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Clarus EX618 Service Manual

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SERVICE MANUAL
DOC. NO. 438.9201-65/08
EDITION 49.2004
EX618, EX625, EX630,
EX640, EX655, EX670
Clarus Control

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Summary of Contents for Clarus EX618

  • Page 1 SERVICE MANUAL DOC. NO. 438.9201-65/08 EDITION 49.2004 EX618, EX625, EX630, EX640, EX655, EX670 Clarus Control...
  • Page 3 NOTICE TO SERVICE PERSONNEL INSTALLATION Improper installation of Wascomat laundry and wet cleaning equipment can result in personal injury and severe damage to the machine. REFER INSTALLATION TO QUALIFIED PERSONNEL! RISK OF ELECTRIC SHOCK The equipment utilizes high Voltages. Disconnect electric power before servicing. The use of proper service tools and techniques, and the use of proper repair procedures, is essential to the safety of service personnel and equipment users.

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  • Page 5 Service Manual EX618, EX625, EX630, EX640, EX655, EX670 Clarus Control WARNING: ALL OPERATING AND MAINTENANCE PROCEDURES SHOWN ON THE NEXT PAGE OF THIS MANUAL MUST BE FOLLOWED DAILY FOR PROPER OPERATION OF YOUR WASCOMAT MACHINE. PLEASE ENTER THE FOLLOWING INFORMATION AS IT APPEARS ON THE MACHINE(S) DATA PLATE(S).
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  • Page 7 SAFETY AND WARNINGS SIGNS Replace If Missing Or Illegible One or more of these signs must be affixed on each machine as indica- ted, when not included as part of the front instruction panel. LOCATED ON THE OPERATING INSTRUCTION SIGN OF THE MACHINE: PRECAUCION CAUTION 1.
  • Page 8 Wascomat. Check the door safety interlock, as follows: OPEN THE DOOR of the machine and attempt to start in the normal manner: For CLARUS microprocessor models, choose a program and press the START button. THE MACHINE(S) MUST NOT START ! CLOSE THE DOOR to start machine operation and, while it is operating, attempt to open the door without exerting extreme force on the door handle.
  • Page 9 Safety precautions Technical data Machine presentation Overview Programmes Regular maintenance Service Troubleshooting instructions Control unit Programme unit Machine components and parts Door and door lock Motor and motor control Drain valve Detergent compartment Heating Instruction for pulley and replacing bearings Frame Options...
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  • Page 11 1. Safety precautions Contents Safety precautions ..................3 Warnings ....................3 438 9144-41/01 00.23...
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  • Page 13: Safety Precautions

    Service Manual 1. Safety precautions Safety Precautions • The machine is only intended for washing with water. • Do not allow minors to operate the machine. • Installation and maintenance work should only be done by authorized persons • Do not bypass the door lock of the machine. •...
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  • Page 15 2. Technical data Contents Technical data................... 3 Physical features .................. 3 Connections ..................4 438 9170-81/02 03.20...
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  • Page 17: Technical Data

    Service Manual 2. Technical data Technical data Physical features Model types Washer extractor EX618 EX625 EX630 EX640 EX655 EX670 Inner drum Volume litres/ft 75/2.6 105/3.7 130/4.6 180/6.4 240/8.5 300/10.6 Diameter mm/inch 520/20 1/2 595/23 7/16 650/25 9/16 725/28 9/16 795/31 5/16 795/31 5/16...

  • Page 18: 2. Technical Data

    Service Manual 2. Technical data Technical data EX618 EX625 EX630 EX640 EX655 EX670 Innerdrum 75/2.6 105/3.7 130/4.6 180/6.4 240/8.5 300/10.6 volume litres/ft 520/20 1/2 595/23 7/16 650/25 9/16 725/28 9/16 795/31 5/16 795/31 5/16 diameter mm/inch Drum speed wash 1100...
  • Page 19 Steam connection Drain Liquid detergent supply Control panel Soap box Door opening, EX618: ø 310 mm/12 3/16", EX625: ø 365 mm/14 3/8", EX630: ø 395 mm/15 9/16", EX640, EX655, EX670: ø 435 mm/17 1/8" in mm EX618 720 690 1115 355...
  • Page 20 12 3/16 48 13/16 13 3/4 15 3/8 3 5/16 14 3/16 20 1/16 EX670 12 3/16 14 15/16 – – 3 15/16 14 3/16 13 3/16 EX618, EX625, EX630 5281 5282 5283 Front Right side Rear side EX640, EX655 EX670 5377 5379...
  • Page 21 Service Manual 2. Technical data EX618 EX625 EX630 EX640 EX655 EX670 Frequency of the dynamic force 18.7 17.1 16.4 15.5 14.8 13.7 435±120 554±120 723±120 940±240 1085±240 1320±312 Max floor load lbs force at extraction 1.8±0.5 2.3±0.5 3.0±0.5 3.9±1.0 4.5±1.0 5.5±1.3...
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  • Page 23: Table Of Contents

    3. Machine presentation Contents Description ....................General ....................Function ....................4 General ....................4 Programme unit ..................5 Motor and motor control ............... 6 Door lock ....................7 Heating ....................8 Water connections ................8 Rear control unit ................... 8 Detergent compartment ...............
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  • Page 25: Machine Presentation

    Service Manual 3. Machine presentation Description General The machines covered in this manual include: Fig. Drum volume Model type litres/ft 75/2.6 EX618 105/3.7 EX625 130/4.6 EX630 180/6.4 EX640 240/8.5 EX655 300/10.6 EX670 The programme unit contains a microprocessor with a number of standard programmes for normal wash cycles.

  • Page 26: Function

    Service Manual 3. Machine presentation Function General This section presents an overview of the functions of the machine. Most Fig. functions are then presented in detail in separate chapters in the service manual. Water inlet valves Rear control unit I/O card Detergent compartment Front control unit Motor control...

  • Page 27: Programme Unit

    Service Manual 3. Machine presentation Programme unit The programme unit is made up of the CPU card, Fig. the display card, card reader and one or two I/O Programme unit I/O card cards. The programme unit holds a number of Fig.

  • Page 28: Motor And Motor Control

    Service Manual 3. Machine presentation Motor and motor control A frequency-regulated motor using a drive belt Fig. drives the drum. The motor is situated on a motor Motor control shelf, under the outer drum with a tensioner device for the drive belt. The motor control relies on microcomputer Fig.

  • Page 29: Door Lock

    Service Manual 3. Machine presentation Door lock Door lock control A31 The door lock is an electro-mechanical type with Fig. double safety switches. The lock is bi-stable, i.e., it needs to receive an active pulse from the control in order to both lock and unlock the door. A separate printed circuit board, called door lock Fig.

  • Page 30: Heating

    Service Manual 3. Machine presentation Heating Rear control unit When using electric heating, the water for Fig. washing is heated by three heating elements Contactor K21 Main power switch accessible from the front of the machine. (heating) The machine can also be fitted with steam heating using a steam valve fitted on the rear of the machine.

  • Page 31: Detergent Compartment

    Service Manual 3. Machine presentation Detergent compartment The compartment is divided into four for pre- Fig. Detergent compartment wash, main wash, rinse and bleaching-agent/ liquid detergent. The detergent compartment of the machines is described in detail in section 39. Detergent compartment.
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  • Page 33 11. Regular maintenance Contents Daily ......................3 Every third month ..................3 438 9145-01/02 04.49...
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  • Page 35 Service Manual 11. Regular maintenance To keep your machine in proper working order, follow the preventive maintenance recommendations provided below. The maintenance interval should be adjusted according to machine usage. The suggested schedule assumes an 8 hour work day, and a 5 day work week..
  • Page 36 Service Manual 11. Regular maintenance - Inspect all internal hoses, seals and gaskets for signs of leakage. Repair as necessary. - Check that water inlet screens are clean of debris. Dirty screens result in longer fill times, which reduce productivity. - Inspect the drive belt.
  • Page 37 12. Troubleshooting Contents General information about troubleshooting ..........3 Precautions ..................3 Measurements ..................3 Errors with no error codes ..............4 Errors with error codes ................ 4 Error indication ................4 Resetting an error indication ............4 Error codes ..................4 Service programme ................
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  • Page 39: General Information About Troubleshooting

    Service Manual 12. Troubleshooting General information about troubleshooting The troubleshooting section is used to pinpoint a fault on the machine to a specific defective component or unit. If the power supply is interrupted, the programme memory will keep the select programme in its memory for approx. 3-5 minutes. Within this time period, the machine automatically restarts after the power interruption.

  • Page 40: 12. Troubleshooting

    Service Manual 12. Troubleshooting Errors with no error codes This section includes troubleshooting charts for errors for which no error code is generated. Errors with error codes Error indication Programme or machine errors are indicated by an alarm text in the display Fig.

  • Page 41: Troubleshooting

    Service Manual 12. Troubleshooting List of errors, functions monitored and relevant error messages displayed Error/Function Error message displayed 01 ERROR. NO WATER Water level has not reached set level within time set. After this error message appears and the machine is reset, the machine will try again.
  • Page 42 Service Manual 12. Troubleshooting List of errors, functions monitored and relevant error messages displayed, cont. Error/Function Error message displayed 15 ERROR. EMERGENCY STOP The emergency stop button has been pressed. EMERGENCY STOP 17 ERROR. DOOR LOCK SWITCH Even though the door lock microswitch indicates that the door is locked, the signal from the microswitch which is used to detect when the door is closed is absent.
  • Page 43 Service Manual 12. Troubleshooting List of errors, functions monitored and relevant error messages displayed, cont. Error/Function Error message displayed ERROR. ERROR CODES FROM MOTOR This function includes a number of error warnings from the motor control system for frequency-controlled motors (EWD) 31 Temperature of MCU control circuits too high HEAT SINK TOO HOT 32 Motor thermal protection has tripped...

  • Page 44: Service Programme

    Service Manual 12. Troubleshooting Service programme The service program Opening the service programme The service program makes fault-finding on the machine easier, as it allows you to control the If this menu is not currently various machine functions individually: displayed: •...
  • Page 45 Service Manual 12. Troubleshooting To prevent unauthorised or accidental use Unauthorised or accidental use of the service program is prevented by requiring the user to locate PRESS BUTTON ON Press the button on the and press the button on CPU board. CPU BOARD CPU circuit board.

  • Page 46: To Control The Machine Functions

    Service Manual 12. Troubleshooting To control the machine functions SERVICE PROGRAM LEVEL TEMP 22°C SPEED DRAIN CLOSED 01 COLD WATER 02 HOT WATER 03 COLD HARD WATER 04 TANK 1 WATER 05 TANK 2 WATER 06 TANK 3 WATER To activate the various 01 COLD WATER machine functions: 02 HOT WATER...

  • Page 47: I/O Card Inputs

    Service Manual 12. Troubleshooting I/O card inputs Press 1. SERVICE PROGRAM LEVEL Now you can check the TEMP 22°C SPEED various input signals from I/O DRAIN CLOSED board 1. EMERGENCY STOP DOOR LOCKED TEMPORARY PAUSE DOOR CLOSED A black square in front of the REMOTE START UNBALANCE SERVICE...

  • Page 48: Errors With No Error Codes

    • verify the fuses F11 and F12 (T 1.25 A) on the Fig. communication card A21. Replace burnt-out fuses. 1. Perform a communication test using the test box. Refer to the manual ”Instructions for Clarus Communication Tests”. OK LED on test box Defective LEDs on test box Troubleshoot according to the manual ”Instructions for...

  • Page 49: Errors With Error Codes

    Service Manual 12. Troubleshooting Errors with error codes NO WATER The water level has not reached the selected level within the given time. Following an alarm and subsequent, the machine will make a new attempt. First verify that: • the programme unit was not incorrectly 3973 programmed Valve...
  • Page 50 Service Manual 12. Troubleshooting Continued from previous page 5. Activate (close) the drain valve in the service programme. Activate another of the water valves and verify the drain valve function. Drain valve OK Drain valve defective Troubleshoot the drain valve according to the instructions under error code WATER IN DRUM later in this troubleshooting section.

  • Page 51: Door Open

    Service Manual 12. Troubleshooting DOOR OPEN No signal from the ”Door closed” during programme operation. If the input signal for ”Door closed” is lost during programme operation, the OPEN DOOR error code is immediately generated. If the power is on, be very careful when working on the the machine.
  • Page 52 Service Manual 12. Troubleshooting Continued from previous page Microswitch S3 4. Disassemble the door lock and verify the function of Fig. S3 using an ohm meter. Correct function Incorrect function Replace S3./Change door lock. 5. Inspect the cabling between X5 and S3 using an ohm meter.

  • Page 53: Door Unlocked

    Service Manual 12. Troubleshooting DOOR UNLOCKED No signal from the ”Door closed” at programme start. At programme start, this error code is suppressed for a few seconds. If the power is on, be very careful when working on the the machine. 1.

  • Page 54: Ntc Low Temp

    Service Manual 12. Troubleshooting NTC LOW TEMP The programme unit indicates an interruption with the temperature sensor or the ° temperature is below -5 Try to restart the machine (i.e. reset the error code) by pressing START. 1. Undo the temperature sensor connections and Fig.

  • Page 55: Ntc High Temp

    Service Manual 12. Troubleshooting NTC HIGH TEMP The programme unit indicates a short-circuit with the temperature sensor or the ° temperature exceeds 98 Try to restart the machine (i.e. reset the error code) by pressing START. Fig. 1. Undo the temperature sensor connections and measure the resistance of the sensor.

  • Page 56: Water In Drum

    Service Manual 12. Troubleshooting WATER IN DRUM Level indication The water level is higher than EMPTY at programme start. SERVICE PROGRAM LEVEL First verify whether: TEMP 22°C SPEED DRAIN CLOSED • the same error appears again following EMERGENCY STOP DOOR LOCKED TEMPORARY PAUSE DOOR CLOSED resetting of the error code...

  • Page 57: Machine Overfilled

    Service Manual 12. Troubleshooting MACHINE OVERFILLED Level indication The water level is above the level for OVERFILLED MACHINE. If this function is SERVICE PROGRAM switched off (=N) the drain valve will open LEVEL TEMP 22°C SPEED instead for a short while to drain some of the DRAIN CLOSED EMERGENCY STOP DOOR LOCKED...

  • Page 58: Heating

    Service Manual 12. Troubleshooting NO HEATING The temperature has not increased the number of degrees specified in the function MIN ALLOWABLE TEMPERATURE INCREASE during the time that is programmed in the function MAXIMUM HEATING TIME (Configuration 1). If the power is on, be very careful when working on the the machine.

  • Page 59: Not Drained

    Service Manual 12. Troubleshooting NOT DRAINED The water level exceeds EMPTY when the drain sequence is completed. Try to restart the machine (i.e. reset the error code) by pressing START. If the error returns, first verify these items: • Is the drain is blocked by fluff or foam? •...

  • Page 60: Unbalance Sensor Fault

    Service Manual 12. Troubleshooting UNBALANCE SENSOR FAULT The imbalance switch is closed when the machine enters a drain sequence. If the power is on, be very careful when working on the the machine. Try to restart the machine (i.e. reset the error code) by pressing START. If the error returns, troubleshoot as follows: Verify: •...

  • Page 61: No Motor Comm

    Try to restart the machine (i.e. reset the error code) by pressing START. If the error returns, troubleshoot as follows: 1. Perform a communication test using the test box. Refer to the manual ”Instructions for Clarus Communication Tests”. OK LED on test box Defective LEDs on test box Troubleshoot according to the manual ”Instructions for...

  • Page 62: Level Calibration

    Service Manual 12. Troubleshooting LEVEL CALIBRATION The water level system has not been correctly calibrated. Each machine has been individually level adjusted at the factory. If the calibration values are missing or outside the limits, an error is generator at programme start.

  • Page 63: Emergency Stop

    Service Manual 12. Troubleshooting EMERGENCY STOP The emergency stop button was pressed. If the power is on, be very careful when working on the the machine. Find out the reason for the emergency stop button having been pressed. Take the necessary measures. Reset the emergency stop button by turning it counter-clockwise.

  • Page 64: Door Lock

    Service Manual 12. Troubleshooting DOOR LOCK The signal from the ”Door locked ” switch is present although there is no signal from the ”Door closed” switch. This error code can only be generated prior to programme start. If the power is on, be very careful when working on the the machine.

  • Page 65: Start Not Allowed

    Service Manual 12. Troubleshooting START NOT ALLOWED The network does not allow start of the washing programme. Try to reset the error code. If the error remains, contact the responsible person for the network and have the error fixed. 438 9152-11/02 04.06...

  • Page 66: Mis Communication

    Service Manual 12. Troubleshooting MIS COMMUNICATION Communication between the programme unit card A1 and the network has been interrupted. If the power is on, be very careful when working on the the machine. Try to restart the machine (i.e. reset the error code) by pressing START.

  • Page 67: Interlock Status

    Service Manual 12. Troubleshooting INTERLOCK STATUS X302 The motor controller does not receiving an interlock signal during programme operation. If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 68: Io Communication

    Try to restart the machine (i.e. reset the error code) by pressing START. If the error returns, troubleshoot as follows: 1. Perform a communication test using the test box. Refer to the manual ”Instructions for Clarus Communication Tests”. OK LED on test box Defective LEDs on test box Troubleshoot according to the manual ”Instructions for...

  • Page 69: Low Oil Level

    Service Manual 12. Troubleshooting LOW OIL LEVEL Low oil level in the oil container. Applies only to machines with oil lubrication. Fill up with oil and restart the machine. Verify for any leaks. 438 9152-11/02 04.06...

  • Page 70: Phase

    Service Manual 12. Troubleshooting PHASE Alarm from the network monitoring equipment. An input on I/O card 1 (X16:7-8) can be connected to external equipment that monitors received network signals in terms of voltage levels, loss of phase, etc. If this input goes high, the error message is displayed. Find out the reason for the error indication by inspecting the network monitoring equipment.

  • Page 71: Aut. Level Calib

    Service Manual 12. Troubleshooting AUT. LEVEL CALIB. Level indication The pressure sensor for the water level signals a value that is so incorrect when the machine is empty that automatic level calibration of the SERVICE PROGRAM level system is not possible. LEVEL TEMP 22°C...

  • Page 72: Heat Sink Too Hot

    Service Manual 12. Troubleshooting HEAT SINK TOO HOT The motor controller indicates too high a temperature at the heat dissipator. This error code appears if the external temperature has been very high. It his has been the case, lower the temperature by e.g., ventilation the room.

  • Page 73: Motor Too Hot

    Service Manual 12. Troubleshooting MOTOR TOO HOT Measure the resistance between pins 7 and 9 The motor controller indicates the thermal protector of the motor has triggered. If the power is on, be very careful when working on the the machine. Contactor X3, female towards motor First verify that: 5420...
  • Page 74 Service Manual 12. Troubleshooting Continued from previous 4. Replace X3. Remove the contactor X312 Fig. and measure the resistance of the contactor with the motor cabling between X312:4 - 5. Contact Interruption Defective cabling between motor controller and motor. Inspect the cabling and replace if necessary.

  • Page 75: No Interlock

    Service Manual 12. Troubleshooting NO INTERLOCK X302 The motor controller received the start command from the programme unit but receives no interlock ACK (”Door locked” signal). If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 76: Motor Shortning

    Service Manual 12. Troubleshooting MOTOR SHORTNING Contactor X3, female towards motor The motor controller indicates a short-circuit in the motor windings, cabling or internally in the motor controller. If the power is on, be very careful when working on the the machine. Measure resistance between pins 1, 2 and 3 Switch off the machine for at least 30 seconds to ensure the motor controller has been completely...

  • Page 77: Interlock Hardware

    Service Manual 12. Troubleshooting INTERLOCK HARDWARE The motor controller indicates an error in the interlock receiving circuit. If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 78: Low Dc Voltage

    Service Manual 12. Troubleshooting LOW DC VOLTAGE X311 The motor controller indicates the DC level is too low. If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 79: High Dc Voltage

    Service Manual 12. Troubleshooting HIGH DC VOLTAGE X311 The motor controller indicates the DC level is too high. If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 80: Rippel On Dc Bus

    Service Manual 12. Troubleshooting RIPPEL ON DC BUS X311 The DC voltage level fluctuates too much. If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 81: Line Interrupt

    Service Manual 12. Troubleshooting LINE INTERRUPT X311 The motor controller is missing a phase. If the power is on, be very careful when working on the the machine. Switch off the machine for at least 30 seconds to ensure the motor controller has been completely reset.

  • Page 82: Klixon Circuit

    Service Manual 12. Troubleshooting KLIXON CIRCUIT The motor controller indicates an error inn the thermal protection circuits of the motor. If the power is on, be very careful when working on the the machine. Switch off the machine and for about 30 seconds. Then switch on the machine again and start a programme.

  • Page 83: Troubleshooting The Keypad In The Display Unit

    Service Manual 12. Troubleshooting Troubleshooting the keypad in the display unit When a key is pressed on the keypad of the programme unit, two of the outputs on the keypad close. By disconnected the flat cable from the display card, pressing a key and the measuring the resistance between the outputs that should close, it is possible to determine correct operation of any one key.

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  • Page 85 21. Control unit Contents Description ....................3 Function ....................4 Front control unit .................. 4 Rear control unit ................... 7 438 9145-21/02 02.49...
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  • Page 87: Control Unit

    Service Manual 21. Control unit Description The control unit of the machine consists of the following parts: Fig. • Front control unit This unit contains two microcomputer controlled electronic programme units consisting of a CPU card A1, display card A2, card reader A3 and one or two I/O cards A11 and A12.
  • Page 88 Service Manual 21. Control unit Function Front control unit Programme unit I/O card 2 The programme unit consists of the following Fig. parts: • CPU card A1 Fig. I/O card 1 The CPU card uses the various control programmes in the card programme memory to check the various functions of the washing machine.

  • Page 89: Section 23. Programme Unit

    Service Manual 21. Control unit • I/O cards A11 and A12 Most smaller machines have only one card: A11. The I/O cards are controlled by the CPU card via a serial interface. The I/O cards feature outputs, which, via the communication card in the rear control unit, control various machine functions, such as the water valves, heating connection and drain valve.

  • Page 90: Section 29. Door And Door Lock

    Service Manual 21. Control unit Door lock control A31 This card serves to perform a safety check of the Fig. door lock function. The card checks the water level using level guard B2 and the drum speed by way of a rotation sensor B3.
  • Page 91 Service Manual 21. Control unit Rear control unit Main power switch Q1 Model with main power switch The main power switch interrupts all received Fig. Heating contactor K21 power phases and is situated on the outside of Main power switch Q 1 the connection box cover.
  • Page 92 Service Manual 21. Control unit Communication card A21 Fig. This card is used to send and receive signals from I/O card 1. It contains: • Fuses F11 and F12 (T 1.25 A) Fig. Protects the received voltage supply in the Communication card A21 timer and door lock controller.
  • Page 93 Service Manual 21. Control unit Communication card A22 Fig. This card is used to send and receive signals from I/0 card 1. It contains: • Input/output connection blocks Fig. Communication card A22 Card No. Function Output (200 - 240 V AC) 0 V (common) Liquid detergent 5 Liquid detergent 6...
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  • Page 95 23. Programme unit Contents Description ....................3 Function ....................5 CPU card A1 ..................5 Display card A2 ..................7 I/O-cards ....................8 Input and outputs on I/O cards 1 and 2 ..........9 The service program ................14 To select the "Service program" function ........... 15 To control the machine functions ............
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  • Page 97: Description

    Service Handbok 23. Programme unit Description The programme unit of the machine consists of Fig. I/O card 2 A12 the following parts: • CPU card A1 Fig. The CPU card uses the various control I/O card 1 A11 programmes in the card programme memory to check all the functions of the washing machine.
  • Page 98 Service Handbok 23. Programme unit • I/O cards A11 and A12 Most smaller machines have only one card: A11. On some machines, there is a greater need for outputs, in which case two I/O cards are used. The I/O cards are controlled by the CPU card via a serial interface. The I/O cards feature outputs, which, via the communication cards in the rear electric box, control various machine functions, such as the water valves, heater connection and drain valve.

  • Page 99: Function

    Service Handbok 23. Programme unit Function CPU card A1 The CPU card controls all functions of the washing machine using various Fig. control programmes in the CPU card memory. The CPU card communicates with the I/O card, display card and motor controller using a serial interface.
  • Page 100 Service Handbok 23. Programme unit The two pins in switch X7 are shorted to confirm changes made in Configuration 1 and 2. Pushbutton SW1: used as an P1, P2 Used for factory acknowledgement button when in the calibration of the Service programme mode (the same pressure sensor.

  • Page 101: Display Card A2

    Service Handbok 23. Programme unit Display card A2 Fig. The display card communicates with the CPU card through a serial interface. The CPU card informs what should be displayed in the display window and the display card converts these messages to information that controls the alphanumeric display window.

  • Page 102: I/O-Cards

    Service Handbok 23. Programme unit I/O cards Fig. The I/O cards are controlled by the CPU card and communicate via a serial interface. Depending on the need for inputs and outputs, one programme unit may have one or two I/O cards. All inputs and outputs are switched from the I/O card to the various functions via the communication cards in the rear electric module.

  • Page 103: Input And Outputs On I/O Cards 1 And 2

    Service Handbok 23. Programme unit Input and outputs on I/O cards 1 and 2 Card switch I/O-card 1 A11 I/O-card 2 A12 Serial interface and voltage supply X1: 1-3 Serial interface to card 2 16 V+ supply to card 2 0 V–...
  • Page 104 Service Handbok 23. Programme unit Inputs and outputs on I/O cards 1 and 2 I/O-card D.card A21 I/O-card 1 A11 Connection block No. Switch No. Relay No. Function Outputs X4: 1 Neutral Door lock relay, phase (normally open) Neutral Door lock relay, phase (normally open) X7: 1 Drain 1 (Y1), phase (usually open) Common neutral...
  • Page 105 Service Handbok 23. Programme unit Inputs and Outputs on I/O card 1 and 2 I/O-card D.card A22 I/O-card 2 A12 Connection block No. Switch No. Relay No. Function Outputs X4: 1 X77:1 Flashlight, phase X7: 1 Cold, hard water (Y35) N (neutral) X8: 1 Heater relay (K22)
  • Page 106 Service Handbok 23. Programme unit I/O-card D.card A21 I/O-card 1 A11 Connection block No. Opto-coupler Relay No. Function Inputs X5: 1 Door lock micro-switch S4/N, Com Door lock micro-switch S4/N, No Door lock position micro-switch S3/N Door lock micro-switch S4/Phase X15:1 X70:4 External start/stop signal, phase...
  • Page 107 Service Handbok 23. Programme unit I/O-card D.card A22 I/O-card 2 A12 Connection block No. Opto-coupler Relay No. Function Inputs X5: 1 X15:1 X74:2 Switch heat 1/heat 2, phase Switch heat 1/heat 2, neutral X16:1-2 438 9145-41/01 00.23...

  • Page 108: The Service Program

    Service Handbok 23. Programme unit The service program The service programme facilitates troubleshooting on the machine by enabling control of all machine functions. Input signals to the various I/O cards that are active are also indicated. The following functions can be controlled: COLD WATER LOW EXTRACT HOT WATER...

  • Page 109: To Select The "Service Program" Function

    Service Handbok 23. Programme unit To select the ”Service Program” function The service program The service program makes fault-finding on the machine easier, as it allows you to control the various machine functions individually: If this menu is not currently displayed: •...
  • Page 110 Service Handbok 23. Programme unit To prevent unauthorised or accidental use Unauthorised or accidental use of the service program is prevented by requiring the user to locate PRESS BUTTON ON Press the button on the and press the button on CPU board. CPU BOARD CPU circuit board.

  • Page 111: To Control The Machine Functions

    Service Handbok 23. Programme unit To control the machine functions SERVICE PROGRAM LEVEL TEMP 22°C SPEED DRAIN CLOSED 01 COLD WATER 02 HOT WATER 03 COLD HARD WATER 04 TANK 1 WATER 05 TANK 2 WATER 06 TANK 3 WATER To activate the various 01 COLD WATER machine functions:...

  • Page 112: I/O Card Inputs

    Service Handbok 23. Programme unit I/O card inputs Press 1. Now you can check the SERVICE PROGRAM LEVEL various input signals from I/O TEMP 22°C SPEED board 1. DRAIN CLOSED EMERGENCY STOP DOOR LOCKED TEMPORARY PAUSE DOOR CLOSED REMOTE START UNBALANCE A black square in front of the SERVICE...

  • Page 113: Settings 1

    Service Handbok 23. Programme unit Settings 1 In the Configuration 1 mode, the variables can be changed without requesting a special password from the supplier: ADJUST TIME ALLOWED LEVEL UNBALANCE ADJUST TEMPERATURE ALLOWED LEVEL LOW RAPID ADVANCE ALLOWED LEVEL MEDIUM SHOW WEIGHT ALLOWED LEVEL HIGH WATER REDUCTION NOT ALLOWED...

  • Page 114: To Select The "Settings 1" Function

    Service Handbok 23. Programme unit To select the ”SETTINGS 1” function If this menu is not currently RUN A WASH PROGRAM displayed: GO TO THE MENU Press repeatedly. MAKE YOUR CHOICE WITH AND PRESS SELECT WEIGHT, KG 000,0 SELECT Press to highlight ”GO TO THE MENU”.

  • Page 115: Password

    Service Handbok 23. Programme unit Password Password protection or not? It is for you to decide whether or not the functions SETTINGS 1 and PROGRAMMING will be To open the function without a password password-protected. Please note that if you do decide to implement password protection for either SETTINGS 1 of them, then access to both these functions will...
  • Page 116 Service Handbok 23. Programme unit To change the password SETTINGS 1 PLEASE ENTER YOUR PASSWORD: ENTER NEW PASSWORD: Enter your four-digit password. Once the correct password has been entered, the display will show and SELECT. Press Enter the new four-digit password.

  • Page 117: Variables Under "Settings 1

    Service Handbok 23. Programme unit Variables under ”SETTINGS 1” When the top line of a menu SETTINGS 1 is highlighted you have the ADJUST TIME ALLOWED option of scrolling down ADJUST TEMPERATURE ALLOWED through the menu faster by RAPID ADVANCE ALLOWED MANUAL FUNCTIONS ALLOWED PAUSE ALLOWED pressing...
  • Page 118 Service Handbok 23. Programme unit Altering ”step time” allowed ADJUST TIME ALLOWED Here you determine if manual adjustment of the ADJUST TEMPERATURE ALLOWED remaining ”step time” (by using to move to RAPID ADVANCE ALLOWED the line for ”STEP TIME” then entering a new time) SHOW WEIGHT ALLOWED will be allowed.
  • Page 119 Service Handbok 23. Programme unit Rapid advance allowed ADJUST TIME ALLOWED Here you determine whether it is allowed to use ADJUST TEMPERATURE ALLOWED rapid advance forwards or backwards through the RAPID ADVANCE ALLOWED wash program during program operation. SHOW WEIGHT ALLOWED WATER REDUCTION NOT ALLOWED 991 NORMAL 95°C STD PROGRAM STEP: MAIN WASH...
  • Page 120 Service Handbok 23. Programme unit For machines with weight measurement installed only! Water reduction not allowed ADJUST TIME ALLOWED If the weight measurement function is installed, the ADJUST TEMPERATURE ALLOWED water level will be reduced automatically if the RAPID ADVANCE ALLOWED machine does not have a full load.
  • Page 121 Service Handbok 23. Programme unit ADJUST TIME ALLOWED ADJUST TEMPERATURE ALLOWED Pause allowed RAPID ADVANCE ALLOWED Here you determine whether it is allowed to use SHOW WEIGHT ALLOWED the pause function during the wash program. This WATER REDUCTION NOT ALLOWED function will not work until the second time the MANUAL FUNCTIONS ALLOWED program is run.
  • Page 122 Service Handbok 23. Programme unit Changing wash program allowed ADJUST TIME ALLOWED ADJUST TEMPERATURE ALLOWED Here you determine whether it is allowed to RAPID ADVANCE ALLOWED change to a different wash program during program operation. SHOW WEIGHT ALLOWED WATER REDUCTION NOT ALLOWED MANUAL FUNCTIONS ALLOWED 991 NORMAL 95°C STD PAUSE ALLOWED...
  • Page 123 Service Handbok 23. Programme unit Altering extraction speed allowed RAPID ADVANCE ALLOWED SHOW WEIGHT ALLOWED Here you determine whether it is allowed to alter the extraction speed during the current extraction WATER REDUCTION NOT ALLOWED sequence by using to move to the DRUM MANUAL FUNCTIONS ALLOWED SPEED line and entering a new value.
  • Page 124 Service Handbok 23. Programme unit MANUAL FUNCTIONS ALLOWED Display actual temperature FREE TEXT ALLOWED Here you determine whether the actual water CHANGE WASH PROGRAM ALLOWED temperature will be displayed during the program. AUTO RESTART ALLOWED ADJUST SPIN SPEED ALLOWED. DISPLAY REMAINING TIME 991 NORMAL 95°C STD DISPLAY ACTUAL TEMPERATURE PROGRAM STEP: MAIN WASH...
  • Page 125 Service Handbok 23. Programme unit Machine not heated Here you determine if the machine is to heat the water to the required temperature before the time CHANGE WASH PROGRAM ALLOWED the wash sequence starts, or if the wash time of the AUTO RESTART ALLOWED sequence is to begin directly after water filling.
  • Page 126 Service Handbok 23. Programme unit ADJUST SPIN SPEED ALLOWED. DISPLAY REMAINING TIME ° DISPLAY ACTUAL TEMPERATURE Temperature in DISPLAY ACTUAL SPEED Here you determine if all temperatures are to be MACHINE NOT HEATED shown in °C or °F. TEMPERATURE CONTROL OF WATER If you answer Yes (Y): °...
  • Page 127 Service Handbok 23. Programme unit DISPLAY ACTUAL TEMPERATURE DISPLAY ACTUAL SPEED No access to standard programs MACHINE NOT HEATED TEMPERATURE CONTROL OF WATER Here you determine whether the user will have TEMPERATURE IN °C access to the machine’s standard programs REPEAT PROGR.
  • Page 128 Service Handbok 23. Programme unit MACHINE NOT HEATED TEMPERATURE CONTROL OF WATER TEMPERATURE IN °C Water level after unbalance halt REPEAT PROGR. MODE QUESTION Here you determine the water level to which the LOCKED STANDARD WASH PROGRAMS N machine fills after a halt in extraction due to LEVEL QUICK COOL-DOWN unbalance.
  • Page 129 Service Handbok 23. Programme unit Middle temperature cool-down Here you determine the middle temperature for cool- LEVEL QUICK COOL-DOWN down. LEVEL UNBALANCE When creating a new wash program you can, to LEVEL LOW prevent creasing of the load, use the COOL-DOWN LEVEL MEDIUM module to achieve controlled cool-down of the water LEVEL HIGH...
  • Page 130 Service Handbok 23. Programme unit LEVEL UNBALANCE LEVEL LOW LEVEL MEDIUM LEVEL HIGH MIDDLE TEMPERATURE COOL-DOWN 70 °C DEFAULT MOTOR ON TIME 0:12 Flush times DEFAULT MOTOR OFF TIME 0:03 Here you determine times relating to flushing clean FLUSH DELAY TIME 0:06 the supply lines of an external system for liquid FLUSH ON TIME...
  • Page 131 Service Handbok 23. Programme unit LEVEL UNBALANCE LEVEL LOW LEVEL MEDIUM LEVEL HIGH MIDDLE TEMPERATURE COOL-DOWN 70 °C DEFAULT MOTOR ON TIME 0:12 DEFAULT MOTOR OFF TIME 0:03 FLUSH DELAY TIME 0:06 Maximum filling time FLUSH ON TIME 0:10 Here you determine the maximum time to be BUZZER ON BUTTON allowed for filling the machine with water to the MAX FILLING TIME...
  • Page 132 MAX FILLING TIME 10:00 restored. MAX HEATING TIME 10:00 SHOW WEIGHT TIMEOUT 0:20 CLARUS CONTROL PC5 BLOCKING OF HEATING WEIGHT, KG: PC5 BLOCKING OF SPINNING Weight display 007,0 HEAT 2 AS STANDARD mode...
  • Page 133 Service Handbok 23. Programme unit MIDDLE TEMPERATURE COOL-DOWN 70 °C DEFAULT MOTOR ON TIME 0:12 DEFAULT MOTOR OFF TIME 0:03 FLUSH DELAY TIME 0:06 FLUSH ON TIME 0:10 BUZZER ON BUTTON MAX FILLING TIME 10:00 MAX HEATING TIME 10:00 Relay for steam as standard SHOW WEIGHT TIMEOUT 0:20 Here you decide if the machine should heat with...
  • Page 134 Service Handbok 23. Programme unit Buzzer length at programme end Here you determine for how long the buzzer should sound at the end of the programme unless BUZZER TIMEOUT AT END 0:20 it is not turned off manually. When programming the main data for a washing programme, it is possible to select whether or not to sound the buzzer at the programme end.
  • Page 135 Service Handbok 23. Programme unit Password set Here you determine whether or not to set a PASSWORD SET password according to the explanations. 438 9145-41/01 00.23...
  • Page 136 Service Handbok 23. Programme unit To conclude making changes in variables To prevent inadvertent changes in variables under ”SETTINGS 1” If you have changed any variables under “Settings 1”, when you have finished keying in the changes, you need to insert a strap between two terminals on the CPU circuit board to register the changes in the SETTINGS 1 CPU.

  • Page 137: Settings 2

    Service Handbok 23. Programme unit Settings 2 In Configuration 2, there are variables that, in case of carelessness or lack of knowledge, may affect the safety systems or operating safety of the machine. Because of this, these variables are protected by a code system.

  • Page 138: To Select The "Settings 2" Function

    Service Handbok 23. Programme unit To select the ”SETTINGS 2” function If this menu is not currently RUN A WASH PROGRAM displayed: GO TO THE MENU Press repeatedly. MAKE YOUR COICHE WITH AND PRESS SELECT WEIGHT, KG 000,0 SELECT Press to highlight ”GO TO THE MENU”.

  • Page 139: Variables In Settings 2

    Service Handbok 23. Programme unit Variables in Settings 2 SETTINGS 2 When the top line of a menu HEATING RELAY ON WHEN NOT HEATED TEMPERATURE INCREASE ALLOWED is highlighted you have the LEVEL EMPTY LEVEL OVERFILL option of scrolling down PAUSE TEST LEVEL PAUSE TEST TEMPERATURE -18°C...
  • Page 140 Service Handbok 23. Programme unit Heating relay on HEATING RELAY ON IF NOT HEATED Here you determine whether the heating relay will TEMPERATURE INCREASE ALLOWED switch on when heating begins. LEVEL EMPTY Note that the heating relay switches on even if the LEVEL OVERFILL answer ”Yes”...
  • Page 141 Service Handbok 23. Programme unit Level empty HEATING RELAY ON IF NOT HEATED Here you determine the water level at which the TEMPERATURE INCREASE ALLOWED drum will be regarded as empty. LEVEL EMPTY It is advisable to set this level so that the inner LEVEL OVERFILL drum will have emptied, but so that some water PAUSE TEST LEVEL...
  • Page 142 Service Handbok 23. Programme unit Test values for pause HEATING RELAY ON IF NOT HEATED Here you determine whether, and if relevant, the TEMPERATURE INCREASE ALLOWED conditions under which it will be allowed for the LEVEL EMPTY user to open the door during a wash program, for LEVEL OVERFILL example to take samples of the water.
  • Page 143 Service Handbok 23. Programme unit HEATING RELAY ON IF NOT HEATED Temperature step in cool-down TEMPERATURE INCREASE ALLOWED Here you determine the maximum reduction in LEVEL EMPTY temperature per minute during the first stage of LEVEL OVERFILL cool-down. PAUSE TEST LEVEL How does cool-down work? -18 °C PAUSE TEST TEMPERATURE...
  • Page 144 Service Handbok 23. Programme unit PAUSE TEST LEVEL -18 °C PAUSE TEST TEMPERATURE 4 °C DEFAULT TEMPERATURE HYSTERIS 4 °C TEMPERATURE STEP IN COOL-DOWN DEFAULT LOW EXTRACT TIME 00:00 Default values for re-start after unbalance DEFAULT MEDIUM EXTRACT TIME 00:00 DEFAULT HIGH EXTRACT TIME 00:00 Here you determine the drain time and distribution...
  • Page 145 Service Handbok 23. Programme unit Drain open delay Here you determine whether you want a delay before the drain valve opens, for example if you want the drum to have time to gather speed first, before the valve opens. The drain module may be structured according to point 1 (here) 4 °C only, according to point 2 only, or a combination...
  • Page 146 Service Handbok 23. Programme unit Rollout time Here you determine whether you want a time delay after each extraction before the machine starts to fill with water, to give the motor time to slow down. This function is useful if the motor is not a frequency-controlled one.
  • Page 147 Service Handbok 23. Programme unit DEFAULT HIGH EXTRACT TIME 00:20 DEFAULT DRAIN TIME 00:40 DEFAULT DISTR. TIME 00:30 DO UNBALANCE MEASUREMENT DRAIN OPEN DELAY 0:13 START EXTRACT TIME 00:30 Pay per wash ROLLOUT TIME 00:01 This question is for special installations with pay PAY PER WASH ALARM systems.
  • Page 148 Service Handbok 23. Programme unit DO UNBALANCE MEASUREMENT Lock test delay DRAIN OPEN DELAY 0:13 Here you determine the length of time between START EXTRACT TIME 00:30 when the door is locked and when the check ROLLOUT TIME 00:01 should be made of the lock’s microswitch. PAY PER WASH ALARM When the machine commands that the door be LOCK TEST DELAY...
  • Page 149 Service Handbok 23. Programme unit Time drain to open after over-filling DRAIN OPEN DELAY 0:13 Here you determine how long the drain valve should open for if the machine has over-filled, START EXTRACT TIME 00:30 provided you ensure that the parameter (response) ROLLOUT TIME 00:01 stored for the function ERROR OVER-FILLED is N...
  • Page 150 Service Handbok 23. Programme unit PAY PER WASH ALARM LOCK TEST DELAY 0:10 DRAIN TIME WHEN OVERFILL 0:05 OIL LUBRICATION HOURS Oil lubrication PULSE TIME OIL LUBR. SEC 0:01 AMOUNT OF I/O MODULES (1-3) Here you determine the lubrication interval and DELAY CLEAR DOOR TEXT 04:00 pulse time for the oil lubrication systems used on...
  • Page 151 Service Handbok 23. Programme unit DRAIN TIME WHEN OVERFILL 0:05 Delay clear door text OIL LUBRICATION HOURS Here you determine how long the text ”WAITING PULSE TIME OIL LUBR. SEC 0:01 FOR DOOR TO UNLOCK” will remain visible if, for AMOUNT OF I/O MODULES (1-3) some reason, the door is not unlocked at the right DELAY CLEAR DOOR TEXT...
  • Page 152 Service Handbok 23. Programme unit Timeout during pause OIL LUBRICATION HOURS Here you determine the maximum time for a pause PULSE TIME OIL LUBR. SEC 0:01 in the program, if it is to be available for use in AMOUNT OF I/O MODULES (1-3) calculating the average length of the program.
  • Page 153 Service Handbok 23. Programme unit Door open delay for ”motor lost” AMOUNT OF I/O MODULES (1-3) DELAY CLEAR DOOR TEXT 04:00 Here you determine the length of time during which MAX DRAIN TIME 4:00 the door will be prevented from opening if, (in TIMEOUT DURING PAUSE 1:00 machines with frequency control) the MCU loses...
  • Page 154 Service Handbok 23. Programme unit List of errors, functions monitored and relevant error messages displayed Error/Function Error message displayed 01 ERROR. NO WATER Water level has not reached set level within time set. NO WATER After this error message appears and the machine is reset, the machine will try again.
  • Page 155 Service Handbok 23. Programme unit List of errors, functions monitored and relevant error messages displayed, cont. Error/Function Error message displayed 15 ERROR. EMERGENCY STOP The emergency stop button has been pressed. EMERGENCY STOP 17 ERROR. DOOR LOCK SWITCH Even though the door lock microswitch indicates that the door is locked, the signal from the microswitch which is used to detect when the door is closed is absent.
  • Page 156 Service Handbok 23. Programme unit List of errors, functions monitored and relevant error messages displayed, cont. Error/Function Error message displayed ERROR. ERROR CODES FROM MOTOR This function includes a number of error warnings from the motor control system for frequency-controlled motors (EWD) 31 Temperature of MCU control circuits too high HEAT SINK TOO HOT 32 Motor thermal protection has tripped...
  • Page 157 Service Handbok 23. Programme unit ERROR, EWD INTERLOCK ERROR, I/O COMMUNICATION ERROR, LOW OIL LEVEL ERROR, LOW OR HIGH VOLTAGE ERROR, ERROR CODES FROM MOTOR Time delay before door opening ERROR.PRESS SENSOR TILT Here you determine the length of time during which ERROR.
  • Page 158 Service Handbok 23. Programme unit Upper limit for manual temperature adjustment (”Max adjust temperature”) ERROR, LOW OR HIGH VOLTAGE ERROR, ERROR CODES FROM MOTOR Here you determine the highest temperature the ERROR.PRESS SENSOR TILT user may alter the wash temperature to manually ERROR.
  • Page 159 Service Handbok 23. Programme unit ERROR.PRESS SENSOR TILT ERROR. PRESSURE SENSOR TIMEOUT ERROR. DOOR SWITCH TILT ERROR. LEVEL OFFSET TIME DELAY BEFORE DOOR OPENING 0:30 UPPER TEMPERATURE FOR ERROR 98°C LOWER TEMPERATURE FOR ERROR -9°C Default wash speed MAX ADJUST TEMPERATURE 97°C MAXIMUM EXTRACT SPEED Here you determine the wash speed the machine...
  • Page 160 Service Handbok 23. Programme unit TIME DELAY BEFORE DOOR OPENING 0:30 Default value, extraction time UPPER TEMPERATURE FOR ERROR 98°C Here you determine the various speeds (low, LOWER TEMPERATURE FOR ERROR -9°C medium and high) for extraction. The instructions MAX ADJUST TEMPERATURE 97°C for determining the length of extraction times are to MAXIMUM EXTRACT SPEED...
  • Page 161 Service Handbok 23. Programme unit LOWER TEMPERATURE FOR ERROR -9°C MAX ADJUST TEMPERATURE 97°C MAXIMUM EXTRACT SPEED 1200 DEFAULT WASH SPEED DISTRIBUTION SPEED DEFAULT LOW EXTRACT RPM DEFAULT MEDIUM EXTRACT RPM Default wash acceleration DEFAULT HIGH EXTRACT RPM Here you determine the acceleration rate (rpm/ START EXTRACT SPEED 1000 second) which the machine can use to reach wash...
  • Page 162 Service Handbok 23. Programme unit LOWER TEMPERATURE FOR ERROR -9°C MAX ADJUST TEMPERATURE 97°C MAXIMUM EXTRACT SPEED 1200 DEFAULT WASH SPEED DISTRIBUTION SPEED DEFAULT LOW EXTRACT RPM DEFAULT MEDIUM EXTRACT RPM DEFAULT HIGH EXTRACT RPM START EXTRACT SPEED 1000 Extraction acceleration DEFAULT WASH ACCELERATION Here you determine the acceleration rate (rpm/ DISTRIBUTION ACCELERATION...
  • Page 163 Service Handbok 23. Programme unit LOWER TEMPERATURE FOR ERROR -9°C MAX ADJUST TEMPERATURE 97°C MAXIMUM EXTRACT SPEED 1200 DEFAULT WASH SPEED DISTRIBUTION SPEED DEFAULT LOW EXTRACT RPM DEFAULT MEDIUM EXTRACT RPM DEFAULT HIGH EXTRACT RPM Extract retardation (i.e. Deceleration rate START EXTRACT SPEED 1000 after extraction)
  • Page 164 Service Handbok 23. Programme unit To conclude making changes in variables To prevent inadvertent changes in variables under ”SETTINGS 2” If you have changed any variables under “Settings 2”, when you have finished keying in the changes, you need to insert a strap between two terminals on the CPU circuit board to register the changes in the SETTINGS 2 CPU.

  • Page 165: To Replace The Cpu Board

    Service Handbok 23. Programme unit To replace the CPU board If the CPU board is faulty and has to be replaced, the correct software for the particular washer extractor will have to be downloaded onto the new CPU board. For this you need: 1.
  • Page 166 Service Handbok 23. Programme unit Fig. 4. Switch off the machine’s main power switch. Install the new CPU board and connect all the PCB connectors. Connect the correct cable between the computer (COM1 or COM2 port) and the interface connector X7 on the CPU board.
  • Page 167 Service Handbok 23. Programme unit 8. Once the new program file is ready, it will start to be downloaded onto the CPU board immediately. The PC screen will show: DOWNLOADING PC PROGRAM to keep you informed. At the bottom of the CPU-kort screen you can see how many of the total of 1020 ”pages”...

  • Page 168: To Replace An I/O Board

    Service Handbok 23. Programme unit To replace an I/O board The procedure described here is for machines with more than one I/O board. On 5 4 3 machines with only one I/O board, that board can be replaced without any need for this procedure.
  • Page 169 Service Handbok 23. Programme unit 5. Start “CLS Service” but starting the PCS.EXE file. 6. Press on “F3” Misc. functions. Pushbutton for programming 7. A menu where various service interventions can be made is displayed. Press ”6” (Set I/O address). 8.

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  • Page 171 29. Door and door lock Contents Description, EX618 up to machine No. –520/19486 and 520/19549-22806 EX625 up to machine No. –595/9040 EX630 up to machine No. –650/14354 EX640 up to machine No. –725/7908 EX655 up to machine No. –795/3769 ............3 General ....................
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  • Page 173: Description

    Service Manual 29. Door and door lock Description Emergency opening arm EX618 Micro switch S3 Up to machine No. –520/19486 Actuator (with 520/19549-22806 micro switch S4a EX625 Up to machine No. –595/9040 and S4b) EX630 Up to machine No. –650/14354 EX640 Up to machine No.

  • Page 174: Function

    Service Manual 29. Door and door lock Function The door lock locks the door When the door is closed (closed door lock Fig. switch S3), the programme unit may request Programme unit door locking by applying a voltage of 200- 240 V on door lock controller A31 input X92.

  • Page 175: The Door Lock Unlocks The Door

    Service Manual 29. Door and door lock The door lock unlocks the door The programme unit requests door unlocking by Fig. applying 0 V on input X92 of the door lock controller. The following check is made prior to unlocking of Programme the door: unit A1...

  • Page 176: Error Codes

    Service Manual 29. Door and door lock Error codes The door lock control has three LEDs that show Fig. whether the door lock operates normally or Reset button whether an error has been detected. During normal operation, the LEDs blink when the drum is not turning and are off when the drum rotates.

  • Page 177: Reset Button

    Service Manual 29. Door and door lock Reset button The door lock control features a reset button Fig. used to reset the programme routines stored in Door lock control A31 the computer. When pressed, any error codes 200- are erased; 240 V Voltage Door lock control inputs/outputs...
  • Page 178 Service Manual 29. Door and door lock Fig. X93: Input from level guard If the input indicates “Water in drum” when the Fig. door is not locked, the door cannot be locked. The LEDs then show the error code ● ● ❍. Door lock control A3 200- 240 V...
  • Page 179 Service Manual 29. Door and door lock Fig. X95: Input from rotation sensor on motor shaft Fig. When the motor is operating, a pulse train is applied on the input. Door lock control A31 Rotation sensor Input Function Pin 1: DC 4-10 V feed Pin 2: Pin 3:...

  • Page 180: Repairs

    Service Manual 29. Door and door lock Repairs Repair work on the machine should only be done by specially trained personnel. Emergency opening of door lock Fig. 1. Switch off power to the machine by turning the main power switch to the 0 position. 2.

  • Page 181: Replacing The Door Lock

    Service Manual 29. Door and door lock Replacing the door lock 1. Switch off power to the machine by turning the main power switch to the 0 position. 2. Remove the front cover alt. side pole. 3. Remove the door (two screws in each hinge). 4.

  • Page 182: Description

    Service Manual 29. Door and door lock Description Emergency opening arm EX618 Micro switch S3 from machine No. 520/22807– Actuator (with 520/19487-19548 micro switch S4a EX625 from machine No. 595/9041– and S4b) EX630 from machine No. 650/14355– EX640 from machine No. 725/7909–...

  • Page 183: Function

    Service Manual 29. Door and door lock Function The door lock locks the door When the door is closed (closed door lock Fig. switch S3), the programme unit may request Door lock door locking by applying a voltage of 200- Programme control 240 V on door lock controller A31 input X92.

  • Page 184: The Door Lock Unlocks The Door

    Service Manual 29. Door and door lock The door lock unlocks the door The programme unit requests door unlocking by Fig. applying 0 V on input X92 of the door lock controller. The following check is made prior to unlocking of Door lock Programme the door:...

  • Page 185: Error Codes

    Service Manual 29. Door and door lock Error codes The door lock control has three LEDs that show Fig. whether the door lock operates normally or Reset button whether an error has been detected. During normal operation, the LEDs blink when the drum is not turning and are off when the drum rotates.

  • Page 186: Reset Button

    Service Manual 29. Door and door lock Reset button The door lock control features a reset button used to reset the programme routines stored in Door lock control A31 the computer. When pressed, any error codes 200- are erased; 240 V Door lock control inputs/outputs Voltage supply to A1...
  • Page 187 Service Manual 29. Door and door lock Fig. X93: Input from level guard If the input indicates “Water in drum” when the Fig. door is not locked, the door cannot be locked. The LEDs then show the error code ● ● ❍. Door lock control A31 200- 240 V...
  • Page 188 Service Manual 29. Door and door lock Fig. X95: Input from rotation sensor on motor shaft Fig. When the motor is operating, a pulse train is applied on the input. Door lock control A31 Tacho generator Input Function Pin 1: Pin 2: Tacho signal X96: Output to door lock...

  • Page 189: Repairs

    Service Manual 29. Door and door lock Repairs Repair work on the machine should only be done by specially trained personnel. Emergency opening of door lock Fig. 1. Switch off power to the machine by turning the main power switch to the 0 position. 2.

  • Page 190: Replacing The Door Lock

    Service Manual 29. Door and door lock Replacing the door lock 1. Switch off power to the machine by turning the main power switch to the 0 position. 2. Remove the front cover alt. side pole. 3. Remove the door (two screws in each hinge). 4.
  • Page 191 30. Motor and motor control Contents Warnings ....................3 Description, EX618 up to machine No. –520/19486 and 520/19549-22806 EX625 up to machine No. –595/9040 EX630 up to machine No. –650/14354 EX640 up to machine No. –725/7908 EX655 up to machine No. –795/3769 ............4 Motor ....................

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  • Page 193: Motor And Motor Control

    Service Manual 30. Motor and motor control Warnings DANGER Be careful when measuring the electric components in the motor control. All components have a potential difference of approx. 300 V in relation to protective earth and neutral. When the green LED on the motor control card is lit, the components carry dangerous voltages.

  • Page 194: Description

    Service Manual 30. Motor and motor control Description EX618 Up to machine No. –520/19486 520/19549-22806 EX625 Up to machine No. –595/9040 EX630 Up to machine No. –650/14354 EX640 Up to machine No. –725/9708 EX655 Up to machine No. –795/3769 Motor Fig.

  • Page 195: Motor Control

    Service Manual 30. Motor and motor control Motor control The motor control unit is microcomputer Fig. Motor control U1 controlled and is situated under the top cover of the machine, right above the outer drum. The unit consists of a PCB (mother board) fitted on a heat sink that does double-duty as part of the housing.

  • Page 196: Function

    Service Manual 30. Motor and motor control Function DANGER Be careful when measuring the electric components in the motor control. All components have a potential difference of approx. 300 V in relation to protective earth and neutral. When the green LED on the motor control card is lit, the components carry dangerous voltages.

  • Page 197: Inputs And Outputs

    Service Manual 30. Motor and motor control The motor control is also able to deliver various instantaneous and output values during constant speed, acceleration and retardation. These values are used to calculate the weight of the X301 X302 loaded laundry and to detect any load imbalances.
  • Page 198 Service Manual 30. Motor and motor control Fig. X304: Door lock connector X308 The collector output function is controlled from X304 the programme unit (X301). The collector output does not switch on if there is no communication with the programme unit. Card No.
  • Page 199 This connector also includes the input from the thermal protector of the motor. The thermal protector switch is usually closed and triggers only in case of overheating. EX618-EX630 Card No. Function X 312:1 AC supply to motor X 312:2...

  • Page 200: Led Indications

    Current limiter of motor control has switched on. approx. 5 seconds Yellow LED LED blinking pattern Error code on display Cause EXACTA CLARUS HEAT SINK TOO HOT Overheated heat sink on motor control. MOTOR TOO HOT Motor thermal protector has triggered. NO INTERLOCK Motor controller receives start request, but receives no lock ACK (input 302).

  • Page 201: Repairs

    Service Manual 30. Motor and motor control Repairs Main power switch Repair work on the machine should only be done by specially trained personnel. Motor replacement Disassembly 1. Swith off power to the machine by turning Fig. the main power switch to the 0 position. 2.

  • Page 202: Adjustments

    Service Manual 30. Motor and motor control 3. Connect the new motor to the motor control and use straps to secure the cable. 4. Connect the motor cable to the motor. 5. Fit the lower rear piece and secure the drain hose connection with screws.

  • Page 203: Description

    Service Manual 30. Motor and motor control Description EX618 from machine No. 520/22807– 520/19487-19548 EX625 from machine No. 595/9041– EX630 from machine No. 650/14355– EX640 from machine No. 725/7909– EX655 from machine No. 795/3770– EX670 Motor The motor is fitted in a bridge carrier under the Fig.

  • Page 204: Motor Control

    Service Manual 30. Motor and motor control Motor control The motor control unit is microcomputer Fig. Motor control U1 controlled and is situated under the top cover of the machine, right above the outer drum. The unit consists of a PCB (mother board) fitted on a heat sink that does double-duty as part of the housing.

  • Page 205: Function

    Service Manual 30. Motor and motor control Function DANGER Be careful when measuring the electric components in the motor control. All components have a potential difference of approx. 300 V in relation to protective earth and neutral. When the green LED on the motor control card is lit, the components carry dangerous voltages.

  • Page 206: Inputs And Outputs

    Service Manual 30. Motor and motor control The motor control is also able to deliver various instantaneous and output values during constant speed, acceleration and retardation. These values are used to calculate the weight of the loaded laundry and to detect any load imbalances.
  • Page 207 Service Manual 30. Motor and motor control Fig. X304: Door lock connector The collector output function is controlled from X311 the programme unit (X301). The collector output does not switch on if there is no communication with the programme unit. Tacho signal from the motor (via door lock control A31) is needed to control the motor.
  • Page 208 This connector also includes the input from the thermal protector of the motor. The thermal protector switch is usually closed FLASH and triggers only in case of overheating. EPROM EX618-EX670 Card No. Function X 312:1 AC supply to motor X 312:2...

  • Page 209: Led Indications

    Current limiter of motor control has switched on. approx. 5 seconds Yellow LED LED blinking pattern Error code on display Cause EXACTA CLARUS HEAT SINK TOO HOT Overheated heat sink on motor control. MOTOR TOO HOT Motor thermal protector has triggered. NO INTERLOCK Motor controller receives start request, but receives no lock ACK (input 302).

  • Page 210: Repairs

    Service Manual 30. Motor and motor control Repairs Main power switch Repair work on the machine should only be done by specially trained personnel. Motor replacement Disassembly 1. Swith off power to the machine by turning Fig. the main power switch to the 0 position. 2.

  • Page 211: Adjustments

    The drive belt tension should be as follows: Fig. Model Force A Post-tensioning B New belt C (mm) (mm) Adjust drive belt tension if values exceed EX618 those shown in the table. EX625 EX630 EX640 EX655 EX670 4741 Fig.

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  • Page 213 38. Drain valve Contents Description ....................3 Function ....................3 Repairs...................... 4 Disassembly ..................4 Assembling ................... 5 438 9146-01/01 00.23...
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  • Page 215: Drain Valve

    Service Manual 38. Drain valve Description Fig. The drain valve is situated on a flange at the bottom of the outer drum and can be accessed from the front after removing the front cover. The drain valve consists of the following principal parts: •...

  • Page 216: Repairs

    Service Manual 38. Drain valve Repairs Main power switch Repair work on the machine should only be done by specially trained personnel. Disassembly For repair works on the drain valve, there is a risk that water still left in the machine may flood onto the floor.

  • Page 217: Assembling

    Service Manual 38. Drain valve Assembling 1. Connect the pressure hose to the lower part of the valve. Verify that the Fig. hose is not bent or pinched. 2. Fit the rubber bellows onto the sleeve coupling. 3. Hook the valve onto the bolts and turn the valve into position. Secure the Fig.
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  • Page 219 39. Detergent compartment Contents Description ....................3 438 9146-21/01 00.23...
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  • Page 221: Detergent Compartment

    Service Manual 39. Detergent compartment Description Fig. The detergent compartment of the machine is Detergent compartment designed for use with powder and liquid detergent. The compartment is divided into four sub-compartments as follows: Fig. • Compartment 1 - For pre wash with powder or liquid detergent.
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  • Page 223 40. Heating Contents Description ....................3 Electric heating ..................3 Steam heating ..................4 Function ....................5 Electric heating ..................5 Steam heating ..................5 Repairs...................... 6 Replacing the heating elements ............6 438 9146-41/02 03.20...
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  • Page 225: Description

    Machine Heating element size model (kW) W365 3x0,665, 3x1, 3x1,8, 3x2,5 W375, EX618 3x0,665, 3x1, 3x1,8, 3x2,5 W3105, EX625 3 x 2,5, 3 x 3,33 W3130, EX630 3 x 2 x 2,165 W3180, EX640 3 x 2 x 3,0...
  • Page 226 Service Manual 40. Heating Steam heating Fig. ???? 438 9146-41/02 03.20...

  • Page 227: Steam Heating

    Service Manual 40. Heating Function Electric heating The three heating elements in the machine are Fig. Heating Programme connected to separate phases and are switched element unit Al on and using one or two heating contactors, K.21 and K22 (two contactors are used for higher I/O card 1 A11 heating power).

  • Page 228: Repairs

    Service Manual 40. Heating Repairs Main power switch Repair work on the machine should only be done by specially trained personnel. Replacing the heating elements When replacing the heating elements, there is a risk that water still left in the machine may flood onto the floor.
  • Page 229 42. Instruction for pulley and replacing bearings Instruktion för remskiva Instruction for pulley W365H/N/M – W3330H/N/M EX618-EX670, E/W/SU620-675 438 9041-53 04.21...
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  • Page 231 Service Manual 42. Instruction for pulley and replacing bearings Instruktion/Instruction Fig. Komplett verktygssats, art. nr: 472 9913-57 Complete tool kit, part No: 472 9913-57 Pos. Art. nr./Part No Beskrivning/Description Antal/Qty 432 1725-01 Avdragare/Puller 432 1728-01 Avdragare remskiva/Pulley drag 2 432 1717-01 Adaptor/Adaptor G1/2"/M10 432 1720-01 Bricka/Washer...
  • Page 232 Service Manual 42. Instruction for pulley and replacing bearings • Tag bort segersäkringen från trumaxeln. • Remove the C-clamp from the drum shaft. • Fixera avdragsklackarna och avdragarna på axeln och remskivan. Fig. • Mount the puller with puller drags on shaft and pulley. •...
  • Page 233 Service Manual 42. Instruction for pulley and replacing bearings • Drag loss remskivan. • Pull off the pulley. Montering av remskiva/Mounting pulley • Gänga axeländan M12 och 20 mm djupt. Fig. • Thread the shaft end with M12 and 20 mm deep. •...
  • Page 234 Service Manual 42. Instruction for pulley and replacing bearings • Montera remskiva, hylsa och bricka över axeln. Skruva avdragarbult Fig. med mutter i adaptern på axeln. • Mount pulley, sleeve and washer over the shaft. Mount the puller screw with nut in the adaptor on the shaft. •...
  • Page 235 42. Instruction for pulley and replacing bearings Instruktion för lagerbyte Instruction for replacing bearings W365H/N/M – W3330H/N/M EX618-EX670, E/W620-675 438 9041-61/02 04.21...
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  • Page 237 Complete tool kit, part No: 472 9913-60 Pos. Art. nr./Part No Beskrivning/Description Antal/Qty 432 1723-01 Dorn för tätningar/Drift for gaskets (W365-3105H/N/M, W3130N/M, EX618, 625, E/W630) 432 1723-02 Dorn för tätningar/Drift for gaskets (W3130-3300H, W3180-3330N/M, EX630-670, E/W640-675) 432 1716-01 Distans/Spacer (W365-385H/N/M, EX618, E/W620) 432 1716-02...
  • Page 238 Service Manual 42. Instruction for pulley and replacing bearings • Avmontering av remskiva, se instruktion 438 9041-53. • Removal of pulley, see instruction 438 9041-53. • Tag bort kilen från axeln. • Remove wedge from shaft. • Mät avståndet A mellan lager och axelända. Fig.
  • Page 239 Service Manual 42. Instruction for pulley and replacing bearings • Skruva loss bultarna i lagerhuset. Fig. • Loosen the bolts in the bearing house. • Montera två bultar i lagerhusets gängade hål och pressa loss Fig. lagerhuset. • Mount two bolts in threaded holes and press until the bearing house is loose.
  • Page 240 Service Manual 42. Instruction for pulley and replacing bearings 341, 342, 343 • Om det främre lagret sitter kvar på axeln, drag av det med avdragaren Fig. och de två avdragarklackarna (på de större maskinerna använd också förlängarna). Försök ej dra av bakgaveln när det främre lagret sitter kvar, då...
  • Page 241 Service Manual 42. Instruction for pulley and replacing bearings • Alt. 1. Knacka på bussningen på tre ställen (ca 120° mellan). Fig. Ibland räcker det för att den skall släppa. • Alt. 1. Tap the bushing in three places (with about 120° in between). Sometimes it is sufficient to loosen it from the shaft.
  • Page 242 Service Manual 42. Instruction for pulley and replacing bearings • Knacka ur lagren ur lagerhuset. Fig. • Tap the bearings from the bearing house. • Rengör lagerhuset noggrant. • Clean the bearing house thoroughly.
  • Page 243 Service Manual 42. Instruction for pulley and replacing bearings • Lagersats Fig. • Bearing kit. W365H, W375H/N, W385N/M, EX618, E/W620 472 9913-12 W3105H/N/M, W3130N/M, EX625, E/W630 472 9913-13 W3250N/M, E/W655 472 9913-15 W3180N/M, E/W640 472 9913-14 W3330N, E/W675 472 9913-19...
  • Page 244 Service Manual 42. Instruction for pulley and replacing bearings 348, 349 • Fyll främre lagret med fett och knacka försiktigt ner lagerhuset med hjälp Fig. av dorn och bricka. • Fill the front bearing with grease and tap it gently into the housing with drift and washer.
  • Page 245 Service Manual 42. Instruction for pulley and replacing bearings 351, 352 • Vänd på lagerhuset och knacka försiktigt ned det bakre lagret med hjälp Fig. av pressdornet. • Turn the housing around and gently tap the rear bearing into the housing using the presser.
  • Page 246 Service Manual 42. Instruction for pulley and replacing bearings • Smörj lagerhusets innersida med lite fett så går det lättare att montera Fig. tätningarna. • Put some grease on the inside of the bearing housing. Then it is easier to mount the sealing rings.
  • Page 247 Service Manual 42. Instruction for pulley and replacing bearings 353, 355 • Fyll den första tätningen med fett. • Fill the first sealing with grease. • Placera tätningen på dornet med tätningens öppning uppåt. Knacka Fig. försiktigt ned den i lagerhuset. Tätningen skall ned tills det tar stopp. •...
  • Page 248 Service Manual 42. Instruction for pulley and replacing bearings 356, 357, 359 • Fyll den andra tätningen med Amblygon fett. Placera distansring och Fig. tätning på dornet. Pressa ner dornet i botten på lagerhuset. • Fill the second sealing with Amblygon grease. Place the spacer and sealing on the drift.
  • Page 249 Service Manual 42. Instruction for pulley and replacing bearings • Montera den tredje tätningen. Läppen skall ligga an mot lagerhuset. Fig. Tryck ej för långt, tätningsläppen kan gå sönder. • Mount the third sealing. The lip shall lay against the housing. Don't push too far as the lip can break.
  • Page 250 Service Manual 42. Instruction for pulley and replacing bearings • Om maskinen är försedd med oljesmörjning, kontrollera att slang och Fig. nippel är hela. Om inte, byt. • If the machine is equipped with oil lubrication, check that the hose and nipple are OK.
  • Page 251 Service Manual 42. Instruction for pulley and replacing bearings • Montera bakgavelpaketet över axeln. Var noga med att hålla gaveln horisontellt och var uppmärksam på att tätningarna inte skadas på axeln. • Mount the rear gable over the drum shaft. Be sure to put it on horizontally so that the sealings don't get damaged on the shaft.
  • Page 252 Service Manual 42. Instruction for pulley and replacing bearings • Montera kilen på axeln. • Mount the wedge on the shaft. • Montera remskiva, hylsa, bricka, mutter och avdragarbult på axeln. Fig. Skruva avdragaren i adaptern på axeln. Pressa ned remskivan på axeln. Det går lättare om remskivan värms.
  • Page 253 Service Manual 42. Instruction for pulley and replacing bearings • Lyft in trumpaketet i yttertrumman. OBS! Texten"Up" på bakgaveln skall peka uppåt. • Lift the drum package into the outer drum. NOTE! The text "Up" on the rear gable must be pointing upwards. •...

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  • Page 255 43. Frame Contents Description ....................3 438 9146-61/01 00.23...
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  • Page 257 Service Manual 43. Frame Description The machine has a freely suspended drum assembly. The inner frame is Fig. suspended in an outer frame. The motor and drum assembly are fitted on the inner frame. The inner frame is suspended in the outer frame by way of four coil springs. It has the shape of a cradle in which the outer drum is placed.
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  • Page 259 50. Weighing equipment Contents Water level reduction ................3 Actual weight display ................3 Resetting the weighing equipment ............3 Calibrating the weighing equipment ............4 Checking accuracy of weighing equipment display ........4 If the weighing equipment has a fault ............4 Fault-finding, weighing equipment ............
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  • Page 261: Water Level Reduction

    SELECT Actual weight display Resets to zero Menu line showing actual weight The Clarus control unit automatically detects if Fig. 3651 weighing equipment is connected, and the actual (current) weight is shown on the display, on one line of the menu (normal display mode).

  • Page 262: Calibrating The Weighing Equipment

    If the weighing equipment does not show the real weight of this object, you will need to follow the “Zero calibration” procedure, a function in the Clarus software. Follow the instructions under “Zero calibration” in the “Machine operation”...

  • Page 263: Fault-Finding, Weighing Equipment

    Service Manual 50. Weighing equipment Fault-finding, weighing equipment Weight-totalling board Error message on display: Weight, kg: 999,9 or -999,9 Probable cause: The weighing equipment is overloaded/ ”underloaded”, i.e. the load cells are sending a signal which is too high/low to the scale unit. Probable cause is one or more load cells faulty.
  • Page 264 Service Manual 50. Weighing equipment • If more than one load cell is faulty, the faulty cells can be identified using a multimeter on the scale unit weight-totalling board to check each cell in turn, as follows: - Remove the four screws on the scale unit cover. - Check that the four load cell cables are connected to the scale unit.
  • Page 265 Service Manual 50. Weighing equipment Menu line which should show actual weight not displayed. Possible causes: The option “DISPLAY WEIGHT ALLOWED” may be switched off (have the answer “No” alongside) in “Settings 1”. Possible fault in communication with CPU board or display. The fault can also be in the scale unit. Fault-finding procedure: •...
  • Page 266 Service Manual 50. Weighing equipment Error message on display: Failed. Press SELECT. Possible causes: Calibration switch incorrectly set. An incorrect calibration weight has been used for calibration. Fault-finding procedure: • If you are or have recently been calibrating the weighing equipment, the Fig.
  • Page 267 Service Manual 50. Weighing equipment Information in display: Function not allowed. Probable cause: A function has been selected in the program which cannot be carried out. Fault-finding procedure: • Check that the function in question is switched on under “Settings”. •...

This manual is also suitable for:

Ex625Ex630Ex640Ex655Ex670

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