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Fisher & Paykel IW509 Service Manual

Smart drive electronic washing machine phase 1 to 5 – 230v
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SMART DRIVE
ELECTRONIC WASHING MACHINE
PHASE 1 to 5 – 230v
This service manual supersedes all previous Smartdrive 230v service manuals. This manual incorporates all
technical bulletins for Smartdrive up to January 2000. Information on IW and IWECO is available in
Appendix E.
Fisher & Paykel Ltd, Laundry Division.
78 Springs Road, East Tamaki, PO Box 58-732, Greenmount, Auckland. NZ
Phone 0064 9 273 0640, Fax 0064 9 273 0649.
Fisher & Paykel Customer Services Pty Ltd.
ACN. 003 3335 171, 19 Enterprise St, Cleveland, PO Box 798,
Cleveland, QLD 4163, Australia.
Phone 0061 7 3826 9100, Fax 0061 7 3826 9164.
Fisher & Paykel Singapore PTE Ltd.
150 Ubi Avenue 4, Sunlight Building #02-00, Singapore.
Phone 0065 547 0100, Fax 0065 547 0123.
Fisher & Paykel Appliances Ltd.
517735
42 Clarendon St, Leamington Spa, Warks, CV32 4PG, UK.
Phone 0044 1 926 88 2220, Fax 0044 1 926 88 3330.
Issue A - October 2000
Try
www.fisherpaykel.com/Service
COPYRIGHT © FISHER & PAYKEL LTD 2000

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  • Page 1 SMART DRIVE ELECTRONIC WASHING MACHINE PHASE 1 to 5 – 230v This service manual supersedes all previous Smartdrive 230v service manuals. This manual incorporates all technical bulletins for Smartdrive up to January 2000. Information on IW and IWECO is available in Appendix E.
  • Page 2 PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE 5 PHASE 1 GW Model ‘xx0’ PHASE 2 GW Model ‘xx1’ PHASE 3 GW Green & yellow PHASE 4 GW Blue & yellow. PHASE 5 (early) GW MW, LW & AW are different colours. PHASE 5 (late) GW MW, LW &...

  • Page 3: What Phase, Size & Model Is Your Smartdrive

    24v water valves. 64 ohms. Stator 32 (Series MW059, LW095, AW095, have thermistor in mixing ohms phase to phase. Reed switch for MW, GW, IW, & Series IW509, IW609, IW709, chamber. AW, LW, MW no lid. Selni pump. 33 ohms. IWECO IWL10, IWM10, IWC09, thermistor.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SMART DRIVE ELECTRONIC WASHING MACHINE PHASE 1 to 5 – 230v ........1 WHAT PHASE, SIZE & MODEL IS YOUR SMARTDRIVE? ............3 TABLE OF CONTENTS .........................1 1.0 INTRODUCTION ..........................1 1.1 HOW TO SERVICE SMARTDRIVE...................1 1.2 SMARTDRIVE SERVICING – Quick Reference Guide! ............2 2.0 SPECIFICATIONS..........................3 3.0 INSTALLATION ..........................4 4.0 SMARTDRIVE COMPONENTS .....................6...
  • Page 5 8.5 RECYCLE..........................33 9.0 SIZE SETTING MODE – Phase 4 and 5 only ................35 10.0 USER WARNINGS ........................36 10.1 Insufficient Hot Water (Hot Water LED flashing) ..............36 10.2 Insufficient Cold Water (Cold Water LED flashing) .............36 10.3 No Water (Both Hot and Cold Water LEDs flashing)............37 10.4 Overloaded Product (High Water LED flashing) ..............37 10.5...

  • Page 6: Smart Drive Electronic Washing Machine Phase 1 To 5 - 230V

    1.0 INTRODUCTION 1.1 HOW TO SERVICE SMARTDRIVE IF SMARTDRIVE HAS NO POWER - SEE SECTION 6.1 Power off at the mains socket. Wait 2 minutes. Power on. IF SMARTDRIVE IS DISPLAYING A FAULT - SEE SECTION 11.0 This may be identifiable by an unusual combination of LEDs displayed on the wash progress LEDs.

  • Page 7: Smartdrive Servicing - Quick Reference Guide

    1.2 SMARTDRIVE SERVICING – Quick Reference Guide! Smartdrive is not isolated. Even low voltage (5v and 15v) are live! During normal operation only one LED should be flashing. This is the leftmost wash progress LED when Smartdrive is Paused. The product has a diagnostic mode which allows the fault information to be displayed. Diagnostic mode level 3, indicates last fault.

  • Page 8: Specifications

    2.0 SPECIFICATIONS Dimensions Compact (5kg) Medium (6kg) Large(7kg) Height to closed Lid 900mm-930mm 900mm-930mm 900mm-930mm Height to open Lid 1280m-1310mm 1305mm-1335mm 1350mm-1380mm Width 560mm 600mm 650mm Depth 560mm 600mm 650mm Inlet hose length 1100mm 1100mm 1100mm Dry weight Packed 48Kg 52Kg 58Kg Dry weight unpacked...

  • Page 9: Installation

    3.0 INSTALLATION REMOVING BOWL PACKER AND ACCESSORIES Remove the outer packaging. Leave Smartdrive standing upright. Lift the lid and remove the bowl packer. Remove hoses and accessories. REMOVING TRANSIT RESTRAINT Rotate the agitator anti-clockwise for 3 revolutions. (This unscrews the transit restraint from the base of Smartdrive.) The wash bowl will then be free to move from side to side.
  • Page 10 LEVELLING SMARTDRIVE It is IMPORTANT to level Smartdrive to ensure even spin performance. Fit the 4 rubber inserts into the feet on the base of Smartdrive. Move Smartdrive to its final position. (a minimum clearance of 20mm each side of Smartdrive for ease of installation.) Adjust the feet so that Smartdrive is level and cannot rock.

  • Page 11: Smartdrive Components

    4.0 SMARTDRIVE COMPONENTS - 6 -...

  • Page 12: Electronics Systems

    Electronics Systems Smartdrive electronics consists of 4 mains parts: - a) Motor, (b) Motor Controller Module, (c) Display Module and (d) Rotor Position Sensor. The interconnections are shown in the block diagrams below:- Wiring diagram for Phase 1. NB. Phase 1 (spare) uses a motor controller similar to Phase 2-4. Wiring diagram for Phase 2-4.
  • Page 13 PHASE 5 WIRING DIAGRAM - 8 -...

  • Page 14: Motor

    Motor The motor is a 3 phase, 42 pole, DC brushless motor, commutation is achieved electronically. The Motor consists of a STATOR (stationary part) and ROTOR (rotating part). The Rotor Position Sensor controls the speed and position of the motor. The STATOR has a 'star point' connection, and motor terminals. The Star point connects the 3 windings to a common point.

  • Page 15: Motor Controller Module

    Motor Controller Module This module contains the circuitry needed to control the water valves, pump and the motor. It also recieves signals from the rotor position sensor, pressure sensor and the display module. The Motor Controller Module and Display Module are continuously communicating. The Motor Controller Module supplies the Display Module with 15v (11v min 17v max).

  • Page 16: Display Module

    Display Module The Display Module contains a microprocessor whose function is to take the inputs from the front panel and send the appropriate command to the Motor Controller Module. It also controls the output to the display LEDs and beeper. Test the Display LEDs.

  • Page 17: Water Valves

    Water Valves The electronics control the water valves so that a constant water temperature is achieved in the bowl irrespective of the temperatures and pressures of the household hot and cold water systems. To achieve accurate water temperatures a proportional water valve is used on the cold water inlet. Unlike conventional water valves which are either fully on or fully off, the proportional water valve can be controlled so that it can turn on at any water flow rate between fully on and fully off.

  • Page 18: Rotor Position Sensor

    Rotor Position Sensor One of the inputs that the Motor Controller Module needs in order to determine which switches to turn on, is the position of the Rotor. This information is supplied by the Rotor Position Sensor (RPS). On the RPS there are three Hall Sensors. These detect the magnetic field of the individual magnets in the Rotor.

  • Page 19: Pump

    Pump The drain pump motor is coupled directly to the base of the outer bowl. This eliminates bowl to pump hoses and the accompanying seals, clips etc. The pump housing is an integral part of the outer bowl. The pump is accessible by removing the inspection hatch on the front of Smartdrive, (Phase 1 to 4 only). It is also accessible from the top by removing the agitator and inner bowl.

  • Page 20: Inner And Outer Bowls

    Inner and Outer Bowls The outer bowl is the assembly to which all the motor, pump system, suspension rods, etc are mounted. Within the outer bowl is the inner bowl and the agitator. During spin, the agitator and inner bowl have to be coupled together and turn as a single unit.

  • Page 21: Lint Removal System

    Detection Of Inner Bowl Float Off Point – Bowl Check During fill the inner bowl will rotate to ensure that the clothes are evenly saturated with water. When the chosen water level is reached, and before the agitate cycle is started, Smartdrive will carry out inner bowl float checks, (bowl check).

  • Page 22: Lid Switch And Out Of Balance Switch

    Lid Switch and Out of Balance Switch Lid Switch If the lid is raised, the lid switch operates and stops the cycle when Smartdrive is stirring during fill or Smartdrive is spinning, (braking). The motor should stop within 10 seconds, all the energy from the motor is dumped into the brake resistor (Phase 1-4) or the pump (phase 5).

  • Page 23: Water Temperature Sensing

    4.10 Water Temperature Sensing Phase 1-4 uses a thermistor for sensing the water temperature. It is located within the Motor Controller. User can adjust the warm temperature by going into the Option Adjustment Mode. Phase 5 GW uses a thermistor for sensing the water temperature. It is located in the mixing chamber. This is a replaceable item and has a resistance of 10k ohms @ 25 o C.

  • Page 24: Smartdrive Information

    5.0 SMARTDRIVE INFORMATION This information is provided to the user in the ‘Use and Care Manual’. It is included here for completeness. The user warning information and some information on Option Adjustment mode is also in this manual. Favourite cycle (GW only) – All Phases The user may have a particular combination of wash cycle settings that are frequently used, i.e.

  • Page 25: Delay Start (Gw Only) - Phase 2 To 5 Only

    Delay Start (GW only) – Phase 2 to 5 only Select your wash cycle and options to suit the clothes load, by pressing the appropriate buttons then press the DELAY START button: - Once for 1 hour Twice for 6 hours (phase 2-4) 3 hours (phase 5). Three times for 9 hour delay Four times to cancel and return Smartdrive to normal operation.

  • Page 26: Fabric Softener Dispenser - All Phases

    AMOUNT OF WATER USED IN THE WATER SAVER RINSE MODEL SHOWER RINSE SPRAY & DEEP RINSE Large 60 litres 115 litres Medium 50 litres 105 litres Compact 40 litres 90 litres Please note, these are approximate figures for high water level. The Time Saver or Soak option can be used with the Water Saver option, push the wash options button until both options have been selected.

  • Page 27: Wash Performance Information - All Phases

    Wash Performance Information – All Phases Creasing Creasing can be caused by Over loading Smartdrive or the dryer. Permanent Press or Delicate cycles have been designed to minimise creasing, they use a lower spin speed. Do not leave wet clothes to sit in the washer or laundry basket.

  • Page 28: Smartdrive Problems

    6.0 SMARTDRIVE PROBLEMS If Smartdrive Appears To Have No Power If the module appears to be dead / no power then check the following:- Is the external mains plug switched on and live? Are all plugs connected into the Motor Controller? Phase 4 Only.

  • Page 29: Flooding

    Flooding Check inlet hoses are not leaking. Check drain hose is inserted correctly, and that the drain is not blocked. Check water valves are not jammed on, or dripping when off. Has the pressure pipe been connected when the bowl contained water? The pressure pipe must be connected when the bowl is empty, otherwise flooding may occur on the next cycle.

  • Page 30: Continuous Spinning Or Slow Spinning

    Check the 2 balance rings in the inner bowl contain water. Check weights. Check for noisy suspension rods. Phase 1 was noisy during Stir. If the inner bowl or agitator is noisy check for obstruction. Check the spline drive is clean. If there is a grating sound check the single stainless steel washer beneath the spline drive.

  • Page 31: Siphoning

    Siphoning Typically this occurs when the Standpipe height is too low. The minimum is 850mm from the floor, this is 90mm ABOVE the drain hose outlet on Smartdrive. With a very low standpipe and a very high water level this could result in water pouring down the standpipe prior to Smartdrive completing fill and resulting in no water in bowl during agitate.

  • Page 32: Option Adjustment Mode

    7.0 OPTION ADJUSTMENT MODE Smartdrive can be adjusted to operate under a number of different conditions OPTION ADJUSTMENT MODE may be used to customise Smartdrive. Some of this information is available to the user in the ‘Use and Care Manual’. For IW see Appendix E. The features that can be adjusted in this mode are:- a) Water Temperature b) Rinse Options...

  • Page 33: Rinse Options - All Phases

    Method of Setting the Wash Temperature 1. Select the OPTION ADJUSTMENT MODE by pressing and holding the START/PAUSE button, then pressing the POWER button. 2. Use WASH TEMPERATURE buttons and LEDs to select the temperature setting to be adjusted, i.e. Cold, Cold/Warm, Warm, Warm/Hot, Hot. 3.

  • Page 34: End Of Cycle Warning Beeps (Gw Only) - All Phases

    FIRST RINSE OPTION (2) Spin only. Does not give as good a suds removal as Option (1) but uses less water than Option (3) FIRST RINSE OPTION (3) Deep Rinse. Gives better suds removal but increases water usage. The first rinse is always followed by a final deep rinse and spin. Method of selecting RINSE OPTIONS 1.

  • Page 35: Adjusting The Volume Of Water Used In The Water Saver Option (Gw Only) - Phase 3 To 5

    7.4 Adjusting the Volume of Water Used in the Water Saver Option (GW only) – Phase 3 to 5 You can increase or decrease the volume of water added during the shower rinse on the Water Saver option. Enter the Option Adjustment Mode. Use the WATER LEVEL buttons to select the volume of water you wish to be used in the shower rinse HIGH WATER LED ON more water...

  • Page 36: Diagnostic Mode

    8.0 DIAGNOSTIC MODE Allows the following status information to be Allows control of the following:- determined: - Pump Last Fault. Hot Water Valve Lid switch status. Cold Water Valve Out of Balance switch status. Restart Size. Recycle Additional information Hot Bowl Flag For IW information see Appendix E.

  • Page 37: Test Lid, Out Of Balance, & Size Switches

    TEST LID, OUT OF BALANCE, & SIZE SWITCHES To enter Diagnostic Mode turn the power on at the power point and off at the console. Press and hold the WASH TEMPERATURE DOWN then press the POWER button. Smartdrive will give 2 short beeps. Phase 3 Only press ADVANCE button once.

  • Page 38: Restart

    RESTART If a problem occurs in Smartdrive, it will try to correct the problem and retry. Smartdrive will rectify any problems of a temporary nature. If there is a continuous problem Smartdrive will retry several times. This process may take up to 10 minutes depending on the type of problem. If Smartdrive still cannot resolve the problem, the fault code is displayed and Smartdrive will beep continuously.
  • Page 39 - 34 -...

  • Page 40: Size Setting Mode - Phase 4 And 5 Only

    9.0 SIZE SETTING MODE – Phase 4 and 5 only Phase 1-3 sizes are determined by 2 switches on the display and protrusions on the console. When replacing Display or Motor Controller enter Option Adjustment mode to set these sizes in EEPROM. To check the size setting on Phase 1-3 use DIAGNOSTIC mode.

  • Page 41: User Warnings

    10.0 USER WARNINGS There are a number of warnings which are generally caused by the user or poor installation. These warnings should be corrected by the user. Smartdrive signals user warnings by flashing LEDs and a rippling set of 5 beeps repeated every 6 seconds. This is the same tone that is heard when Smartdrive is first plugged into the mains power.

  • Page 42: No Water (Both Hot And Cold Water Leds Flashing)

    10.3 No Water (Both Hot and Cold Water LEDs flashing) This warning is indicated by the cold and hot water LEDs flashing. Smartdrive will also be making a rippling set of 5 beeps repeated every 6 seconds and the product will be paused.

  • Page 43: Suds (First Rinse Led Is Flashing Or Final Spin Led Is Flashing)

    10.6 Suds (First Rinse LED is flashing or Final Spin LED is flashing) This warning is indicated by a rinse or spin LED flashing. Smartdrive will also be making a 'rippling sound of 5 beeps repeating every 6 seconds' and the product will be paused. Too much Detergent has been used and Smartdrive has a suds build up.

  • Page 44: Demonstration Mode (All Leds Flashing In Patterns)

    10.8 Demonstration Mode (All LEDs flashing in patterns) This feature is designed for in store demonstration purposes. Smartdrive can draw attention to itself with a selection of flashing LEDs. In this mode Smartdrive cannot be started. To Select DEMONSTRATION MODE press hold ADVANCE...

  • Page 45: Fault Codes

    GW709 GW609 GW509 MW059 LW095 AW095 GWC09 GWM09 GWL09 Phase 5 IW IW509 IW609 IW709 IWL10 IWM10 IWC09 IW710 IW810 IWM09 IWL09 The format for fault description in this booklet follows the Primary, Secondary and Tertiary fault source system. These sources have mostly been arranged in order of most likely source of fault, but in some cases the sequence has been modified to aid the servicing procedure.

  • Page 46: Smartdrive Phases 1 To 5 Fault Descriptions

    SMARTDRIVE PHASES 1 to 5 FAULT DESCRIPTIONS When Smartdrive detects a fault it stops. Smartdrive beeps continuously, once per second, and displays a fault code in binary using the 8 wash progress LEDs. The possible fault codes are listed in numeric order with their associated service procedure.
  • Page 47 (00000101) Phase 1 – Communications Fault The Display Module has had difficulty communicating with the Motor Controller. Primary Source - Display Module Action – Turn off at the wall and on again after 5 seconds and try again. If still faulty, then: 1.
  • Page 48 Phase 4 to 5 The Display size switch setting does not match that stored in memory. Action - Reselect the size of Smartdrive by using the SIZE SETTING MODE. Push and hold the water temp up button, then press the power button to enter SIZE SETTING MODE. Three LEDs are used to identify size.
  • Page 49 (00001011) Phase 1 to 5 - Pressure Sensor Fault While measuring the water level the Motor Controller has detected a negative pressure. Reconnecting the pressure tube to the pressure sensor while the bowl contains water can cause this. Primary Source – Pressure Tube. Action - Check bowl is fully pumped out.
  • Page 50 (00001110) Phase 1 - Pump Connection Fault The Display Module has detected that the pump is not on when it should be. Primary Source - Pump Action 1. The pump is fitted with a thermal cut out device. Check if this device has been activated. If the device is activated wait until pump cools down before restarting.
  • Page 51 (00100000) Phase 1 - Pump Circuit Error The Display Module has detected that the pump is on when it is off. Primary Source - Display Module Action 1. Check for moisture in the console area. 2. Replace the Display Module. (00100001) Phase 1 - Water Valve Fault The Module has detected a water valve fault.
  • Page 52 (00100100) Phase 1 to 5 - Water Leak Fault The Motor Controller has needed to top up the water level more than 4 times during agitate. This is excessive as normally only one or two top ups are required to replace the air that has escaped from a full load during agitate.
  • Page 53 The Motor Controller has recorded a water level of empty while it is agitating. The water level must have been greater than empty for Smartdrive the enter the agitate mode initially. The most likely cause of this fault is that the pressure transducer hose has been severed or fallen off during agitate.
  • Page 54 (00101001) Phase 1 to 5 - Temperature Sensor Fault The resistance of the Thermistor is outside the normal limits, the fault is probably due to a short circuit in the Sensor line. Primary Source - Thermistor (Phase 5), Motor Controller (Phase 1 to 4) Action Phase 1 1.
  • Page 55 (00101100) Phase 2 to 5 - Water in Bowl During Spin The Display has sensed a water level in the bowl during spin. This may be caused by a slow pump out rate due to pump hose or pump partial blockage. Primary Source - Pump System Action 1.
  • Page 56 (00101111) Phase 2 to 3 - Bowl Dis-engaged Fault While carrying out a bowl check, the Motor Controller has found that the bowl is not engaged even though the pressure sensor indicates that the bowl is empty. The Motor Controller continues to check for 2 minutes.
  • Page 57 (00110010) Phase 2 to 5 - Hot Valve Fault The Motor Controller has measured a voltage from the valve diagnostic circuit that indicates that the hot valve is faulty. The most likely cause is that the valve harness has not been connected correctly.
  • Page 58 (00110011) Phase 2 to 5 - Rotor Position Sensor Fault The Motor Controller has attempted a motor step test and has found that the motor has not stepped to the correct position. It has detected that the motor is connected and that the Motor Controller drive is operational.
  • Page 59 (00111000) Phase 4 to 5 - Bowl Check Fault While carrying out a bowl check Smartdrive has not been able to determine a valid bowl status and so the Display flags this fault. This fault differs from fault 40 in that a valid bowl status could not be determined.
  • Page 60 (00111101) Phase 4 - Motor Controller Fault The Motor Controller has been attempting to perform an internal EEPROM write. Prior to writing the Motor Controller has tested the 15 Volt supply and found that it is below the safety level for writing EEPROM and has reported this to the display. This may be due to mains transients at the time of write or due to a faulty Motor Controller.
  • Page 61 104. (01101000) Phase 2 to 5 - Comms. Error Refer to Fault code 105 for action. 105. (01101001) Phase 2 to 5 - Comms. Error Time-out These faults are reported when the Display module detects an error in the communications between the Display module and the Motor Controller.
  • Page 62 identify size, cold water temperature LED identifies 5kg, the low water level LED identifies 6kg, the hold spin speed LED identifies 7kg. If the product has not been setup before all 3 LEDs will be on. To set the size for 5kg push the wash temp up button. To set the size for 6kg push the water level up button.
  • Page 63 Secondary Source - Rotor Position Sensor Action - If the harness seems to be correct, check the Rotor Position Sensor for loose, damaged, or faulty components. Tertiary Source - Motor Controller Action - The Motor Controller motor sensing circuitry may be faulty. Replace Motor Controller.
  • Page 64 136. (10001000) Phase 1 to 5 - Motor Stall The Motor Controller has been unable to start the motor rotating and signals the Display module with motor stall error. Possible causes of this fault are: Faulty motor harness, faulty or jammed motor, seized bearings or seals, faulty Motor Controller, faulty Rotor Position Sensor or harness.
  • Page 65 160. (10100000) Phase 1 to 5 - Bowl Engaged During Agitate The bowl has re-engaged itself during agitate. Possible causes for this are a leak in the air bell, bowl is over-loaded with clothes, the clutch has jammed or is fouled with a foreign object. Primary Source - Mechanical Action 1.
  • Page 66 164. (10100100) Phase 4 to 5 - Brake Function Time-out Fault This fault indicates that the Motor Controller has been attempting to brake for 20 seconds. All spin loads should come to rest within 10 seconds something must have gone wrong during the brake to prevent the bowl stopping in time.

  • Page 67: Mechanical Service Section

    12.0 MECHANICAL SERVICE SECTION 12.1 COMPLETE DISASSEMBLY CAUTION: Ensure power and water supplies are disconnected before servicing. There is still mains power within the console when on/off switch in the `off' position. Isolate from the power supply. To remove the lid, open it to the upright position and lift it clear. An anti-static wrist strap must be used when handling electronic modules.
  • Page 68 PHASE 2 TOPDECK SHOWING WIRING CONNECTIONS Disconnect the pressure tube from the pressure sensor. Disconnect display module plug, the motor/pump harness plug and Rotor Position Sensor plug. Remove the pump earth lead and mains cable earth lead from the Motor Controller Module. Remove the plugs from the back of the mains cable clamp, undo the 2 screws holding the clamp and remove the clamp from the console feed the mains cable earth wire through the cable clamp opening.
  • Page 69 Unclip the bias spring from the front left suspension rod. Unclip the neck ring from the top of the outer bowl. Remove the fabric softener dispenser, unscrew the agitator retaining nut and remove the agitator. The inner bowl may now be lifted clear. (If the inner bowl is not easy to lift clear, then remove the three spline retaining screws and remove the driven spline.
  • Page 70 Lay the cabinet on its back, on protective material, and slide the outer bowl assembly out, but note that approximately 1 litre of water must be removed from the pump sump before laying the cabinet on its back. To remove the pump, release the locking tab.

  • Page 71: Assembly Guidelines

    12.2 ASSEMBLY GUIDELINES Assembly is the reverse of disassembly. The following points are worth noting. Drain Hose Outlet Elbow. Refit to the base. NB: Ensure the lugs on the elbow are located underneath the pump bracket. Clamp into position. Pump. Turn the pump clockwise when refitting it into the bayonet fixture.

  • Page 72: Motor Assembly & Disassembly

    12.3 MOTOR ASSEMBLY & DISASSEMBLY 1. Remove the rotor by using a 16mm or 5/8" socket. Lift the rotor clear, and place in a plastic bag. The rotor has strong magnets and can attract metal objects. If any foreign objects are caught in the rotor area these may cause the magnets to wear and create a fine black powder which will permeate through the whole appliance.

  • Page 73: Pump Blockage

    12.4 PUMP BLOCKAGE Pump Block error is fault code 37. This is one of most likely problems encountered Smartdrive. See section 11.0 for more information on fault code 37. Drain the Bowl. This can either be done using the pump or emptying the bowl manually. If there is a service hatch (Phase 1-4).

  • Page 74: Shaft & Bearing Removal

    12.5 SHAFT & BEARING REMOVAL Fit the spline tool over the shaft. Remove the 1 1/4"AF shaft retaining nut securing the shaft. Lay the outer bowl on its side before removal of the shaft. This ensures that the shaft does not fall directly onto the floor.

  • Page 75: Shaft & Bearing Assembly

    12.6 SHAFT & BEARING ASSEMBLY 1. The bearings must be inserted separately with the inner bearing fitted first and pulled down with the bearing tool onto the shoulder in the bearing housing. IMPORTANT: There must be no gap between the bearing outer race and the shoulder of the aluminium extrusion. Remove the insertion tool at this point and check that the inner bearing is fully home.
  • Page 76 Ease the shaft through the bearings from inside the outer bowl. Take care the shaft is fitted with the threaded retaining nut section facing downwards in the direction of the base. Fit the shaft retention nut. Use the spline tool and spanner to tighten the shaft retention nut. Invert the outer bowl.

  • Page 77: Appendix A: Binary Decoding Chart - 8 Bits (0-255)

    Appendix A: Binary Decoding Chart – 8 Bits (0-255) 8 WASH PROGRESS LEDs short rinse spin wash The above chart shows the 8 wash progress LEDs with the SPIN LED corresponding to the leftmost. 8 bit binary calculations: LSB is the SPIN LED. If it is on this has a value of 1. The MSB is the first wash LED, this has a value of 128 if it is on.

  • Page 78: Appendix B: Technical Bulletins

    Appendix B: Technical Bulletins These are extracts from previous technical bulletins. WM011 ALTERNATIVE SPARE PARTS FOR PHASE 1 MOTOR CONTROLLER – June 1999 – Phase 1 only Fisher &Paykel is no longer able to obtain some electronic components to continue the manufacture of the current Motor Controllers, part number 425243P.

  • Page 79: Wm013 Pump Hood Kit - January 2000 - Phases 2 To 5

    WIRING CONNECTIONS WATER VALVES ROTOR POSITION SENSOR DISPLAY PRESSURE SENSOR PUMP MOTOR HARNESS PUMP EARTH End view of 426418P Motor Controller Module wiring connections. WM013 PUMP HOOD KIT – January 2000 – Phases 2 to 5 Changes have been made to the pump hood, cap and the impeller to decrease the possibility of small pieces of grit and lint blocking the pump.

  • Page 80: Wm51 Diagnostic Flow Chart - Sept 1992- Phase 1 Only

    WM51 DIAGNOSTIC FLOW CHART – Sept 1992– Phase 1 only This is a flow chart for original Phase 1 Smartdrive Motor Controllers and Displays. These are fitted with a slow blow 32mm 6A fuse. Use this flow chart when there is no power to the display module and Smartdrive is powered on.

  • Page 81: Wm65 Bib Deflector - April 1994- Phase 1 Only

    WM65 BIB DEFLECTOR – April 1994– Phase 1 only Fisher & Paykel have introduced a new bib deflector with 3 vertical fins to replace the early Phase 1 deflector part number 425768. It is recommended that whenever a phase 1 Smartdrive is serviced the new bib part number 425968 be fitted.

  • Page 82: Wm80 Condensation Kit - May 1996 - Phase 2 & 3 Only

    WM80 CONDENSATION KIT – May 1996 – Phase 2 & 3 only A condensation kit is available to reduce build up in the console area and around the electronics is available as part number 472976. This kit must be fitted to all Phase 2 & 3 Smartdrive where the display module has failed due to condensation or there is condensation present in the console area.

  • Page 83: Appendix C: Smarttool

    Appendix C: Smarttool Smarttool is an Application which is run on a PC or a Casiopea Palm-Top. This application may be used with the following Fisher & Paykel products :- Smartdrive. Phase 1-5. Washing Machine. ActiveSmart. Refrigerator. DishDrawer. Dishwasher. The fault information is downloaded from the products front panel LEDs via a light pen.

  • Page 84: Appendix D: Tools For Servicing Smartdrive

    Appendix D: Tools for Servicing Smartdrive SERVICE TOOL KIT PART NUMBER 502009 502009 Bearing Puller Kit. This kit is shown above and is used for insertion and extraction of bearings. The extraction washer is available separately. 502034 Rotor Puller Adapter. This tool is used to extract the rotor when the plastic nut is broken. 502105 Rotor Position Sensor.

  • Page 85: Appendix E: Iw Smartdrive Servicing

    Display, 426961 not for IWECO. Motor Controller, 426520 not for any IW. Smarttool may be used to extract more service information. To download data use the ‘Start/Pause’ button from fault mode or diagnostic mode. IW Models IW509, IW609, IW709 IWECO Models IWC09, IWM10, IW710, IWL10, IW810 Specifications for IW...

  • Page 86: Introduction To Iw

    The first Intuitive Washer(IW) was introduced in Phase 5 Smartdrive in 1999. Three models were released, IW509, IW609 and IW709. These products were upgraded in 2000 to include recirculation, these products are called Intuitive ECO. These products were IWC09 (non recirc), IWM10, IW710, IWL10 and IW810.
  • Page 87 recirculation will not work. It is important not to mix the different coloured modules as they are not compatible and Smartdrive will not work. It will normally display a fault code and beep if the modules have been mismatched. Delay start is 1 to 9 hours, (IW) or 18 hours (IWECO) in increments of 1 hour. WATER TEMPERATURE SENSING The thermistor for sensing the water temperature in Smartdrive is located in the inlet chamber and is available as a separate spare part, part number 479164P.

  • Page 88: Option Adjustment Mode For Iw

    RECIRCULATING VALVE PUMP The pump is the same as Phase 5. The pump forms part of the power supply. If it not connected Smartdrive will appear to have no power. The pump resistance is 33 ohms. OPTION ADJUSTMENT MODE for IW In Option Adjustment Mode the following adjustments may be made: - Adjust Options Menu The fill level selected by Auto Water Level.
  • Page 89 AUTO WATER - Auto Water Level Adjustment The water level that Smartdrive fills to on auto water level may be Auto Water Adjust adjusted. Select AUTO WATER. Use the MORE or LESS buttons to decrease or increase the fill level. NB: If there is not enough water for the less ß...

  • Page 90: Diagnostic Mode For Iw

    DIAGNOSTIC MODE for IW DIAGNOSTIC MODE incorporates tests for the pump, diverter valve, water valves, and also the data display mode. To enter DIAGNOSTIC MODE, turn the power on at the power point and off at the console. Press and hold the ‘SPECIALs’ / ’LifeCycles’ button and then the POWER button. Smartdrive will give 2 short beeps and the LCD screen will go blank.

  • Page 91: Drain Pump Test

    FAULT STATUS Fault Status The Fault Status screen will display the fault code for the current or Fault code: 130 last fault that has occurred in Smartdrive. It will also display how 5 cycles ago many cycles ago the fault occurred and at what part of the cycle. The at progress SPIN fault code can be checked in Section 11 to identify the repairs that may be necessary.

  • Page 92: Size Setting Mode For Iw

    CARE button, then press the POWER button. This will give either of the following options in the LCD screen. MACHINE SIZE SETUP IW509, IW609, IW709 ‘size’ is determined in the conventional way, with sizes 5, 6 & 7. no size MACHINE...

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