Fisher & Paykel AQUASMART WL37T26CW2, AQUASMART WL37T26KW2, AQUASMART WL37T27DW2, aquasmart WL70T60CW, aquasmart WL80T65CW Service Manual
478182
Service Manual
AQUASMART™
Hi-Efficiency washer
Model:
WL37T26CW2
WL37T27DW2
WL37T26KW2
478182 JAN 2010
Fisher & Paykel Appliances Ltd
78 Springs Road,
East Tamaki,
Manukau 2013
PO Box 58-732, Botany
Manukau 2163
New Zealand
Telephone: 09 273 0600
Facsimile: 09 273 0656
Fisher & Paykel Appliances Inc
5900 Skylab Road
Huntington Beach
CA 92647
USA
Phone: 1 888 936 7872
COPYRIGHT FISHER & PAYKEL LTD 2010 - ALL RIGHTS RESERVED
- 2 -
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.
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FISHER & PAYKEL
ELECTRONIC WASHING MACHINE
Covering the following models
Market Model Number Product codes
US CA
North America WL37T26CW2 96108 96109
WL37T26DW2 96112 96113
WL37T26KW2 96100 96104
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CONTENTS
1 SPECIFICATIONS...............................................................................................................7
1.1 Model Information ...........................................................................................................7
1.2 Dimensions .....................................................................................................................7
1.3 Maximum Capacity (AS/NZS 2040.1:2005) ....................................................................7
1.4 Water Consumption ........................................................................................................7
1.5 Water Fill Temperature (Approximate Factory Settings).................................................7
1.6 Wash Motor..................................................................................................................... 8
1.7 Pump Motor.....................................................................................................................8
1.8 Water Valves................................................................................................................... 8
1.9 Thermistor.......................................................................................................................8
1.10 Cabinet............................................................................................................................ 8
1.11 Lid ...................................................................................................................................8
1.12 Top Deck......................................................................................................................... 8
1.13 Inner Basket....................................................................................................................9
1.14 Outer Tub........................................................................................................................9
1.15 Console...........................................................................................................................9
1.16 Facia ...............................................................................................................................9
1.17 Neck Ring / Straps ..........................................................................................................9
1.18 Low Profile Agitator.........................................................................................................9
1.19 Energy Label / Water Rating...........................................................................................9
1.20 Bleach Dispenser............................................................................................................9
1.21 Fabric Softener Dispenser ..............................................................................................9
1.22 Electric Supply ................................................................................................................9
1.23 User Guide......................................................................................................................9
1.24 Lid Lock......................................................................................................................... 10
1.25 Control Panel LCD Model .............................................................................................10
1.26 Control Panel Triple Dispensing LED Model.................................................................10
1.27 Control Panel Non Dispensing LED Model ...................................................................10
1.28 Important Screw / Bolt Torque Settings ........................................................................10
2 THE UNIQUE AQUASMART™ WASH............................................................................. 11
3 CONTROL PANEL............................................................................................................12
4 TECHNICAL OVERVIEW.................................................................................................. 14
4.1 Electronics ....................................................................................................................14
4.1.1 Motor Control Module.............................................................................................14
4.2 Stand By Mode .............................................................................................................14
4.3 Out of Balance Detection – ‘Bump Detect’.................................................................... 14
4.4 Water temperature Sensing ..........................................................................................15
4.5 Water Valves................................................................................................................. 15
4.6 Dispensing System .......................................................................................................15
4.6.1 Detergent Dispensing.............................................................................................16
4.6.2 Bleach Dispensing .................................................................................................16
4.6.3 Fabric Softener Dispensing....................................................................................16
4.6.4 Inlet Nozzle ............................................................................................................17
4.7 Water Level Measurement ............................................................................................ 17
4.8 Motor.............................................................................................................................17
4.8.1 Stator......................................................................................................................17
4.8.2 Rotor ......................................................................................................................18
4.8.3 Rotor Position Sensor ............................................................................................19
4.9 Smart Pump ..................................................................................................................20
4.9.1 Hood and Cap ........................................................................................................20
4.9.2 Flapper Valve ......................................................................................................... 20
4.9.3 Impeller (non-field serviceable) .............................................................................. 20
4.9.4 Rotor and Stator.....................................................................................................21
4.9.5 Pump Housing........................................................................................................21
4.9.6 SmartPump™ Spare Parts..................................................................................... 22
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4.9.7 SLR Feature .......................................................................................................... 22
4.9.8 Testing the Pump Stator ........................................................................................ 23
4.9.9 Testing SmartPump™ Stator from the Console..................................................... 23
4.9.10 SmartPump™ Test Routine................................................................................... 24
4.9.11 Bypassing .............................................................................................................. 24
4.10 Lid Lock ........................................................................................................................ 25
4.11 Neck Ring ..................................................................................................................... 26
4.12 Inner Basket and Outer Tub ......................................................................................... 26
4.12.1 Detection of Inner Basket Float Off Point – Basket Check ....................................27
4.12.2 Detection of Inner Basket Re-Engagement – Basket Check ................................. 27
4.12.3 Inner Basket........................................................................................................... 27
4.12.4 Balance Ring ......................................................................................................... 27
4.12.5 Inner Basket Base ................................................................................................. 27
4.13 Suspension Rods.......................................................................................................... 28
4.14 Agitator Low Profile....................................................................................................... 29
4.15 Control Panel ................................................................................................................ 29
5 VOLTAGE AND RESISTANCE READINGS FROM THE CONTROLLER ...................... 31
5.1 Voltage Readings ......................................................................................................... 31
5.2 Resistance Readings.................................................................................................... 32
6 DIAGNOSTIC MODE – LCD MODEL............................................................................... 33
6.1 Service Screen ............................................................................................................. 33
6.1.1 Warning Status Screen / Fault Status Screen .......................................................33
6.1.2 Machine Status Screen.......................................................................................... 34
6.2 Control Screen.............................................................................................................. 34
6.2.1 Hot Bowl Flag ........................................................................................................ 34
6.2.2 Restart Feature...................................................................................................... 35
6.2.3 Recycle Feature..................................................................................................... 35
6.2.4 Restart / Recycle Table LCD .................................................................................35
6.2.5 Restart/Recycle Features Permanently Programmed ........................................... 36
6.3 Data Download ............................................................................................................. 36
6.4 Showroom Mode........................................................................................................... 37
7 DIAGNOSTIC MODE – LED MODEL ............................................................................... 38
7.1 Fault Codes .................................................................................................................. 38
7.2 Component Testing ...................................................................................................... 39
7.3 Hot Bowl Flag ............................................................................................................... 39
7.4 Restart Feature............................................................................................................. 39
7.5 Recycle Feature............................................................................................................ 40
7.6 Restart/Recycle Features Permanently Programmed .................................................. 41
7.7 Restart / Recycle Table LED ........................................................................................ 41
7.8 Data Download ............................................................................................................. 42
7.9 AquaSmart™ LED Diagnostic Table ............................................................................ 42
7.10 Showroom Mode........................................................................................................... 44
8 FAULT CODES................................................................................................................. 45
9 WIRING DIAGRAM........................................................................................................... 57
10 SERVICE PROCEDURES ................................................................................................58
10.1 Accessing Components in Console Area ..................................................................... 58
10.2 Removal of Display Module .......................................................................................... 58
10.3 Removal of motor Control Module ................................................................................ 58
10.4 Removal of Inlet Valve Assembly .................................................................................59
10.5 Removal of Thermistor ................................................................................................. 59
10.6 Removal of the Cord Set .............................................................................................. 60
10.7 Removal of Lid Lock ..................................................................................................... 60
10.8 Raising Top Deck ......................................................................................................... 61
10.9 Removal of Top Deck ................................................................................................... 61
10.10 Removal Of Softener and Bleach Funnel .....................................................................62
10.11 Removal Of Detergent Cover ....................................................................................... 62
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10.12 Removal Of Dispensing Hoses .....................................................................................63
10.13 Removal of Straps.........................................................................................................63
10.14 Removal of Neck Ring ..................................................................................................63
10.15 Removal of Low Profile Agitator....................................................................................64
10.16 Removal of Inner Basket............................................................................................... 66
10.17 Removal of Clutch Mechanism (Spline Drive / Spline Driven) ......................................66
10.18 Removal of Pump Hood & Cap (Impeller & Flapper Inspection)...................................67
10.19 Removal of Stator (SmartPump™) – Testing / Inspection Purposes Only.................... 68
10.20 Removal of Pump Housing ...........................................................................................68
10.21 Removal of Recirculation Hose..................................................................................... 70
10.22 Removal of outer Tub From The Cabinet......................................................................71
10.23 Removal of Rotor ..........................................................................................................71
10.24 Removal of Stator .........................................................................................................72
10.25 Removal of Rotor Position Sensor ................................................................................ 72
11 SPECIALISED SERVICE PROCEDURES........................................................................ 73
11.1 Pump Housing - Stripped Bolt Procedure .....................................................................73
11.2 Blocked Pump Procedure .............................................................................................73
11.3 Shaft & Bearing Replacement.......................................................................................74
11.4 Shaft & Bearing Assembly ............................................................................................76
12 SOLVING WASH PROBLEMS .........................................................................................78
13 NOTES ..............................................................................................................................79
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1 SPECIFICATIONS
1.1 Model Information
AquaSmart introduces the new Fisher & Paykel model numbering system, which provides a
clearer description of the product and its features. The new model numbering system will come in
to affect with each new model released.
The model identification is explained below.
W
Washer
W
Washer
W
Washer
L
Low (Profile Agitator)
L
Low (Profile Agitator)
L
Low (Profile Agitator)
37
Capacity cu/ft (3.7) IEC
37
Capacity cu/ft (3.7) IEC
37
Capacity cu/ft (3.7) IEC
T
Top Loading
T
Top Loading
T
Top Loading
26
26 inches wide
26
26 inches wide
26
26 inches wide
C
LCD Screen
D
LED Display
K
LED Display Non Dispense
W
White
W
White
W
White
2
Series
2
Series
2
Series
1.2 Dimensions
Height to lid
Open 55.5in – 56.7in / 1410mm – 1440mm
Closed 37.4in – 38.6in / 950mm – 980mm
Height to console 39.8in – 41 3in / 1010mm – 1050mm
Width 26in / 650mm
Depth 26in / 650mm
Inlet hose length 47.24in / 1200mm
Packed weight 133.4lb / 60.5 kg
Unpacked weight 114.64lb / 52.0kg
Note: The exact height of AquaSmart™ is dependent on how far the feet are inserted into
the base of the machine.
1.3 Maximum Capacity (AS/NZS 2040.1:2005)
Dry Weight: 15.4 lb / 7 kg
1.4 Water Consumption
Load Size Regular High Efficiency*
15.5 lb / 7kg 21.7 G / 82 litres
11 lb / 5kg 18.2 G / 69 litres
6.6 lb / 3kg 15.85 G / 60 litres
2.2 lb / 1kg 14.5 G / 55 litres
*Regular High Efficiency is the default wash cycle for AquaSmart
1.5 Water Fill Temperature (Approximate Factory Settings)
Supply
Water Fill Temp*
Hot
140F (60c)
Hot / Warm
115F (46
o
C)
Warm
102F (39
o
C)
Warm / Cold
91F (33
o
C)
Cold Plus
68F (20
o
C)
Cold Supply temperature
Recommended hot water inlet temperature 149F (65 oC) (Maximum)
*Dependent on hot and cold supply temperatures and water pressures
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1.6 Wash Motor
Electronically commutated 36 pole direct drive 3 phase brushless DC motor.
Motor Resistance @68
o
F (20oC): 19.5Ω +/- 10% (39Ω +/- 1.95Ω across any two phases)
1.7 Pump Motor
The motor is a fully electronically controlled 325V, 3 phase, 6 pole, brushless DC motor.
The speed of the motor will vary depending on whether it is draining or re-circulating the water.
Motor Resistance @68
o
F (20oC): 8.1Ω +/- 10% per phase (16.2Ω +/- 10% across any two phases)
Maximum Wattage: 200W
Nominal Wattage: 60W
Drain Speed: 2500rpm
Recirculation Speed: 2000 rpm
Head Height Drain Speed Flow Rate
4ft (Nominal) 2500rpm 6.2 gallons (23.6 litres) per minute
8ft (Maximum) 2500rpm 3.9 gallons (15 litres) per minute
1.8 Water Valves
Supply Operation Mode Voltage Resistance Flow Rate
Cold Digitally Operated 24VDC 64Ω @ 68oF (20oC) 2.6 Gal (10 litres) per min. max
Hot Digitally Operated 24VDC 64Ω @ 68oF (20oC) 2.6 Gal (10 litres) per min. max
Detergent Digitally Operated 24VDC 64Ω @ 68oF (20oC) 2.1 Gal (8 litres) per min. max
Fabric Digitally Operated 24VDC 64Ω @ 68oF (20oC) .5 Gal (2 litres) per min. max
Bleach Digitally Operated 24VDC 64Ω @ 68oF (20oC) .66 Gal (2.5 litres) per min. max
Note: The flow rate will vary slightly depending on pressure.
Water Supply
For the best operating conditions the hot water temperature should be approximately 149˚F.
The hot or cold-water temperature should not exceed 167˚F (75
o
C) or 95˚F (35oC) respectively.
Temperatures above these may cause the machine to fault or cause damage to the machine.
If there is an uncontrolled water-heating source (e.g. a wet back or solar heating) a tempering
device should be fitted. This will ensure the hot water temperature remains within safe limits.
For the most suitable type of tempering device we recommend contacting a local plumber or
plumbing supply merchant.
Inlet Water Static Pressure 3psi (20kPa) to 150psi (1MPa).
Note: If using a header tank, then the outlet of the header tank must be at least 2 metres
above the top of the clothes washer.
The water supply flow rate should be greater than 1.6 gallons (6 litres) per minute (assumes ½
inch diameter pipes).
The minimum height of the taps to clear the top of the machine is 45.25 inches (1150mm).
1.9 Thermistor
NTC-type temperature sensor (Thermistor) Resistance 10,000Ω @ 77oF (25oC)
1.10 Cabinet
Pre-painted steel
1.11 Lid
ABS plastic (co-injected)
1.12 Top Deck
Polypropylene
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1.13 Inner Basket
Stainless steel: Grade 430T
Bowl base and balance ring: Polypropylene
Inner Basket Weight
24lb 3oz (10.965kg) +/- 4.2oz (120g)
1.14 Outer Tub
Aluminium insert over-moulded with polypropylene
1.15 Console
ABS plastic
1.16 Facia
IMD (In-mould decorative) Polycarbonate/PET
1.17 Neck Ring / Straps
Neck Ring: Polypropylene
Straps: Dynaflex TPE (Thermoplastic Elastomer)
1.18 Low Profile Agitator
Low profile agitator: Polypropylene
Low profile agitator Cap: Polypropylene
Low profile agitator Bolt: Acetyl
1.19 Energy Label / Water Rating
Modified Energy Factor – 2.15
Water Factor – 4.3
1.20 Bleach Dispenser
Dosage 120mls (To the Max indicator level).
Note: Any amount above the Max level may cause the bleach to self-siphon into the
machine.
1.21 Fabric Softener Dispenser
Dosage 70mls (To the Max indicator level).
Note: Any amount above the Max level may cause the fabric softener to self-siphon into the
machine.
1.22 Electric Supply
Operating Voltage: 110/120V AC 60Hz
Maximum Current: 7 amps
1.23 User Guide
User Guide: Part Number
LCD 478153
LED 478139
Inner Basket Speed
Fast Spin 1,000 RPM
Medium Spin 700 RPM
Slow Spin 300 RPM
Stir Speed 25 RPM
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1.24 Lid Lock
Resistance: 63Ω +/- 10% @ 68oF (20oC)
Note: Normally low voltage, potentially 110V if harness is grounded on the cabinet!
1.25 Control Panel LCD Model
1.26 Control Panel Triple Dispensing LED Model
1.27 Control Panel Non Dispensing LED Model
1.28 Important Screw / Bolt Torque Settings
Below are the important screw torque settings on the AquaSmart™ washer. These settings must
be adhered to. For all other screws and bolts that are not listed, we recommended that they are
tightened sufficiently without being over-tightened.
Screw / Bolt Torque (in/lbs) Torque (Nm)
Pump hood to cap to outer tub 27 in/lbs 3Nm
Rotor bolt to shaft 70 in/lbs 8Nm
Pump housing to outer tub 18 in/lbs 2Nm
Stator to Outer Tub 44 in/lbs 5Nm
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2 THE UNIQUE AQUASMART™ WASH
The AquaSmart is a EcoSmart based washing machine that has two modes of washing, High
Efficiency & Conventional. It is essentially a front loader (high efficiency mode) and a top loader
(conventional mode) washer in one.
Both washing modes start the same way, with a detergent activating wash.
Detergent Activating Wash
AquaSmart™ fills at the selected water temperature, with just enough water
so that the clothes are saturated. This concentrated detergent solution is
then re-circulated through the wash. This thoroughly dissolves and
activates the detergent.
High Efficiency Mode (front loader type wash)
In the High Efficiency mode, the AquaSmart™ fills with just enough water to
lift the clothes off the low profile agitator, so that when it rotates, the clothes
gently roll over each other. This wash uses similar quantities of water to
most Front Loaders and so, not only are there the benefits of water savings,
but also the higher detergent concentrations give optimum soil removal.
Conventional Mode (top loader type wash)
The Conventional mode is the immersion wash all Top Loader users are
familiar with. After the Detergent Activating Wash, the AquaSmart™ fills
with water until the clothes are underwater, whilst gently turning the clothes
over. We recommend this mode when the dilution effect of water can solve
or prevent common wash problems. For example when dye or colour run
can be a problem or when washing sandy towels. Sheets are better
washed in this mode. Some cycles can be used in both modes, whilst
others work in only one.
Cycle Modes Available
Regular High Efficiency
Sheets Conventional
Whites High Efficiency and Conventional
Colors Conventional
Heavy Duty High Efficiency and Conventional
Delicate High Efficiency and Conventional
Easy Iron Conventional
Bulky Conventional
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3 CONTROL PANEL
LCD Model
1. Power On/Off button.
2. High-Efficiency mode On/Off. When off, the machine uses the conventional wash mode
3. High-Efficiency LED used also for data download (refer to Section
6.3).
4. Start/Pause button
5. LCD Screen.
6. Left arrow (used when scrolling through options on the LCD screen).
7. Right arrow (used when scrolling through options on the LCD screen).
8. Select button – Use to confirm setting.
9. Back button - Use to cancel setting.
1 2 4
5
6 7 8 9
3
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LED Model
1. Power On/Off button.
2. Service Spanner LED.
3. Lid Lock LED.
4. Regular button.
5. Heavy button.
6. Delicate button.
7. Sheets button.
8. Colours button.
9. Bulky button.
10. Easy Iron button.
11. High-Efficiency mode On/Off. When off, the machine uses the conventional wash mode
12. Start/Pause button.
13. Advance button.
14. Soak button.
15. Bleach button. (Not present on Non-dispensing model)
16. Fabric Softener button. (Not present on Non-dispensing model)
17. Spin Speed button.
18. Temperature button.
1
4 5 678910 11
12
2 3
13 1415161718
1
2 34 5 678910 11
12
13 141718
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4 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 AquaSmart
washing machines.
4.1 Electronics
4.1.1 Motor Control Module
The Motor Control Module used on the
AquaSmart washer is similar to the other
washers in its physical size and shape, however
the electronics have different software to control
the unique aspects of this machine.
Therefore the Motor Control Module is specific
to this machine and is not interchangeable with
any other machines.
The text on the yellow identifier label (P7SPL)
stands for Phase 7, SmartPump™, Low profile
Agitator.
4.2 Stand By Mode
If the machine has not received any instructions for 10 minutes after being switched on at the
power point, or after completing the cycle, it will automatically go into a low power “Stand By”
mode. The control panel will be blank as if it was powered off at the wall.
Before entering the Diagnostic or Option Adjustment mode, the machine must be taken out of the
Stand-By mode. To do this, the POWER button will have to be pressed, or the machine turned off
and back on at the power point.
4.3 Out of Balance Detection – ‘Bump Detect’
Past electronic machines have used a lever connected to a mechanical switch to detect if the load
in the inner bowl is out of balance. On this series of machine the system has been replaced with
electronic sensing known as ‘Bump Detect’. ‘Bump Detect’ is software written into the Motor
Control Module, which looks at specific feedback from the Rotor Position Sensor.
No fault codes are associated with ‘Bump Detect’, and there are no hard and fast tests that can be
carried out.
If a machine continually goes into an out of balance condition, then the following need to be
checked in the order given.
1. Even distribution of the clothes load.
2. Ensure that the machine is both level and stable on the floor.
3. Ensure that the feet have the rubber inserts fitted and the cabinet corners are clear of the
floor.
3. Check that any of the straps on the neck ring are not broken and that they are fitted
correctly.
4. Check the weight of the inner bowl. Bowl weight is as follows.
24lb 3oz +/- 10oz (10.965kg +/- 275g).
5. Check the RPS using a RPS Tester.
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4.4 Water temperature Sensing
The thermistor for sensing the water temperature is located in the back of the outlet elbow on the
valve assembly, and is connected directly to the Motor Control Module.
Details for adjusting the wash temperature, Refer to the Use & Care Book.
Specifications
NTC-type temperature sensor (Thermistor)
Resistance 10,000Ω @ 77
o
F / 25oC
4.5 Water Valves
The water valve assembly incorporates up to
five valves that are joined by a common valve
body. The two main inlet coils control the flow
of water into the valve body assembly that then
in turn supplies water into the machine through
the inlet nozzle.
Up to three additional coils are used that
control the valves for the fabric, detergent and
bleach dispensing. They control the flow of
water to the fabric, detergent and bleach
dispensing system via hoses that run
underneath the top deck.
1. Hot coil (White Clip)
2. Cold coil (White Clip)
3. Fabric coil (Yellow Clip)
4. Detergent coil (Purple Clip)
5. Bleach Coil (Red Clip)
4.6 Dispensing System
Three hoses of different lengths run
underneath the top deck and connect to the
detergent dispenser, the bleach dispenser and
the fabric softener dispenser. The detergent
dispenser hose has cream elbows. The fabric
softener dispenser hose has grey elbows and
the bleach dispenser has red elbows.
Moulded into the top deck at the valve end are
identification letters (‘D’ for Detergent and ‘S’
for softener & ‘B’ bleach). At the dispenser
end are moulded the words ‘Detergent’,
‘Softener’ and ‘Bleach’.
It is important that the hoses are retained in the
clips around the perimeter of the opening of
the top deck correctly.
5
3
4
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4.6.1 Detergent Dispensing
During fill, the detergent valve is also energised. This allows a proportion of the inlet water to flow
into the detergent dispenser.
The flow rate through the detergent valve is dependent on the inlet water pressure, but it is less
than the flow rate of water entering the machine. The valve will remain energised until the water
level reaches 1 inch (25mm), at which point the bowl starts stirring until the desired water level has
been achieved.
The detergent valve can be tested in diagnostics (refer to Section
6.1.2 for LCD models, or Section
7.2 for LED models).
4.6.2 Bleach Dispensing
The design of the bleach dispenser is such that it creates a self-siphoning effect. When the motor
control module calls for bleach ¾ of the way through the wash portion of the cycle, the bleach
valve will energise. This allows water to flow into and through the dispenser mechanism. The
valve is pulsed on and off for a total of 95 seconds (see table below) to ensure that all of the
bleach has dispensed.
Siphon Pulse On Off
1st 10 s 15 s
2nd 10 s 10 s
3rd 10 s 10 s
4th 10 s 10 s
5th 10 s remains off
Note: The 1st off time of 15 seconds is to ‘kick start’ the siphoning process.
If the bleach valve was to run continuously, the water would cut a path through the bleach and the
bulk of the bleach would remain in the dispenser. The maximum level of the bleach is 120mls to
the ‘Max’ mark. If the bleach dispenser was to be filled higher than this mark, the bleach may selfsiphon into the machine.
The bleach valve can be tested in diagnostics (refer to Section
6.1.2 for LCD models, or Section
7.2 for LED models).
4.6.3 Fabric Softener Dispensing
The design of the softener dispenser is such that it creates a self-siphoning effect. When the
motor control module calls for softener at the beginning of the deep rinse cycle, the softener valve
will energise. This allows water to flow into and through the dispenser mechanism. The valve is
pulsed on and off for a total of 95 seconds (see table below) to ensure that all of the bleach has
dispensed.
Siphon Pulse On Off
1st 10 s 15 s
2nd 10 s 10 s
3rd 10 s 10 s
4th 10 s 10 s
5th 10 s remains off
Note: The 1st off time of 15 seconds is to ‘kick start’ the siphoning process.
If the softener valve was to run continuously, the water would cut a path through the softener and
the bulk of the softener would remain in the dispenser. The maximum level of the softener is
70mls to the ‘Max’ mark. If the softener dispenser was to be filled higher than this mark, the
softener may self-siphon into the machine.
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The Softener valve can be tested in diagnostics (refer to Section
6.1.2 for LCD models, or Section
7.2 for LED models).
4.6.4 Inlet Nozzle
In addition to its design, which ensures excellent rinse water distribution, the nozzle shares an
important relationship with the inlet valve assembly and the dispensing system as described
above.
An internal piston within the nozzle moves with the amount of water pressure against it. When the
water pressure is high, more holes in the nozzle are exposed, and the backpressure on the
dispensing valves is less.
When the pressure is low, more backpressure is created, which ensures that either during
detergent dispensing or bleach dispensing the dispensing system takes priority.
If the water pressure was very low during dispensing, it is conceivable that no water would enter
the machine via the inlet nozzle until the dispensing has been completed.
Conversely, if the piston was jammed and the water pressure was high, a high flow rate of water
would go through the dispensing system and may result in water on the floor.
4.7 Water Level Measurement
The AquaSmart uses the same pressure sensing system used in the EcoSmart and Intuitive
Eco™ machines to determine the water level. The difference with AquaSmart is that on both the
Conventional and High Efficiency modes, AquaSmart will automatically choose the water level,
as the precise water level for the clothes load is critical to the performance of the wash. The
amount of water used in either mode is unable to be selected or adjusted by the user.
So now there are an infinite number of water levels that AquaSmart can choose depending on
the weight and type of the clothes being washed.
4.8 Motor
4.8.1 Stator
This stator used on the AquaSmart machine is unique to this series only and therefore are not
interchangeable with any previous phase or series of machines. The stator has 36 poles with
pole tips being curved. The windings are Aluminium and can be Identified by the printed marking
AL 60 190T it looks the same as the Previous copper Stator but is 19.5 per winding. The rotor
position sensor is also unique to this stator. (Refer to Section
4.8.3)
Aluminium Stator (36 Poles) Curved pole tips
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Testing the Stator
If the stator needs to be tested we would first recommend testing the resistance of the windings
from the harness end that is connected to the Motor Control Module. (Refer to Section
5.2).
Note: Ensure that the Rotor or basket is stationary when measurements are made.
Testing the stator from the console
The resistance of each individual winding is approximately 19, however when testing the stator
from the console we are testing across two windings therefore the resistance should be approx.
39 +/- 10%.
To test all windings you will need to measure across:
Red & Blue
Blue & Yellow
Yellow & Red
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
10.23and 10.24).
Note: Two clamp plates are used to secure the Stator, one on each side. The four bolts are
tightened to a torque of 44in/Lbs (5Nm). The plastic bolt for securing the Rotor requires a
5/8” (16mm) socket and should be tightened to70 in/lbs (8Nm)
Testing the Stator
After removing the Stator, it can now be tested.
Test points are:
R / B
B / Y
Y / R
The value should be approx. 39 +/- 10%
across any of the two windings.
4.8.2 Rotor
The rotor is also unique to this series of AquaSmart machines. It has 48 blocks of individual
magnets in a black moulding, as opposed to earlier machines having 16 blocks, containing 3
magnets in a white moulding.
The rotor is not interchangeable with any previous phase or series of machine.
The rotors can physically be interchanged, however electrically they are incompatible.
If the black rotor is fitted to earlier machines, fault code 240 will occur. Conversely fault code 240
will also occur if a white rotor is fitted to an AquaSmart machine.
The photographs below show the difference between black and white Rotors.
39.0
Ω
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Current Black Previous White
4.8.3 Rotor Position Sensor
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 rotor position sensor (RPS) is a printed
circuit board that contains three Hall Sensors,
which detect the magnetic field of the individual
magnets in the rotor. The RPS provides this
information to the Motor Control Module. The
printed circuit board sits in a black plastic
housing encapsulated by resin to protect the
board. The only exposed area of the board is
the connector for the main harness. Only the
black RPS will work with the black rotor.
Note: The RPS is not interchangeable with
any previous phase or series of machine.
Testing the Rotor Position Sensor
To test the RPS use a RPS tester kit, part number 479413, this is powered by a 9V battery. To
test the RPS follow the detailed instructions which are enclosed with the tester. The tester has 3
LEDs, and the pattern of these LEDs will change as the magnetic field of the Rotor passes the hall
sensors.
Connect the RPS tester to the RPS harness. Slowly turn the basket and note the pattern of lights.
A valid pattern is a pass. A fail will indicate a failure of either the harness or the RPS. If a failed
pattern is showing, connect the RPS tester directly on to the RPS at the stator and retest.
A pass is when 1 or 2 LEDs are illuminated at a
time, 0 or 3 LEDs illuminated indicates fail. Any
flickering of the fail LED will indicate that the
RPS or rotor is faulty. A faulty rotor would give
a fail at certain points of rotation.
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Note: This tester does not test all the functionality of the RPS. It tests the 3 outputs but
cannot indicate all faults, for example if a capacitor on the RPS is cracked.
The rotor may also be tested with a RPS Tester. A complete rotation will test all the magnets.
If the rotor has cracked or chipped magnets it will work fine, and does not need to be replaced.
4.9 Smart Pump
SmartPump™ provides a more flexible and efficient pumping system than a conventional
pump/diverter valve combination. SmartPump™ can be diverted quickly; it reacts faster and is
better controlled. In addition, SmartPump™ has the capability of pumping to a much higher head
whilst maintaining a constant volume flow rate regardless of pump efficiency degradations due to
age.
4.9.1 Hood and Cap
The hood and cap form the top of the pump
housing, which must seal to the outer bowl.
The hood and cap filters out objects that
cannot pass through the pump system.
4.9.2 Flapper Valve
A diverter valve has been integrated into the
pump cavity and operates automatically with a
change in pump direction. This change of
direction moves a flapper valve, which diverts
the water to the drain hose or to the recirculation hose. The valve is sealed off
against the port face with water pressure.
4.9.3 Impeller (non-field serviceable)
The impellor imparts rotational energy into the
water and keeps sand away from the shaft
seal.
Cap including integrated seal
Hood
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4.9.4 Rotor and Stator
The rotor and stator magnetically interact with each other in order to convert electrical energy into
rotational movement of the rotor
Rotor
The rotor assembly is a complete unit that is
permanently fixed into the pump housing. The
resulting cavity is charged with water, which
acts as a lubricant. In the event of a failure of
the rotor, the whole assembly must be
replaced.
Note: Contained within the rotor cavity are
seals and bearings that are non field
serviceable. The bearings provide a low
friction wear surface for the rotor shaft to run
on, and the seals eliminate grit from the rotor
and bearing cavity
Stator & Shield
The Stator is mounted to the base of the pump
housing together with the shield & cap. The
harness connector inserts into the underside of
the motor. Care must be taken to isolate the
machine from the mains power before
servicing the pump, and it is important that the
harness connector cover has been refitted
after reassembly.
4.9.5 Pump Housing
The pump housing is bolted directly to the
outer bowl. It contains the volute shape and
flapper sealing faces and also provides a
structure to attach stator and rotor assemblies.
Rotor within water filled cavity
Stator
Shield
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4.9.6 SmartPump™ Spare Parts
The following spare parts service kits are available for SmartPump™.
Hood And Cap (SmartPump™) Kit
P/N 479418
Flapper (SmartPump™)
P/N 420403
Seal (SmartPump™) Housing
P/N 479420
Pump Assembly (SmartPump™) Kit
P/N 479417
Note: The pump assembly is supplied with
the connector removed from the stator
shield. The cover must be fitted in place
after the wiring harness has been attached.
4.9.7 SLR Feature
SLR stands for Simplified Leak Recirculation.
This feature has been added so that should the
flapper not completely seal against the housing
of the pump when draining, water can bypass
through this hole and back into the pump,
avoiding re-circulating back into the bowl and on
to the washing load.
It is important that this hole remains clear, and it
should be checked whenever the pump is
serviced.
Connector cove
r
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4.9.8 Testing the Pump Stator
SmartPump™ Wiring Diagram
The stator resistance can either be tested from the harness at the motor controller or at the
connections to the stator itself.
4.9.9 Testing SmartPump™ Stator from the Console
The resistance of each individual winding is
approximately 8.1Ω +/- 10%, however when
testing the stator from the console we are
testing across two windings, therefore the
resistance should be approximately 16.2Ω +/10%.
To test all windings you will need to measure
across:
• Red and White
• White and Blue
• Blue and Red
If the meter shows an incorrect reading, we would recommend testing the stator from underneath
the machine, as there could be a fault in the wiring harness. To test the stator it will need to be
removed from the machine (refer to Section
10.19).
BLUE
RED
WHITE
16.2Ω
16.2Ω
8.1Ω
8.1Ω
8.1Ω
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4.9.10 SmartPump™ Test Routine
Use the following procedure to test the SmartPump™. It is equally important to test both the drain
and recirculation modes. In diagnostic mode the lid lock is disabled, which allows the technician to
visually inspect both aspects of the pump.
1. Enter diagnostic mode. (Refer to Section
6 for LCD models, or Section 7 for LED models.)
2. If the inner basket is empty of water, activate either or both of the water valves until the inner
basket is approximately 1/4 full with water. (Refer to Section
6.1.2 for LCD models, or Section
7.2 for LED models.)
3. While in diagnostic mode, set the pump to Recirculation Mode (refer to Section
6.1.2 for LCD
models, or Section
7.2 for LED models), run for at least 1 minute and observe the following:
Ensure that a good flow rate is being delivered through the portal of the hose.
Ensure that a good pattern of flow is being delivered. If a poor flow rate is apparent, firstly
check that the neck ring is fitted correctly and is not obstructing the flow of water.
Secondly, remove the neck ring and check the shape and location of the recirculation
nozzle is as expected. If no faults are found, the pump must be inspected. To access the
pump cavity, (refer to Section
0).
Ensure that no leaks are occurring from either the recirculation hose where it attaches to
the outer bowl (to do this the top deck will need to be lifted, refer to Section Error!
Reference source not found.), or where it attaches to the SmartPump™.
Ensure that no water is exiting from the drain hose. If it is, this indicates that water is
bypassing. For the description of bypassing, refer to Section
4.9.11.
4. Again, whilst in diagnostic mode, set the machine to drain (refer to Section
6.1.2 for LCD
models, or Section
7.2 for LED models), run for at least 1 minute or until all water has been
drained, and observe the following:
Ensure that a good pattern of flow is being delivered. If a poor flow rate is apparent the
pump must be inspected. To access the pump cavity, refer to Section
0.
Ensure there are no leaks from where the drain hose exits from the cabinet or at the pump
housing.
Ensure no water is exiting from the recirculation hose. Again, this would indicate that
bypassing is occurring.
4.9.11 Bypassing
Bypassing is the term given to water that either flows from the recirculation hose when the pump is
draining, or from the drain hose when the pump is re-circulating. No water at all should exit from
the opposing hose. The flapper valve not sealing against the face of the pump cavity, or a poor fit
of the hood and cap can generally cause bypassing.
If bypassing occurs, the pump (including the SLR Feature (refer to Section
4.9.7) must be
inspected. To access the pump cavity (refer to Section
0).
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