Whirlpool CALYPSO WashMotion GVW9959K-0 User Manual
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Whirlpool CALYPSO WashMotion GVW9959K-0 User Manual

Electronic control washer with calypso wash motion
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Summary of Contents for Whirlpool CALYPSO WashMotion GVW9959K-0

  • Page 2 GOALS AND OBJECTIVES The goal of this Job Aid is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair the unique features of Whirlpool Electronic Control washers with Calypso Wash Motion. The objectives of the Job Aid are: The service technician will - •...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS M O D E L / S E R I A L M O D E L / S E R I A L M O D E L / S E R I A L M O D E L / S E R I A L M O D E L / S E R I A L DESIGNATOR...ii DESIGNATOR...ii...

  • Page 4: Designator

    MODEL/SERIAL NUMBER PLATE SERIAL NUMBER DESIGNATOR C L 36 50001 SERIAL NUMBER MANUFACTURING SITE C = Clyde, OH YEAR OF MANUFACTURE L = 2001 WEEK OF MANUFACTURE PRODUCT SEQUENCE NUMBER MODEL NUMBER DESIGNATOR MODEL NUMBER G = Domestic Laundry Gold L = Domestic Laundry V = Vanguard Technology W = Resource Saver...

  • Page 5: Section One

    INSTALLATION CONSIDERATIONS INSTALLATION INSTRUCTIONS Proper installation is your responsibility. You will need A water heater set to deliver a minimum of 120°F (49°C) water to the washer. A grounded electrical outlet located within 4 ft. (1.2 m) of where the power cord is attached to the back of the washer. See “Electrical Requirements.”...

  • Page 6: Selecting A Location

    Tools needed and Parts Supplied Assemble the necessary tools and supplies before beginning the washer installation. Do not re-install into the washer, the styrofoam that contains the supplied parts. To connect the drain hose and water inlet hoses You will need these following tools Flashlight (optional) Pliers (that open to 1 9/16 in (3.95 cm)) You will need the following supplied parts...

  • Page 7: Drain System

    Drain System The washer can be installed using the standpipe drain system (floor or wall), the laundry tub drain system or the floor drain sys- tem. Select the drain hose installation method you need. See “Alternate Parts You May Need.” Fig.

  • Page 8: Connecting The Drain Hose

    Tilt the washer forward and remove the wood block. Gently lower the washer to the floor. Prop up the front of the washer about 4 in. (10.2 cm) with a wood block or similar object. The block needs to support the weight of the washer.

  • Page 9: Leveling The Washer

    Attach the hose with the blue coupling to the COLD (left) inlet valve. Screw on coupling by hand. Using the pliers, tighten the coupling an additional two-thirds turn. NOTE: Do not overtighten. Damage to the valve may result. 1. Cold water inlet valve (blue) 2.

  • Page 10: Tion

    Use & Care Information Due to the unique washing action of the CALYPSO™ washer, it is strongly recommended that the consumer use a High Efficiency detergent. High Efficiency detergents are formulated to control sudsing which may occur with use of regular detergents. If the consumer does not wish to use HE detergent, it is recommended to use 1/2 the normal amount.

  • Page 11: Section Two

    THEORY OF OPERATION nu-ta-tion \ n(y)ü-’ta-shen\ n The spiral movement of the axis of a rotating body, such as the oscillation of a spinning top. CONTROL PANEL Extra He a vy Hea vy Norm a l Norm a l Options Light Refre sh CYCLE DESCRIPTIONS...

  • Page 12: Operational Cycle Defaults

    OPERATIONAL CYCLE DEFAULT WASH AND SPIN CYCLES Whitest Whites Heavy Duty Normal Jeans/Darks Bulky Items Quick Wash Delicate Casual Wool Hand Wash Rinse & Spin Extend Spin NOTE: NPM = Nutations per minute RPM = Revolutions per minute Soil Level Soil Level adjusts the amount of nutation or spray wash time in the selected cycle.
  • Page 13 Water Temp The WATER TEMP keypad provides for selection of different wash and rinse combinations. Water fill temperatures can be either HOT (hot water valve only), WARM (both the hot and cold water valves) or COLD (cold water valve only). Fills during rinses may be COLD until the final rinse/spin interval. The WATER TEMP can be changed at any time during the wash cycle.

  • Page 14: Thermistor Resistance Chart

    THERMISTOR RESISTANCE CHART THERMISTOR RESISTANCE Additional Options OPTIONS Soak Extra Rinse Extend Spin End of Cycle Signal There are three (3) volume levels for the End of Cycle Signal, HIGH, LOW and OFF. Pressing the END OF CYCLE SIGNAL keypad toggles between these options by lighting one of the LEDs and beeping the corresponding end of cycle signal at the volume level selected.

  • Page 15: Drive Motor

    MACHINE CONTROLLER The Machine Controller interprets the consumer inputs from the keyswitch pads to operate the cycle selected. The Machine Controller interfaces with the Motor Controller to operate the Drive motor and Pump motor through their vari- ous functions during the cycle. The Machine Controller also directly operates the water fill and dispenser solenoids, interprets the thermistor readings, lid switch condition, as well as the position of the contacts in the Operating and...
  • Page 16 Peekaboo Mode The Peekaboo mode allows the user the opportunity to look into the washer during a wash action. During the Peekaboo Mode, the electronic control will allow the machine to nutate at 150 NPM for a maximum of 5-seconds after the washer lid is opened. When the lid is closed, the Start pad must be pressed to continue the cycle.
  • Page 17 In the spin mode, the top of the leveler is positioned to be in line with the nutate shaft. This levels the outer wash plate so that the spin basket spins without an out of balance condition that would be caused by a tilted wash plate.
  • Page 18 DRIVE SYSTEM The Drive Motor operates the nutate and spin functions by reversing direction. The Drive Motor is linked to the drive mechanisms by a stretch belt. The belt transfers the motion of the Drive Motor to a Drive Pulley. The Drive Pulley has a splined hub, into which the Nutate Shaft is inserted and is in motion in whichever direction the Drive Pulley is turning.
  • Page 19 PRESSURE SWITCHES The washer uses two pressure switches to control the amount of water entering the tub and to protect against an overfill condition. The operating pressure switch, marked OPR, controls the amount of water that enters the tub during normal wash and rinse functions. This switch operates in the same manner as similar pressure switches through a pressure switch tube, diaphragm and switch.

  • Page 20: Outer Tub

    RECIRCULATION AND DRAIN Water Pump/Pump Motor The pump is directly driven by a separate reversible 120 VAC 60 Hz motor. By being reversible, the motor provides for two separate operations of the washer. Outer Tub The Outer Tub sump plays a role in the drain and water recirculation function The sump area includes two check balls that direct water flow when the water pump operates in the drain and recirc direction.
  • Page 21 Drain During the Drain Mode, the pump motor turns clockwise (as viewed from underneath the washer). This causes the water pump to draw the water from the tub through the recirculation port, forcing the drain check ball to seal the drain sump port and force the water through the drain hose. Drain Check Ball seals off Drain port, due to positive pump pressure, forcing water out the drain hose.

  • Page 22: Operational Cycle Notes

    OPERATIONAL CYCLE NOTES The following notes apply to all cycle sheets where indicated in the NOTES colum n of the cycle sheet. W hen there is a contradiction, the cycle sheet itself has priority. WATER FILL NOTES A “W ATER TEMP” of “W ASH” m eans that the v alv es are controlled by the tem perature selection from the W ASH/RINSE TEMP key.
  • Page 23 DRIVE MOTOR NOTES Spin is defined as a clockwise (CW ) Motor and Basket rotation when looking down from the top of the m achine. Nutate is a counter-clockwise (CCW ) rotation of the m otor. 16. Step Spin. Driv e m otor ram ps up to speed following specific m otor profiles. 17.

  • Page 24: Cycle Charts

    Whitest Whites This cycle introduces liquid chlorine bleach to the load at the proper time for improved whitening of your heavily soiled white fabrics. Use this cycle to get 13 to 17 minutes of medium speed wash action and high speed final spin. For maximum soil and stain removal, liquid chlorine bleach must be used. The preset cycle wash time is 15 minutes.

  • Page 25: Heavy Duty

    Heavy Duty Use this cycle to get 15 to 19 minutes of wash time for loads of sturdy, colorfast fabrics such as work clothes. Cycle combines high speed wash action and high spin speed. The preset cycle wash time is 19 minutes.
  • Page 26 Normal Use this cycle to get 12 to 16 minutes of wash time for normally soiled cottons and linens. Cycle combines medium speed wash action and high speed spin. The preset cycle wash time is 14 minutes. DESCRIPTION OF SEQUENCE PHASE STEP WASH...
  • Page 27 Jeans/Darks Use this cycle to get 14 to 18 minutes of wash time for dark, colored items that may run or fade. Cycle combines low/medium speed wash action and high spin speed. The preset cycle wash time is 16 minutes. DESCRIPTION OF SEQUENCE PHASE...
  • Page 28 Bulky Items Use this cycle to get 13 to 17 minutes of wash time for large items like blankets and comforters. Cleaning starts with a spray of water and detergent mixture to thoroughly saturate your large load. This is followed by a low/medium wash action and low/medium spin speed to maintain load balance. The preset cycle wash time is 15 minutes.

  • Page 29: Quick Wash

    Quick Wash Use this cycle to get 7 to 11 minutes of wash time for small, lightly soiled loads that are needed in a hurry. Fast cleaning starts with a continuous spray of water and detergent mixture as the load is spun at extra-low speed, followed by a brief period of low/medium speed wash action.
  • Page 30 Delicate/Casual Use this cycle to get 12 to 16 minutes of low speed wash action for no-iron fabrics and garments indicating “Gentle” cycle on the care label. Low/medium spin is used to reduce wrinkling. The preset cycle wash time is 14 minutes. DESCRIPTION OF PHASE STEP...
  • Page 31 Wool Use this cycle to get 6 to 10 minutes of wash time for washable items that are normally dry cleaned. Cycle combines extra-low speed spray cleaning and wash action to provide gentle care for delicate items such as wool sweaters and silk blouses. Low spin speed helps garments maintain their shape. The preset wash time is 6 minutes.
  • Page 32 Handwash Use this cycle to get 7 to 11 minutes of wash time for garments labeled “Hand Wash” and special care items. Gentle cleaning starts with a continuous spray of water and detergent mixture as the load is spun at an extra-low speed. This lasts for about one minute and is followed by a brief period of extra- low wash action.

  • Page 33: Soak Cycle

    Soak Cycle Use this option for set-In stains and soil that need extra time for removal. Soaking in this washer is different than in a conventional washer. The washer sprays the load with water and detergent for 4 minutes at extra low spin speed followed by a brief period of wash action at the speed of the selected cycle.
  • Page 34 Rinse & Spin Use this option to get a combination of rinses and spins followed by a high-speed spin. The time displayed will include an estimate of how long it will take to fill and drain the washer. Fabric softener can be added to the Fabric Softener dispenser.

  • Page 35: Section Three

    COMPONENT ACCESS COMPONENT LOCATION Motor Control Board Log Valve Assembly Interlock Switch Suspension Assembly Drive Motor SPECIAL TOOLS/PARTS REQUIRED FOR SERVICE Putty Knife T-40 Torx Spanner Wrench Volt-Ohm Meter SECTION THREE Machine Control Board Shock Interlock Switch Fig. 3-1 Seal Kit, Part #285842 Pressure Switches Line Filter...

  • Page 36: Accessing Components In The Console

    Electrostatic Discharge (ESD) Sensitive Electronics ESD problems are present everywhere. ESD may damage or weaken the electronic control as- sembly. The new control assembly may appear to work well after repair is finished, but failure may occur at a later date due to ESD stress. •...
  • Page 37 Removing the Console 1. Disconnect power from the washing machine. 2. Slide the blade of a putty knife between the bottom of the console and the washer top at each front corner (Arrow in Fig. 3-3) and push the spring clip back far enough to release it from the slot in the washer top.
  • Page 38 Removing the Pressure Switches The overfill and operating pressure switches are located next to each other on the console mount- ing plate. Both pressure switches are removed in the same manner. 1. Disconnect power from the washing ma- chine. 2. Place the console in the service position. 3.

  • Page 39: Accessing Components Beneath The Washer Top

    ACCESSING COMPONENTS BENEATH THE WASHER TOP Components accessible beneath the washer top are: • Tub Ring • Balance Ring • Inner/Outer Wash Plates • Leveler • Universal Joint • Dispensers • Bleach Venturi • Lid Switch Raising the Washer Top to the Service Position The washer top is hinged at the back edge.
  • Page 40 Removing Components in the Tub 1. Disconnect power from the washing ma- chine. 2. Raise the washer top to the service posi- tion. 3. Disconnect the fresh water inlet hose from the tub ring. (Fig. 3-10) 4. Unsnap the tabs that secure the tub ring to the tub.
  • Page 41 11. Remove the spanner nut. Once this is done, the universal joint assembly can be lifted from the basket. 12. The basket can now be lifted from the tub. NOTE: It may be necessary to spread apart one of the drive block sections to loosen the basket from the splines of the spin tube.
  • Page 42 6. There is a tab on the underside of the inner wash plate that corresponds to a slot on the universal joint. These should fit together when reassembling the inner wash plate over the universal joint. U-Joint Grommets NOTE: Do not rotate the inner wash plate when reassembling to the universal joint. Rotating the plate may move the leveler to it’s tilted position which may cause the grommets to slip.

  • Page 43: Accessing Components Beneath The Tub

    ACCESSING COMPONENTS BENEATH THE TUB Components accessible beneath the tub are: • Suspension Assemblies • Pump, Pump Motor and Capacitor • Drive Motor and Drive Pulley Assembly • Drain and Recirculation Hoses • Brake and Drive Tube Assembly Removing the Front Cabinet Panel Access to many of the components beneath the tub can be gained by removing the front cabinet panel.
  • Page 44 Servicing Components from the Bottom of the Washer Removing the Drive Motor 1. Disconnect the power from the washing machine. 2. Carefully lay the washer on its back. 3. Remove the two screws securing the bottom panel to the washer frame. 4.
  • Page 45 2. Remove the T-40 Torx head bolt securing the drive shaft bearing to the thrust plate. 3. Remove the four (4) T-40 Torx head bolts securing the thrust plate to the posts on the motor mounting plate. NOTE: The two (2) screws at the top of the bracket have ball ends. (Fig. 3-31) Figure 3-32 shows all the components of the thrust plate assembly.
  • Page 46 Removing the Pump and Pump Motor Refer to Figure 3-34 for these procedures. 1. Disconnect power from the washing machine. 2. Carefully lay the washer on its back. 3. Remove the bottom panel secured to the washer frame. 4. Disconnect the pump motor wiring harness from the connector block attached to the front bottom frame rail.

  • Page 47: Section Four

    TROUBLESHOOTING AND DIAGNOSIS TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE 120VAC electrical supply. Won’t Power Up Open AC cord. Line filter open. Machine control board open. Won’t Start Cycle Lid Switch failure. Loose harness connections at control board(s). “Start” touchpad failure. Control Won’t Accept Touch Pad failure.
  • Page 48 PROBLEM POSSIBLE CAUSE Overfills Operating Pressure Switch fail- ure. Pressure Switch tube off at Pressure Switch or tub pressure dome or kink in tubing. Not draining. Won’t Nutate Machine or motor controller con- nections loose. Drive motor inoperative. Drive belt broken. Drive mechanism failure.
  • Page 49 PROBLEM POSSIBLE CAUSE Won’t Drain Foreign material in pump, tub sump or drain hoses. Pump impellar cracked/broken. Pump bound. Pump motor failure. Washer Vibrating Improperly installed. Levelling legs not properly in- stalled. Balance ring cracked or loose on basket. Basket drive block loose or im- properly installed.

  • Page 50: Error Codes

    PROBLEM POSSIBLE CAUSE Load is Wrinkled Not removing load promptly. Wrong cycle for fabrics being washed. Overloading. Wash water not warm enough to relax wrinkles. Using warm rinses. Hoses reversed. Load is Tangled/ Overloading. Twisted Clogged Dispensers/ Use of color-safe bleach in chlo- rine bleach dispenser Bleach Leaking/ Bleach on Wrong...
  • Page 51 Communications Error Long Drain Average Current Limit Instantaneous Current Limit Off Balance Stuck Relay Lid Switch Error ERROR CODES If there is any breakdown in communication between the machine controller and the motor controller, “CE” flashes and the unit beeps once. Some common causes of “CE”...

  • Page 52: Automatic Service Diagnostics Mode

    Flashing Open Lid Display Time Suds Lock SELF DIAGNOSTIC ROUTINES Automatic Service Diagnostics Mode Options The automatic service diagnostics mode is a short demonstration to provide an automatic check for major wash functions. The automatic service diagnostics mode is activated by pressing: SOAK - SOIL LEVEL - SOAK - SOIL LEVEL within five (5) seconds while the machine is in Standby Mode.
  • Page 53 Manual Diagnostic Mode Options The manual diagnostic mode will enable activation of specific machine functions without having to run a cycle. Each function test will time out in three (3) minutes. To enter the manual diagnostic mode: 1. Press: SOAK - CYCLE SIGNAL - SOAK - CYCLE SIGNAL within five (5) seconds while the machine is in Standby Mode.
  • Page 54 Pump Drain/Recirculation 4. Press the EXTRA RINSE keypad to operate the pump motor in Drain. Press the EXTEND SPIN keypad to run the pump motor in Recirculation. Pressing these keypads a second time turns the pump motor off. NUTATE AND RECIRCULATE TEST This test sequence assumes the control is off.
  • Page 55 WATER INLET AND DISPENSER VALVE, OPERATING PS TEST If Operating Pressure Switch trips at any time, all water valves should turn off. Press EXTRA RINSE to start draining after key press #5 to start draining. Press EXTRA RINSE again to turn off the pump. PRESS TOUCHPAD DISPLAY SOAK...
  • Page 56 Console Switches and Indicators Test The console switches and indicators can be tested by pressing the following touchpads: SOAK - CYCLE SIGNAL - SOAK - CYCLE SIGNAL within five (5) seconds while the machine is in Standby Mode. The 7-segment LED will display “dt”.

  • Page 57: Overlay Key Matrix

    Checking Touchpad Functioning: Before replacing the control board, check for proper touchpad functioning as follows: • Disconnect the power cord from the outlet. • Remove the connectors P11 and P12 from the control board. • Using the Key Switch Matrix below, measure the resistance across the switch when the touchpad is pressed.

  • Page 58: Checking Motor Continuity

    Sales Demo Mode The Sales Demo mode is activated by pressing: SOAK - WATER TEMP - SOAK - WATER TEMP within five (5) seconds. “Sd” should be displayed in the seven-segment display when activated and the following cycle should progress. The STOP/CANCEL key can be used to return to standby mode at any time during the cycle.

  • Page 59: Troubleshooting Tests

    TROUBLESHOOTING TESTS 120VAC Electrical Supply Check for 120VAC on the power cord connection to the line filter. If no AC power is present, replace the power cord. Check for 120VAC on the line filter connection to the machine controller. If no AC power is present, replace line filter.
  • Page 60 Motor and Motor Control System Test These tests check the machine controller power to the motor controller, the motor controller board, the wiring connections between the control board and the drive motor, and the drive motor itself. Machine Control Relay Check for 120VAC on the power cord connection to the line filter.
  • Page 61 Drive Motor and Wiring Harness • Check the drive motor windings and wiring harness by removing connector P6 from the motor controller. Check for resistance values as shown: WINDING RESISTANCE ( ) Main to FHOT AUX to FHOT MAIN to AUX FTC to FHOT less than .5 (short) MAIN to Ground...
  • Page 62 If the resistance is not within this range, check for continuity between the connector and the sensor. If continuity is good, replace the log valve assembly If the valves and temperature sensor are functioning properly: Replace the control board. Operating and Over Fill Pressure Switch Test Check the hose connections between each pressure switch in the console and the pressure dome attached to the tub.
  • Page 63 • Remove the connector at the motor and take measurements as shown in the following table. Recirc to Neutral 10 - 12 Drain to Neutral 10 - 12 Recirc to Drain 20 - 25 • If the resistance is much higher than shown, replace the pump motor. •...
  • Page 64 - NOTES -...

  • Page 65: Section Five

    SECTION FIVE TECH TIPS WIRING DIAGRAM Fig. 5-1...

  • Page 66: Component Resistance Chart

    For one year from the date of purchase, when this washer is operated and maintained according to instructions attached to or furnished with the product, Whirlpool Corporation will pay for FSP placement parts and repair labor to correct defects in materials or workmanship. Service must be provided by a Whirlpool designated service company.
  • Page 67 WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-253-2870...
  • Page 68 CO RPO RATIO N...

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