Fisher & Paykel DD601V2, DS601IV2, DS601V2, DD601IV2 User Manual

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DD601v2 DD601Iv2
DS601v2 DS601Iv2
1.1 Health & Safety 1
1.2 Specialised Tools 3
3.1 Electronics 5
3.2 Motor 5
3.3 Cabinet 5
3.4 Filling 6
3.5 Dispensing Detergent 7
3.6 Lid Seal 7
3.7 Wash Cycle 8
3.8 Heating 8
3.9 Filter Plate 9
3.10 Drain Cycle 9
3.11 Drying Cycle 10
3.12 Deflating 10
3.13 Lockring Nut 10
3.14 Wiring Cover 11
4.1 Setup & Diagnostics 12
4.2 Fault Modes 12
4.3 Diagnostic Modes 13
4.4 Diagnostics Quick Reference Flow Chart 18
4.5 Fault Codes 20
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6.1 Drawer Front Removal 34
6.2 Handle and LCD Display Removal 34
6.3 Drying Fan Removal 34
6.4 Detergent Dispenser 35
6.5 Electronic Controller 35
6.6 Top Kick Strip Removal 35
6.7 Lower Kick Strip Removal 36
6.8 Wiring Cover Removal 36
6.9 Filter Plate Removal 36
6.10 Rotor Assembly Removal 36
6.11 Tub Removal 37
6.12 Locking Ring, Element Plate & Motor Assembly Removal 37
6.13 Lid Assembly Removal 38
6.14 Lid Seal Replacement 38
6.15 Slide Runner Replacement 39
6.16 Front Trim Replacement 39
6.17 Sound Gasket Replacement 39
6.18 Link Assembly Removal 40
6.19 Air Pump Removal 40
6.20 Exhaust Valve Removal 41
6.21 Water Valve Removal 41
6.22 Flood Switch Removal 41
6.23 EMI Filter Removal 42
6.24 Tub Microswitch Removal 42
1.1 Health & Safety
Note: When servicing the dishdrawer, health and safety issues must
be considered at all times. Specific safety issues are listed below with their appropriate icon. These are illustrated throughout the service information to remind service people of the issues.
1.1.1 Electrical Safety
Ensure the mains power has been disconnected before servicing the DishDrawer. If the mains supply is required to be on to service the DishDrawer, make sure it is turned off when removing any electrical component or connection to avoid electrical shock.
1.1.2 Electrostatic Discharge
An anti-static strap is to be used as electrical static discharge (ESD) protection when servicing electronic components.
1.1.3 Good Working Practices
Ensure the work area is in a tidy and orderly condition at all times so as not to cause a hazard while service work is being completed. Always clean and tidy the DishDrawer and work area after service is completed.
1.1.4 Isolate Water Supply
Turn off the water connection tap before servicing.
1.1.5 Water Leak Check
Check for water leaks as part of the testing after the service has been completed.
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1.1.6 Insulation Test
Megger test to check insulation.
Warning: Short together the phase and neutral pins on the plug so as not to damage any electronic circuitry.
1.1.7 Solvent and Excessive Heat Damage
Plastic surfaces can be damaged by solvents and excessive heat.
1.1.8 Sheet Metal Edges
When working around cut sheet metal edges use appropriate gloves or protection to eliminate the chance of receiving a laceration.
1.1.9 Diagnostics
While in diagnostics some safety devices are bypassed.
Ensure you do not run components unattended. They may overheat, flood, burnout or cause water damage.
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1.2 Specialised Tools
For servicing this product Specialised tools are required.
1.2.1 Static Strap: To be used as ESD protection when replacing or handling electronic components.
1.2.2 Down Load Pen Connection: P/N 425930C. To be used to retrieve data from the electronic controller along with the diagnostic program on your laptop.
1.2.3 Down Load Serial Connection: P/N 425376C. To be used to retrieve and download data from the electronic controller along with the diagnostic program on your laptop.
1.2.4 Perspex Test Lid: P/N 525826. To be used on the drawer while extended to observe water fill, wash and drain operations.
1.2.5 Air Gauge and Plumbing. P/N 525819. To be used to measure the air pressure in the lid seal and plumbing.
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Product Size (mm) Minimum Cavity Size
Height 817-877mm 820-880mm Width 595mm 600mm Depth 570mm 580mm Drawer Open (incl cab) 1080mm Electrical 230-240V AC 50Hz 10amp max.
Lid Seal P/N525878 Exhaust Valve P/N525415
Lid Seal Air Pump P/N525430
Water Inlet Valves P/N525113 Dual P/N525842 Single
Flood Switch P/N525941
EMI Filter P/N525908P
Motor Drain Wash
30-40 Kpa
12 Volt ac 70 ± 5 Ohms
5 Volt ac 16 ± 2 Ohms
24Volt dc 70 ± 5 Ohms 5 Lt/min
24Volt dc Double Pole
240Volt ac
40 Volt dc 3 Phase 4200RPM 2300-2850RPM
Detergent Dispenser P/N525675
Rinse Aid Dispenser
Electronic P.C.B. P/N525832P
Control Panel Std P/N525192P
24 volt dc 70 ± 5 Ohms 5 grams 10 grams 15 grams 5 gram pre-rinse
24 Volt dc 70 ± 5 Ohms 50 mls 25 reg. Washes approx
230-240 Volt Input Outputs: ­230 Volt ac 40 Volt dc 24 Volt dc
24 Volt dc
Stator P/N525933
Rotor P/N525736
Temperature Sensor (Part of Heater Plate)
Inlet Hose P/N525151
Drain Hose
P/N525435 P/N525495
2.5 ± 0.2 Ohms per winding
962-Ohms @ 20°C 1000-Ohms@ 30°C 1202-Ohms @ 60°C
1.7m 960Kpa
2.0m from rear of cabinet
2.5m bottom tub
2.9m top tub
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Control Panel Integrated P/N525185P
Heater Plate P/N525169
24 Volt dc
240 Volt ac 55 ± 5 Ohms
3.1 Electronics
The DD601 electronic controller has two separate micro controllers on the main printed circuit board. One is for motor control and output switching and the other is for controlling interface and console functions.
The user interface comprises a printed circuit board for front controls and a touch switch panel for internal controls.
The electronics can connect to a computer service tool via a serial communications port for fault finding and product information.
All output peripherals (solenoids, fans etc), except the heating element, are run on low voltage (24v).
The power for all low voltage devices comes from a 100w switchmode power supply, which is cooled by a heatsink and when necessary the drying fan.
The element is switched by a relay and protected by a fail safe relay.
3.2 Motor
The motor is a fully electronically controlled 40V 60w 3 phase 6 pole brushless DC motor, running at approximately 2300-2850 depending on wash cycle selected, 2500 rpm on Normal, Fast, and Rinse cycles, 2300 on Delicate and 2850 on Heavy Wash, 4200 rpm on Drain.
3.3 Cabinet
3.3.1 Chassis
On the double drawer the double chassis is one complete assembly composed of 5 steel metal components locked together by a proprietry riveting process. The chassis exterior is made of white prepaint, while other components are made of electrogalvanised material. On the single drawer four bolts and washers are used to secure the chassis to the shelf using the steel inserts.
Unlike most other dishwashers, the chassis assembly is a load carrying structure designed to impart stiffness to the product and to ensure deflection is minimised.
The feet of the cabinet are assembled into the chassis by means of four steel inserts which are clinched in place to form a permanent threaded connection.
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The tub extends 510mm out of the cabinet by travelling along two rigidly attached slides on either side of the tub.
3.3.2 Drawer Fronts
Prefinished drawer fronts are formed from a prepainted blank of steel. The drawer fronts are attached to the tub by means of formed hooks and two pins which are inserted through either side of the tub.
On the integrated model, the front panel supplied on each drawer is the mounting panel for the joinery finished drawer front. The joinery finished drawer front is supplied by the customer.
3.4 Filling
3.4.1 Cold Inlet
The tub of the dishwasher fills by a cold water inlet hose only. From the connection to the cold water pipe in the kitchen, the inlet hose enters the cabinet of the dishwasher at the base, onto a dual water valve. Each tub is supplied water independently via one of the dual valve coils and a fill hose that runs through customised link assemblies at the back of the tub and travels along the base of the tub under the wiring cover to the front. At the front of the tub, the fill hose connects to the detergent dispenser which allows water to enter the tub, firstly through the pre rinse section of the dispenser for the pre rinse cycle and secondly through the main wash section for all other cycles.
3.4.2 Mixing the Detergent
Filling cold water enters the detergent dispenser, flushing the detergent from the cup, through the dispenser into the tub.
3.4.3 Amount of Water
The tub fills with approximately 2.2 litres of water, level with the base of the spray arm attachment. Once this level is reached, the wash pump (which has sensed the fill at 30 second intervals during the fill), becomes primed and pumps the water through the spray arm which will then rotate.
The water level is monitored by sensing the motor load through the electronics.
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3.5 Dispensing Detergent
The dispenser is mounted in the front wall of the wash tub.
The detergent dispenser consists of two detergent chambers, one for pre wash and the other for the main wash.
The detergent dispenser door is opened manually for detergent loading and then manually closed ready for the detergent to be transported to the wash tub by the inlet water. To enable each detergent chamber to be dispensed separately, an inlet water diverter valve controlled by the electronics is necessary.
Additionally a positive displacement pump unit and storage tank are incorporated within the dispenser to supply rinse aid. The rinse aid dispensed volume is adjusted utilising the dishwasher electronic controller. A glowing red light on the tank filler cap indicates an empty rinse aid tank.
3.6 Lid Seal
3.6.1 When Activated
At the beginning of each wash cycle, the lid seal inflates while the pre wash drain cycle removes any residue water from the tub. This runs for approximately 60 seconds, then the tub fills.
3.6.2 What is the Lid Seal
The lid seal is a static plastic moulding retained in the lid which provides a dynamic seal to the tub. The dynamic seal is created by a bellows section gasket bridging between the top flange of the tub and the lid. The dynamic seal also locks the tub/drawer during washing.
3.6.3 During Wash
The bellows section gasket is inflated by a solenoid activated diaphragm air pump. This cycles during the complete cycle at timed intervals to maintain a 35kpa sealing pressure.
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3.7 Wash Cycle
3.7.1 Tub
The tub is the main cavity where all the wash activity occurs. The tub is a plastic recepticle which has a wash pump and sprayarm at the base. The tub also has guide vanes around its walls which direct falling water from the wash cycle in a clockwise direction around the filter plate. This clears the filter plate of food particles into the sump where they can be trapped or pumped out during the drain cycle.
3.7.2 Rotor
The rotor is a four pole permanent magnet rotor with a graphite bearing at each end of the vertical shaft. At the lower end of the rotor shaft is the drain impellor and at the upper end is the wash impellor.
3.7.3 Spray Arm
The spray arm is shaped for most efficient waterflow. The holes are positioned for best penetration into the washload, with the water jets angled to ensure the sprayarm rotates at the most efficient speed.
3.8 Heating
3.8.1 The Element
The heater plate is an element consisting of a porcelain enamelled steel plate with a thick film resistive circuit written onto the dry side. The element is clamped in place by a lockring nut and supports the motor at the base of the tub.
3.8.2 Heating the Water
The heater plate lies beneath the filter plate. This creates a flow through water heating system during the wash cycle by allowing water to flow through the filter plate, over the surface of the element and into the wash pump.
3.8.3 Maintaining the Temperature
Attached to the element is a sub printed circuit board with a temperature sensitive thermistor . This connects by means of a RAST 2.5 connector system to the wiring harness of the element. Sensor components are unservicable.
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3.8.4 Overheating Control
The heater plate is only activated during the wash cycles. It is not used for drying. The temperature is maintained by the thermistor. The element circuit is continuously monitored by the electronic controller and will switch a fail safe relay if a fault is detected in the heater circuit. The element is thermally monitored by the thermistor on the element through the electronic controller.
3.9 Filter Plate
The filter plate is a stainless steel disk which lies below the dishrack and sprayarm and completely encompasses the base of the tub.
3.9.1 The Filter System
The tub is designed with vanes which swirl the water around and over the filter plate. At the front of the tub, located as part of the filter plate, is the drain filter. Large soils collect in the drain filter and only 1.5mm or smaller soils flow through its micro mesh filter, eliminating re-depositing of soil during the wash. Only soils up to 6mm pass through the drain filter during the drain cycle. This requires the drain filter to be regularly emptied and cleaned.
3.9.2 Removing and Cleaning the Filter Plate
The drain filter can be emptied with the dishrack in place by removing the cutlery basket and opening the plastic section of the dishrack. The filter plate is removable for cleaning by removing the dishrack and sprayarm and unlocking the lockring nut anti­clockwise.
3.10 Drain Cycle
The drain pump is a self priming centrifugal pump which only pumps when the motor is rotating in the drain direction (anti-clockwise). It has a five bladed impellor made from acetal pushed into a spline on the end of the rotor shaft. The drain cycle is a 60 second timed drain period.
The drain pump housing, which incorporates an inlet and outlet pipe, is welded to the motor housing, hence captivating the motor.
The inlet pipe plugs straight into the sump and is sealed there by a small ‘o’ ring.
The outlet pipe has a non return flap valve to prevent soiled water returning to the tub.
The drain hose is an extruded blow mould hose which is routed over the link assembly and exits out of the base of the product and is connected to a domestic drain.
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3.11 Drying Cycle
Immediately after water from the final hot rinse has been drained from the tub, the drying system begins operation.
The fan draws air through the tub, where it absorbs water from the dishload. The moisture laden air is then mixed with a larger quantity of ambient air (from the kitchen), to minimise the amount of vapour visible when exiting from the drawer front.
The fan runs continuously during the drying cycle and will restart if the tub is opened and closed again. After the drying cycle is complete, the fan continues to run for 30 minutes, but will not restart if the tub is opened.
The fan is pulsed when needed throughout the entire wash cycle. This draws ambient air through the electronics heatsink to maintain the electronics components within their specified operating temperatures.
3.12 Deflating
3.12.1 Lid Seal
The lid seal is a static plastic moulding retained in the lid which provides a dynamic seal to the tub during the washing cycles.
3.12.2 When the Lid Seal Deflates
At the end of the dishwasher programme, or a pause in the programme, an exhaust valve releases the air pressure from the bellows section gasket. This deflates the seal and unlocks the tub and drawer.
3.13 Lockring Nut
The lockring nut holds the heater plate into the base of the tub and motor housing assembly to form a watertight seal. It does this by compressing two large ‘o’ rings between the heater plate and tub and between the heater plate and the motor assembly.
It has clips which hold the drain hose, fill hoses and the wiring loom in place.
Another function of the lockring nut is to support the wiring cover with three clips.
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3.14 Wiring Cover
The wiring cover protects the customer from the 240V mains supply which passes over the link assembly and under the lockring to the front of the tub. It also serves to protect the motor assembly, drain and fill hoses from damage when opening and closing drawers. The wiring cover acts as a cosmetic part of the product.
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