC obtained by using a True RMS multimeter. 2.

  • Page 40: Resistance Readings From The Controller

    479602 Resistance Readings from the Controller 1. Water Valves 4. Wash Motor (Stator) 64 Ω +/- 10% 39Ω across any two windings 2. Pump Motor Selni 33Ω 5. Lid Lock 63Ω +/- 10% @ 68 F / 20 Pump Motor Hanning 93Ω...

  • Page 41: Binary Decoding Chart - 8 Bits (0-255) Quicksmart, Washsmart, Mw, Gw & Wa

    421827 5.10 Binary Decoding Chart – 8 Bits (0-255) QuickSmart, WashSmart, MW, GW & WA 8 WASH PROGRESS LEDs short rinse spin wash 00000 00001 00010 00011 00100 00101 00110 00111 01000 01001 01010 01011 01100 01101 01110 01111 10000 10001 10010 10011...

  • Page 42: Wiring Diagram

    421827 WIRING DIAGRAM Resistance Table Water Valve 64Ω @ 20 Recirculating Valve Between 700Ω and 2.5KΩ Pump Selni 33Ω Hanning 93 Ω Lid Lock 63Ω +/- 10% @ 20 Thermistor 10KΩ @ 25 Stator 39Ω +/- 10%...

  • Page 43: Detailed Fault Codes

    421827 DETAILED FAULT CODES DETAILED FAULT CODES INTRODUCTION The format for fault description in this booklet follows the Primary, Secondary, Tertiary and Quaternary fault source system. These sources have mostly been arranged in order of most likely source of fault, but in some cases the sequence has been modified to aid the servicing procedure. It should be noted that the fault source Pump System includes the pump and drain hose assembly.
  • Page 44 421827 Action: 1. Check the connection of the thermistor to the Motor Control Module. 2. Check resistance of temperature sensor. Resistance should be 10k @ 77 F / 25 C or 12.5k @ 68 F / 20 Replace if faulty. 3.
  • Page 45 421827 (00100101) No change in the water level (Pump Blocked Error) While draining, the water level reading from the pressure sensor has not changed for over 3 minutes. There are three likely reasons for this fault. One is that the drain hose or the pressure switch hose has been squashed or kinked and the pump out rate has been dramatically reduced.
  • Page 46 421827 (00101000) Inner Bowl Disengage Fault While carrying out a bowl check, the Motor Control Module has found that the bowl is not engaged even though the pressure sensor indicates that the bowl is empty. The Motor Control Module continues to check for 2 minutes, after which time it displays this fault. The first two areas to check are the clutch and the pressure tube.
  • Page 47 421827 (00110001) Cold Valve or Cold Valve & Hot Valve Faulty The Motor Control Module has measured a voltage from the valve diagnostic circuit that indicates the cold valve or both the hot and cold valves are open circuit. The most likely cause is that the valve harness has not been connected correctly or the valve(s) is open circuit.
  • Page 48 421827 between 0.7kΩ and 2.5kΩ. Resistance will depend on ambient temperature and when the valve was last actuated. Anything outside of these resistances and the valve should be automatically replaced. (00111000) Inner Bowl Check Not Valid Fault While carrying out a bowl check, the machine has not been able to determine a valid bowl status and so the Display flags this fault.
  • Page 49 421827 (01000110) Pressure Transducer Error – Zero Too High Similar to fault code 69, however, it protects against a zero, which is too high and could cause flooding. Primary Source: Motor Control Module. Action: Replace Motor Control Module. (01001000) Pressure Transducer Error – Maximum Positive Drift Over the life of a product it is expected that the pressure transducer characteristics will drift slightly.
  • Page 50 421827 109. (01101101) AC Pump Triac Over Temperature This fault occurs when the electronics have detected that the temperature of the pump Triac has exceeded what would be expected under normal conditions. The most likely cause of this is that the pump has gone low in resistance. Primary Source: Pump Action:...
  • Page 51 421827 (10001001) Motor loss of a Phase The Motor Control Module has detected the loss of one of the phases of the motor. Possible causes of this fault are: Faulty motor harness, an open circuit winding of motor or faulty motor controller. Primary Source: Wiring Action:...
  • Page 52 421827 (11100000) Motor Control Module Fault The motor control has encountered a peripheral error Primary Fault: Motor Control Module. Action: Change Motor Control Module. (11100001) Motor Control Module Fault The motor control has encountered a clock error Primary Fault: Motor Control Module. Action: Change Motor Control Module.
  • Page 53 421827 Primary Fault: The sensor has failed either in the harness or the connection to the thermistor. Action: Replace the thermistor (temperature sensor). Secondary Source: Motor Control module has failed to read the temperature. Check connections. Action: Replace Motor Control Module if the connections look fine and the fault still occurs.

  • Page 54: Service Procedures

    421827 SERVICE PROCEDURES In order to service and to gain access to components within the machine, certain procedures must be followed. These procedures are set out below. Servicing note (a) To avoid stripping screws, do not over tighten when re-assembling parts. If using a power screwdriver, have the torque setting on low.

  • Page 55: Removal Of Display Module Fabricsmart Iw

    421827 Removal of Display Module FabricSmart IW Follow instructions for removal of console. (Refer to Section 8.2). Disconnect the wiring harness from the motor control module Remove the 4 screws securing the display module to the console Remove the display module from the housing by pivoting the display away from the console Reassembly:...

  • Page 56: Removal Of Thermistor

    421827 Removal of Thermistor (a) Follow the procedure for removal of Console. (Refer to Section8.2). (b) Disconnect the Display wiring harness from the Motor Control module & place console out of the way. (c) Disconnect thermistor-wiring harness to the Motor Control Module. (d) Slide body of thermistor out from the valve.

  • Page 57: Removal Of Cord Set

    421827 Removal of Cord Set (a) Follow the procedure for removal of water valves. (Refer to Section 8.5). (b) Disconnect the mains plug to the Motor Slide Control Module. (c) Slide the strain relief to the left and slide out. Reassembly: Refit in reverse manner.

  • Page 58: Removal Of Top Deck

    421827 8.11 Removal of Top Deck Follow the procedure for removal of console. (Refer to Section 8.2). Disconnect the Display wiring harness from the Motor Control module & place console out of the way. (c) Follow the procedure for removal of water valves.

  • Page 59: Removal Of Inner Bowl

    421827 8.14 Removal of Inner Bowl (a) Follow the procedure for removal of Neck Ring. (Refer to Section 8.12). (b) Follow the procedure for removal of Agitator. (Refer to Section 8.13). (c) Lift inner bowl upwards and clear of machine. Note: If the inner bowl is tight on the shaft pressure may need to be placed on the top of the shaft, while at the same time jiggling the inner bowl upwards.

  • Page 60: Removal Of Hanning Pump Hood

    421827 8.17 Removal of Hanning Pump Hood (c) Follow the procedure for removal of Inner Bowl. (Refer to Section 8.14). (d) Remove the bolt securing the pump Hood to the outer bowl. Reassembly: Refit in the reverse manner. Ensure that the gasket is not pinched between the pump hood and outer bowl.

  • Page 61: Removal Of Rotor

    421827 8.19 Removal of Rotor (a) Tilt the rear of the machine carefully against the wall ensuring that the machine is stable and locked in position; take necessary precautions not to damage the wall or the machine. (b) Using 16mm or 5/8” socket, loosen Rotor bolt.

  • Page 62: Removal Of Pump

    421827 8.21 Removal of Pump Note: Approximately 250mls of water remains in the pump sump after pump out and will spill when the pump is removed. Take care not to spill this water over electrical connections by using a towel or small container to catch the water 8.21.1 Selni (a) Tilt the rear of the machine carefully against...
  • Page 63 421827 8.21.2 Hanning (a) Tilt the rear of the machine carefully against the wall ensuring that the machine is stable and locked in position; take necessary precautions not to damage the wall or the machine. (b) Remove the wiring harness to the pump with the aid of a small slot screw driver.

  • Page 64: Specialised Service Procedures

    421827 SPECIALISED SERVICE PROCEDURES Blocked Pump Procedure Selni It is possible to clear a blockage/obstruction from the pump without having to drain the water from the machine or disturbing the pump. If however there are concerns over the condition of the water and there may be a risk of infection, i.e.

  • Page 65: Blocked Pump Procedure Hanning

    421827 Blocked Pump Procedure Hanning In the unlikely event that you encounter a blocked Hanning pump ensure that the bowl is empty before proceeding and check that the blockage is not associated with the pump cap. (a) Follow the procedure for removing the pump hood as per section 8.17 and check that there are no obstructions.

  • Page 66: Shaft & Bearing Replacement

    421827 Shaft & Bearing Replacement Procedures described in this section as well as section 9.4 can only be carried out by using the Bearing Removal Tool Kit, part number 502009. The contents of the kit are as follows: Bearing Removal Tool Kit 502009 Note: The extractor mandrel was designed for the older shaft with the external thread, however will work with the shaft on this machine with the internal thread.
  • Page 67 421827 WARNING: Make sure the Stator clamp plate is flat before reusing. If in doubt, replace. (c) Remove the outer bearing using the bearing removal tool. WARNING: Do not remove the bearings with a hammer and drift as serious damage to the bearing housing or outer bowl may result.

  • Page 68: Shaft & Bearing Assembly

    421827 Note: The outer bearing will be proud of the housing by approximately 3mm. Shaft & Bearing Assembly (a) The bearings must be inserted separately with the inner bearing fitted first and pulled down with the bearing tool onto the shoulder in the bearing housing. IMPORTANT: There must be no gap between the bearing outer race and the shoulder of the aluminium extrusion.
  • Page 69 421827 (c) Ease the shaft through the bearings from inside the outer bowl. Take care the shaft is fitted with the threaded retaining nut section facing downwards in the direction of the base. (d) Fit the shaft retention nut. Use the spline tool and spanner to tighten the shaft retention nut. (e) Invert the outer bowl.

  • Page 70: Wash Performance Information

    421827 WASH PERFORMANCE INFORMATION 10.1 Creasing Creasing can be caused by over loading the washer or the dryer. Permanent Press or Delicate cycles have been designed to minimise creasing as they use a lower spin speed. Do not leave wet clothes to sit in the washer or laundry basket.

  • Page 71: Operating Problems

    421827 OPERATING PROBLEMS 11.1 No Power If the machine appears dead, and there is no response from pressing the power button, then check the following.  Check the supply voltage and that the machine is plugged in and switched on. ...

  • Page 72: Continuous Or Slow Spinning

    421827  Check that the 2 balance rings in the inner bowl contain water. Check the bowl weight.  Check for noisy suspension rods.  If the inner bowl or agitator is noisy, check for obstructions. Check the spline drive is clean. If there is a grating sound, check the single stainless steel washer beneath the spline drive.
  • Page 73 421827 NOTES...

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