Electrolux W455 H Service Manual
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Electrolux W455 H Service Manual

Electrolux W455 H Service Manual

Quick wash compass control
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Service Manual

W455 H, Quick Wash
Compass Control
438 9226-51
06.18

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Summary of Contents for Electrolux W455 H

  • Page 1: Service Manual

    Service Manual W455 H, Quick Wash Compass Control 438 9226-51 06.18...

  • Page 3: Table Of Contents

    Contents Safety regulations..................5 Techical data ....................7 Machine presentation................... 9 Description....................9 Function....................10 Periodic maintenance................. 17 Daily....................... 17 Every three month ................. 17 Troubleshooting ..................19 General information on troubleshooting..........19 Description of fault and causes ............. 23 Program unit....................

  • Page 5: Safety Regulations

    Safety regulations Safety regulations • The machine is intended for washing with water only. • Do not allow children to use the machine. • Installation and service must be carried out by authorised personnel. • The machine’s door lock must under no circumstances be bypassed. •...

  • Page 7: Techical Data

    Technical data Technical data Physical properties Drum volume diameter depth Capacity dry weight fill factor 1:10 fill factor 1:13 Drum rpm washing washing, mild and wool programmes extraction 1300 G-factor washing extraction Dimensions width depth height 850/875 Free service space, recommended side rear...
  • Page 8 Technical data Connections Max floor load when spin drying 1.2±0.3 Frequency (dynamic load) 1.2±0.3 Water valves connection DN20 BSP3/4 rec. water pressure 200-500 pressure limits 40-1000 Drain valve outer connection diameter capacity l/min 438 9047-21/01...

  • Page 9: Machine Presentation

    Machine presentation Description General Information Fig. The machine has an electronic program unit with fixed wash programs that can be changed with options. The program unit also has an integrated troubleshooting program for extended possibility of rational service. The motor is frequency controlled through an advanced motor control unit.

  • Page 10: Function

    Machine presentation Function General Information The machine is freely suspended, which means the outer drum and motor Fig. are mounted on a supporting ”cradle” that rests on four shock absorbers for dampening the imbalance in the machine. The washer drum (inner drum) is belt driven by a motor. This motor is located at the bottom of the machine and is mounted on the cradle with a belt tensioner.
  • Page 11 Machine presentation Program unit The control panel contains a program knob and a Fig. Program unit display. The panel can also be equipped with two preset buttons. The control panel and display are used by: • the user to select the machine’s fixed wash programs, to select up to two options for each wash program and for information on the wash process and any fault indicators.
  • Page 12 Machine presentation Motor and motor control The washer drum (inner drum) is belt driven by a Fig. frequency controlled motor. The motor is located on a motor shelf under the outer drum and has been arranged with a belt tensioner. Motor control is microprocessor controlled and Fig.
  • Page 13 Machine presentation Door lock The door lock is electromechanical with twin Fig. safety breakers. The lock is bi-stable, i.e. the lock must be given an active signal from the program unit to lock as well as unlock the door. A separate circuit integrated in the program unit Fig.

  • Page 14: Water Connections

    Machine presentation Heating Fig. Electric heating heats the washing water with two elements accessible from the rear of the machine. The machine’s heating system is described more thoroughly in the section Heating. Water connections Fig. The machine can have one, two, three or four water inlet valves depending on the machine size and customer requirements.

  • Page 15: Detergent Drawer

    Machine presentation Detergent Drawer The drawer has four compartments for prewash, Fig. main wash, rinse and bleaching agent/liquid detergent. The machine’s detergent drawer is described more thoroughly in the section Detergent drawer. Drain valve Fig. The valve is a diaphragm valve that is opened and closed through water pressure.

  • Page 17: Periodic Maintenance

    Periodic maintenance The following maintenance procedures should be followed to ensure good and safe operation and to prevent functional disturbances. The time for maintenance should be adapted to the degree of usage of the machine. Daily • Check door and door lock: - Leave the door open and try to start the machine.
  • Page 18 Periodic maintenance - Check that none of the inner hose connections are leaking. - Check the drive belt and tighten or replace as appropriate (see section on Motor). - Make sure water has not leaked onto the floor. - If the warm-up time has been abnormally long, check the heater element (see section of Heating).

  • Page 19: Troubleshooting

    Troubleshooting General information on troubleshooting The troubleshooting section is used to trace faults in the machine to a defective component or unit. There is a memory in the program unit that will save the selected program for approx. 3-5 minutes in the case of power cuts. The machine will restart automatically if the power is turned on again within this time.
  • Page 20 Troubleshooting Faults with fault code Illustration A fault in the program or in the machine is indicated on the display by an error message comprising an error code and a descriptive text. Fault code FAULT NO WATER 6204 Fault code The following is a brief description of all fault codes.
  • Page 21 Troubleshooting Fault code Text message Program fault No motor comm. Level adjust. Emergency stop Door lock MIS/CMIS approval Master comm. I/O Interlock I/O Communication No I/O address. Checksum from DLCU Level offset CPU/DLCU low level Cool flange high temp Motor too hot No interlock Short in motor Interlock hardware...

  • Page 22: Engaging Servicemode

    Troubleshooting General This programming manual is intended for per- sonnel with the authority to adjust parameters in the machine’s existing wash programs, programming slot meters, reading statistics and configuring certain machine interfaces with the user. Programming is achieved using menus in the display while the machine is in service mode.

  • Page 23: Description Of Fault Codes And Causes

    Troubleshooting Description of fault codes and causes Fault code 01, NO WATER This fault code is generated by the programming CPU card. When filling with water, the level specified by the wash program must be attained within a certain time. This time is normally set to 10 minutes but can vary depending on the type of machine and the software.
  • Page 24 Troubleshooting Fault code 04, NTC LOW TEMP This fault code is generated by the programming CPU card. This fault code is displayed if the temperature around the NTC sensor is below approx. -9 degrees C. A low temperature means the resistance in the sensor is too high, above approx.
  • Page 25 Troubleshooting Action: • Check drain for dirt. • Blow through the level hose and check that it is not blocked and does not contain any water. • Check in the service program that the level control is working correctly. Fault code 07, DRUM OVERFULL This fault code is generated by the programming CPU board.
  • Page 26 Troubleshooting Fault code 09, KLIXON This fault code is generated by the programming CPU board. The fault code means that the temperature in the motor has been so high that the klixon breaker in the motor has been triggered. It can be caused by overloading the motor due to an overloaded drum, low rpm for long periods, defective klixon breaker in motor, short in cable between motor and CPU board, etc.
  • Page 27 Troubleshooting Fault code 12, PROGRAMME ERROR This fault code is generated by the programming CPU board. This fault code means that one of the CPU board memories can be defective. Action: • Try reloading the software into the machine memory. If this does not help, the CPU board will have to be replaced.
  • Page 28 Troubleshooting Fault code 15, EMERGENCY STOP This fault code is generated by the programming CPU board. The fault code arises if the emergency stop switch has been activated on the machine. The cause can be inadvertent activation of the emergency stop, defective emergency stop switch, incorrect or shorted cable, etc.
  • Page 29 Troubleshooting Fault code 20, I/O INTERLOCK This fault code is generated by the programming CPU board. The program controller has read from the motor control or I/O board that the interlock is not active. The reason for interlock failure can be a problem with the hatch lock, damaged motor supply cables or the I/O board with interlock voltage etc.
  • Page 30 Troubleshooting Fault code 23, NO I/O ADDRESS. The fault code means that there is no I/O board addressed in the system at all. Action: • (Requires password) Readdress the existing I/O board from the service menu. Fault code 24, CHECKSUM FROM DLCU This fault code is generated by the programming CPU board.
  • Page 31 Troubleshooting Fault code 28, CPU/DLCU LOW LEVEL The DLCU contains a mechanical level monitor which ensures that there is no water in the machine when the lock opens. To ensure that the level monitor functions correctly, the mechanical level monitor is compared with a nominal value generated by the CPU, which is compared with the electronic level check.
  • Page 32 Troubleshooting The cause of high cooling flange temperature can be e.g. a stiff drum in combination with intensive use and high ambient temperature. There may also be a fault in the motor (sticking bearings or short circuit in windings, which impairs the efficiency of the motor). There may also be a fault in the motor control temperature measuring circuits.
  • Page 33 Troubleshooting Actions: • Make sure the drum turns easily. • Check the value on the fault code counter for fault code 32. • Check the last 8 motor control fault codes. • Measure the three phases to the phase resistors on the motor control motor connector (disconnect motor control and take the reading in the cable connector) to make sure they are the same.
  • Page 34 Troubleshooting Fault code 35, SHORT CIRCUIT MOTOR This fault code is generated by the motor control. The motor control reads the power consumption of the motor continuously. If the current for some reason gets too high (= exceeds a certain limit), the motor control will cut the current to the motor.
  • Page 35 Troubleshooting Fault code 36, INTERLOCK HARDWARE This fault code is generated by the motor control. The motor control must be powered with 230V/50 Hz on the interlock input in order to drive the motor. The interlock circuits in the motor control have been split into two channels so that a component fault in motor control cannot give a false confirmation that the door is locked.
  • Page 36 Troubleshooting Undervoltages can be registered even during normal operation. Consequently, a small number of registrations need not mean that there is a fault in the motor control. Measure: • Check that the supply voltage is stable and never drops below nominal voltage - 10%.
  • Page 37 Troubleshooting Fault code 45, MOTOR NOT FOLLOWING This fault code is generated by the motor control. The motor control must always receive information on the rotation of the motor from the tacho sensor in order to rotate. If the tacho sensor is not working, the motor can rotate for max.
  • Page 38 Troubleshooting Reason: Strong interference from surrounding equipment etc. can cause fault codes. Action: Re-set the fault codes. If the fault codes can not be re-generated or if they return, rectify the adjacent equipment that causes the interference. If this does not help, try changing the CPU board, since the interference sensitivity of different CPU boards can vary to some extent.
  • Page 39 Troubleshooting Reason: • The level controller can be damaged: • Open circuit in the cables for the level controller. • Blocked air hoses in the level controller system. Action: • Check the level controller function. (Switch-on level = 40 mm, switch-off level = 15 mm Wg) •...
  • Page 40 Troubleshooting Fault code 56, SHOULD ROTATE LOCK OPEN DLCU counts the tacho pulses from the motor in order to guarantee that the drum is stationary when the door is opened. To ensure that the signal from the tacho generator is working correctly, DLCU compares the tacho signal to a default value from the CPU processor, which is due to the CPU having activated the motor.

  • Page 41: Program Unit

    Troubleshooting 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 default value ceases. The DLCU processor will reset itself when the fault has disappeared. CPU reads the fault message when the program finishes and generates a fault code, the fault message is ignored between these two occasions.
  • Page 42 Troubleshooting 438 9047-81/02...
  • Page 43 Program unit Description General Information Fig. The program unit is electronic and comprises a circuit board containing microprocessor, program memory, current regulating circuits, temperature and level control, etc. Fig. The program unit receives its power from a separate voltage unit. The program unit receives information from the temperature sensor, door lock and level switches.
  • Page 44 Program unit Inputs and outputs Fig. The program unit board has the following inputs and outputs: Board connector Function Con 1 Input from temperature sensor Con 2 D-bus Con 3 D-bus Con 4 Tacho Con 5 M-com, Motor control unit Con 6 P-load Con 7...

  • Page 45: Menu Tree

    Program unit Menu tree The machine software is constructed with menus that are structured according to the menu tree below. The menus become available when the machine is in service mode, see under the heading ”Engaging service mode”. SERVICE CONFIG 1 PAUSE PERMITTED ACTIVATE OUTPUTS RAPID ADVANCE...

  • Page 46: Engaging Servicemode

    Program unit Engaging servicemode Service mode is engaged by using one of the following alternative: Alt. 1 Service switch on the CPU board under the top cover on the front of the machine. Alt. 2 Service switch on the I/O board at the rear of the machine to the right of the electrical connection.

  • Page 47: Service Program

    Program unit Service program The service program is used to facilitate troubleshooting the machine. Using this program MAIN MENU 01.00.00.00 you can: SERVICE PARAMETER PROGR. • control the machine functions individually STATISTICS CONFIG 1 • check the sensor signals to the CPU CONFIG 2 ADJUST DISPLAY •...
  • Page 48 Program unit ACTIVATE OUTPUTS Select the ACTIVATE OUTPUTS row and press Fig. the knob. *SERVICE* 01.01.00.00 The display now shows the functions (outputs) ACTIVATE OUTPUTS that can be activated. SHOW INPUTS ARTICLE NUMBER • DOOR SHOW DLCU COM. • NORMAL DRAIN RESET DLCU •...
  • Page 49 Program unit SHOW INPUTS Fig. Select the SHOW INPUTS row and press the knob. The display now shows the sensor signals *SERVICE* Fig. (inputs) that can be activated. 01.02.00.00 ACTIVATE OUTPUTS • COUNT 1 SHOW INPUTS • DOOR LOCK ARTICLE NUMBER •...
  • Page 50 Program unit ARTICLE NUMBER Fig. Select the ARTICLE NUMBER row and press the knob. You can now choose on the display to show *SERVICE* 01.03.00.00 the article numbers for the program units, I/O Fig. SHOW INPUTS boards, motor control or DLCU fitted in the ARTICLE NUMBER SHOW DLCU COM.
  • Page 51 Program unit SHOW MCU COM. Fig. Select the SHOW MCU COM. row and press the knob. *SERVICE* 01.06.00.00 Fig. The display shows the status of the RESET DLCU communication to and from the frequency control. SHOW MCU COM. RESET MCU SHOW SINGLE SHOW COM.PORTS RESET MCU...
  • Page 52 Program unit WEIGHT CALIBRATION Select the WEIGHT CALIBRATION row and Fig. press the knob. *SERVICE* 01.10.00.00 • Operate the machine with an empty drum. SHOW COM.PORTAR WEIGHT CALIBRATION • After weight calibration, the weight deviation MEASURE WEIGHT MEASURE UNBALANCE will be shown in a hexadecimal format on the DISPLAY TEST bottom line of the display.
  • Page 53 Program unit MEASURE UNBALANCE Select the MEASURE UNBALANCE row and Fig. press the knob. *SERVICE* 01.12.00.00 Fig. Confirm that measurement is to be performed MEASURE WEIGHT MEASURE UNBALANCE with YES or return to the previous menu with NO. DISPLAY TEST EXIT Put in a known unbalance weight.

  • Page 54: Config 1

    Program unit CONFIG 1 The configuration 1 menu contains all the functions and parameters that service personnel MAIN MENU 01.04.00.00 can change without a password. STATISTICS CONFIG 1 Engage the machine’s service mode. CONFIG 2 Fig. ADJUST DISPLAY Select the CONFIG 1 row in the main menu and RESET TO FACTORY ACTIVATE WASH PROGR.
  • Page 55 Program unit • TIMEOUT,PAUSE BUZZ. SEC • MAX FILL TIME, SEC • 6. WATER IN DRUM • 7. DRUM OVERFILLED CONFIG 1 • 10. DRUM NOT DRAINED 04.01.00.00 • MACHINE ADDRESS 0000 PAUSE PERMITTED • PASSWORD 0000 RAPID ADVANCE • SHOW WEIGHT TIME, SEC NEW PROG.
  • Page 56 Program unit PAUSE PERMITTED Select whether it should be possible to pause during an on-going wash program. Yes = A pause is allowed during a wash program. No = A pause is not allowed during a wash program. RAPID ADVANCE Select whether is should be possible to step rapidly forward or backward through the wash program while it is in progress.
  • Page 57 Program unit SHOW TEMP Select whether the current water temperature is to be shown on the display window while a wash program is in progress. This function cannot be shown on the display at the same time as the SHOW IS LEVEL function, only one of the functions can be shown at one time.
  • Page 58 Program unit TEMP CONTROL WATER Select whether the machine is to control and adjust the water temperature by opening and closing the main valves for hot and cold water during filling. Yes =Control of main valves during filling. - Alt.1: Hot and cold water valves both open. If the set water temperature is exceeded, the hot water valve will be shut automatically.
  • Page 59 Program unit AUTO START PAID Select whether the machine is to be able to start automatically, when full price has been paid, for the chosen wash program. Yes =Automatic start engaged. Note! If the signal for blocking the start button is engaged, it also applies to the blocking signal for the automatic starting function.
  • Page 60 Program unit SHOW PROG. COUNTER Select whether the contents of the machine’s counter of completed wash programs should be shown in the display window while a wash program is in progress or outside the wash program without going into service mode. The counter is shown on the display after pressing the control knob twice in quick succession.
  • Page 61 Program unit COUNT WEIGHT Select whether the count weight function should be activated. Note that the function cannot be activated for wash programs that are programmed for no weight count. Yes = Count weight activated. No = Count weight not activated. POWER CTRL HEAT Select whether the power priority function (PC5) for heating should be engaged.
  • Page 62 Program unit LANGUAGE TIMEOUT SEC. Specify with the knob the time after which an unused machine should return to the set default language. The time is given in steps of 1 second; 0 - 2550 seconds. COIN VALUE 1 and 2 Specify with the knob the value (0 999) for the respective coin slot.
  • Page 63 Program unit MACHINE ADDRESS Specify with the knob the machine’s address (0 - 127) that is used when the machine is connected to the CMIS system. PASSWORD Select whether the functions under CONFIG 1 should be password protected or not. The password comprises four numerals.

  • Page 64: Aktivate Washing Programme

    Program unit OFFS.LEVEL READING MM Specify how large a deviation in level control from zero is to be allowed before the fault code for empty drum is displayed DISPLAY WARNING, SEC Specify with the knob the number of seconds the warnings are to be displayed.

  • Page 65: Unbalance Detecting

    Program unit FLUSH ON, POWD.SEC Rinse times for rinsing detergent after the drum has been filled with water. The time is given in steps of 1 second in the range 0 -255 seconds. LEVEL COOL DOWN, SCU Select the level to which the machine should be filled with the cold water valve if the wash program includes the rapid cooling function.

  • Page 66: Activate Wash Progr

    Program unit ACTIVATE WASH PROGR. The ACTIVATE WASH PROGR. menu is used to specify the wash programs in the program library MAIN MENU 08.00.00.00 that are to be made available to the user and in RESET TO FACTORY which order the wash programs are to be ACTIVATE WASH PROGR.

  • Page 67: Door And Doorlock

    Door and door lock Door Description The door is mounted on the balance weight attached to the machine outer drum. The door glass is held in the door by the door gasket, which also forms a seal directly against the outer drum when the door is shut.

  • Page 68: Door And Door Lock

    Door and door lock Function When the door is closed, the lock’s safety switch closes, which indicates to the timer that the door is locked and the machine is ready to start. A safety switch sends a go-ahead signal to the motor control. When the start button is activated the machine starts the program selected.

  • Page 69: Motor

    Motor Description General The motor is mounted on a shaft under the outer drum and drives the inner drum by means of a drive belt. To reduce motor noise and vibrations the motor mountings have rubber mountings. Between the motor and the outer drum is a belt tensioner which also has a rubber damper.

  • Page 70: Program Start

    Motor Program start The following conditions must be fulfilled before the motor can start: • Motor not overloaded. • Door shut. • Go-ahead signal from timer. Once the door is closed, a program is selected and the start button is activated, the machine carries out a short extraction which does not form part of the program selected.
  • Page 71 Motor Calculation of weight of wash load At the start of every program, the machine runs a special sequence. Four different torque parameters are calculated during this sequence. 1. Distribution to distribute the load evenly in the drum. Then deceleration. 2.
  • Page 72 Motor Extraction For extraction the motor operates in an extraction pattern which is always the same. The pattern is as follows: • A distribution period, with unbalance sensing – 20 seconds • Extraction at 550 rpm - 30 seconds • Extraction at 850 rpm - 30 seconds •...

  • Page 73: Motor Control Unit

    Motor Motor control unit The motor control unit communicates with the program control unit board via a serial (input/output) interface. With the aid of the motor control unit the program control unit can control not only 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.

  • Page 74: Troubleshooting

    Motor Troubleshooting • Check the motor windings with an ohmmeter Black to detect any possible short-circuit or fault. Blue • The motor winding shall have the resistance of 2,6 ohm, measured between two phases. • Check that the motor shaft can be turned. If it can’t, the problem is probably bearing failure.
  • Page 75 Motor Fault/error indication If a fault or error occurs in the motor or motor control unit, the latter will indicate this to the program control unit board. Information on these errors, besides appearing as an error code on the display, is also provided by a yellow LED on the motor control unit board. To understand this additional inform-ation, the pattern of flashes from the LED has to be observed and compared with this chart: LED pattern of flashes...
  • Page 76 Motor The motor is very noisy or seizing The cause will be bearing failure. Replace the motor (see below under ”To replace the motor”). To replace the motor 1. Release the belt tensioner and lift off the drive belt. 2. Undo and remove the holder securing the wiring harness to the motor’s quick connector.
  • Page 77 Motor Belt tension The tensioning of the drive belt is preset at the factory. When checking belt tension, or after replacing components which affect belt tension, follow Fig. 5 here. Max 12 mm Min 10 mm Belt tension is an important aspect of the machine’s operation and should always be checked as part of service and F = 30 N...

  • Page 79: Drain Valve

    Drain valve Description The water pressure in the cold water intake is used for closing the drain valve. There is a hose (1) connected between the water intake and the control valve (2). When the control valve is activated it opens and lets water into the supply line (3) which is connected to the drain valve.
  • Page 80 Drain valve To replace entire valve or valve components This work can be carried out more easily if the machine is inclined backwards. Check first which way the individual machine is mounted on/in the floor. Removal 1. Remove the front panel. 2.
  • Page 81 Drain valve Installation 1. First fit the valve onto the right-hand bolt in the saddle. 2. Fit and then tighten the two bolts on the left-hand side. Tighten the bolt on the right. 3. Connect the hose for water supply. 4.
  • Page 82 Drain valve To replace a component between the drum and the valve This work can be carried out more easily if the machine is inclined backwards. Check first which way the individual machine is mounted on/in the floor. Removal 1. Remove the front panel. 2.
  • Page 83 Drain valve 5. First fit the valve onto the right-hand bolt in the saddle. 6. Fit and then tighten the two bolts on the left-hand side. Tighten the bolt on the right. 7. Fit the hose from the drum on the valve. Use the rubber edge on the hose and pull down the hose over the valve cover.
  • Page 84 Drain valve To clean the hose between drum and junction This work can be carried out more easily if the machine is inclined backwards. Check first which way the individual machine is mounted on/in the floor. Removal 1. Remove the front panel. 2.
  • Page 85 Drain valve Installation 1. Fit the hose to the junction. 2. First fit the valve onto the right-hand bolt in the saddle. 3. Fit and then tighten the two bolts on the lefthand side. Tighten the bolt on the right. 4.

  • Page 87: Drain Pump

    Drain pump Description The pump is located under the drum inside the front of the machine. Access for cleaning foreign matter (out of the discharge water) from the pump is through a cover on the machine front. The motor which drives the pump is activated from the timer.

  • Page 89: Detergent Dispenser

    Detergent dispenser Detergent dispenser The detergent dispenser is divided into four compartments: One compartment for prewash detergent, powder or liquid detergent Two compartments for main wash detergent, one for powder detergent (1) and one for liquid detergent (2). One compartment for fabric conditioner. Water connections into the dispenser are fitted with dispersers which mix the detergent thoroughly with water and flush the compartments clean.

  • Page 91: Heating

    Heating Description The two heating elements are in the lower part of the outer drum, accessible from the machine rear. They are switched by a heating relay (K21), which is controlled by the timer, level control and thermostat. The elements must never be activated without water in the drum.

  • Page 93: Drum

    Drum Changing lifters � � 2595 6440 2598 2597 438 9048-41/01...
  • Page 94 Drum 2599 2600 2601 2660 438 9048-41/01...
  • Page 95 Drum 2602 2603 2604 2605 438 9048-41/01...
  • Page 96 Drum 2606 2622 � � 2624 6439 438 9048-41/01...

  • Page 97: Frame

    Frame Description The frame consists of a ”saddle” with straps which is attached to a base plate by four strut dampers. The drum unit is mounted on the cradle and secured by the strap which is held together at the top of the outer drum. The base plate stands on four adjustable feet on the floor.

  • Page 99: Tightening Torques

    Tightening torques Tightening torques for especially important bolted unions The following unions must be tightened to the torques specified here: Between bearing strut and outer drum. 38 ±5.7 Nm Between pulley and shaft. 38 ±5.7 Nm Between shaft strut and inner drum. 24 ±1.2 Nm For strap between front gable and outer drum.
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