Page 4 - TABLE OF CONTENTS
TABLE OF CONTENTS SMART DRIVE ELECTRONIC WASHING MACHINE PHASE 1 to 5 – 230v ..................................1 WHAT PHASE, SIZE & MODEL IS YOUR SMARTDRIVE? .........................................................3 TABLE OF CONTENTS ................................................................
Page 6 - HOW TO SERVICE SMARTDRIVE; IF SMARTDRIVE HAS NO POWER - SEE SECTION 6.1
- 1 - 1.0 INTRODUCTION 1.1 HOW TO SERVICE SMARTDRIVE IF SMARTDRIVE HAS NO POWER - SEE SECTION 6.1 Power off at the mains socket. Wait 2 minutes. Power on. IF SMARTDRIVE IS DISPLAYING A FAULT - SEE SECTION 11.0 This may be identifiable by an unusual combination of LEDs displayed on thewash progress L...
Page 7 - SMARTDRIVE SERVICING – Quick Reference Guide!
- 2 - 1.2 SMARTDRIVE SERVICING – Quick Reference Guide! • Smartdrive is not isolated. Even low voltage (5v and 15v) are live! • During normal operation only one LED should be flashing. This is the leftmost wash progress LED when Smartdrive is Paused. • The product has a diagnostic mode which allows ...
Page 11 - SMARTDRIVE COMPONENTS
Page 12 - Electronics Systems; Wiring diagram for Phase 1.
- 7 - 4.1 Electronics Systems Smartdrive electronics consists of 4 mains parts: - a) Motor, (b) Motor Controller Module, (c) DisplayModule and (d) Rotor Position Sensor. The interconnections are shown in the block diagrams below:- Wiring diagram for Phase 1. NB. Phase 1 (spare) uses a motor controll...
Page 14 - Motor; Specifications; Phase 1
- 9 - 4.2 Motor The motor is a 3 phase, 42 pole, DC brushless motor, commutation is achieved electronically. The Motorconsists of a STATOR (stationary part) and ROTOR (rotating part). The Rotor Position Sensor controlsthe speed and position of the motor. The STATOR has a 'star point' connection, and...
Page 15 - Motor Controller Module; Water Level Measurement - Pressure Sensor
- 10 - 4.3 Motor Controller Module This module contains the circuitry needed to control the water valves, pump and the motor. It alsorecieves signals from the rotor position sensor, pressure sensor and the display module. The Motor Controller Module and Display Module are continuously communicating....
Page 16 - Display Module; Size Setting Mode
- 11 - 4.4 Display Module • The Display Module contains a microprocessor whose function is to take the inputs from the frontpanel and send the appropriate command to the Motor Controller Module. It also controls the outputto the display LEDs and beeper. • Test the Display LEDs. Power onat the wall. ...
Page 17 - Water Valves
- 12 - 4.5 Water Valves The electronics control the water valves so that a constant water temperature is achieved in the bowlirrespective of the temperatures and pressures of the household hot and cold water systems. To achieveaccurate water temperatures a proportional water valve is used on the col...
Page 18 - Rotor Position Sensor; Installation
- 13 - 4.6 Rotor Position Sensor One of the inputs that the Motor Controller Module needs in order to determine which switches to turnon, is the position of the Rotor. This information is supplied by the Rotor Position Sensor (RPS). On the RPS there are three Hall Sensors. These detect the magnetic ...
Page 19 - Pump
- 14 - 4.7 Pump The drain pump motor is coupled directly to the base of the outer bowl. This eliminates bowl to pumphoses and the accompanying seals, clips etc. The pump housing is an integral part of the outer bowl. Thepump is accessible by removing the inspection hatch on the front of Smartdrive, ...
Page 20 - Inner and Outer Bowls; Diagram showing the Floating Bowl
- 15 - 4.8 Inner and Outer Bowls The outer bowl is the assembly to which all the motor, pump system, suspension rods, etc are mounted.Within the outer bowl is the inner bowl and the agitator. During spin, the agitator and inner bowl have tobe coupled together and turn as a single unit. In agitate th...
Page 22 - Lid Switch and Out of Balance Switch; Lid Switch; Out of Balance Switch; Check operation using a multimeter; Out of Balance and Lid Switch Test; Diagnostic
- 17 - 4.9 Lid Switch and Out of Balance Switch Lid Switch If the lid is raised, the lid switch operates and stops the cycle when Smartdrive is stirring during fill orSmartdrive is spinning, (braking). The motor should stop within 10 seconds, all the energy from the motoris dumped into the brake res...
Page 23 - Water Temperature Sensing; Phase 5 GW
- 18 - 4.10 Water Temperature Sensing • Phase 1-4 uses a thermistor for sensing the water temperature. It is located within the Motor Controller. User can adjust the warm temperature by going into the Option Adjustment Mode. • Phase 5 GW uses a thermistor for sensing the water temperature. It is loc...
Page 24 - SMARTDRIVE INFORMATION; Customising Wash Cycles (GW only) – Phase 3 to 5 only; TO CUSTOMISE THE WASH CYCLES
- 19 - 5.0 SMARTDRIVE INFORMATION This information is provided to the user in the ‘Use and Care Manual’. It is included here forcompleteness. The user warning information and some information on Option Adjustment mode is also inthis manual. 5.1 Favourite cycle (GW only) – All Phases The user may hav...
Page 25 - Delay Start (GW only) – Phase 2 to 5 only; Auto Water Level (GW only) – Phase 3 to 5 only; MANUAL WATER LEVEL SELECTION; Water Saver (GW only) – Phase 3 to 5 only
- 20 - 5.3 Delay Start (GW only) – Phase 2 to 5 only Select your wash cycle and options to suit the clothes load, by pressing the appropriate buttons then pressthe DELAY START button: - • Once for 1 hour • Twice for 6 hours (phase 2-4) 3 hours (phase 5). • Three times for 9 hour delay • Four times t...
Page 26 - AMOUNT OF WATER USED IN THE WATER SAVER RINSE; Fabric Softener Dispenser – All Phases; Scrud
- 21 - AMOUNT OF WATER USED IN THE WATER SAVER RINSE MODEL SHOWER RINSE SPRAY & DEEP RINSE Large 60 litres 115 litres Medium 50 litres 105 litres Compact 40 litres 90 litres Please note, these are approximate figures for high water level. The Time Saver or Soak option can be used with the Water ...
Page 27 - Wash Performance Information – All Phases
- 22 - 5.7 Wash Performance Information – All Phases Creasing Creasing can be caused by Over loading Smartdrive or the dryer. Permanent Press or Delicate cycles havebeen designed to minimise creasing, they use a lower spin speed. Do not leave wet clothes to sit in thewasher or laundry basket. Soilin...
Page 28 - SMARTDRIVE PROBLEMS; If Smartdrive Appears To Have No Power; Phase 1 Only; If Smartdrive Powers Off mid cycle; Phase 4 Only
- 23 - 6.0 SMARTDRIVE PROBLEMS 6.1 If Smartdrive Appears To Have No Power If the module appears to be dead / no power then check thefollowing:- • Is the external mains plug switched on and live? • Are all plugs connected into the Motor Controller? • Phase 4 Only . Check that the product is not "...
Page 30 - Continuous Spinning or Slow Spinning; Intermittent Lid switch; Poor Wash Performance
- 25 - • Check the 2 balance rings in the inner bowl contain water. Check weights. • Check for noisy suspension rods. Phase 1 was noisy during Stir. • If the inner bowl or agitator is noisy check for obstruction. Check the spline drive is clean. If there is agrating sound check the single stainless ...
Page 32 - OPTION ADJUSTMENT MODE; PAUSE; POWER; Wash Water Temperature – All Phases
- 27 - 7.0 OPTION ADJUSTMENT MODE Smartdrive can be adjusted to operate under a number of different conditionsOPTION ADJUSTMENT MODE may be used to customise Smartdrive.Some of this information is available to the user in the ‘Use and CareManual’. For IW see Appendix E. The features that can be adju...
Page 33 - Method of Setting the Wash Temperature; sound; Rinse Options – All Phases
- 28 - Method of Setting the Wash Temperature 1. Select the OPTION ADJUSTMENT MODE by pressing and holding the START/PAUSE button, thenpressing the POWER button. 2. Use WASH TEMPERATURE buttons and LEDs to select the temperaturesetting to be adjusted, i.e. Cold, Cold/Warm, Warm, Warm/Hot, Hot. 3. Us...
Page 34 - End of Cycle Warning Beeps (GW Only) – All Phases
- 29 - FIRST RINSE OPTION (2) Spin only. Does not give as good a suds removal as Option (1) butuses less water than Option (3) FIRST RINSE OPTION (3) Deep Rinse. Gives better sudsremoval but increases water usage. The first rinse is always followed by a final deep rinse and spin. Method ofselecting ...
Page 35 - Adjusting the Volume of Water Used in the Water Saver
- 30 - 7.4 Adjusting the Volume of Water Used in the Water Saver Option (GW only) – Phase 3 to 5 You can increase or decrease the volume of water added during the shower rinse on the Water Saveroption. Enter the Option Adjustment Mode. Use the WATER LEVEL buttons to select the volume ofwater you wis...
Page 36 - WHAT WAS THE LAST FAULT?; Diagnostic Mode; Note
- 31 - 8.0 DIAGNOSTIC MODE Allows the following status information to bedetermined: - Last Fault.Lid switch status.Out of Balance switch status.Size.Additional information Allows control of the following:- PumpHot Water ValveCold Water ValveRestartRecycleHot Bowl Flag For IW information see Appendix...
Page 37 - TO TEST PUMP & WATER VALVES
- 32 - 8.2 TEST LID, OUT OF BALANCE, & SIZE SWITCHES To enter Diagnostic Mode turn the power on at the power point and off at the console. Press and hold the WASHTEMPERATURE DOWN then press the POWER button.Smartdrive will give 2 short beeps. Phase 3 Only press ADVANCE button once. Phase 4 &...
Page 40 - SIZE SETTING MODE – Phase 4 and 5 only
- 35 - 9.0 SIZE SETTING MODE – Phase 4 and 5 only Phase 1-3 sizes are determined by 2 switches on the display and protrusions on the console. When replacing Display or Motor Controller enter Option Adjustment mode to set these sizes in EEPROM. To check the size setting on Phase 1-3 use DIAGNOSTIC mo...
Page 42 - No Water (Both Hot and Cold Water LEDs flashing); Overloaded Product (High Water LED flashing)
- 37 - 10.3 No Water (Both Hot and Cold Water LEDs flashing) This warning is indicated by the cold and hot water LEDs flashing. Smartdrive willalso be making a rippling set of 5 beeps repeated every 6 seconds and the product willbe paused. 1. Check that the taps are turned on. 2. Check that the inle...
Page 43 - Restart and Recycle (Wash Progress LEDs flashing)
- 38 - 10.6 Suds (First Rinse LED is flashing or Final Spin LED isflashing) This warning is indicated by a rinse or spin LED flashing. Smartdrive will also be making a 'ripplingsound of 5 beeps repeating every 6 seconds' and the product will be paused. Too much Detergent has beenused and Smartdrive ...
Page 44 - Demonstration Mode (All LEDs flashing in patterns)
- 39 - 10.8 Demonstration Mode (All LEDs flashing in patterns) This feature is designed for in store demonstration purposes. Smartdrive can draw attention to itself with aselection of flashing LEDs. In this mode Smartdrive cannot be started. To Select DEMONSTRATIONMODE press and hold the ADVANCE but...
Page 45 - Fault code shows the last recorded fault. Always confirm fault.
- 40 - 11.0 FAULT CODES FAULT CODES FOR ALL SMARTDRIVE MODELS Phase 1 GW500 GW600 GW700 GW050 GW060 GW070 GW650 Phase 2 GW701 GW601 GW501 MW051 LW015 MW061 MW071 Phase 3 GW703 GW603 GW503 MW053 LW035 Phase 4 GW708 GW608 GW508 MW058 LW085 AW085 GWC08 GWM08 GWL08 THC08 THM08 THL08 Phase 5 GW709 GW609 ...
Page 46 - SMARTDRIVE PHASES 1 to 5 FAULT DESCRIPTIONS; Phase 2 to 5 - Motor Controller Fault
- 41 - SMARTDRIVE PHASES 1 to 5 FAULT DESCRIPTIONS When Smartdrive detects a fault it stops. Smartdrive beeps continuously, once per second, and displays afault code in binary using the 8 wash progress LEDs. The possible fault codes are listed in numeric orderwith their associated service procedure....
Page 53 - Action
- 48 - The Motor Controller has recorded a water level of empty while it is agitating. The water levelmust have been greater than empty for Smartdrive the enter the agitate mode initially. The mostlikely cause of this fault is that the pressure transducer hose has been severed or fallenoff during ag...
Page 56 - Secondary Source
- 51 - 47. (00101111) Phase 2 to 3 - Bowl Dis-engaged Fault While carrying out a bowl check, the Motor Controller has found that the bowl is not engagedeven though the pressure sensor indicates that the bowl is empty. The Motor Controllercontinues to check for 2 minutes. During this time the module ...
Page 61 - Tertiary Source –
- 56 - 104. (01101000) Phase 2 to 5 - Comms. Error Refer to Fault code 105 for action. 105. (01101001) Phase 2 to 5 - Comms. Error Time-out These faults are reported when the Display module detects an error in the communicationsbetween the Display module and the Motor Controller. NB. If the product ...
Page 62 - Set Phase to Phase 1 to 5.
- 57 - identify size, cold water temperature LED identifies 5kg, the low water level LED identifies6kg, the hold spin speed LED identifies 7kg. If the product has not been setup before all 3 LEDswill be on. To set the size for 5kg push the wash temp up button. To set the size for 6kg pushthe water l...
Page 63 - Primary Source –; Action –
- 58 - Secondary Source - Rotor Position Sensor Action - If the harness seems to be correct, check the Rotor Position Sensor for loose, damaged, or faulty components. Tertiary Source - Motor Controller Action - The Motor Controller motor sensing circuitry may be faulty. Replace Motor Controller. 131...
Page 67 - MECHANICAL SERVICE SECTION; COMPLETE DISASSEMBLY; PHASE 5 TOPDECK SHOWING WIRING CONNECTIONS
- 62 - 12.0 MECHANICAL SERVICE SECTION 12.1 COMPLETE DISASSEMBLY CAUTION: Ensure power and water supplies are disconnected before servicing. There is stillmains power within the console when on/off switch in the `off' position. 1. Isolate from the power supply. 2. To remove the lid, open it to the u...
Page 68 - PHASE 2 TOPDECK SHOWING WIRING CONNECTIONS; NB: DON’T REMOVE THE EARTH CONNECTION FROM THE WRAPPER
- 63 - PHASE 2 TOPDECK SHOWING WIRING CONNECTIONS 4. Disconnect the pressure tube from the pressure sensor. 5. Disconnect display module plug, the motor/pump harness plug and Rotor Position Sensor plug.Remove the pump earth lead and mains cable earth lead from the Motor Controller Module.Remove the ...
Page 71 - ASSEMBLY GUIDELINES
- 66 - 12.2 ASSEMBLY GUIDELINES Assembly is the reverse of disassembly. The followingpoints are worth noting. Drain Hose Outlet Elbow . Refit to the base. NB: Ensure the lugs on the elbow are located underneath the pumpbracket. Clamp into position. Pump. Turn the pump clockwise when refitting it int...
Page 72 - MOTOR ASSEMBLY & DISASSEMBLY; NB; Do not place the stator inside the rotor.; ASSEMBLY; CHECK Red Blue & yellow wiring is correct
- 67 - 12.3 MOTOR ASSEMBLY & DISASSEMBLY 1. Remove the rotor by using a 16mm or 5/8" socket. Liftthe rotor clear, and place in a plastic bag. The rotor hasstrong magnets and can attract metal objects. If anyforeign objects are caught in the rotor area these maycause the magnets to wear and c...
Page 73 - PUMP BLOCKAGE; Other Checks
- 68 - 12.4 PUMP BLOCKAGE Pump Block error is fault code 37. This is one ofthe most likely problems encountered inSmartdrive. See section 11.0 for more informationon fault code 37. Drain the Bowl. This can either be done using thepump or emptying the bowl manually. If there is a service hatch (Phase...
Page 74 - SHAFT & BEARING REMOVAL; WARNING
- 69 - 12.5 SHAFT & BEARING REMOVAL 1. Fit the spline tool over the shaft. Remove the 1 1/4"AF shaft retaining nut securing the shaft. 2. Lay the outer bowl on its side before removal of the shaft. This ensures that the shaft does not falldirectly onto the floor. NB: The shaft can only be re...
Page 75 - SHAFT & BEARING ASSEMBLY; inner bearing fitted first; IMPORTANT
- 70 - 12.6 SHAFT & BEARING ASSEMBLY 1. The bearings must be inserted separately with the inner bearing fitted first and pulled down with the bearing tool onto the shoulder in the bearing housing. IMPORTANT : There must be no gap between the bearing outer race and the shoulder of the aluminium e...
Page 76 - Fit the assembly thimble; NB: The seal should be flush with the lip on the base of the outer bowl.
- 71 - 3. Ease the shaft through the bearings from inside the outer bowl. Take care the shaft is fitted withthe threaded retaining nut section facing downwards in the direction of the base. 4. Fit the shaft retention nut. Use the spline tool and spanner to tighten the shaft retention nut. 5. Invert ...
Page 77 - If; WASH PROGRESS LEDs
- 72 - Appendix A: Binary Decoding Chart – 8 Bits (0-255) short wash rinse spin 1 2 4 8 16 32 64 128 ΟΟΟ ΟΟΟ ΟΟΟ ΟΟΟ ΟΟ ΟΟ ΟΟ ΟΟ ✹ ✹ ✹ ✹ Ο Ο Ο Ο ✹ ✹ ✹ ✹ Ο Ο Ο Ο Ο Ο Ο Ο ✹✹ ✹✹ ✹✹ ✹✹ ✹ ✹ ✹ ✹ ΟΟ ΟΟ ΟΟ ΟΟ ✹ ✹ ✹ ✹ Ο Ο Ο Ο ✹ ✹ ✹ ✹ ✹✹ ✹✹ ✹✹ ✹✹ Ο Ο Ο Ο ✹✹✹ ✹✹✹ ✹✹✹ ✹✹✹ ΟΟΟΟΟ ΟΟΟΟΟ ΟΟΟΟΟ ΟΟΟΟΟ 0 1 2 3 4 5 6 7...
Page 78 - Technical Bulletins; WM011 ALTERNATIVE SPARE PARTS FOR PHASE 1
- 73 - Appendix B: Technical Bulletins These are extracts from previous technical bulletins. WM011 ALTERNATIVE SPARE PARTS FOR PHASE 1 MOTOR CONTROLLER – June 1999 – Phase 1 only Fisher &Paykel is no longer able to obtain some electronic components to continue the manufacture of thecurrent Motor...
Page 79 - WIRING CONNECTIONS
- 74 - WIRING CONNECTIONS DISPLAY PUMP ROTOR POSITION SENSOR PRESSURE SENSOR MOTOR WATER VALVES OOB HARNESS PUMP EARTH End view of 426418P Motor Controller Module wiring connections. WM013 PUMP HOOD KIT – January 2000 – Phases 2 to 5 Changes have been made to the pumphood, cap and the impeller to de...
Page 80 - WM51 DIAGNOSTIC FLOW CHART – Sept 1992– Phase 1 only
- 75 - WM51 DIAGNOSTIC FLOW CHART – Sept 1992– Phase 1 only This is a flow chart for original Phase 1 Smartdrive Motor Controllers and Displays. These are fitted witha slow blow 32mm 6A fuse. Use this flow chart when there is no power to the display module andSmartdrive is powered on.
Page 81 - Kit Lever Out of Balance & Bracket Phase 2 - Part Number 502220
- 76 - WM65 BIB DEFLECTOR – April 1994– Phase 1 only Fisher & Paykel have introduced a new bib deflector with 3 vertical fins to replace the early Phase 1deflector part number 425768. It is recommended that whenever a phase 1 Smartdrive is serviced the newbib part number 425968 be fitted. This r...
Page 82 - WM81 PUMP SHIELD 5KG SMARTDRIVE – September 1996 -
- 77 - WM80 CONDENSATION KIT – May 1996 – Phase 2 & 3 only A condensation kit is available to reduce build up in the console area and around the electronics isavailable as part number 472976.This kit must be fitted to all Phase 2 & 3 Smartdrive where the display module has failed due toconde...
Page 83 - Smarttool
- 78 - Appendix C: Smarttool Smarttool is an Application which is run on a PC or aCasiopea Palm-Top. This application may be used with thefollowing Fisher & Paykel products :- • Smartdrive. Phase 1-5. Washing Machine. • ActiveSmart. Refrigerator. • DishDrawer. Dishwasher. The fault information i...
Page 84 - Tools for Servicing Smartdrive; SERVICE TOOL KIT
- 79 - Appendix D: Tools for Servicing Smartdrive SERVICE TOOL KIT PART NUMBER 502009 502009 Bearing Puller Kit. This kit is shown above and is used for insertion and extraction ofbearings. The extraction washer is available separately. 502034 Rotor Puller Adapter. This tool is used to extract the r...
Page 85 - IW SMARTDRIVE SERVICING; IW Quick Reference Guide; IW Models; Specifications for IW; Water consumption per fill with clothes load
- 80 - Appendix E: IW SMARTDRIVE SERVICING E.1 IW Quick Reference Guide • The Intuitive Washer can display the most recent user warning and fault. • The Intuitive Washer uses the motor to detect the fabric type. • The Intuitive Washer uses the same motor, bowl and wrapper as Phase 5 Smartdrive. • Tw...
Page 86 - INTRODUCTION to IW; PERFORMANCE CHANGES; The Eco Active wash with Recirculation; ELECTRONICS
- 81 - E.3 INTRODUCTION to IW This Service Supplement contains specifications,size setting and diagnostic mode. The first Intuitive Washer(IW) was introduced inPhase 5 Smartdrive in 1999. Three models werereleased, IW509, IW609 and IW709. Theseproducts were upgraded in 2000 to includerecirculation, ...
Page 88 - RECIRCULATING VALVE; PUMP; OPTION ADJUSTMENT MODE for IW; Adjust Options Menu; push the OPTIONS button and hold down for 4 seconds.
- 83 - RECIRCULATING VALVE PUMP The pump is the same as Phase 5. The pump forms part of the power supply. If it not connectedSmartdrive will appear to have no power. The pump resistance is 33 ohms. E.4 OPTION ADJUSTMENT MODE for IW In Option Adjustment Mode the following adjustments may be made: - T...
Page 90 - DIAGNOSTIC MODE for IW; STATUS DISPLAY; WARNING STATUS; cycles ago; MACHINE STATUS; Machine Status
- 85 - E.5 DIAGNOSTIC MODE for IW DIAGNOSTIC MODE incorporates tests for the pump, diverter valve, water valves, and also the datadisplay mode. To enter DIAGNOSTIC MODE, turn the power on at the power point and off at theconsole. Press and hold the ‘SPECIALs’ / ’LifeCycles’ button and then the POWER...
Page 92 - RECYCLE; HOT BOWL FLAG; SIZE SETTING MODE for IW
- 87 - RECYCLE In the Control Option mode, similar to setting the RESTART. Push the button beside the wordRECYCLE to toggle on and off Recycle. At the end of servicing, Smartdrive may require an extendedtest where it can be left to complete a number of wash cycles. By turning on RECYCLE Smartdrive w...
