Fisher Paykel SMART DRIVEELECTRONIC WASHING MACHINEPHASE 1 to 5 230v Service Manual 517735

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. 42 Clarendon St, Leamington Spa, Warks, CV32 4PG, UK. Phone 0044 1 926 88 2220, Fax 0044 1 926 88 3330. Try www.fisherpaykel.com/Service 517735 Issue A - October 2000 COPYRIGHT © FISHER & PAYKEL LTD 2000

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 & AW are different colours. PHASE 5 IW Bottom right button is ‘Specials’ PHASE 5 IWECO Size 6 & 7 have recirculation fitted. Bottom right button is ‘LifeCycles’

WHAT PHASE, SIZE & MODEL IS YOUR SMARTDRIVE? PHASE YEAR FRONT PANEL COLOURS MODEL NUMBERS MOTOR CONTROLLER COMPONENTS MODEL TYPES PHASE 1 1991-93 Grey Background GW500, GW600, GW700, MW050, MW060, GW650, MW070 Blue. (A few white) Pressure Transducer in display. Water cooled. PHASE 1 spare has phase 4 fault codes. ** 12v water valves. 15 ohms. Stator 2.6 ohms phase to phase. Mechanical lid switch. Selni (33 ohms) & Compreci (26 ohms) pump. MW, GW PHASE 2 1993-95 Grey Background GW501, GW601, GW701, MW051, MW061, MW071, LW015 Blue. Water cooled. 12v water valves. 15 ohms. Stator 12.2 ohms phase to phase. Mechanical lid switch (mostly). Compreci (26 ohms) or Selni (33 ohms) pump. LW, MW, GW PHASE 3 1995-96 White Background with yellow and green buttons GW503, GW603, GW703, MW053,LW035 Green. Water cooled. 12v water valves. 15 ohms. Stator 12.2 ohms phase to phase. Reed switch for lid. Selni pump. 33 ohms. LW, MW, GW PHASE 4 (Series 8) 1996-98 White Background with yellow and blue buttons GW508, GW608, GW708, MW058, LW085, AW085 Yellow. Water cooled.. 12v water valves. 15 ohms. Stator 12.2 ohms phase to phase. Reed switch for lid. Selni pump. 33 ohms. AW, LW, MW, GW PHASE 5 (Series 9 & Series 10) 1998-2001 Various colours. GW509, GW609, GW709, MW059, LW095, AW095, IW509, IW609, IW709, IWL10, IWM10, IWC09, IW710, IW810 Grey. Air cooled. GW & IW have thermistor in mixing chamber. AW, LW, MW no thermistor. 24v water valves. 64 ohms. Stator 32 ohms phase to phase. Reed switch for lid. Selni pump. 33 ohms. AW, LW, MW, GW, IW, IWECO (recirc) DISPLAY TYPE * IDENTIFIER SIZE CAPACITY DIMENSIONS AW, LW No cycle buttons Compact 5kg + 560x560x920h MW 4 cycle buttons. Medium 6kg + 600x600x920h GW Favourite button. Large 7kg + 650x650x920h IW LCD Display * The front panel label names “Fisher & Paykel”, “Frigidaire”, “Kelvinator”, “Shacklock” etc are identical ** A simple test to see if module is phase 1 (spare) enter Diagnostic mode (Press WASH TEMP & POWER). Press ADVANCE if it beeps then the motor controller is a PHASE 1 spare p.n. 426418. Size setting and all fault codes are as phase 4.

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 4.1 Electronics Systems ...................................................................................................................... 7 4.2 Motor ............................................................................................................................................ 9 4.3 Motor Controller Module ........................................................................................................... 10 4.4 Display Module .......................................................................................................................... 11 4.5 Water Valves .............................................................................................................................. 12 4.6 Rotor Position Sensor ................................................................................................................. 13 4.7 Pump........................................................................................................................................... 14 4.8 Inner and Outer Bowls ................................................................................................................ 15 4.9 Lid Switch and Out of Balance Switch ...................................................................................... 17 4.10 Water Temperature Sensing ................................................................................................... 18 5.0 SMARTDRIVE INFORMATION ................................................................................................... 19 5.1 Favourite cycle (GW only) – All Phases .................................................................................... 19 5.2 Customising Wash Cycles (GW only) – Phase 3 to 5 only ........................................................ 19 5.3 Delay Start (GW only) – Phase 2 to 5 only ................................................................................ 20 5.4 Auto Water Level (GW only) – Phase 3 to 5 only..................................................................... 20 5.5 Water Saver (GW only) – Phase 3 to 5 only .............................................................................. 20 5.6 Fabric Softener Dispenser – All Phases ..................................................................................... 21 5.7 Wash Performance Information – All Phases............................................................................. 22 6.0 SMARTDRIVE PROBLEMS ........................................................................................................ 23 6.1 If Smartdrive Appears To Have No Power................................................................................. 23 6.2 If Smartdrive Powers Off mid cycle ........................................................................................... 23 6.3 Flooding...................................................................................................................................... 24 6.4 Leaking ....................................................................................................................................... 24 6.5 Noisy........................................................................................................................................... 24 6.6 Continuous Spinning or Slow Spinning ..................................................................................... 25 6.7 Poor Wash Performance ............................................................................................................. 25 6.8 Siphoning.................................................................................................................................... 26 6.9 Radio Frequency Interference (RFI) ........................................................................................... 26 6.10 Earth Leakage ......................................................................................................................... 26 6.11 It Appears Smartdrive is doing nothing.................................................................................. 26 7.0 OPTION ADJUSTMENT MODE ................................................................................................. 27 7.1 Wash Water Temperature – All Phases ...................................................................................... 27 7.2 Rinse Options – All Phases ........................................................................................................ 28 7.3 End of Cycle Warning Beeps (GW Only) – All Phases ............................................................. 29 7.4 Adjusting the Volume of Water Used in the Water Saver Option (GW only) – Phase 3 to 5.... 30 7.5 Auto Water Fill Level Adjustment (GW only) Phase 3-5 ......................................................... 30 7.6 Out Of Balance Recovery Adjustment (GW and MW only) Phase 3-5 .................................... 30 8.0 DIAGNOSTIC MODE ................................................................................................................... 31 8.1 WHAT WAS THE LAST FAULT? ........................................................................................... 31 8.2 TEST LID, OUT OF BALANCE, & SIZE SWITCHES............................................................ 32 8.3 TO TEST PUMP & WATER VALVES .................................................................................... 32 8.4 RESTART .................................................................................................................................. 33

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 Out of Balance (First Rinse or Final Spin and Current Spin Speed LED is flashing) ............ 37 10.6 Suds (First Rinse LED is flashing or Final Spin LED is flashing) ......................................... 38 10.7 Restart and Recycle (Wash Progress LEDs flashing) ............................................................. 38 10.8 Demonstration Mode (All LEDs flashing in patterns) ........................................................... 39 11.0 FAULT CODES ........................................................................................................................... 40 SMARTDRIVE PHASES 1 to 5 FAULT DESCRIPTIONS ............................................................ 41 12.0 MECHANICAL SERVICE SECTION .................................................................................... 62 12.1 COMPLETE DISASSEMBLY .............................................................................................. 62 12.2 ASSEMBLY GUIDELINES .................................................................................................. 66 12.3 MOTOR ASSEMBLY & DISASSEMBLY........................................................................... 67 12.4 PUMP BLOCKAGE .............................................................................................................. 68 12.5 SHAFT & BEARING REMOVAL ........................................................................................ 69 12.6 SHAFT & BEARING ASSEMBLY ...................................................................................... 70 Appendix A: Binary Decoding Chart – 8 Bits (0-255)......................................................................... 72 Appendix B: Technical Bulletins ......................................................................................................... 73 WM011 ALTERNATIVE SPARE PARTS FOR PHASE 1 MOTOR CONTROLLER – June 1999 – Phase 1 only..................................................................................................................................... 73 WM013 PUMP HOOD KIT – January 2000 – Phases 2 to 5 ........................................................... 74 WM51 DIAGNOSTIC FLOW CHART – Sept 1992– Phase 1 only.............................................. 75 WM65 BIB DEFLECTOR – April 1994– Phase 1 only................................................................. 76 WM70 PREMATURE OUT OF BALANCE – February 1995 – Phase 2 only ............................. 76 WM80 CONDENSATION KIT – May 1996 – Phase 2 & 3 only.................................................. 77 WM81 PUMP SHIELD 5KG SMARTDRIVE – September 1996 - Phases 1 to 4 ........................ 77 Appendix C: Smarttool ........................................................................................................................ 78 Appendix D: Tools for Servicing Smartdrive ...................................................................................... 79 Appendix E: IW SMARTDRIVE SERVICING .................................................................................. 80 E.1 IW Quick Reference Guide ........................................................................................................ 80 E.2 Specifications for IW.................................................................................................................. 80 E.3 INTRODUCTION to IW ............................................................................................................ 81 E.4 OPTION ADJUSTMENT MODE for IW.................................................................................. 83 E.5 DIAGNOSTIC MODE for IW ................................................................................................... 85 E.6 SIZE SETTING MODE for IW.................................................................................................. 87

- 1 - 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. Smartdrive will be making a continuous sound of beeping repeating once every second and will be PAUSED. Phase 1-3 Only press spin buttons until the SPIN HOLD and SPIN SLOW LEDs are on. The wash progress LEDs correspond to the 8 bit binary fault code with the spin LED representing the least significant bit. On LW or AW leftmost LED may be obscured by the front panel overlay, this is the most significant bit. (NB. The LEDs will not be flashing). IF SMARTDRIVE IS DISPLAYING A USER WARNING – SEE SECTION 10.0 This may be identifiable by an unusual combination of LEDs flashing and / or Smartdrive may be making a rippling sound of 5 beeps repeating every 6 seconds. IF SMARTDRIVE APPEARS TO HAVE NO FAULT Find the last fault. It may be accessed from Diagnostic Mode. Diagnostic mode is accessed by pressing ‘Wash Temp Down’ and ‘Power’ buttons together, Smartdrive will give 2 quick beeps in acknowledgement. (Phase 1 & 2 Only press ADVANCE key once). Go to level 3 by pressing the Spin buttons until the SPIN HOLD and SPIN SLOW LEDs are on. The wash progress LEDs correspond to the 8 bit binary fault code with the spin LED representing the least significant bit. This fault would have occurred within the last 8 cycles. If all the wash progress LEDs are off, there is no fault. Do not change Motor Controller. If there is no fault, (above) and the product will not start check that the lid switch is operating correctly. This may also be done from Diagnostic Mode, see SECTION 8.2. Set Restart OFF, (activate the Low Water LED while in Diagnostic mode). This will allow Smartdrive to detect faults quicker, it will not retry. Exit Diagnostic mode. Test Smartdrive by filling (using both valves), draining and spinning to 1000RPM. Open lid when at 1000RPM. Check the size and the operation of the Out of Balance lever. IF SMARTDRIVE WILL NOT START it could be that the lid switch indicates that the lid is open. IF SMARTDRIVE IS LEAKING – SEE SECTION 6.4 IF SMARTDRIVE IS NOISY – SEE SECTION 6.5 IF SMARTDRIVE HAS OTHER FAULTS – SEE SECTION 6.0 If you have Smarttool, it will identify the last four faults and the last user warning. It will provide appropriate servicing instructions.

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Fisher Paykel SMART DRIVEELECTRONIC WASHING MACHINEPHASE 1 to 5 230v Service Manual 517735

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