Fisher & Paykel SMARTDRIVE PHASE 7 Service Manual
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Fisher & Paykel SMARTDRIVE PHASE 7 Service Manual

Phase 7 electronic washing machines
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SMARTDRIVE
PHASE 7
ELECTRONIC WASHING MACHINES
517790D

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Summary of Contents for Fisher & Paykel SMARTDRIVE PHASE 7

  • Page 1 ® SMARTDRIVE PHASE 7 ELECTRONIC WASHING MACHINES 517790D...
  • Page 2 517790D MARCH 2006 The specifications and servicing procedures outlined in this manual are subject to change without notice. The latest version is indicated by the reprint date and replaces any earlier editions.
  • Page 3 517790D FISHER & PAYKEL PHASE 7 ELECTRONIC WASHING MACHINE Covering the following product codes New Zealand Australia Rest of World Markets MW512-NZ 92194-A/B MW512-AU 93194-A/B MWC12-HK 94194-A/B GW512-NZ 92195-A/B GW512-AU 93195-A/B MWC12-PF 95194-A/B MW612-NZ 92186-A GW612-AU 93196-A GWC12-HK 94195-A/B GW612-NZ 92196-A GW712-AU 93200-A...

  • Page 4: Table Of Contents

    517790D CONTENTS SPECIFICATIONS ........................6 Dimensions ........................6 Maximum Capacity (Full Load) (AS 2040)..............6 Water Consumption ....................... 6 Water Fill Temperature (Approximate Factory Settings) ..........6 Wash Motor ........................6 Pump Motor ........................6 Water Valves ......................... 7 Thermistor (GW Only)....................7 Cabinet ..........................
  • Page 5 517790D DETAILED FAULT CODES ....................34 FAULT DESCRIPTIONS ..................... 34 SERVICE PROCEDURES ..................... 46 10.1 Removal of Lid......................46 10.2 Components in Console Area.................. 46 10.3 Removal of Display Module ..................46 10.4 Removal of Water Valves ..................47 10.5 Removal of Thermistor (if fitted) ................

  • Page 6: Specifications

    517790D SPECIFICATIONS Dimensions Compact Washer Medium Washer Large Washer Height to lid Open 1320mm – 1350 mm 1360mm – 1390 mm 1410mm – 1440mm Closed 950 mm – 980 mm 950 mm – 980 mm 950mm – 980mm Height to console 1010 mm –...

  • Page 7: Water Valves

    517790D Water Valves Supply Mode of Operation Voltage Resistance Flow Rate Cold Digitally Operated 24V DC 64Ω @ 20 16 litres per minute Digitally Operated 24VDC 64Ω @ 20 10 litres per minute Note: Flow rate will vary slightly depending on pressure. Operating pressures: Maximum 1034 kPa (150psi) / Minimum 34 kPa (5psi) Note:...

  • Page 8: Water Conservation Rating

    517790D 1.16 Water Conservation Rating* AAAA: A very high level of water efficiency *Issued by the Water Services Association of Australia 1.17 Fabric Softener Dispenser Dosage 75cc 1.18 Electric Supply Operating Voltage 220/240V AC 50Hz Maximum Current 2.8 amps 1.19 User Guide User Guide 420706...

  • Page 9: Technical Overview

    517790D TECHNICAL OVERVIEW This Service Manual contains information on the Product Specifications, Diagnostic Mode, Detailed Fault Codes and the complete disassembly and assembly instructions for the Phase 7 ® SmartDrive washing machine. Electronics 2.1.1 Motor Control Module The Motor Control microprocessor performs a wide variety of tasks. Primarily it controls the electronic switching hardware to control the three phase currents in the Smart Drive DC motor.

  • Page 10: Stand By Mode

    517790D 2.1.2 Display Module The Display Module provides the link between the washing machine electronics and the user. Input on wash type, water level, spin speed, start/stop and wash cycle time is given by the user via the display push buttons. Feedback on selection is given to the user by Light Emitting Diodes (LEDs).

  • Page 11: Water Temperature Sensing

    517790D Water Temperature Sensing GW Washer The thermistor for sensing water temperature in the GW Washer is located in the back of the outlet elbow on the valve assembly, and is connected directly to the Motor Control Module. For details on the wash temperature adjustment Refer to Section 2.4.2 &...
  • Page 12 517790D 2.4.1 Warm Wash Temperature Adjustment (MW Only) The warm wash temperature adjustment will alter the amount of time that the hot valve pulses on and off for. 1. Turn machine on at the wall but do not press POWER. 2.

  • Page 13: Water Valves

    517790D 2.4.3 Controlled Cold (GW Only) If the cold water temperature is very low (below 20 C), a very effective wash will not be obtained. The controlled cold option solves this problem by adding a small amount of hot water to raise the temperature of the wash.
  • Page 14 517790D 2.6.1 Manual Water Level – (MW & GW) The agitator has 5 levels marked on its stem that can be used to help the user select the correct water level. Select the correct water level by using the mark nearest to the top of the clothes. The levels marked on the agitator are a guide for the clothes and do not correspond exactly to the water level.

  • Page 15: Motor

    517790D Motor 2.7.1 Copper Stator This stators used on the Phase 7 machines are unique to this Phase only and therefore it is not interchangeable with any previous phase or series of machines. The stator has 36 poles instead of 42 poles, and the pole tips are curved. The resistance of the windings remains the same as for the Phase 5, Series 9, and Phase 6, Series 11 and 12 machines at 16 ohms per winding.
  • Page 16 517790D 2.7.2.1 Testing the Stator If the stator needs to be tested we would first recommend testing the resistance of the windings from the harness that is connected to the Motor Control Module. (Refer to Section 7). Note: Ensure that the Rotor or bowl is stationary when measurements are made. Testing the stator from the console The resistance of each individual winding is approximately 16 ohms (25.5 ohms aluminium stator), however when testing the stator from the console we are testing across two windings therefore the...
  • Page 17 517790D The photographs below show the difference between a Phase 7, and a Phase 6 Rotor. Phase 7 Phase 6 2.7.4 Rotor Position Sensor (RPS) One of the inputs that the Motor Control Module module needs in order to determine which switches to turn on is the position of the rotor.

  • Page 18: Pump

    517790D 2.7.4.1 Testing the Rotor Position Sensor To test the RPS use a RPS tester, part number 502105, which is powered by a 9V battery. To test the RPS of a Phase 7 Washer it will also require an adaptor harness, part number 420892. tester has 3 LEDs, and the pattern of these LEDs will change as the magnetic field of the Rotor passes the hall sensors.

  • Page 19: Lid Lock

    517790D Lid Lock The Phase 7 Washer uses the same lid lock that is used on the Phase 6 series 11 & 12 machines. During the spin and drain out part of the cycle prior to spray rinse, the lid will lock down until the completion of the spin.

  • Page 20: Inner And Outer Bowls

    517790D 2.10 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 are 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: Agitator

    517790D 2.10.2 Detection of Inner Bowl Re-Engagement – Bowl Check ® After SmartDrive has pumped out the water, the inner bowl will sink down and re-engage onto the ® drive spline. To ensure the inner bowl has re-engaged correctly, SmartDrive will carry out a bowl re-engage test sequence (bowl check).

  • Page 22: Fabric Softener Dispensing

    517790D 2.13 Fabric Softener Dispensing TYPE: It is recommended that softener sheets should be used in the dryer rather than using liquid softener in the washing machine. Liquid softener has been known to produce a waxy build-up inside washing machines, called Scrud. We do however, provide a fabric softener dispenser for those who prefer liquids.
  • Page 23 517790D 2.13.1 Scrud If fabric softener is used regularly it will eventually cause a build up within the outer bowl. This can result in black flakes present in the wash load that can stain garments. To remove scrud follow the procedure below.

  • Page 24: Size Setting Mode

    517790D SIZE SETTING MODE To set the size switch, turn the power on at the power point and off at the console. Press and hold ® WASH TEMPERATURE SETTING UP then press POWER. SmartDrive will give 4 short beeps and the pattern of LEDs will change. One of the following buttons needs to be pushed to lock the size into memory.

  • Page 25: Water Valve Test

    517790D Water Valve Test The water valves can be activated in diagnostic mode by pushing WASH TEMPERATURE SETTING UP to activate the Hot Valve and WASH TEMPERATURE SETTING DOWN to activate the Cold valve as with previous models. Pressing each button once will activate the valve. To de-activate valve press the same button again.

  • Page 26: Hot Bowl Flag

    517790D To turn the recycle feature on follow the procedures below: 1. Enter diagnostic mode (Refer to Section 4). 2. Press WATER LEVEL UP so that the Medium water level LED is lit. 3. Press POWER to turn the display off (the 3 rightmost wash progress LEDs will be flashing). 4.
  • Page 27 517790D 4.8.1 Hot Water Temperature LED Flashing (Insufficient Hot Water) - GW Machine only Possible causes: 1. Check that the hot water is connected and that the tap is turned on. 2. Check that the water temperature is not too low. The water temperature may need to be 60 o C for a hot wash.

  • Page 28: Out Of Balance

    517790D 4.8.5 First Rinse or Final Spin and Current Spin Speed LED Flashing (Out of Balance) Possible causes: ® 1. Check that SmartDrive is correctly installed, is level and does not rock on the floor. 2. Check the bias spring is fitted between the top of the neck ring and the front left hand suspension rod.
  • Page 29 517790D Diagnostic mode 0, Last User Warning Number: When in this level, use the binary count on the Wash Progress LEDs as used to obtain the last fault data. Use the chart below to identify which was the last user warning. Binary Count User Warning No warning...

  • Page 30: Wiring Diagram

    517790C WIRING DIAGRAM...

  • Page 31: Voltage Readings From Controller

    517790C VOLTAGE READINGS FROM CONTROLLER 1. Water Valves 6. Display Module Varies between 13 – 22V DC Note: Accurate voltages can only be obtained by using a True RMS multimeter. 2. Supply voltage 230 VAC 0 – 5 V DC 3.

  • Page 32: Resistance Readings From Controller

    517790C RESISTANCE READINGS FROM CONTROLLER 1. Water Valves 5. Lid lock 64 Ω +/- 10% 63Ω +/- 10% @ 20 C (68 2. Wash Motor 32Ω across any two windings 6. Thermistor 10,000Ω @ 25oC 3. Pump Motor 33Ω 4. RPS - Unable to be tested with multimeter.

  • Page 33: Binary Decoding Chart - 8 Bits (0-255)

    517790C BINARY DECODING CHART – 8 BITS (0-255) 8 WASH PROGRESS LEDs rinse spin short wash ΟΟΟ ΟΟ Ο Ο Ο ΟΟ Ο Ο ΟΟΟΟΟ ΟΟΟΟ ΟΟΟ Ο ΟΟΟ ΟΟ ΟΟ ΟΟ Ο ΟΟ Ο ΟΟ Ο ΟΟΟ Ο ΟΟ Ο...

  • Page 34: Detailed Fault Codes

    517790C DETAILED FAULT CODES PHASE 7 DETAILED FAULT CODES INTRODUCTION The format for fault description in this booklet follows the Primary, Secondary, Tertiary and Quaternary 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. It should be noted that the fault source Pump System includes the pump and drain hose assembly.
  • Page 35 517790C • Press Spin Speed Up, the Spin Hold LED is on for 7.5 / 8.0kg (650mm wide). • Press Power to confirm the setting and also exit this mode. Action IW Machines: To access Size Setting Mode, push and hold the Fabric Care button and then press the Power button to enter Size Setting mode.
  • Page 36 517790C Action 1) Check the height of the drain hose outlet. Minimum 850mm, maximum 1200mm. 2) Check that the hose guide is fitted and check that the hose does not protrude more than 20mm beyond the guide. Secondary Source: Mechanical. Action: 1) Check the pressure tube connections on the outer bowl and Motor Control Module.
  • Page 37 517790C (00100111) Pressure Tube Fault The probable cause of this fault is that the pressure tube has become blocked or kinked or has fallen off completely. Alternatively, the pressure sensor may be faulty. Primary Source: Mechanical. Action: Check that the pressure tube is intact and not blocked with water or dirt and is not kinked.
  • Page 38 517790C (00110010) Hot Valve Faulty The Motor Control Module has measured a voltage from the valve diagnostic circuit that indicates the hot valve is faulty. The most likely cause is that the valve harness has not been connected correctly or the valve is open circuit. See fault 48 for service procedure. (00110011) Diverter Valve Fault The motor controller has registered a drop in water level in the recirculation phase of the wash cycle.
  • Page 39 517790C (00111001) Brown Out During Display EEPROM Write Fault The Display has requested the Motor Control Module to perform an EEPROM write. Prior to writing, the Motor Control Module 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.
  • Page 40 517790C 106. (01101010) Display Module to Motor Control Module Communications Error These faults are reported when the Display Module detects an error in the communications between the Display Module and the Motor Control Module. Primary Source: Display Module. Action: Replace Display Module. Secondary Source: Motor Control Module.
  • Page 41 517790C 130. (10000010) Single Rotor Position Sensor Error The Motor Control Module has found an error in the pattern received from the Rotor Position Sensor. Likely causes of this fault are a bad connection on the harness between the Rotor Position Sensor and the Motor Control Module, or a faulty Rotor Position Sensor. Primary Source: Wiring.
  • Page 42 517790C 220. ) EEPROM Model Map Not Programmed 11011100 Similar to fault code 60. Primary Source: Motor Control Module Action: Replace Motor Control Module 230. (11100110) EEPROM Value out of Range Wrong version detected Primary Source: Motor Control Module is the wrong version. Action: Change Motor Control Module.
  • Page 43 517790C 238. (11101110) Lid Lock Fail In-Line Test (1) Final on line tests, final check before going to the field. 239. (11101111) Lid Lock Fail In-Line Test (2) Final on line tests, final check before going to the field 240. (11110000) Hall Out Of Order.
  • Page 44 517790C 248. (11111000) SmartPump Top Up Fault More than 6 attempts have been made to top-up the water level in the bowl during recirc. This then signifies that the flapper valve has not closed full and some water is diverting to drain. Primary Source: Poor Flapper Seal.
  • Page 45 517790C 250. (11111010) SmartPump Loss Of Sync This fault is normally as a result of the pump not starting. This fault is usually caused by an object that has gotten into the pump, and is either under or on top of the impeller, which is causing the motor to stall when it is trying to start.

  • Page 46: Service Procedures

    517790C SERVICE PROCEDURES ® In order to service and to gain access to components within SmartDrive , certain procedures must be followed. These procedures are set out below. Servicing note (a) To avoid stripping screws, do not overtighten when re-assembling parts. If using a power screwdriver, have the torque setting on low.

  • Page 47: Removal Of Water Valves

    517790C 10.4 Removal of Water Valves (a) Follow procedures for removal of Display Module. (Refer to Section 10.2). (b) Disconnect wiring harness to each coil by first pulling downwards on the retaining clip. (c) Remove screw securing the outlet nozzle to the top deck.

  • Page 48: Removal Of Cord Set

    517790C 10.7 Removal of Cord Set (a) Follow procedures for removal of water valves. (Refer to Section 10.4). (b) Disconnect the mains plug to the Motor Slide Control Module. (c) Slide the strain relief to the left and slide out. Reassembly: Refit in reverse manner.

  • Page 49: Removal Of Neck Ring

    517790C Reassembly: Refit in reverse manner. Note: The inlet nozzle can be removed when the top deck is lifted. 10.10 Removal of Neck Ring (a) Follow procedures for removal of lid. (Refer to Section 10.1). (b) Carefully remove the two lid buffers from the front side top of the deck by levering upwards, taking care not to damage the top deck.

  • Page 50: Removal Of Inner Bowl

    517790C 10.12 Removal of Inner Bowl (a) Follow procedures for removal of Neck Ring. (Refer to Section 10.10). (b) Follow procedures for removal of Agitator. (Refer to Section 10.11). (c) Lift inner bowl upwards and clear of machine. Note: If the inner bowl is tight on the shaft pressure may need to be placed on the top of the shaft, while at the same time jiggling the inner bowl upwards.

  • Page 51: Removal Of Outer Bowl From The Cabinet

    517790C 10.15 Removal of Outer Bowl From The Cabinet (a) Follow procedures for removal of the Top Press tab and rotate fixture carefully Deck. (Refer to Section.10.9). (b) Follow procedures for removal of Inner Bowl. (Refer to Section 10.12). (c) Thread the drain hose back in to the cabinet.

  • Page 52: Removal Of Stator

    517790C 10.17 Removal of Stator (a) Follow procedures for removal of Rotor. (Refer to Section 10.16). (b) Unscrew the four bolts securing the Stator to the outer bowl. (c) Lift Stator off the base of the outer bowl and clear of the shaft. (d) Disconnect the wiring to the terminals.

  • Page 53: Removal Of Pump

    517790C 10.19 Removal of Pump (a) Lay machine down or against a wall. leaning the machine against a wall ensure that the machine is stable, and take necessary precautions not to damage the wall or the machine. (b) Remove the wiring harness to the pump and the earth wire.

  • Page 54: Specialised Service Procedures

    517790C SPECIALISED SERVICE PROCEDURES 11.1 Blocked Pump Procedure It is possible to clear a blockage/obstruction from the pump without having to drain the water from the machine or disturbing the pump. If however there are concerns over the condition of the water and there may be a risk of infection, ie from hepatitis etc, then bail the water from the machine first.

  • Page 55: Shaft & Bearing Replacement

    517790C 11.2 Shaft & Bearing Replacement Procedures described in this section as well as section 11.3 can only be carried out by using the Bearing Removal Tool Kit, part number 502009. The contents of the kit are as follows: Bearing Removal Tool Kit 502009 Note: The extractor mandrel was designed for the older shaft with the external thread, however will work with the shaft on this machine with the internal thread.
  • Page 56 517790C WARNING: Make sure the Stator clamp plate is flat before reusing. If in doubt, replace. (c) Remove the outer bearing using the bearing removal tool. WARNING: Do not remove the bearings with a hammer and drift as serious damage to the bearing housing or outer bowl may result.

  • Page 57: Shaft & Bearing Assembly

    517790C Note: The outer bearing will be proud of the housing by approximately 3mm. 11.3 Shaft & Bearing Assembly (a) 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.

  • Page 58: Bearing Installation

    517790C (c) 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. (d) Fit the shaft retention nut. Use the spline tool and spanner to tighten the shaft retention nut. (e) Invert the outer bowl.

  • Page 59: Wash Performance Information

    517790C WASH PERFORMANCE INFORMATION 12.1 Creasing ® Creasing can be caused by over loading SmartDrive or the dryer. Permanent Press or Delicate cycles have been designed to minimise creasing as they use a lower spin speed. Do not leave wet clothes to sit in the washer or laundry basket.

  • Page 60: Operating Problems

    517790C OPERATING PROBLEMS 13.1 No Power If the machine appears dead, and there is no response from pressing the power button, then check the following. • Check the supply voltage and that the machine is plugged in and switched on. •...

  • Page 61: Continuous Or Slow Spinning

    517790C • If the inner bowl or agitator are noisy, check for obstructions. Check the spline drive is clean. If there is a grating sound, check the single stainless steel washer beneath the spline drive. • If the motor is abnormally noisy, chipped or cracked Rotor magnets are unlikely to affect the noise.
  • Page 62 517790C Notes...

This manual is also suitable for:

Smartdrive mw512Smartdrive gw512Smartdrive mw612Smartdrive gw612Smartdrive gw712Smartdrive mwc12 ... Show all

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