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

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

DishDrawer

Models

DD601v2 DD601Iv2

DS601v2 DS601Iv2

599039

Contents

1.0

SERVICE REQUIREMENTS

1

1.1

Health & Safety

1

1.2

Specialised Tools

3

2.0

DIMENSIONS & SPECIFICATIONS

4

3.0

TECHNICAL OVERVIEW

5

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

4.0

DIAGNOSTICS

12

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

5.0

WIRING DIAGRAM

33

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6.0

SERVICE PROCEDURES

34

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

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1.0SERVICE REQUIREMENTS

1.1Health & 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.

1.1.1Electrical 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.

1.1.2Electrostatic Discharge

An anti-static strap is to be used as electrical static discharge (ESD) protection when servicing electronic components.

1.1.3Good 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.

1.1.4Isolate Water Supply

Turn off the water connection tap before servicing.

1.1.5Water Leak Check

Check for water leaks as part of the testing after the service has been completed.

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1.1.6Insulation 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.

1.1.7Solvent and Excessive Heat Damage

Plastic surfaces can be damaged by solvents and excessive heat.

1.1.8Sheet Metal Edges

When working around cut sheet metal edges use appropriate gloves or protection to eliminate the chance of receiving a laceration.

1.1.9Diagnostics

While in diagnostics some safety devices are bypassed. D Ensure you do not run components unattended. They may

overheat, flood, burnout or cause water damage.

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1.2Specialised Tools

For servicing this product Specialised tools are required.

1.2.1Static Strap:

To be used as ESD protection when replacing or handling electronic components.

1.2.2Down Load Pen Connection: P/N 425930C.

To be used to retrieve data from the electronic controller along with the diagnostic program on your laptop.

1.2.3Down 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.

1.2.4Perspex Test Lid: P/N 525826.

To be used on the drawer while extended to observe water fill, wash and drain operations.

1.2.5Air Gauge and Plumbing. P/N 525819.

To be used to measure the air pressure in the lid seal and plumbing.

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2.0DIMENSIONS & SPECIFICATIONS

 

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.

Specifications

Lid Seal

30-40 Kpa

P/N525878

 

Exhaust Valve

12 Volt ac

P/N525415

70 ±5 Ohms

Lid Seal Air Pump

5 Volt ac

P/N525430

16 ±2 Ohms

Water Inlet Valves

24Volt dc

P/N525113 Dual

70 ±5 Ohms

P/N525842 Single

5 Lt/min

Flood Switch

24Volt dc

P/N525941

Double Pole

EMI Filter

240Volt ac

P/N525908P

 

Motor

40 Volt dc 3 Phase

Drain

4200RPM

Wash

2300-2850RPM

Stator

2.5 ±0.2 Ohms

P/N525933

per winding

Rotor

 

P/N525736

 

Temperature Sensor

962-Ohms @ 20°C

(Part of Heater

1000-Ohms@ 30°C

Plate)

1202-Ohms @ 60°C

Inlet Hose

1.7m

P/N525151

960Kpa

Drain Hose

2.0m from rear of

P/N525435

cabinet

2.5m bottom tub

P/N525495

2.9m top tub

Detergent

24 volt dc

Dispenser

70

±5 Ohms

P/N525675

5 grams

 

10 grams

 

15 grams

 

5 gram pre-rinse

Rinse Aid

24

Volt dc

Dispenser

70

±5 Ohms

 

50 mls

 

25 reg. Washes

 

approx

Electronic P.C.B.

230-240 Volt Input

P/N525832P

Outputs: -

 

230 Volt ac

 

40 Volt dc

 

24 Volt dc

Control Panel Std

24

Volt dc

P/N525192P

 

 

Control Panel

24

Volt dc

Integrated

 

 

P/N525185P

 

 

Heater Plate

240 Volt ac

P/N525169

55

±5 Ohms

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3.0TECHNICAL OVERVIEW

3.1Electronics

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.

3.2Motor

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.

3.3Cabinet

3.3.1Chassis

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.

3.3.2Drawer 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.

3.4Filling

3.4.1Cold 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.

3.4.2Mixing 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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3.5Dispensing 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.

3.6Lid Seal

3.6.1When 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.

3.6.2What 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.

3.6.3During 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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3.7Wash Cycle

3.7.1Tub

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.

3.7.2Rotor

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.

3.7.3Spray 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.

3.8Heating

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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3.8.4Overheating 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.

3.9Filter Plate

The filter plate is a stainless steel disk which lies below the dishrack and sprayarm and completely encompasses the base of the tub.

3.9.1The 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.

3.9.2Removing 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.

3.10Drain 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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3.11Drying 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.

3.12Deflating

3.12.1Lid 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.

3.12.2When 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.

3.13Lockring 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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3.14Wiring 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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