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Related Manuals for Kuppersbusch 634 Series
Summary of Contents for Kuppersbusch 634 Series
- Page 1 Integrated Dishwashers Series 634 with Automatic Progams IGVS 649..IG 657..IG 669..IGVS 659..IG 647..IG 659..IGVS 659..IG 656..IG 644..IG 634..
- Page 2 Service Manual: H7-71-02 Responsible: Dieter Rutz KÜPPERSBUSCH HAUSGERÄTE AG E-mail: dieter.rutz@kueppersbusch.de Phone: (0209) 401-733 Kundendienst Fax: (0209) 401-743 Postfach 100132 Date: 28.09.2005 45801 Gelsenkirchen...
- Page 3 Service Manual Contents Safety ..........................5 Technical Description ....................6 General........................6 Installation and connection ................... 6 Installing ........................ 6 Water connection ....................6 Electric connection ....................6 Description of operation ....................7 General........................7 Control panel design, depending on the model............. 7 Programs.......................
- Page 4 Service Manual Operation and function ....................39 IGV 659.2 and IGV 659.3 operation ..............39 IGV 657.1 and IGV 644.4 operation ..............40 IGV 647.1 and IGV 647.2 operation ..............41 IGV 634.4 operation .................... 41 IGV 659.4 and IGV 6508.0E operation..............42 IGV 657.1 and IGV 644.4 operation ..............
- Page 5 Service Manual Safety Danger! Repairs may only be carried out by a qualified electrician! Inexpert repairs may lead to risks and damages for the user! To prevent electric shocks, please observe the following tips: • In the event of faults, housing and frame may be live! •...
- Page 6 Service Manual Technical Description General This service manual serves the purpose of providing customer service technicians who already have the know-how required to repair dishwashers with specific information on the operating mode of the appliances indicated on the title page. Descriptions and operating modes of components that are not new have therefore not been included in this edition.
- Page 7 Service Manual Description of operation General The appliances are equipped with an alternating rinse system and a glass protection system. The alternating rinse system is explained under the sub-title water diverter. The glass protection system comprises the prewashing program, the natural water valve and the heat exchanger. Control panel design, depending on the model LEDs = L0 to L6 Buttons Sa - Sc and S0 to S6...
- Page 8 Service Manual 4.2.2 Termination of a program (reset) (see instruction summary for button assignment) Press the respective buttons for 3 seconds (for button allocation see the marking on the panel) with the appliance switched on. The display will indicate a "0" and the appliance will pump off for approx. one minute.
- Page 9 Service Manual Auto 55° / 65° (depending on the model) In the automatic program the aqua sensor not only decides on a change of water after the pre-rinse cycle; it also determines the washing temperature and the number of intermediaterinses. Depending on the aqua sensor decision, the program comprises: •...
- Page 10 Service Manual 4.4.4 Combined detergents (3 in 1), according to the model (See rapid guide for key configuration) The clear rinse temperature is raised by 3K (the same temperature as for intensive drying). This impro- ves the drying result. The 3 in 1 detergent recognition device will be activated when: •...
- Page 11 Service Manual 4.5.3 Regeneration electronics system On comparing the degree of water hardness set in the appliance, the electronics system determines what quantity of water is possible before the water softener is exhausted. The quantity of water used is calculated. Once the subsequent maximum number of rinses has been reached, recovery is carried out. The discharge behaviour of the regeneration electronics system can be seen in the description under initial operation / replacing the electronics unit.
- Page 12 Service Manual 4.5.8 Procedure for initial start-up - appliances with a heat exchanger In the case of initial operation or electronics exchange, the following program procedure is to be observed. (Program scaler = 0!) Program- counter Pump 15 sec. Lack of salt display Lack of salt = Off Lack of salt = On...
- Page 13 Service Manual 4.5.9 Procedure for initial start-up - appliances without a heat exchanger PC > 0 Program counter (PC) PC = 0 Pump 15 sec. Salt refill indicator Lack of salt = Off Lack of salt = On Filling valve on, 10 sec.
- Page 14 Service Manual Listing the triacs (consumers and relays) When a module is replaced due to a defective triac it is essential to check the component selected too. Observe EGB instructions! IG 644. to 5 IG 657.2E IGS 644.0 Drain valve heat exchanger Regeneration valve Filling valve Water diverter...
- Page 15 Service Manual Triacs When a module is replaced due to a defective triac it is essential to check the component selected too. Observe EGB instructions! IG 6508.0E / IGVS 659.4 Water diverter Filling valve Raw water valve Regeneration valve ----- Drain-off valve Dispenser Circulation pump...
- Page 16 Service Manual IGV 649.0 IGVS 649..Drain-off valve Regeneration valve Filling valve Aktuator water diverter Dispenser actuator Triacs Filling valve Drain valve heat exchanger SICSYM activation Raw water valve Regeneration valve Water diverter Circulation pump Dispenser actuator Motor lock Relay Rinse-water pump Heater...
- Page 17 Service Manual When a module is replaced due to a defecti- ve triac it is essential to check the compo- nent selected too. Salt/clear rinse fill-up Option Filling valve/Aqua-Stop Regeneration valve Dispenser actuator Drain-off valve Heat exchanger Option Dispenser actuator Dispenser Drain-off valve Heat exchanger Actuator...
- Page 18 Service Manual Aqua sensor I and II In addition to an infra-red LED, the aqua sensor II is also equipped with a green LED, which means that undissolved substances such as tea or spinach can also be recognised. In the automatic program, for example, the aqua sensor II has the following functions: Aqua sensor infra-red LED check in the pre-wash cycle Depending on the result of this check, the water is either exchanged (extremely dirty) or still used...
- Page 19 Service Manual Fill system Regeneration with heat exchanger After the fill solenoid is opened, the water flows to the integrated inlet over the free flow line into the softener and then as softened water into the heat exchanger. After the regeneration chamber is filled the water flows through the overflow channel into the thredtle cup of the level sensor.
- Page 20 Service Manual Intake of water with heat exchanger After the fill solenoid is opened, the water flows to the integrated inlet over the free flow line into the regeneration chamber. When the regeneration chamber has been filled the water will flow through the overflow channel in the softening equipment and as soft water into the level sensor and the pump cavity.
- Page 21 Service Manual Filling procedure for appliances with a heat exchanger The electronic system determines the time between the open command of the fill solenoid and the clo- sing of the level switch (f1). From this time the additional fill time of the fill solenoid is calculated. For every initial fill-up in a rinsing program, 200ml more water than the standard water volume will be filled in.
- Page 22 Service Manual Functions and components Safety function Should functional defects in the dishwasher control system or in the structural elements occur, resulting in an over-filling of the machine, the valve combination will be closed by means of the safety system, thus blocking off the water supply.
- Page 23 Service Manual Thermohydraulic system (actuator) The thermohydraulic system comprises a metal cylinder with a push rod. The cylinder is filled with a sub- stance which greatly expands when heated. A PTC serves as a source of heat (Postive Temperature Coefficient), and this makes direct contact with the metal cylinder. Subsequent to switch-off of the heat source, a strong compression spring returns the push rod back to its original position.
- Page 24 Service Manual Regeneration, drain-off and raw water valves The regeneration valve and the drain-off valve are located on the softening equipment. When the regeneration valve is activated the volume of water stored in the regeneration chamber is lead through the softening equipment. When the drain-off valve is activated the volume of water stored in the heat exchanger is lead through the softening equipment to the rinsing cavity.
- Page 25 Service Manual Change in degree of hardness of the water in the appliance during several rinses ° d H °dH A g g r e s s iv e r Regeneration of Aggressive B e r e ic h ion exchanger zone R e g e n e r ie r e n d e s I o n e n ta u s c h e r s...
- Page 26 Service Manual Temperature cut-out switch IG 634.4 The temperature cut-out switch (>85°C) is combined with the temperature cut-out switch (65°C). In the event of a fault the heater will be switched off when the water temperature reaches 85°C (clocked). Water softener Screw off the outer door, the base cover, the L-strap and the side panels.
- Page 27 Service Manual Salt container - filling capacity Fine-grained salt approx. 2.0 kg Coarse-grained salt approx. 1.5 kg Salt tablets approx. 0.7 kg Aqua Stop System The valve system comprises two series-connected, parallel- activated electrical solenoid valves, the filling valve and the safety valve.
- Page 28 Service Manual Flow sensor The flow sensor is integrated in the water intake device. It registers the volume of water flowing in. It comprises a casing, an impeller wheel with a permanent magnet and a circuit board with a Reed switch. The water sets the impeller wheel in motion.
- Page 29 Service Manual Accessing individual components Hinge Unscrew the outer door, the base, the angle plate, and the side walls. Detach the traction rope from the hinge lever. Unscrew the hinge lever from the inner door. Unscrew the hinge plate from the cavity frame. Unscrew the fixing screw from between the hinge and the base pan.
- Page 30 Service Manual Technical Data Rinsing agent fill quantity 120 ml Setting 1-6 each 1 ml Cleaning agent capacity max. 45 g For further technical data, see the actuator. Disassembly Screw off the outer door. Disconnect the electrical connections. A Dosing plunger D Float magnet Use a screwdriver to lift the holding flaps that B Socket...
- Page 31 Service Manual After the drying phase the pump will be activated alternately 3 times for 5 seconds and there will be a break of 5 sec. (sputter pumping). This step is required to deaerate the pump. Disassembly Remove the base cover and the base sheet. The detergent water pump is engaged in the pump cavity on the front.
- Page 32 Service Manual Technical Data Nominal voltage 230-240 V Frequence 50 Hz Output 2150 W Resistance 22 approx.Ω Equipotential system with a safety function Should functional defects in the dishwasher control system or in the structural elements occur, resulting in an over-filling of the machine, the valve combinati- on will be closed by means of the safety system, thus blocking off the water supply.
- Page 33 Service Manual Sieve system To prevent dirt particles from getting into the rinsing circuit, the coarse sieve cylinder must be engaged tightly with the pump cavity (observe marking). Fourfold sieve system Threefold sieve system Coarse sieve B Flat sieve C Micro-fine sieve cylinder D Fine sieve cylinder The sieve system comprises a fourfold filter system (a course filter, fine sieve cylinder, a fine flat sieve and a micro-fine sieve).
- Page 34 Service Manual Rotary spray system The rotary spray system consists of three spray levels, the lower and upper spray arm and a top spray . The water supply to the upper spray arm and the top spray is brought through the inlet pipe attached to the inside of the container rear wall.
- Page 35 Service Manual Rinsing and pump system The circulating pump and the discharge pump as well as the continuous flow heater are connected to the pump cavity by means of plug connections. The continuous flow heater is also screwed to the pump cavity in such a manner that no pressure can occur.
- Page 36 Service Manual 8.10 Door spring The weight of the front of the unit is balanced with the door springs. The door springs are located on the right and on the left side below the base pan. The traction force is transmitted to the door hinge with a cable drawn over a deflection pulley.
- Page 37 Service Manual Disassembly Remove the side panels and the base sheet. Remove the 2 screws (at the front and the rear) con- necting the stainless steel shell and the plastic base pan on the right-hand side. Lift up the shell and secure it with an object which is approx.
- Page 38 Service Manual 8.12 Water diverter The water diverter is responsible for alternating rinses (the dishwasher rinses the top basket and the bottom basket in alternation, bottom basket 30 sec. / top basket 50 sec., the switchover takes approx. 6 sec.). It comprises a synchronous motor with power transmission, a cam disk, a microswitch and a slide.
- Page 39 Service Manual Operation and function IGV 659.2 and IGV 659.3 operation The electronics system comprises two modules installed in a cabinet. The control / output modul is connected to the operating /indicating module by means of a flat cable. 9.1.1 Function LEDs •...
- Page 40 Service Manual Rapid 35° This program comprises cleaning at 35°, an intermediate rinse, rinsing with a rinsing agent at 55°, and no drying. Pre-wash The program only comprises a cold rinse for the dishes. 9.1.3 Program-reset With the appliance switched on, press the S2-button and the S4-button simultaneously for 3 sec. The water will be pumped off for approx.
- Page 41 Service Manual IGV 647.1 and IGV 647.2 operation The electronics system comprises two modules installed in a cabinet. The control / output modul is con- nected to the operating /indicating module by means of a flat cable. IGV 634.4 operation The electronics system comprises two modules installed in a cabinet.
- Page 42 Service Manual IGV 659.4 and IGV 6508.0E operation 9.5.1 Pushbuttons/ supplementary functions (Sa – Sc) Main switch Double-polar On/Off switch with wiping contact. Soaking (optional) The button for soaking can be pressed as a supplement to any program. When the button is pressed, an additional pre-rinse program with heating up to 55°C will take place in the lower basket, resulting in an extension of the program time of approx.
- Page 43 Service Manual IGV 657.1 and IGV 644.4 operation Pre-set time (ZVW) The time-setting button enables the starting time to be postponed by up to 19 hours (setting between 0h – 19h). The button must be pressed for at least one second. Display The display consists of a 2½...
- Page 44 Service Manual IG 634.4 special functions Setting the hardness range Keep the S3-button pressed and switch on the appliance. The LED for fill-up salt will blink. The fault is indicated by means of the program LEDs (see chart “Setting the hardness range”). The setting will go up one step every time the S3 button is pressed.
- Page 45 Service Manual Hardness range chart °dH °fH °Clarke mmol / l Setting (display) IG 647..IGV 659 from 4 IG 644.4 IGVS 659 from 3 IG 644.5 IG 6508.0E IGS 644.0 0 - 3 0 - 6 0 -4 0 - 0.6 H:00 4 - 6...
- Page 46 Service Manual Remedying faults for all of the series 630 – 634 appliances Should your dishwasher develop a fault, please check up on the following before contacting our customer service (*see, too, the relevant section in the instructions for use) 10.1 Smell Customer information...
- Page 47 Service Manual 10.2 Noises Customer information Cause Remedy Knocking noises in the pipes when • Improper installation or cross section of the water pipes • Advise the customer and refer him to a plumber (have a water is being taken in (usually only occurs with appliances fitted with an aqua-stop pressure reducer installed).
- Page 48 Service Manual 10.3 Food or sandy deposits Customer information Cause Remedy Residual food or sandy deposits • Coarse, micro or fine sieve clogged • Advise the customer; sieve and care. Clean parts if necessary, Sieve not engaged in the pump cavity instruct customer on inserting the proper sieve •...
- Page 49 Service Manual Customer information Cause Remedy Residual food or sandy deposits • Snorting noises; circulation pump does not run smoothly, too • Check the functioning of the equipotential transducer (carry out little water in the dishwasher (attention in the case of a filling procedure) alternating rinse technology) •...
- Page 50 Service Manual 10.5 Starch deposits Customer information Cause Remedy Lime deposits on the dishe, starch • Insufficient detergent (unsuitable detergent) • Advise the customer; use a detergent with enzymes • Wrong program selected (program selected too weak) • Advise the customer; select the right program, •...
- Page 51 Service Manual 10.7 Discolouration / residual colour Customer information Cause Remedy Residual colour • Too little detergent used • Advise customer, increase the quantity of detergent • Plastic becomes discoloured, for example by tomato deposits, • Use a detergent with chlorine bleaching. If the dishwasher tea, coffee, etc.
- Page 52 Service Manual 10.8 Residual detergent Customer information Cause Remedy Residual detergent • Detergent dispenser lid blocked by dishes (does not fully open • Advise the customer, dishes not well loaded • Detergent dispenser lid does not fully open up • Renew the spring of the dispenser •...
- Page 53 Service Manual 10.9 Damage to rinsed dishes Customer information Cause Remedy Commencing or already present, • Degree of hardness set too high, residual hardness in washing • Optimise the setting after measuring irreversible (not rectifiable) or clear rinse cycle <5°dH cloudiness of glass •...
- Page 54 Service Manual 10.10 Drying results Customer information Cause Remedy Does not dry properly • No clear rinse in the dispenser • Advise the customer • Appliance connected to a hot water supply; appliance is • Advise the customer; point out the function of the heat suitable for hot water, but it is not recommendable.
- Page 55 Service Manual Technical data IG 6... and IGV 6... 11.1 Technical Data The data indicated may deviate upwards or downwards. The figures are those resulting from laboratory tests in accordance with EN 50242 for the start of a series. Continuous flow heater Dimensions Height 85,0 cm...
- Page 56 Service Manual IGV 647..11.2 Consumption data 11.2.1 Appliance with water diverter and heat exchanger Intensive 70° Auto 55-65° Normal 65° ECO 50° Gentle 40° Rapid 35° Pre-wash Time in min. 100-145 Power consumption in 1.15 - 1.46 1.85 1.05 Water consumption in 14 - 19...
- Page 57 Service Manual IG 644 to .4. 11.3 Consumption data 11.3.1 Appliance with water diverter and heat exchanger Intensive 70° Auto 55-65° ECO 50° Gentle 40° Rapid 35° Pre-wash Time in min. 95 - 145 Power consumption in kWh 1.15 - 1.60 1.06 Water consumption in litres 11 - 19...
- Page 58 Service Manual IG 634 to 0,3. 11.4 Consumption data 11.4.1 Appliance with water diverter and heat exchanger Intensive 70° Auto 55-65° ECO 50° Gentle 40° Rapid 35° Pre-wash Time in min. 95 - 145 Power consumption in kWh 1.15 - 1.50 1.05 Water consumption in litres 11 - 19...
- Page 59 Service Manual IG 647.2E 11.5 Consumption data 11.5.1 Appliance without heat eschanger Intensive 70° Normal 65° ECO 50° Gentle 40° Rapid 35° Pre-wash Time in min. Power consumption in kWh 1.75 1.44 Water consumption in litres The data indicated may deviate upwards or downwards. The figures are those resulting from laboratory tests in accordance with EN 50242 for the start of a series.
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