Fisher & Paykel MW512, GW612, GW512, MW612, GW712 Service Manual
...
517790D
SMARTDRIVE
PHASE 7
ELECTRONIC WASHING MACHINES
517790D MARCH 2006
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.
517790D
3
FISHER & PAYKEL
PHASE 7
ELECTRONIC WASHING MACHINE
Covering the following product codes
New Zealand Australia Rest of World Markets
MW512-NZ 92194-A/B MW512-AU 93194-A/B MWC12-HK 94194-A/B
GW512-NZ 92195-A/B GW512-AU 93195-A/B MWC12-PF 95194-A/B
MW612-NZ 92186-A GW612-AU 93196-A GWC12-HK 94195-A/B
GW612-NZ 92196-A GW712-AU 93200-A GWC12-HK (SA) 95195-A/B
GW712-NZ 92200-A GWM12-HK 94196-A
GWL12-HK 94200-A
GWL12-TW 95199-A
GWL12-PH 94199-A
GWL12-TH 95200-A
Fisher & Paykel Appliances
Ltd
PO Box 58-732, Greenmount
78 Springs Rd
East Tamaki
New Zealand
Ph: (09) 2730660
Fax: (09) 2730580
Fisher & Paykel Customer
Services Pty Ltd
PO Box 798, Cleveland,
QLD 4163
A.C.N. 003 3335 171
19 Enterprise Street
Cleveland, QLD 4163
Ph: (07) 3826 9100
Fax: (07) 3826 9164
Fisher & Paykel Appliances
Singapore
150 Ubi Avenue 4,
Sunlight Building #02-00
Singapore 408825
Ph: 6547 0100
Service Ph: 6741 0777
Fax: 6547 0123
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CONTENTS
1
SPECIFICATIONS .................................................................................................................... 6
1.1 Dimensions ....................................................................................................................6
1.2 Maximum Capacity (Full Load) (AS 2040)..................................................................... 6
1.3 Water Consumption ....................................................................................................... 6
1.4 Water Fill Temperature (Approximate Factory Settings) ............................................... 6
1.5 Wash Motor ................................................................................................................... 6
1.6 Pump Motor ................................................................................................................... 6
1.7 Water Valves ................................................................................................................. 7
1.8 Thermistor (GW Only).................................................................................................... 7
1.9 Cabinet .......................................................................................................................... 7
1.10 Lid .............................................................................................................................. 7
1.11 Top Deck ................................................................................................................... 7
1.12 Inner Bowl.................................................................................................................. 7
1.13 Outer Bowl ................................................................................................................. 7
1.14 Console...................................................................................................................... 7
1.15 Agitator ...................................................................................................................... 7
1.16 Water Conservation Rating* ...................................................................................... 8
1.17 Fabric Softener Dispenser ......................................................................................... 8
1.18 Electric Supply ........................................................................................................... 8
1.19 User Guide................................................................................................................. 8
1.20 Lid Lock ..................................................................................................................... 8
1.21 Control Panel - GW.................................................................................................... 8
1.22 Control Panel - MW ................................................................................................... 8
2 TECHNICAL OVERVIEW ......................................................................................................... 9
2.1 Electronics ..................................................................................................................... 9
2.2 Stand By Mode ............................................................................................................ 10
2.3 Out of Balance Detection – ‘Bump Detect’ .................................................................. 10
2.4 Water Temperature Sensing........................................................................................ 11
2.5 Water Valves ............................................................................................................... 13
2.6 Water Level Measurement........................................................................................... 13
2.7 Motor............................................................................................................................ 15
2.8 Pump ........................................................................................................................... 18
2.9 Lid Lock .......................................................................................................................19
2.10 Inner and Outer Bowls ............................................................................................. 20
2.11 Agitator .................................................................................................................... 21
2.12 Lint Removal System............................................................................................... 21
2.13 Fabric Softener Dispensing ..................................................................................... 22
3 SIZE SETTING MODE ............................................................................................................ 24
4 DIAGNOSTIC MODE .............................................................................................................. 24
4.1 Last Fault Data ............................................................................................................24
4.2 Drain Pump Test.......................................................................................................... 24
4.3 Water Valve Test ......................................................................................................... 25
4.4 Restart Feature............................................................................................................ 25
4.5 Recycle Feature........................................................................................................... 25
4.6 Hot Bowl Flag .............................................................................................................. 26
4.7 Data Download ............................................................................................................ 26
4.8 User Warnings ............................................................................................................. 26
4.9 SmartDrive Diagnostic Table ..................................................................................... 28
5 WIRING DIAGRAM ................................................................................................................. 30
6 VOLTAGE READINGS FROM CONTROLLER...................................................................... 31
7 RESISTANCE READINGS FROM CONTROLLER................................................................ 32
8 BINARY DECODING CHART – 8 BITS (0-255) ..................................................................... 33
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9
DETAILED FAULT CODES .................................................................................................... 34
9.1 FAULT DESCRIPTIONS ............................................................................................. 34
10 SERVICE PROCEDURES..................................................................................................... 46
10.1 Removal of Lid......................................................................................................... 46
10.2 Components in Console Area.................................................................................. 46
10.3 Removal of Display Module ..................................................................................... 46
10.4 Removal of Water Valves ........................................................................................47
10.5 Removal of Thermistor (if fitted) .............................................................................. 47
10.6 Removal of Motor Control Module ........................................................................... 47
10.7 Removal of Cord Set ............................................................................................... 48
10.8 Removal of Lid Lock ................................................................................................ 48
10.9 Removal of Top Deck .............................................................................................. 48
10.10 Removal of Neck Ring ............................................................................................. 49
10.11 Removal of Agitator ................................................................................................. 49
10.12 Removal of Inner Bowl............................................................................................. 50
10.13 Removal of Clutch Mechanism (Spline Drive / Spline Driven)................................. 50
10.14 Removal of Pump Hood........................................................................................... 50
10.15 Removal of Outer Bowl From The Cabinet.............................................................. 51
10.16 Removal of Rotor..................................................................................................... 51
10.17 Removal of Stator .................................................................................................... 52
10.18 Removal of Rotor Position Sensor........................................................................... 52
10.19 Removal of Pump .................................................................................................... 53
11 SPECIALISED SERVICE PROCEDURES............................................................................ 54
11.1 Blocked Pump Procedure ........................................................................................ 54
11.2 Shaft & Bearing Replacement ................................................................................. 55
11.3 Shaft & Bearing Assembly ....................................................................................... 57
12 WASH PERFORMANCE INFORMATION............................................................................. 59
12.1 Creasing .................................................................................................................. 59
12.2 Soiling ...................................................................................................................... 59
12.3 Linting ...................................................................................................................... 59
12.4 Detergent Residue................................................................................................... 59
12.5 Black Marks on Clothes ........................................................................................... 59
12.6 Grey Marks on Clothes ............................................................................................ 59
12.7 Dye Transfer ............................................................................................................ 59
12.8 Tangling ................................................................................................................... 59
13 OPERATING PROBLEMS ....................................................................................................60
13.1 No Power ................................................................................................................. 60
13.2 Flooding / Leaking ................................................................................................... 60
13.3 Noisy........................................................................................................................ 60
13.4 Continuous or Slow Spinning................................................................................... 61
13.5 Siphoning................................................................................................................. 61
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1 SPECIFICATIONS
1.1 Dimensions
Compact Washer Medium Washer Large Washer
Height to lid
Open 1320mm – 1350 mm 1360mm – 1390 mm 1410mm – 1440mm
Closed 950 mm – 980 mm 950 mm – 980 mm 950mm – 980mm
Height to console 1010 mm – 1050 mm 1010 mm – 1050 mm 1010mm – 1050mm
Width 560 mm 600 mm 650mm
Depth 560 mm 600 mm 650mm
Inlet hose length 1200 mm 1200 mm 1200mm
Packed weight 50.4 kg 55.3 kg 60.5
Unpacked weight 43.5 kg 47.7kg 52.0
Note: Exact height of the SmartDrive
is dependent on how far the feet are inserted into the
base of the machine.
1.2 Maximum Capacity (Full Load) (AS 2040)
Compact Washer Medium Washer Large Washer
Dry Weight 5.5kg 6.5kg 7.5kg
1.3 Water Consumption
Compact Washer Medium Washer Large Washer
Fill (High) 65 litres 75 litres 90 litres
Spray & Deep Rinse 130 litres 150 litres 175 litres
Save Water 110 litres 130 litres 150 litres
Eco Rinse 73 litres 90 litres 105 litres
1 Deep Rinse 120 litres 140 litres 165 litres
2 Deep Rinse 160 litres 190 litres 215 litres
*Note: Approximate water consumption for a high water level load for each rinse option
offered.
1.4 Water Fill Temperature (Approximate Factory
Settings)
MW Washer GW Washer
Supply Water Fill Temp Supply Water Fill Temp
Hot Supply temperature Hot 60
o
C
Warm 36 - 38
o
C* Hot / Warm 50 oC
Cold Supply temperature Warm 40
o
C
Warm / Cold 35
o
C
Cold Plus 20
o
C
Cold Supply temperature
Recommended hot water inlet temperature 65
o
C. (Max)
*Dependent on hot and cold supply temperatures and water pressures
1.5 Wash Motor
Electronically commutated direct drive 3 Phase brushless DC Motor’ 36 Poles.
Copper Wound Stator: Resistance per Phase 16Ω +/- 10% @ 20
o
C. Refer Section 2.7.
Aluminium Wound Stator: Resistance per Phase 25.5Ω +/- 10% @ 20
o
C. Refer Section 2.7.
1.6 Pump Motor
Part Number Voltage Frequency Resistance
420324P 230V AC 50Hz 33Ω +/- 8% @ 20
o
C
426491P 230V AC 60Hz 28.8Ω +/- 8% @ 20
o
C
Note: Thermal cut-out fitted
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1.7 Water Valves
Supply Mode of Operation Voltage Resistance Flow Rate
Cold Digitally Operated 24V DC 64Ω @ 20
o
C 16 litres per minute
Hot Digitally Operated 24VDC 64Ω @ 20
o
C 10 litres per minute
Note: Flow rate will vary slightly depending on pressure.
Operating pressures: Maximum 1034 kPa (150psi) / Minimum 34 kPa (5psi)
Note: Pressures below 34kPa (5psi) can create seating problems with the internal
diaphragm of the valve, and may cause water to drip into the inner bowl when the machine
is not in use.
1.8 Thermistor (GW Only)
NTC-type temperature sensor (Thermistor) Resistance 10,000Ω @ 25oC
1.9 Cabinet
Pre-painted steel
1.10 Lid
ABS plastic (co-injected)
1.11 Top Deck
Polypropylene
1.12 Inner Bowl
Stainless steel: Grade 430T
Bowl base and balance ring: Polypropylene
Inner Bowl Weights
Compact 7.303kg +/- 225g
Medium 9.225kg +/- 175g
Large 10.480kg +/- 275g
Inner bowl speed
Fast Spin 1,000 RPM
Medium Spin 670 RPM
Slow Spin 300 RPM
Stir Speed 25 RPM
1.13 Outer Bowl
Aluminium insert over-moulded with polypropylene
1.14 Console
ABS plastic with ABS plastic insert for display module.
1.15 Agitator
Polypropylene
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1.16 Water Conservation Rating*
AAAA: A very high level of water efficiency
*Issued by the Water Services Association of Australia
1.17 Fabric Softener Dispenser
Dosage 75cc
1.18 Electric Supply
Operating Voltage 220/240V AC 50Hz
Maximum Current 2.8 amps
1.19 User Guide
User Guide 420706
1.20 Lid Lock
Resistance 63Ω +/- 10% @ 20oC (68oF)
Note: Normally low voltage, potentially 230V if harness is grounded on the cabinet!
1.21 Control Panel - GW
1.22 Control Panel - MW
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2 TECHNICAL OVERVIEW
This Service Manual contains information on the Product Specifications, Diagnostic Mode, Detailed
Fault Codes and the complete disassembly and assembly instructions for the Phase 7
SmartDrive
washing machine.
2.1 Electronics
2.1.1 Motor Control Module
The Motor Control microprocessor performs a wide variety of tasks. Primarily it controls the
electronic switching hardware to control the three phase currents in the Smart Drive DC motor.
The micro can accurately control not only the velocity of the motor but also the acceleration. This
accurate control is required to perform all the different agitator profiles, or wash actions, that are
used for caring for clothes. The Motor Control module performs the functions of spin, fill, wash,
drain and spray rinse when commanded to by the Display.
The Motor Control module microprocessor has a wide range of control with great accuracy over
spin speed, agitate action, fill temperature and water level. Having such control insures the wash
cycle selected provides the optimum soil removal combined with appropriate gentleness for the
washing and care of the clothes load.
The Motor Control Modules for the Phase 7 Washers are air-cooled in the same way as the Phase
5, and 6 machines are, and are coloured brown, the same colour that is used for Phase 6, Series
11 & 12 machines.
This Motor Control Module is not inter-changeable with other any other Phase or Series of
machines.
Identification
The physical shape of the Motor Control Module is different to the Phase 6 machines. The Phase
7 module also has a yellow label attached to the top of the housing stating P7CP (Phase 7,
Conventional Pump).
Motor Control Module
Phase 7
Identifier Label Motor Control Module
Phase 6 – Series 11 & 12
Note: When replacing a Motor Control Module ensure that the pressure tube is clear of any
water droplets before operating the machine on a fill cycle. If the bowl is full of water drain
the water then blow down the tube.
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2.1.2 Display Module
The Display Module provides the link between
the washing machine electronics and the user.
Input on wash type, water level, spin speed,
start/stop and wash cycle time is given by the
user via the display push buttons.
Feedback on selection is given to the user by
Light Emitting Diodes (LEDs). Sound effects
accompany button presses.
2.2 Stand By Mode
If a Phase 7 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 in the same way as the Series 9, 11 & 12 SmartDrives
. The control panel will be blank as if
it was powered off at the wall.
Before entering the Diagnostic or Option Adjustment modes, 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.
2.3 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 Phase 7 machines this 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 needs 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. Check the weight of the inner bowl. Bowl weights are as follows:
Compact: 7.303kg +/- 225g
Medium: 9.225kg +/- 175g
Large 10.48kg +/- 275g.
4. Check the RPS using a RPS Tester.
Note: If the OOB problem persists after checking the above, we would then recommend
replacing both the suspension rods and the rotor. It is highly unlikely that the Motor
Control Module will be the cause.
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2.4 Water Temperature Sensing
GW Washer
The thermistor for sensing water temperature in
the GW Washer is located in the back of the
outlet elbow on the valve assembly, and is
connected directly to the Motor Control Module.
For details on the wash temperature adjustment
Refer to Section
2.4.2 & 2.4.3.
Specifications
NTC-type temperature sensor (Thermistor)
Resistance 10,000Ω @ 25
o
C
MW Washer
As there is no thermistor (temperature sensor) in the MW Washer the only temperature that can be
adjusted is the warm wash temperature. The temperature of the warm wash is entirely dependent
on a number of factors:
a. Cold water temperature
b. Cold water pressure
c. Hot water temperature
d. Hot water pressure.
e. Warm wash setting.
As the above will vary from installation to installation it would be impossible to predict what
temperature each installation will ultimately achieve.
However under the conditions outlined below, a temperature of between 36–38
o
C should be
achieved.
Cold water temperature: 20
o
C
Cold water pressure: 320 kPa (46.5 psi)
Hot water temperature: 60
o
C
Hot water pressure: 320 kPa (46.5 psi)
Warm wash setting: Default setting (9 min wash LED – 3rd Green wash LED from the left).
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2.4.1 Warm Wash Temperature Adjustment (MW Only)
The warm wash temperature adjustment will alter the amount of time that the hot valve pulses on
and off for.
1. Turn machine on at the wall but do not press POWER.
2. Press START/PAUSE and hold down, then press POWER. Two quick beeps will be heard and
the machine will show an unusual pattern of lights. In this mode the lights are used to indicate
the different options available.
3. Select the Warm Wash Temperature.
4. Advancing the Wash Progress LED by pressing ADVANCE will increase the wash
temperature. If the ADVANCE button is kept pressed, the light will scroll back to the coldest
setting available for that wash temperature.
5. Press the POWER to ‘lock’ in the setting.
Note:
If the required temperature still can’t be obtained, advance the wash progress LED (as
described in the procedure above) across to the spin LED and manually adjust the flow of
the taps.
2.4.2 Wash Temperature Adjustment (GW Only)
1. Turn machine on at the wall but do not press POWER.
2. Press START/PAUSE and hold down, then press POWER. Two quick beeps will be heard and
the machine will show an unusual pattern of lights. In this mode the lights are used to indicate
the different options available.
3. Select the WASH TEMPERATURE to be adjusted.
4. The wash progress lights show the temperature adjustment possible for that temperature.
Pressing the ADVANCE will cause the wash progress light that is on to change. Advancing the
Wash Progress light will increase the wash temperature. If the ADVANCE button is kept
pressed, the light will scroll back to the coldest setting available for that wash temperature
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2.4.3 Controlled Cold (GW Only)
If the cold water temperature is very low (below 20oC), a very effective wash will not be obtained.
The controlled cold option solves this problem by adding a small amount of hot water to raise the
temperature of the wash. We have called this ‘Controlled Cold’.
1. Turn machine on at the wall but do not press POWER.
2. Press START/PAUSE and hold down, then press POWER. Two quick beeps will be heard and
the machine will show an unusual pattern of lights. In this mode the lights are used to indicate
the different options available.
3. Select COLD wash temperature.
4. The Wash Progress lights show the temperature adjustment possible. When the first progress
light is on, the machine will fill with cold water only. Press ADVANCE to select the second light
and the SmartDrive
will control the temperature to approximately 20°C. Each following light
equals approximately a 1°C temperature rise.
2.5 Water Valves
The Phase 7 machines use a new dual valve
block assembly. Independent coils control the
hot and cold water supply, which feeds the
water through a common outlet.
The GW valve block has a location feature for
the thermistor. There is no thermistor location
feature on the MW Washer.
2.6 Water Level Measurement
SmartDrive is fitted with a pressure sensor, which can control the fill to any water level. The
pressure sensor is incorporated within the Motor Control Module and cannot be removed. The
pressure tube connects from the Motor Control Module to the air bell at the bottom of the outer
bowl, and is part of the harness assembly. Care must be taken when removing or refitting the
pressure tube to the pressure sensor as too much force can damage this device.
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2.6.1 Manual Water Level – (MW & GW)
The agitator has 5 levels marked on its stem that can be used to help the user select the correct
water level. Select the correct water level by using the mark nearest to the top of the clothes.
The levels marked on the agitator are a guide for the clothes and do not correspond exactly to the
water level.
SmartDrive
may occasionally add water during agitation. This is to maintain the water level due
to the release of air trapped in the garments.
As the MW Washer only has 3 water levels (low, medium and high), if the garments sit between
these levels we would recommend using a lower water level than that of the garments or more
garments be added to the load.
For example: If the garments sat between the medium and high marks on the agitator, choosing a
medium water level would be better than choosing a high water level. Alternatively additional
garments could be added so that the garments were brought closer to the high mark.
SmartDrive
Water Level Settings
Tolerance for each water level = +/- 15mm
2.6.2 Auto Water Level – (GW only)
SmartDrive automatically selects the appropriate water level for the load when AUTO Water Level
is selected, and will choose one of the pre-existing 5 water levels (low, medium low, medium,
medium high and high). During fill SmartDrive
pauses occasionally to sense the water level.
SmartDrive
checks if the water level is correct by using a series of 2 different agitate strokes. A
slow stroke to sense the load and an agitate stroke to mix the load. If SmartDrive
detects that
that water level is too low it will fill with more water and check the level again.
When washing an unusual load eg. large bulky garments, pillows, it is recommend that the
water level is manually selected.
Manually select the water level if there is already water in the bowl.
If SmartDrive
does not fill to the correct level, the water level that SmartDrive selects can be
modified using Option Adjustment Mode.
High GW712 (54mm)
GW612 (50mm)
MW612 (50mm)
GW512 (60mm)
MW512 (60mm)
Medium High GW712 (105mm)
GW612 (110mm)
GW512 (115mm
)
Medium GW712 (170mm)
GW612 (175mm)
MW612 (175mm)
GW512 (180mm)
MW512 (180mm)
Medium Low GW712 (245mm)
GW612 (250mm)
GW512 (255mm
)
Low GW712 (300mm)
GW612 (305mm)
MW612 (50mm)
GW512 (310mm)
MW512 (310mm)
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2.7 Motor
2.7.1 Copper Stator
This stators used on the Phase 7 machines are unique to this Phase only and therefore it is not
interchangeable with any previous phase or series of machines. The stator has 36 poles instead
of 42 poles, and the pole tips are curved. The resistance of the windings remains the same as for
the Phase 5, Series 9, and Phase 6, Series 11 and 12 machines at 16 ohms per winding. The
rotor position sensor is also unique to this stator. (Refer to Section
2.7.4.)
Phase 7 Stator (36 Poles) Curved pole tips
2.7.2 Aluminium Stator – Introduced April 2007
In April 2007 an aluminium wound stator was introduced to the MW & GW compact machines. As
a result the service code changed from A to B.
The aluminium stator must not be fitted to a GW Medium or GW Large, all Intuitive models or the
AquaSmart machines. They also shouldn’t be fitted GW Compact or MW Compact prior to the
change, the reason for this is that the models which are produced with the aluminium stator, have
also had changes to the software in the electronics.
Visually the aluminium stator is similar to that of the copper stator however the resistances
between them are different (Refer to the wiring diagram below).
Wiring Diagram
32 32
32
16
16
1
6
RED BLUE YELLOW
STAR POINT
32 32
32
16
16
1
6
RED BLUE YELLOW
STAR POINT
Copper Stator Aluminium Stator (MW & GW Compact
Machines only)
51
51
25.5
25.5 25.5
51
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2.7.2.1 Testing the Stator
If the stator needs to be tested we would first recommend testing the resistance of the windings
from the harness that is connected to the Motor Control Module. (Refer to Section
7).
Note: Ensure that the Rotor or bowl is stationary when measurements are made.
Testing the stator from the console
The resistance of each individual winding is approximately 16 ohms (25.5 ohms aluminium stator),
however when testing the stator from the console we are testing across two windings therefore the
resistance should be approx 32 ohms (25.5 ohms aluminium stator) +/- 10%.
To test all windings you will need to measure across:
Red & Blue
Red & Yellow
Blue & Yellow
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
10.16 and 10.17.
Note: Two clamp plates are used to secure the Stator, one on each side. The four bolts are
tightened to a torque of 5 Nm. The plastic bolt for securing the Rotor requires a 16mm
socket and should be tightened to 8 Nm.
Testing the Stator
After removing the Stator, it can now be tested.
Test points are:
Red / Blue
Red / Yellow
Blue / Yellow
The value should be approx 32 (25.5 ohms
aluminium stator) +/- 10% across any of the two
windings.
2.7.3 Rotor
The rotor is also unique to the Phase 7 machines. It has 16 blocks containing 3 individual
magnets, as opposed to 14 blocks, containing 4 magnets for Phase 5, and Phase 6 machines.
The rotors between Phase 7 and previous Phases of machines can physically be interchanged,
however electrically they are incompatible.
If a Phase 7 rotor is fitted to a Phase 6 or earlier machine, fault code 240 will occur. Conversely
fault code 240 will also occur if a rotor from a Phase 6 or earlier machine is fitted to a Phase 7
machine.
Apart from the number of magnets the other (and easiest) way to identify the Phase 7 rotor is by
the number of holes. The Phase 7 rotor has larger holes around the outer perimeter and an
additional set of large holes on the inner perimeter.
32.0
Ω
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17
The photographs below show the difference between a Phase 7, and a Phase 6 Rotor.
Phase 7 Phase 6
2.7.4 Rotor Position Sensor (RPS)
One of the inputs that the Motor Control Module module needs in order to determine which
switches to turn on is the position of the rotor. The rotor position sensor (RPS) supplies this
information.
The RPS is a printed circuit board that contains
three Hall Sensors. These detect the magnetic
field of the individual magnets in the rotor. As
the motor turns, the position of a group of
magnets is detected. There are 5 wires on the
RPS, 2 for power supply and 3 signal wires.
Data on the position of the rotor is supplied to
the microprocessor in the Motor Control Module
module via the three signal wires.
The printed circuit board sits in a plastic housing
encapsulated by resin to protect the board. The
only exposed area of the board is the connector
for the main harness.
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2.7.4.1 Testing the Rotor Position Sensor
To test the RPS use a RPS tester, part number 502105, which is powered by a 9V battery. To test
the RPS of a Phase 7 Washer it will also require an adaptor harness, part number 420892. 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. Turn the bowl 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 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.
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.
2.8 Pump
The pump is coupled directly to the outer bowl.
This eliminates bowl to pump hoses and the
accompanying seals, clips etc. The pump
housing is an integral part of the outer bowl.
When removing the pump up to a litre of water
may leak from the pump cavity. When refitting
the pump lubricate the seal face with liquid soap
or detergent (do not use grease).
Blocked Pump Detection
This is achieved by monitoring the water level
during drain. If the water level has not dropped
by approximately 3mm within a predetermined
time period (approximately 9-10 minutes), then the product will report a blocked pump fault.
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2.9 Lid Lock
The Phase 7 Washer uses the same lid lock that is used on
the Phase 6 series 11 & 12 machines. During the spin and
drain out part of the cycle prior to spray rinse, the lid will lock
down until the completion of the spin. Once the spin has
completed, the lock will release and the lid can be opened.
The Lid Locked LED will illuminate on the GW and MW
machines.
If the lid is left open, the machine will be unable to lock the lid
and the cycle will be halted. The machine will play a tune
and the lid lock will flash until the lid is closed and
START/PAUSE is pressed.
If the lid-lock fails in the closed position, the locked lid can be forced upwards and out of the
lock. Note: This is the only time in which we would recommend doing this.
If the harness is damaged, the complete lid lock assembly will need to be replaced.
The chart below shows the stages when the lid is locked.
Fill Unlocked
Agitate Unlocked
Spray Rinse Locked
Deep Rinse Unlocked
Spin Locked
If the power supply is cut during the spin cycle, the machine
will keep the lid locked until the rotor has ceased to turn (3 to
10 secs). Only then will it release the lock. The motor is
acting like a generator and allows the lock to stay energised
under the bowls inertia.
In a brown out situation, the machine will restart at the start of whatever section of the cycle it was
on and continue the wash. The lid lock would then be reactivated if it happened to be on a spin
cycle.
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