Fisher & Paykel Ecosmart GWL15-US-96200 Service Manual
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Fisher & Paykel Ecosmart GWL15-US-96200 Service Manual

Fisher & paykel ecosmart phase 7 electronic washing machines
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ECOSMART
PHASE 7
ELECTRONIC WASHING MACHINES
517792A

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Summary of Contents for Fisher & Paykel Ecosmart GWL15-US-96200

  • Page 1 ECOSMART PHASE 7 ELECTRONIC WASHING MACHINES 517792A...
  • Page 2 517792A NOVEMBER 2005 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 517792A FISHER & PAYKEL PHASE 7 ELECTRONIC WASHING MACHINES Covering the following product codes GWL15-US - 96200 Fisher & Paykel Appliances Inc 5800 Skylab Road, Huntington Beach, California, CA92647, USA Ph: 888 936 7872 (F&P), Ph: 888 396 2665 (DCS)

  • Page 4: Table Of Contents

    517792A CONTENTS SPECIFICATIONS ........................6 Dimensions.......................6 Maximum Capacity (Full Load) .................6 Water Consumption....................6 Water Fill Temperature (Approximate Factory Settings) ...........6 Wash Motor ......................6 Pump Motor......................6 Water Valves ......................7 Thermistor ........................7 Cabinet ........................7 1.10 Lid ..........................7 1.11 Top Deck ........................7 1.12 Inner Basket ......................7 1.13 Outer Basket ......................8 1.14...
  • Page 5 517792A Removal of Water Valves ..................42 Removal of Thermistor ...................42 Removal of Motor Control Module ................42 Removal of Cord Set ....................43 Removal of Lid Lock ....................43 Removal of Top Deck .....................44 9.10 Removal of Neck Ring ....................44 9.11 Removal of Agitator ....................44 9.12 Removal of Inner Basket ..................45 9.13...

  • Page 6: Specifications

    517792A SPECIFICATIONS Dimensions Height to lid Open 55.5in – 56.6in / 1410mm – 1440mm Closed 37.4in – 38.5 / 950mm – 980mm Height to console 39.7in – 41.3in / 1010mm – 1050mm Width 25.5in / 650mm Depth 25.5in / 650mm Inlet hose length 47.24in / 1200mm Packed weight...

  • Page 7: Water Valves

    517792A Water Valves Supply Mode of Operation Voltage Resistance Flow Rate Cold Digitally Operated 24V DC 64Ω @ 68 F / 20 16 liters per minute Digitally Operated 24VDC 64Ω @ 68 F / 20 10 liters per minute Note: Flow rate will vary slightly depending on pressure. Operating pressures: Maximum 150psi / 1034 kPa - Minimum 5psi / 34 kPa Note: Pressures below 5psi / 34kPa can create seating problems with the internal...

  • Page 8: Outer Basket

    517792A 1.13 Outer Basket Aluminium insert over-moulded with polypropylene 1.14 Console ABS plastic with ABS plastic insert for display module. 1.15 Agitator Polypropylene 1.16 Fabric Softener Dispenser Dosage 75cc 1.17 Electric Supply Operating Voltage 110/120V AC 60Hz Maximum Current 7.0 amps 1.18 User Information User Guide...

  • Page 9: Technical Overview

    517792A 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 washing machines. 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

    517792A 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

    517792A Water Temperature Sensing The thermistor for sensing water temperature 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 2.4.1 & 2.4.2. Specifications NTC-type temperature sensor (Thermistor) Resistance 10,000Ω...

  • Page 12: Water Valves

    517792A Water Valves The Phase 7 machines use a new dual valve block assembly. Independent coils control the hot and cold water supply, which feeds the water through a common outlet. The valve block has a location feature for the thermistor.
  • Page 13 517792A 2.6.1 Manual Water Level 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 14: Motor

    517792A Motor 2.7.1 Stator This stator 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 16W per winding.
  • Page 15 517792A If the meter shows an incorrect reading we would then recommend testing the stator from underneath the machine as there could be a fault in the wiring harness. To test the stator, both rotor and stator need to be removed. Refer to Sections 9.16 and 9.17. Note: Two clamp plates are used to secure the Stator, one on each side.
  • Page 16 517792A 2.7.3 Rotor Position Sensor (RPS) One of the inputs that the Motor Control Module needs in order to determine which switches to turn on is the position of the rotor. The rotor position sensor (RPS) supplies this information. The RPS is a printed circuit board that contains three Hall Sensors.

  • Page 17: Pump

    517792A Pump The pump is coupled directly to the outer basket. This eliminates basket to pump hoses and the accompanying seals, clips etc. The pump housing is an integral part of the outer basket. When removing the pump up to a liter of water may leak from the pump cavity.
  • Page 18 517792A When the water is draining, the pressure on the air trapped in the cells of the flotation chamber decreases allowing the inner basket to settle back down onto the drive spline and re-engage the driven spline, thus allowing the agitator and inner basket to turn as one unit. The floating basket is also used to detect if the user has selected the correct water level for the size of the clothes load.

  • Page 19: Agitator

    517792A 2.11 Agitator The agitator design differs from conventional designs in that it is made of very flexible plastic that bends and flexes as the clothes are moved around the basket. The agitator action is similar to that of a fish moving through the water, so the side-wards motion is translated to forward thrust. This is not only more forgiving on the clothes but helps to slowly move the clothes around the basket in a toroidal motion, ie.
  • Page 20 517792A Pour fabric softener into the dispenser as shown The dispensing stages 1. Fabric softener remains in the dispenser cup during the fill, agitate and drain phase of the wash program. 2. During the first phase of the spray rinse it is centrifuged out of the cup into the body of the dispenser.

  • Page 21: Size Setting Mode

    517792A SIZE SETTING MODE To set the size switch, turn the power on at the power point and off at the console. Press and hold â WASH TEMPERATURE SETTING UP then press POWER. EcoSmart will give 4 short beeps and the pattern of LEDs will change. To lock the size into memory.

  • Page 22: Restart Feature

    517792A Restart Feature If a fault occurs in the machine, the diagnostic system will detect it. However, instead of displaying a fault code immediately, the machine will try to restart. If the fault was only of temporary nature, the machine will restart and finish the cycle. If there is a continuous fault the machine will try to restart a number of times.

  • Page 23: Hot Basket Flag

    517792A Hot Basket Flag â If a EcoSmart machine has been filled with hot water and has not had a cold rinse, it will not spin up to its full speed of 1000 RPM. Its maximum speed will instead be restricted to a maximum of 700 RPM.

  • Page 24: Out Of Balance

    517792A 4.8.3 Hot & Cold Water Temperature LED’s Flashing (No Water) Possible causes: 1. Check that water is connected and that the taps are turned on. 2. Check that there are no kinks in the inlet hoses. 3. Check that the filters on the inlet hoses at the tap end are not blocked. 4.

  • Page 25: Diagnostic Table

    517792A Diagnostic Table To use this table, firstly enter Diagnostic Mode (Refer to Section 4). The different levels of information can be extracted by using the Spin Speed up and down buttons. Diagnostic Spin Speed LEDs Diagnostic Info Displayed Level Fast Slow Hold Last User Warning Number...
  • Page 26 517792A Diagnostic mode 7: Cycle position at last fault An LED that is illuminated on the Wash Progress will indicate the cycle where the last fault occurred. Diagnostic mode 8: Water Temperature (deg C) By adding up the LEDs on the wash progress in binary form (Refer to Section 4), this will give the temperature of the thermistor in Note: This feature is not available on the MW model, as there it has no thermistor.

  • Page 27: Wiring Diagram

    517792A WIRING DIAGRAM...

  • Page 28: Voltage Readings From Controller

    517792A 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 29: Resistance Readings From Controller

    517792A RESISTANCE READINGS FROM CONTROLLER 1. Water Valves 6. Thermistor 64 Ω +/- 10% 10,000Ω @ 77 F / 25oC 2. Wash Motor 32Ω across any two windings Pulses up to 30V when locking, when locked, sits at approx 10V DC 3.

  • Page 30: Binary Decoding Chart - 8 Bits (0-255)

    517792A BINARY DECODING CHART – 8 BITS (0-255) 8 WASH PROGRESS LEDs short rinse spin wash OOOOO OOOOY OOOYO OOOYY OOYOO OOYOY OOYYO OOYYY OYOOO OYOOY OYOYO OYOYY OYYOO OYYOY OYYYO OYYYY YOOOO YOOOY YOOYO YOOYY YOYOO YOYOY YOYYO YOYYY YYOOO YYOOY YYOYO...

  • Page 31: Detailed Fault Codes

    517792A DETAILED FAULT CODES PHASE 7 EcoSmartä & Intuitive Ecoä 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.
  • Page 32 517792A 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. Push the Adjust button to select the 650mm (L) size on the display screen.
  • Page 33 517792A (00100101) Pump Blocked Error (No change in the water level) While draining, the water level reading from the pressure sensor has not changed for over 3 minutes. There are three likely reasons for this fault. One is that the drain hose or the pressure switch hose has been squashed or kinked and the pump out rate has been dramatically reduced.
  • Page 34 517792A (00101000) Basket Dis-engage Fault While carrying out a basket check, the Motor Control Module has found that the basket is not engaged even though the pressure sensor indicates that the basket is empty. The Motor Control Module continues to check for 2 minutes, after which time it displays this fault.
  • Page 35 517792A (00110001) Cold Valve Coil Faulty The Motor Control Module has measured a voltage from the valve diagnostic circuit that indicates the cold 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. (00110010) Hot Valve Coil Faulty The Motor Control Module has measured a voltage from the valve diagnostic circuit that indicates the hot valve is faulty.
  • Page 36 517792A 2. Check that there are no clothes or other foreign objects preventing the clutch from re-engaging, and that there aren’t any defects with the clutch mechanism. 3. Check that the pressure tube has not come off and that it is not kinked.
  • Page 37 517792A 104. (01101000) See Fault Code 106 105. (01101001) 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 Control Module. Primary Source: Display Module. Action: Replace Display Module.
  • Page 38 517792A 112. (01110000) Motor Current Sense Too High This fault occurs if the Motor Control Module detects that the motor current has reached an unrealistically high level for greater than 2 seconds. This suggests that the motor current sense circuit is faulty. Primary source: Motor Control Module.
  • Page 39 517792A 2) Check that the clutch teeth are not locked together with dirt, lint, etc. 3) Make sure the basket is not overloaded with too many clothes. 4) If none of the above appear to be at fault, then check the air bell at the bottom of the inner basket for leaks.
  • Page 40 517792A Action: Replace the Thermistor (temperature sensor). Secondary Source: Motor Control Module has failed to read the temperature. Check connections. Action: Replace Motor Control Module if connections look fine and the fault still occurs. 238. (11101110) Lid Lock Fail In-Line Test (1) Final on line tests, final check before going to the field.

  • Page 41: Service Procedures

    517792A SERVICE PROCEDURES ä In order to service and to gain access to components within EcoSmart and Intuitive Ecoä 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 42: Removal Of Water Valves

    517792A Removal of Water Valves (a) Follow procedures for removal of Display Module. (Refer to Section 9.2). (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 43: Removal Of Cord Set

    517792A Removal of Cord Set (a) Follow procedures for removal of water valves. (Refer to Section 9.4). (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 44: Removal Of Top Deck

    517792A Removal of Top Deck (a) Follow procedures for removal of Motor Control Module. (Refer to Section 9.6). (b) Follow procedures for removal of water valves. (Refer to Section 9.4). (c) Follow procedures for removal of cord set. (Refer to Section 9.7). (d) Carefully remove the two lid buffers from the front side top of the deck by levering upwards, taking care not to damage the top...

  • Page 45: Removal Of Inner Basket

    517792A 9.12 Removal of Inner Basket (a) Follow procedures for removal of Neck Ring. (Refer to Section 9.10). (b) Follow procedures for removal of Agitator. (Refer to Section 9.11). (c) Lift inner basket upwards and clear of machine. Note: If the inner basket 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 basket upwards.

  • Page 46: Removal Of Outer Basket From The Cabinet

    517792A 9.15 Removal of Outer Basket From The Cabinet (a) Follow procedures for removal of the Top Press tab and rotate fixture carefully Deck. (Refer to Section.9.9). (b) Follow procedures for removal of Inner Basket. (Refer to Section 9.12). (c) Thread the drain hose back in to the cabinet.

  • Page 47: Removal Of Stator

    517792A 9.17 Removal of Stator (a) Follow procedures for removal of Rotor. (Refer to Section 9.16). (b) Unscrew the four bolts securing the Stator to the outer basket. (c) Lift Stator off the base of the outer basket and clear of the shaft. (d) Disconnect the wiring to the terminals.

  • Page 48: Removal Of Pump

    517792A 9.19 Removal of Pump (a) Lay machine down or against a wall. If 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 49: Specialised Service Procedures

    517792A SPECIALISED SERVICE PROCEDURES 10.1 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 50: Shaft & Bearing Replacement

    517792A 10.2 Shaft & Bearing Replacement Procedures described in this section as well as section 10.3 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 51 517792A 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 basket may result.

  • Page 52: Shaft & Bearing Assembly

    517792A .07 in / 3mm Note: The outer bearing will be proud of the housing by approximately .07in /3mm. 10.3 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.
  • Page 53 517792A (c) Ease the shaft through the bearings from inside the outer basket. 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 basket.

  • Page 54: Wash Performance Information

    517792A WASH PERFORMANCE INFORMATION 11.1 Creasing Creasing can be caused by over loading the washer 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 55: Operating Problems

    517792A OPERATING PROBLEMS 12.1 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 56: Continuous Or Slow Spinning

    517792A · Check for noisy suspension rods. · If the inner basket 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. ·...
  • Page 57 517792A Notes...

This manual is also suitable for:

Ecosmart gwl15Ecosmart phase 7Gwl15

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