Fisher & Paykel DD601v2 User manual

DishDrawer
Models
DD601v2 DD601Iv2
DS601v2 DS601Iv2
599039

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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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1.0 SERVICE REQUIREMENTS
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.
D

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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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2.0 DIMENSIONS & 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
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
Stator
P/N525933
Rotor
P/N525736
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
2.5 ±0.2 Ohms
per winding
Detergent
Dispenser
P/N525675
Rinse Aid
Dispenser
Electronic P.C.B.
P/N525832P
Control Panel Std
P/N525192P
Control Panel
Integrated
P/N525185P
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
24 Volt dc
Temperature Sensor
(Part of Heater
Plate)
Inlet Hose
P/N525151
Drain Hose
P/N525435
P/N525495
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
Heater Plate
P/N525169 240 Volt ac
55 ±5 Ohms

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3.0 TECHNICAL OVERVIEW
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 anti-
clockwise.
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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4.0 DIAGNOSTICS
4.1 Setup & Diagnostics
The DishDrawer comes with comprehensive fault codes and built in diagnostics, to
save the user & service person time and worry, if the dishwasher ever exhibits a fault.
4.2 Fault Modes
The faults are displayed in the LCD as one of 8 F (fatal) faults or one of 3 U (user)
faults. A Fatal fault will usually require the assistance of a qualified service person,
while many User a faults are simply blockages or installation errors, easily fixed by the
user. In the Integrated models, an LCD is not available, and faults are indicated by a
Red center LED, with the fault number indicated on the touch switch panel with Red
LED’s. The indication below for the Touch Switch Panel is from left to right, with ‘_’
meaning the LED is Off, and ‘#’ meaning the LED is On. A fatal fault is accompanied
by a continuous pulsating beep, while a user fault is accompanied by a more pleasant
continuous pulsating tone pattern. The last two faults are logged into EE memory,
with 8 bytes of information logged to aid location of the fault. These bytes are
available for interrogation by a PC if required. The fault codes shown on Pages 20/21
have been implemented in the DishDrawer.
To clear any fault press the Power button. It the fault is still present then it cannot be
cleared.

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4.3 Diagnostic Modes
4.3.1 Temperature Display Mode
During a wash cycle, the current water temperature can be displayed on the LCD
instead of the time remaining. To enter temperature display mode, start a wash cycle
as normal. Initiate a keylock by pushing and holding the Keylock button for 4
seconds.
Once in keylock mode push and hold Start/Pause for 8 seconds to enter temperature
display mode. The temperature is now displayed and the MIN symbol is switched off.
Keylock mode can now be exited.
To cancel temperature display mode, either repeat the above procedure or enter power
off mode by pressing Power. Temperature display mode is automatically cancelled at
the end of a wash program (even in CC mode).
4.3.2 Rinse Aid / Tub-Open Beep Water Pressure Setup Mode
To enter this setup mode, hold the Programme and Eco touch switches
simultaneously for 5 seconds. Once the setup mode is entered a beep is emitted and
the LCD is red with ‘HP’ displayed.
Push Power at any time to exit this setup mode.
4.3.3 Rinse Aid Setup
The current rinse aid setting is shown using orange LED’s on the touch switch panel.
The amount of rinse aid dispensed into a rinse cycle can be varied to suit the level of
hardness of the local water supply. It is adjusted for 1 - 5 dispenser levels
(1 = approx 1ml of rinse aid , 5 = approx. 5mls of rinse aid).
Push Programme to advance the rinse aid setting. Once the desired setting is
achieved, push Power to exit. The rinse aid index is stored in EE memory, so even
with the power removed, the rinse aid level is retained.
4.3.4 Tub-Open Beep Setup
The beep sequence that occurs when the tub is opened can be turned on or off using
the Keylock button. If the Smily Face on the LCD is On then the beep sequence will
occur when the tub is Opened. If the Smiley face is Off then no beeps will occur when
the tub is Opened. Push Power to exit when the desired setting has been selected.
The Integrated Model will sound a single beep when turning this option off, while the
actual beep sequence is sounded when turning this option on. The DishDrawer will
default to 'beeps on' if the mains power is removed.

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4.3.5. Water Pressure Set Up
The DishDrawer can be set to either High(Standard) or Low inlet water pressure. The
LCD displays the current water pressure setting.
If “HP” is displayed then the setting is High Pressure.
If “LP” is displayed then the setting is Low Pressure. Low pressure is generally less
than 50kPa or equivalent to that supplied by a ceiling tank.
Push the Start/Pause button to alternate between HP and LP.
Integrated: A high beep is sounded when changing the HP, and a low beep is sounded
when changing to LP. Push Power to exit when the desired setting has been selected.
4.3.6 Dishwasher Diagnostics
Dishwasher Diagnostics can only be entered in Power Off mode, ie. When there is no
display on the LCD or the badge LED’s are off. Diagnostics is entered by holding the
Keylock and Start/Pause buttons simultaneously for 6 seconds. Ensure that Keylock
is pushed first to prevent the dishwasher from starting a wash, from a Start/Pause
keypress.
There are currently four levels of diagnostics. To move to next level push Power.
Once a mode has been entered, pushing Power will exit diagnostics completely
(except Display & Show Off modes). If no mode is entered then the display will cycle
through the four levels and exit after the last. On entering diagnostic mode the first
level is Download Mode.
4.3.7 Display / Download Mode
In this mode all LED’s (except Rinse program) and LCD segments (except keylock)
are illuminated.
4.3.8 Optical LED Download / Fault Display
An optical data download is available here to download all EE data to a PC via the
Rinse Program Red LED. Hold the reader pen over the Rinse Program LED and press
Start / Pause to initiate the download. A short beep indicates the start and finish of
download.
The last two faults are displayed on the LCD during the optical download, with the
Current Fault code displayed first followed by the Previous Fault Code.

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4.3.9 Clearing Fault Logs
To Clear the current Fault press the Keylock button until a beep is sounded. This
action moves the Current Fault into the Previous Fault while clearing the Current
Fault. To Clear the Previous Fault press Keylock once more until the beep is
sounded. Warning: Once a fault has been cleared it is permanently removed from
Memory and cannot be recovered.
Press Power to advance to the next mode.
4.3.10 Show Off Mode
This mode initiates a shop show off display and operation demonstration. The LCD
display is Red backlight ‘Ad’. The touch switch LED’s are - Grn Grn __ Grn Grn.
Press Power to skip show off mode and move onto the next mode.
Press Start/Pause to initiate show off mode:
A short series of tones indicates that Show Off mode has been entered. The Show Off
display cycles through every LED, & LCD segment. If any front panel key is pressed
the dishwasher will re-initiate a series of short tones.
Once Show Off mode has been initiated, the mains power must be removed to exit out
of Show Off mode.
4.3.11 Hardware Output Diagnostic Test Mode
This mode tests all the hardware outputs and inputs. The LCD display is Red
backlight and ‘HO’.
Press Power to skip hardware diagnostics and advance to the next mode.
Press Start/Pause to enter hardware diagnostics.
Once hardware diagnostics has been entered the current hardware output being tested
is indicated in green on the touch switch panel, using binary encoding, and also on the
LCD as shown below.
Any combination of outputs can be switched on or off. Load sensing is enabled when
the motor is running.
Press Start/Pause to advance to next hardware output.
Press Keylock to turn the currently displayed output On or Off. If the currently
displayed output has a green backlight then that output has been switched on, and if
the backlight is red then that output is off.
Press Power to Exit at any time (All outputs will be switched off on exit).
The LCD display and touch switch panel green LED’s are illuminated to correspond to
a particular hardware device. The following table details the display order of the test.

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LCD Heavy Norm Fast Deli Hardware Output
-------------------------------------------------------------------------------------------
EU Off Off Off On Exhaust Valve
FU Off Off On Off Fill Water Valve
dd Off Off On On Detergent Diverter Valve
LS Off On Off Off Lid Seal Pump
rd Off On Off On Rinse Aid Dispenser (dispenses
current setting)
P1 Off On On Off Motor Wash direction
(2300-2850 rpm)
P2 Off On On On Motor Drain direction
(4200 rpm)
dF On Off Off Off DC drying fan (On
100% duty)
Er On Off Off On Element Relay
‘temp’On Off On Off Displays current water
temperature.
WARNING : As there is no protection in this mode it is possible to turn the element
on with no water in the tub. It is advisable to avoid turning on the element without
water in the tub.
NB : No Fault codes will come up while in diagnostics mode.
Tub Open Microswitch Test: At any time during HO test mode the Rinse red LED
indicates the tub position. On = Open, Off = Closed.
Note : There maybe a short delay (up to 0.5sec) from when the tub has changed state
to the position that is indicated on the LED. This is due the communication delays
between the two micro-controllers.
4.3.12 Continuous Cycle Life Test Mode
In this mode the dishwasher can be run continuously in any wash cycle. Once the cycle
has finished, the dishwasher automatically restarts the same wash cycle.
The LCD is Red backlight and display CC. The touchswitch panel is -
Red Red __ Red Red.
To exit diagnostic mode push Power.
To initiate a continuous cycle press Start/Pause. The dishwasher will enter standby
mode. Choose the required cycle and operate the dishwasher as normal. Continuous
cycling can be canceled at any time by pushing the Power button, or removing the
mains power. Continuous cycling is indicated by the backlight alternating between
green and orange.
In continuous cycle a delay occurs when a cycle has finished before the next cycle
starts. This delay is currently 1 min. During this time the LCD displays a finish cycle
display, and the backlight alternates between RED and OFF.

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Cycle Count Retrieval
To display the cycle count on the LCD screen, Pause the dishwasher while running a
Continuous Cycle. The two bytes of the cycle count will be displayed alternately, in
syncronisation with the changing backlight.
The Low byte is displayed when the backlight is Green.
The High byte is displayed when the backlight is Orange.
To calculate the Total diswasher cycle count use the formula below.....
Cycle_Count = ((200 x High_byte) + Low_byte).
Eg. Low_byte = 156
High_byte = 21
Cycle_count = ((200 x 21) + 156) = 4,356.