Laundrylux CROSSOVER 2.0 Series Training Manual
  1. Manuals
  2. Brands
  3. Laundrylux Manuals
  4. Washer
  5. CROSSOVER 2.0 Series
  6. Training manual

Laundrylux CROSSOVER 2.0 Series Training Manual

Hide thumbs Also See for CROSSOVER 2.0 Series:

Advertisement

Table of Contents

CROSSOVER 2.0
TRAINING MANUAL

Advertisement

Table of Contents
loading

Related Manuals for Laundrylux CROSSOVER 2.0 Series

Summary of Contents for Laundrylux CROSSOVER 2.0 Series

  • Page 1 CROSSOVER 2.0 TRAINING MANUAL...
  • Page 2 CROSSOVER 2.0 SERIES W A S H E R S E R V I C E S C H O O L DOC. NO. 098017 EDITION 25.2018...
  • Page 3 Technical Data Contents Technical Data Machine Overview Machine Presentation Component Identification Display Panel Control Board (A1) Inverter (U1) Drum Motor (M1) Doorlock (A111) Door Unlock Delay Unit (A31) Water Valves (Y11, Y13, & Y21) Drain Pump (M2) Level Sensor (B1) Anti-siphon tube Loading door Door Bellows-gasket...

  • Page 4: Technical Data

    Technical Data Crossover 2.0 Technical Data Inner drum volume liters/ft 98/3.5 diameter mm/inch 554/21 13/16 Drum speed wash extraction max rpm 1050 G-factor Weight, net kg/lbs. 136/300 Connections Water valves DN20 connection 3/4" Garden Hose via included hoses Rec. water pressure 30-90 200-600 Functioning limits...
  • Page 5 Technical Data Crossover 2.0 Power Line Air Vent for Safety Cold Water Hot Water Drain Outlet Coin Meter (coin operated models only) Control Panel Detergent Dispenser Door Fig. 2.2 NOTES: 1098mm = 43 1/4 inch 584mm = 23 inch 310mm = 12 3/16 inch 686mm = 27 inch 765mm = 30 1/8 inch...

  • Page 6: Machine Overview

    Machine Overview General: The machine features an electronic control unit (CPU) with wash programs and options that can be modified in Service Mode by register programming and augmented with hardware options such as external liquid dosing, “promotion” event discount price programming, or networking. The drum motor is powered by an inverter that synthesizes three-phase power from a single phase 120 VAC input.
  • Page 7 The machine has an independent door-unlock delay unit, which will unlock the door 180 seconds after power is removed allowing extracting clothes to come to a compete stop. The water level is not monitored. If power is reestablished, the door will relock and the cycle will continue.
  • Page 8 Crossover 2.0 Fig 2.4 Crossover 2.0 Machine Presentation Soap dispenser Doorlock (A111) Water inlet valves (Y11, Y13, Y21) Door Anti-siphon Hose Door Closed Switch (S3) Inverter/Power Controller (U1) Display Controller (A1) Drum Pump (M2) Motor (M1) Shock Absorbers (x4) Compression spring (x2) EMI filter Level Sensor (B1) Security bolt (Service key required)

  • Page 9: Component Identification

    Component Identification A1 CPU Circuit Board A31 Door Unlock Delay Unit A111 Door Lock B1 Water Level Sensor F1 Motor Overheat Switch M1 Drum Motor M2 Drain Pump U1 Power Module / Inverter S2 Service Switch S3 Door Closed Switch S4 Door Locked Switch Y11 Cold Detergent Valve Y13 Cold Bleach Valve...

  • Page 10: Display Panel

    Display Panel Fig. 2.5 Display Board The control panel consists of program selection buttons (A), option buttons (B), a start button (C), and a display (D) Depending on the mode these have different functions. Operating Mode Service Mode Program selection buttons Change register parameter Wash program option buttons Register navigation...
  • Page 11 Control Board (A1) Fig 2.6 Control Board (A1) The CPU control board (A1) is mounted directly behind the display panel. It has: seven switches activated by the buttons on the display panel; a CPU reset switch on the back; four 7-segment digits; and an audio chime.
  • Page 12 The A1 board on some models has a 24-hour Real Time Clock/Calendar. The clock is set up by the installer and is synchronized to the start-of-minute when time adjustments are made, allowing all machines to be synchronized. The clock is used to time-stamp error codes, time-stamp coin vault access, and allow up to four day-of-week and time-specific price promotion events.
  • Page 13 Power Controller/Inverter (U1) CN13 N.C. CN22 CN17 CN18 Fig 2.7 U1 Power Controller/Inverter The power module/inverter U1 is located on the rear wall of the machine. Connections include: power and INTERLOCK, display board, drum motor, water valves, pump, doorlock, and external liquid supply.
  • Page 14 Drum Motor (M1) The drum motor (M1) is a synchronous 3 phase motor with tachometer and overheat switch (F1) that opens at 150 C. These components connect to the machine’s main harness using a single seven position connector that in turn, connects to the U1:CN1, CN17 &...
  • Page 15 Doorlock (A111) The electromechanical doorlock (A111) is secured to the right side of the front panel with three screws. A111 has a lock and unlock coil sharing a COMMON line bi-stable S3 Switch unlocked/locked condition when activated with a 24 vdc pulse. Lock/Unlock Coil The doorlock engages the door catch to ensure...
  • Page 16 Doorlock Unlock Delay Unit (A31) The Door Unlock Delay Unit (A31) will unlock the machine approximately 3 minutes after disconnecting power. A31 has two onboard capacitors that are charged via the A31’s direct connection to L1 and N. When power is disconnected from the machine an onboard timer activates.
  • Page 17 Inlet Valves (Y11, Y13, & Y21) There are two water inlets feeding two cold water valves (Y11) and (Y13) and hot water valve (Y21). The valve is METRIC DN20, 20 mm thread. Do not use standard ¾ in G.H thread as this will damage the valve. Use the two provided supply hoses included in the drum kit.
  • Page 18 Drain Pump (M2) The drain pump (M2) is a 120-vac electrical pump located on the bottom of the machine at the front-left. The filter basket is accessible from the front of the machine for cleaning either by removing the plastic caps on the left side of the kick panel on or demounting the kick panel depending on model.

  • Page 19: Loading Door

    Loading Door The loading door is demounted by removing four screws and lifting the door up and forward to clear the mounting hooks. The door can be disassembled to correct mis-alignment caused by wear and tear or excessive force applied to the door. Fig 2.21 Loading Door Mounting Fig 2.22 Loading Door Hinge Assembly...
  • Page 20 Door Bellows-gasket The door bellows is oriented with its drain holes at the bottom. The bellows is secured to the outer drum with a wire ring, tightened by a 7mm hex-head screw. Fig 2.23 Bellows-boot drain holes The outer, front part of the bellows is secured to the front panel with a clamp spring.

  • Page 21: Front Panel

    Front panel On some models the front panel can be demounted by removing the kick panel, the two lower panel tab screws and the three screws located at the top of the loading door inset. Disconnect the doorlock harness connecters before fully removing the panel.

  • Page 22: Wash Program Description

    Wash Program Description The machine offers four standard wash programs, and two optional features. The basic wash programs are Cold, Warm, Hot, and Delicate. The optional features are Heavy Soil and Extra Rinse. The options can be added to the basic wash programs (except for Delicate), in any combination. On coin-operated models, a different price can be charged for each program, and an additional price can be programmed for each of the two option buttons.
  • Page 23 Extra Rinse Option The Extra Rinse option adds one additional cold-water rinse to any wash program except the Delicate cycle. The extra rinse repeats the second- to-last rinse. Program End The display will show “donE” when the program ends. Then door can then be opened.
  • Page 28 Coin (Pulse) or Serial Mode Configuration The washer can accept payment using coins or tokens in COIN MODE or using payment cards in CARD MODE (serial). Setting the machine to COIN MODE and setting all wash program and option prices to “0.00” will allow the machine to operate for free in OPL mode. 1.

  • Page 29: Coin-Operated Machines

    Coin-Operated Machines In coin-operated machines, prices for programs and options must be programmed during machine setup, and can be modified at any time. The machine must be set to COIN MODE. Prices can be programmed as dollars and cents or as the number of coins or tokens required to start.
  • Page 30 Service mode Crossover 2.0 The machine’s software provides a “Service Mode” (SM) to adjust operating parameters and view usage statistics. The service mode also allows a technician to activate individual components of the machine, for troubleshooting. The software also provides a “Limited Service Mode” (LSM) that allows a technician to activate machine components, via PIN entry, without having access to the coin vault service switch.

  • Page 31: Service Mode

    Service Mode STATISTICS (NON-RESETTABLE): 000 - Cold program counter. Range: 0000 to F999, (A=10, ... F=15 e.g. “B101” = 11,101) 001 - Warm program counter. Range: 0000 to F999 002 - Hot program counter. Range: 0000 to F999 003 - Delicate program counter. Range: 0000 to F999 004 - Rinse and Spin program counter.
  • Page 32 Service Mode 025 - Main wash time: from 0-999 seconds, default=”360”, i.e. six minutes. 026 - Decimal in price: “00” = default=decimal displayed, ”01” = no decimal (token). 027 - Silence buzzer: Range: “00” =default=enabled, “01” = disabled. 028 - Regret Time: The allowable time, after program start, that a user can change the wash program/options or add items to the wash.
  • Page 33 *055 - Buzzer test. *056 - Detergent pump trigger signal. *057 - Bleach pump trigger signal. *058 - Softener pump trigger signal. *059 - Coin meter test, each dropped coin adds 1 to displayed total. Registers 009 and 010 unaffected. Real Time Clock (RTC), Calendar and Time-of-day Discount Promotion.
  • Page 34 Discount price “promotion” programming using the real time clock or external signal. The washer can apply a “promotion” percentage discount to the vend price of a program selection at specified times and days. Up to four different promotion discount event times and percentages can be selected using the washer’s built-in Real Time Clock (RTC).
  • Page 35 When the external signal is activated, the washer will apply a promotion percentage discount, set in register 79, to the displayed vend price. Please contact Laundrylux’s Technical Support team at (516) 371-0700 if you have any questions or need assistance with price programming or implementing discount price...

  • Page 36: Troubleshooting

    Trouble Shooting Error Codes and Indicators Fig 7.1 Error code display ERROR CODES Faults/errors in the program or machine are indicated by a numerical error code on the panel display. Some error codes are cleared automatically when the Start button is pressed to restart the machine and some when the door is opened.
  • Page 37 Crossover 2.0 Error Codes Error Code Cause Er1A Door fails to lock on wash program. Er1b Doorlock error during wash program. INTERLOCK lost Er1C Door fails to unlock at the end of wash program. Er1d Door switch opened during wash program. Make sure machine was not overloaded.

  • Page 38: Doorlock Operation

    Doorlock Operation When the Start button is pressed, and there is no payment required, the A1 controller checks that the S3 door switch is closed (detected by the U1 power module as a closed circuit between the two wires at U1, CN13 (pins 1 and 2), Fig 7.1.
  • Page 39 Fig 7.4 At the end of a wash program, an unlock pulse is sent by the U1 power module on the CN13-5 (+12VDC) and CN13-4 (COM). The doorlock mechanically moves (snaps) to the unlocked position, and releases the door catch, allowing the loading door to be opened. The 2-pole S4 switch also opens, removing the line- Voltage “interlock”...
  • Page 40 storage capacitor, sending a 12VDC unlock signal to the doorlock. This allows garments to be removed from the machine approximately three minutes after a power-failure has occurred, Fig 7.6. Fig 7.6...
  • Page 41 DOOR SWITCH AND DOORLOCK DIAGNOSTIC PROCEDURE Error Codes: 1, 1a, 1b, 1c, and 1d. Fig 7.7...
  • Page 42 Error code “Err1”: Door lock failure Models: WHWF09810M/NM Description: One of several conditions related to the doorlock system Error Trigger Conditions: INTERLOCK voltage not present at U1:CN2 after doorlock pulse sent OR, INTERLOCK voltage established and lost during a wash program OR, INTELOCK voltage present after door unlock pulse sent Recommend actions: Use doorlock diagnostic flowchart to determine cause.
  • Page 43 Error code “Er1c”: Door fails to unlock at end of cycle (Display shows “dOnE”) Models: WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/DC Error Trigger INTELOCK voltage present at U1:CN2 after door unlock pulse sent Recommend actions: Use doorlock diagnostic flowchart to determine cause. Error code Er1d: Door closed switch (S3) opened during wash program Models: WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/DC Error Trigger...
  • Page 44 Error code Err2: Not drained within 10 minutes. Models: WHWF09810M/NM WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/DC Trigger Condition Level Sensor (B2) does not indicate drum is empty after 10 minutes of pump operation. Recommended actions Use Error 2 diagnostic flowchart to determine cause. Fig. 7.8...
  • Page 45 Error code Err5: Water level not reached within 8 minutes. Models: WHWF09810M/NM WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/DC Trigger Condition Level Sensor (B2) indicates water is below the programmed level after 8 minutes of filling. Recommended actions Use Error 5 diagnostic flowchart to determine cause Fig.
  • Page 46 Error code Err7: No Motor Rotation Models: WHWF09810M/NM See Err7a Error code Err7a: No Motor Rotation Models: WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/DC Trigger Conditions 1. Motor thermal protector circuit (F1) is open. 2. No signal from motor tachometer (with or without motor rotation.) Recommended actions Use Error 7/7a diagnostic flowchart Fig.
  • Page 47 Error code “Err8”: Water level too high. Models: WHWF09810M/NM WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/ Trigger Condition Level Sensor indicates water level is too high. Recommended actions Use Error 8 diagnostic flowchart Fig 7.11...
  • Page 48 Error code Err10: Water level sensor error Models: WHWF09810M/NM WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/ Trigger Condition: Level sensor is outside normal operating range. This condition is tested for in standby and when a cycle is running. Recommended actions 1. Check individual level sensor harness leads for continuity (A1, CN1-5&6) 2.
  • Page 49 Error code “Unb” Unbalanced load Models: WHWF09810M/NM WHLFP715M/MI/NM/DC WHLFP817M/MI/NM/ Trigger Condition: Load cannot be balanced during final extract, (Display < “7”) Recommended actions: In final extract if the load cannot be balanced, (e.g. a water pocket in a waterproof table cloth). “Unb” will be displayed.
  • Page 50 Fig. 7.13 WHLFP715, WHLFP817 Wiring Diagram...
  • Page 51 Appendix 1 Crossover 1 and 2 Washer Bearing Replacement Instructions Figure 1: Kit # 098019 Supplied components 098019 KIT,TOOLS BEARING REPLACEMENT CROSSOVER 1 and 2 WASHER Part Description 098021 2x WASHER,ZINC YLW-CHROMATE, 1.572" ID, 2.780" OD, 0.25" THICK 098020 1x WASHER,SS 1.125" ID, 3.75" OD,0.250" THICK 432172201 1x WASHER 098023...
  • Page 52 Other required Parts, Tools and Supplies Additional required parts 096725 KIT,BEARING REPLACEMENT-XOVER WASHER W/SHAFT SPIDER Required tools not supplied with the tool kit Torque wrench Sledge or heavy duty mallet T15 tamper-proof security Torx bit (to remove the top cover) Pinch bar or crowbar Flexible 1/4 inch socket driver with an 8mm socket (Required to demount coin meter housing Crossover 1)
  • Page 53 Bearing replacement should only be performed by qualified service personnel. !!! UNPLUG THE MACHINE’S POWER CORD!!! Disassembly To replace the bearings, the drum assembly must be removed from the top of the machine. See figure 1. To allow this, remove all top-mounted components including the harnesses and the money box and coin meter housing.
  • Page 54 Secure strong belts, chains, or ropes to the steel rods at either side of the top of the drum, and lift the drum assembly out of the machine. See figure2. The air-shock absorbers will separate into two pieces when the drum assembly is removed. For field repair, the machine can be laid on the floor on its left (door-hinge) side.
  • Page 55 Bearing and Seal assembly Prepare a clean surface to lay down the seals and bearings. Make sure all tools, anvils, and washers are cleaned so as to not to contaminate the bearings and seals, reducing bearing life. Step#1: Water-side bearing (larger) Apply a thin film of Amblygon grease, provided with the bearing kit, to the outer and inner walls of the larger of the two supplied bearings.
  • Page 56 Figure 4: Seal Orientation Step #2: Pulley Wheel-side seal (smallest) Apply a thin film of Amblygon grease to the outside wall of the smallest seal. Seat the seal in the bearing housing noting the orientation (Figure 4). Using the same tool set up as Step #1, “GENTLY” tap the seal into place.
  • Page 57 Figure 5: Middle Seal covered by washer (Item #3) Step #4: Water-side seal (largest) Apply a thin film of Amblygon grease to the outside wall of the seal. Seat the seal in the bearing housing noting the orientation (Figure 4). Center the 3.75" dia. washer, (item #2) over the seal (figure 6.) Place washer, (Item #3), over washer and gently tap the seal into place.
  • Page 58 Flip the rear outer drum over (pulley side up). Apply a thin film of Amblygon grease on the outer and inner walls of the smaller bearing and center on the bearing housing. Cover bearing with one of the two 2.75" dia.
  • Page 59 Figure 8. Shaft end should be flush with pulley-wheel bolt mounting surface. If the bearings were not properly, the shaft assembly may not fit into place easily by gravity alone. In this case, position the supplied pipe, (Item #6), over the inner raceway See figure 9. Cover with Washer (item #3) and gently tap the shaft assembly into place.
  • Page 60 Machine Reassembly and Test Replace the outer drum gasket with the one supplied with the bearing kit. Make sure the gasket channel is clean. Reassemble the machine. Use the supplied boot tool, (Item #8), to reattach the outer boot clamp. Make sure the drum motor-machine harness connector is snapped in place and secured to the motor housing with the previously removed cable tie.
  • Page 61 Crossover 2.0 Dryer Stacking Instructions Applicable Models: DLHS0817E DLHS0817G Caution: Follow the instructions in the Installation and Operating manual to properly install and operate the machines. When stacked units are installed, it is advised to tether the top machine to the wall behind the units, to avoid tipping over.
  • Page 62 Bottom-Control Dryer (DLHS) over a Crossover 2.0 Top-Control Dryer (DLHF) Stacking an Demount the top panel of the Top Control Dryer 1. Demount the control panel by using the provided service key. Disconnect the cables between the control module, and the machine, and set the control module aside. 2.
  • Page 63 3. Remove 2 screws from the front of the top panel 4. Remove the 2 top panel screws from the tabs in the back of the machine. 5. Slide the top panel rearward and lift to remove the top panel from the machine...
  • Page 64 6. The disassembly process is similar for the bottom-control machine, except instead of removing the control panel remove the two screws from the front top blank panel and demount the panel 7. Swap the TOP panels between the top-and-bottom-control machines After swapping the TOP panels 8.
  • Page 65 Remove rectangular knockout 12. Loosen slightly, but do not remove, the 4 shouldered screws that are already attached to the base panel of the top dryer (circled in the photo)
  • Page 66 13. Remove the screw (circled in the photo) from the raised part of the right-front stacking bracket on the bottom dryer , and retain it for later use (Step 15)
  • Page 68 14. Stack the bottom-control machine (DLHS) onto the top-control machine (DLHF). The four shouldered screws in the base panel of the top dryer must slide into the open back side of the stacking-brackets on the top panel of the bottom machine. Apply force to the top machine from the rear until the fronts of the top and bottom machines are aligned.
  • Page 69 17. Install and tighten the locking-screw that was taken from the stacking bracket in step 12 back into the bracket through the clearance hole provided in the base of the top dryer. 18. Re-assemble the control console of the top machine and re-connect the CN8 and CN3 connectors of the control board back to machine.
  • Page 70 bottom control dryer (DLHS) on the Crossover 2.0 washer (WHLFP) Stacking a Additional Item Needed: Washer Top Panel for Dryer Mounting (Part Number: Attaching the brackets to the Washer Top Panel The washer top panel for dryer mounting (0020809423F) does not come with the stacking brackets attached.
  • Page 71 6. From the bottom control machine, remove the rectangular knock-out plate, as indicated in the picture using a hammer and screw driver. 7. Also, remove the four leveling legs from the base panel of the machine. 8. Loosen slightly, but do not remove, the 4 shouldered screws that are already attached to the base panel of the top dryer (circled in the photo)
  • Page 72 9. Remove the screw (circled in the photo) from the raised part of the right-front stacking bracket 23. Stack the bottom-control machine (DLHS) onto the Encore Washer. The four shouldered screws in the base panel of the top dryer must slide into the open back side of the stacking-brackets on the top panel of the bottom machine.
  • Page 73 10. Install and tighten the locking-screw that was taken from the stacking bracket in step 12 back into the bracket through the clearance hole provided in the base of the top dryer. 26. Re-assemble the control console of the top machine and re-connect the CN8 and CN3 connectors of the control board back to machine.
  • Page 74 ons of the Top Control Machines. 28. Once the connections are properly made, mount back the control panel frame and the cross frame. 29. Before remounting the control, panel reconnect the harness connections. 30. Lock the controller using the service key.

Table of Contents