Kleenmaid KFL2000 Setup guide

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1SAFETY........................................................2
2INSTALLATION............................................3
2.1 Basic installation ................................................................3
2.2 Feet (leveling legs)..............................................................3
2.3 Aquasecure inlet hoses...................................................... 3
2.4 Water connections..............................................................4
2.5 Transport (shipping bolts) .................................................4
2.6 Drain hoses .........................................................................5
3OPERATION.................................................6
3.1 Controls...............................................................................6
3.2 Child lock.............................................................................6
3.3 Display symbols..................................................................7
4COMPONENTS.............................................8
4.1 Washer components...........................................................8
4.2 Operation........................................................................... 15
5REPAIR.......................................................17
5.1 Disassembly / Reassembly..............................................17
5.2 Diagnosing (troubleshooting)..........................................24
5.3 Washer vibration...............................................................26
5.4 Motor control troubleshooting.........................................26
5.5 Customer diagnosing (from Operating Instructions).....27
5.6 Customer fault displays (from Operating Instructions).29
5.7 Customer maintenance ....................................................29
6FAULT DIAGNOSTICS...............................32
6.1 Test program / fault (error) codes................................... 32
7TECHNICAL SPECIFICATIONS.................35
7.1 Washer ratings.................................................................. 35
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1 SAFETY
cDanger of electric shock.
cWARNING Modern appliances are very powerful and use high
technology devices to safely control that power. Failure to use
the correct procedures and the approved parts can create
serious hazards for the person servicing the appliance and for
the user of an appliance with a bad repair. If you do not know
how to service the appliance, do not attempt to do so!
To avoid the risk of serious injury or death while servicing these
appliances:
cBe certain that all power is removed from the appliance before
beginning service.
cCarefully follow all servicing instructions. Verify the instructions
if there are any that you don't fully understand.
cRead and heed all Cautions and Warnings on the appliance
and those with the replacement parts.
cUse caution and proper protective gear when handling chassis
panels. Some of the edges that are not normally exposed may
be very sharp.
To avoid risk of serious injury or death to the users of the appliances:
cCarefully follow all service instructions.
cUse only parts authorized for the application.
cKnow the testing requirements needed to verify the safety of
the service action.
cUse proper, calibrated test equipment.
cDo all indicated safety tests and record results.
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2 INSTALLATION
2.1 Basic installation
Washers shall be installed according to national and local codes.
2.2 Feet (leveling legs)
Using a level front to back and side to side, adjust feet until washer is
level. Leveling washers is the most important factor in providing
minimal vibration during operation (see vibration checklist section 5.3).
Before moving washers, screw in feet completely to avoid damage.
2.3 Aquasecure inlet hoses
Aquasecure water inlet hoses prevent water from leaking. They
connect like standard hoses with no special installation needed. If an
inner hose ever should leak, the hose shuts off and it’s indicator
shows red. Hoses are one-time and must be replaced when
indicators are red.
For best results, Aquasecure water inlet hoses should be installed
vertically – and not above horizontal.
Cold water
inlet hose
connection
Power
cord
To adjust feet
(leveling legs),
rotate left to right
to lower washer.
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2.4 Water connections
To eliminate possibility of leaking, don’t over tighten fittings. Teflon
tape can also be used on all threads.
2.5 Transport (shipping bolts)
Four transport bolts secure the tub during shipment and must be
removed for operation.
Bolts include plastic inserts which must also be removed – don’t
unscrew bolts completely, only until bolts and plastic inserts can be
removed together. If bolts are unscrewed completely, inserts will drop
inside washer frames.
Keep transport bolts for future washer moving.
Once bolts have been removed, snap the supplied plastic plugs up
into the bolt holes in the rear of washers.
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2.6 Drain hoses
Drain hoses connect to the rear of washers and allow washers to be
drained into utility tubs or drain lines using the supplied “U” elbow.
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3 OPERATION
3.1 Controls
Controls are shown below. Rotate the program knob to the desired
wash cycle and push the Start/Pause button.
3.2 Child lock
Child lock prevents children from inadvertently changing wash cycle
settings. When Child lock has been activated, cycles can’t be
changed while they’re running and the door remains locked at the end
of cycles.
3.2.1 Selecting Child lock
Rotate the program knob to the desired wash cycle to turn on the
washer. Press the Menu button until “Child lock: off” is displayed – the
key (³) symbol flashes. Press the Select button until “Child lock: on”
is displayed.
Child lock can be selected only before starting wash cycles or when
wash cycles have been paused.
Kleenmaid MaxiWasher
Contains optional functions Pre-wash,
Rinse Plus and Reduced Ironing.Displays selected or about
to be changed settings.
Turns washer on and of
f
and selects wash cycles.
Menu button selects settings to be changed. Selec
t
button changes settings currently shown in display.
Start/Pause button starts or interrupts wash cycles. The
indicator light flashes red to show cycle can be started, cycle
has been paused, Child lock is on or door is locked. When the
indicator light stays lit (red), cycle is running. When light is off,
cycle is done, no cycle has been selected or door is open.
3.2.2 Starting wash cycles with Child lock
Rotate the program knob to the desired wash cycle, load laundry and
close the door -- the Start/Pause light flashes red. Press and hold the
Start/Pause button until the wash cycle starts (~ 5 seconds) – the
Start/Pause light stays red and Child lock is activated once the cycle
starts.
3.2.3 Pausing wash cycles
Even when Child lock.has been activated, wash cycles can be paused
to add / remove laundry or change wash cycles. Press and hold the
Start/Pause button until the Start/Pause light flashes red. Wash
cycles can now be changed. Pressing the Start/Pause button until the
Start/Pause light stays red resumes the interrupted cycle (if it wasn’t
changed) and reactivates Child lock.
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To interrupt a wash cycle (while keeping Child lock), rotate the
program knob to Off. Rotating the knob back to the selected wash
cycle resumes the cycle.
3.2.4 Unloading laundry
Once the wash cycle has ended, press and hold the Start/Pause
button for ~ 5 seconds. The door can be opened and laundry
removed. Child lock stays selected and will be activated when the
next wash cycle is run. When the next wash cycle is run, press and
hold the Start/Pause button (~ 5 seconds) to open the door to add
laundry.
3.2.5 Deactivating Child lock
Rotate the program knob to the desired wash cycle to turn on the
washer. Press the Menu button until “Child lock: on” is displayed – the
key (³) symbol flashes. Press the Select button until “Child lock: off”
is displayed.
Child lock can be selected only before starting wash cycles or when
wash cycles have been paused.
3.3 Display symbols
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4 COMPONENTS
4.1 Washer components
Basic components are control module, electric heater, drive motor /
control, drain pump, sump, NTC temperature sensor and door lock.
4.1.1 Electric heater / NTC
Heaters include an NTC (negative temperature coefficient) sensor and
are accessed from the back of the tub. Heaters are rated 230VAC,
1300W, 5.7A, 38.1 – 45.2Ωand can heat water up to 174ºF (79ºC),
depending on the cycle used.
The heater is removed from the rear of the tub – remove rear panel for
access.
NTC’s, mounted in heater assemblies, provide accurate temperature
measurements.
Control
module
Heate
r
Drain
p
um
p
Tub
Moto
r
Sum
p
NTC NTC
NTC ratings:
• 36 – 44 kΩ@ 10ºC (50ºF)
• 22.8 – 27.4 kΩ@ 20ºC (68ºF)
• 14.8 – 17.5 kΩ@ 30ºC (86ºF)
• 9.8 – 11.5 kΩ@ 40ºC (104ºF)
• 6.6 – 7.7 kΩ@ 50ºC (122ºF)
• 4.6 – 5.3 kΩ@ 60ºC (140ºF)
• 3.73 – 4.29 kΩ@ 66ºC (151ºF)
• 2.94 – 3.36 kΩ@ 73ºC (163ºF)
• 1.93 – 2.19 kΩ@ 86ºC (187ºF)
Heater
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4.1.2 Drive motor
The drum drive motor is attached to the bottom of the tub and moves
with the tub. The 3-phase, asynchronous, variable frequency motor
has a speed sensor and is controlled by a separate motor control
which provides variable speed control.
4.1.3 Drive motor control
Drive motors have a separate control, which starts and stops motors
and controls motor speed as directed by washer controls.
See section 5.4 on troubleshooting motor controls.
Drum drive motors and controls have changed a few
times – motors and motor controls can’t be mixed.
4.1.4 Pressure switch and pressure sensor
The water level system consists of a pressure switch and pressure
sensor, which reliably measure water levels.
The pressure switch (brown) has (3) switching positions:
•Water level < level 1 (1 – 1.6 gal. / 4 – 6 l)
CAUTION: The drum drive motor
& tub are grounded through the
motor control. Since the tub is
plastic and the motor is isolated
from the frame, It’s critical the
ground leads from the tub, drive
motor & motor control are
connected properly.
Pressure
sensor
Pressure
switch
•Water heating level (4 – 4.5 gal. / 15 – 17 l)
•Overflow level (15 gal. / 57 l)
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4.1.5 Free-stroke shock (damper)
Two 110 N free-stroke shocks (one / side) dampen washer vibrations,
especially during spinning. Free-stroke shocks have an improved
slide piston design preventing shock parts from hitting during high-
speed spinning, providing dampening with resistance at all times.
Most shocks returned for analysis (from washer vibration) haven’t
failed. A rule of thumb is if the shock has resistance when pulled, it
hasn’t failed. Most vibration has been due to sub floors inadequate for
modern high-speed appliances or washers not properly leveled (see
section 5.3).
If shocks being replaced are older style, both shocks must be
replaced (so matching free-stroke shocks are used).
As the washer fills, water not
absorbed by the laundry fills the
sump. As the water level rises into
the pressure chamber, it increases
the air pressure in the chamber, which
is sensed by the pressure switch and
pressure sensor. The washer control
reads the resulting signals and
accurately determines the water level.
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4.1.6 Door lock
The door lock reliably locks washer doors while washers are filling,
washing or spinning. Doors can be opened at certain times during
wash cycles only when washers are paused using the Start/Pause
button.
Door locks lock in ≤2 seconds and unlock in ≤4 seconds.
If necessary, door locks can be opened manually by pulling down the
white manual release rod located behind the access (maintenance)
cover.
4.1.7 Tub support and dampening system
The tub has a 5-point support and dampening system, allowing it to
move independently. The tub is supported by two springs.
Dampening is accomplished by two free-stroke shocks (dampers), a
rear spring and three counterweights.
To remove the access cover to use
the door lock manual release, insert
a pointed object (or tool) into the
hole, push in to release the latch
and rotate the cover clockwise.
Release
rod
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4.1.8 Fascia (control) panel
Fascia panel contains knob and all buttons – knob and buttons are
factory built into the panel and cannot be obtained separately.
4.1.9 Door glass cover
The plastic door glass cover can be replaced by carefully prying it out
and snapping it into place.
4.1.10 Aquasecure inlet hoses
Hot and cold water Aquasecure inlet hoses eliminate leaking. The
Aquasecure hose consists of an inner hose (~ inlet water tubing) and
an outer hose (corrugated, ~ to drain hoses). If the inner hose leaks,
a small indicator window will show red, meaning the hose must be
replaced (hoses cannot be reused once a leak occurs).
Aquasecure hoses can be used with any washer (or misting dryer)
with standard G3/4 DIN ISO 228-1 threads. They protect homes and
provide peace of mind for people on vacation and those asleep, busy
or who don’t shut off water valves when washers (and misting dryers)
aren’t in use.
Indicator
window
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4.1.11 Drain non-return assembly and sump
Both the drain non-return assembly and sump were designed to
remove suds caused by excessive detergent usage.
Oversudsing occurs from excessive detergent usage or using the
wrong type of detergent. When encountering oversudsing, advise
customers to use less detergent and use a detergent for front loading
washers (with “HE” on the package).
4.1.11.1 Drain non-return assembly
The drain non-return assembly prevents waste water from entering
washers. It doesn’t use a reservoir and provides excellent suds
removal.
4.1.11.2 Sump
The sump removes suds well since it has a large opening and doesn’t
have a sump ball.
4.1.12 Drain pump
The drain pump reliably pumps waste water from the sump through
the non-return assy and the drain hose to the customer drain system.
It mounts to the washer base by four rubber feet to help eliminate
vibration and is thermally protected.
The drain pump pumps 18 liters/minute @ 2.5m (8’) head and 30
liters/minute @ 1.25m (4’) head. Pumping height 8’ (2.4 m) max.
4.1.13 Drum bearings
Washer drums use two rear bearings factory assembled into rear tubs,
so bearings aren’t available separately. When replacing rear
bearings, rear tubs or complete tub assemblies must be replaced.
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4.1.14 Laundry deflector
The laundry deflector prevents small items such as socks and wash
rags from collecting in door seals. When small clothes items get
jammed in door seals, they can apply pressure to bottoms of doors.
4.1.15 Agitator paddles
Paddles direct water toward front of washer – water drains into
paddles from outside of inner drum, flows toward front of paddles and
exits holes in front of paddles onto clothing in front of washer.
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4.2 Operation
4.2.1 Sensors
4.2.1.1 Water / load sensor
Using the pressure switch and pressure sensor, washers determine at
predetermined points during the 1st fill if they need more water. Once
the laundry has absorbed all the water it can, the water level rises,
causing the pressure (in the pressure chamber) to increase to the
level the pressure switch and sensor don’t provide more water.
This water saving feature is needed due to different laundry water
absorption levels and load sizes.
4.2.1.2 Digital temperature sensor
Along with the washer control, the NTC monitors the water
temperature and controls how long the heating element is on, insuring
proper temperatures.
4.2.1.3 Suds sensor
Using the pressure switch and motor speed, washers determine
during the start of the 1st rinse if there are excessive suds and add 2
rinses (if necessary).
With oversudsing (or suds lock) where washers can’t remove the
excessive sudsing, washers won’t spin and laundry will be wet.
4.2.1.4 Unbalanced load sensor
During final spin, washers monitor motor speed changes to determine
if loads are unbalanced. If so, washers stop, adjust loads and reduce
spin speeds up to 15 times to allow wash cycles to finish.
With excessively unbalanced loads that can’t be balanced, washers
will stop during spin cycles and laundry will be wet.
Load
distribution Unbalance Spin speed (rpm) # of balancing attempts Spinning profile
Good Small 1200 (max.) 4 I
Uneven Medium 1000 (reduced) 7 II
Bad Large 800 (low) 14 III
None Dangerous 0 (no spinning) 15 IV
Spin speed
(rpm)
…max. 15 trials…
I
II
III
IV
1200
1000
800
600
400
200
0
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4.2.2 Aqua secure hose operation
The Aquasecure hose consists of a sealed inner and outer hose and a
leak detection / shut-off assembly. A spring holds a plunger open
allowing the inner hose to carry water. If an inner hose ever should
leak, water fills the outer hose where a sponge in the hose end
(connected to the water line) absorbs water, pulling a plunger down to
stop water flow and show red in the indicator window. The outer hose
is sealed and won’t leak.
Any remaining water pressure won’t re-open the hose, but will help
keep the hose closed.
The hose has a one-time failure duty. If an inner hose should ever
leak where the indicator shows red,the hose must be replaced.
Aquasecure hoses stop hose leaks, whether appliances are on or not.
They’re superior to braided hoses, whether nylon or ss, and can be
used with any washer (or misting dryer) with standard G3/4 DIN ISO
228-1 threads.
Plunger
Sponge
Indicator
window
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5 REPAIR There are smaller latches, joining the control module housing and
holding the (slotted) wire guide to the housing, which don’t need to be
released to remove the control module.
Don’t remove the knob to remove the control module. The module lifts
off completely from the panel, knob & buttons.
5.1 Disassembly / Reassembly
5.1.1 Fascia (control) panel
Carefully pry off four screw covers, remove four T-20 Torx screws and
lift up panel. For reassembly, note panels have two square slots (near
the dispenser door) that mesh with top panel tabs.
5.1.2 Control module
Remove control module from fascia panel progressively from left to
right, carefully releasing (3) inside and (7) outside plastic latches (so
latches don’t break). Gently pry up left side of control so latches don’t
re-close. Module will release from fascia panel and knob.
Don’t force modules out from fascia panels to avoid breaking plastic
parts. If modules don’t come out
followed an
Don’t cut cable mounts – cut cable ti
When reassembling, use new cab
easily, the procedure hasn’t been
d plastic parts will break.
es holding cables to mounts.
le ties.
8
Locate
module tabs
1
2
3
4
6
5
10
9
7
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Some control modules have been wrongly replaced since fault codes
stored in module or motor control can’t be cleared. Modules are
operating properly and shouldn’t
5.1.4 Rear panel
Remove top panel (5.1.3). Remove (18) T-20 screws, then pull out
panel until top tabs clear. Don’t remove the top rear panel (with “
be replaced to clear fault codes.
5.1.3 Top panel (worktop)
H” &
“C” stampi
Rear panel access is best for most repairs
Remove two T-20 Torx screws (with washers) from top rear corners of
washer, slide panel toward rear of washer (~ ½ cm) and lift up panel.
When reassembling, place panel over two plastic mounting tabs, slide
panel forward and replace two screws.
ngs).
mCAUTION – 75% of all controls returned
for analysis check out OK. Most control
issues are due to loose connections.
.
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5.1.5 Front panel
Remove hinge cover and hinge.
Remove door seal front clamp, door lock screws and front shield.
Remove top and bottom front panel screws, then lift front panel up
until it clears six plastic mounting tabs.
5.1.6 Tub, drum & dampers (shocks)
1) Remove fascia panel with dispenser tray (5.1.1), top panel
(5.1.3), rear panel (5.1.4) and front panel (5.1.5).
2) Disconnect wire harnesses (as needed) – wire ties can be cut off,
but clips shouldn’t be cut.
3) Remove door seal, top counterweight and both front
counterweights.
4) Disconnect dampers (shocks) from tub and slip belt off pulley.
5) Remove tub / drum through rear of washer.
6) Remove (18) T-25 Torx screws holding front & rear tubs
together.
7) Lift front tub off rear tub, then lift drum from tub.
Rear drum bearings are factory pressed into rear outer tubs and
cannot be removed or serviced separately. To replace rear bearings,
replace rear tub or complete tub assembly.
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5.1.7 Drum drive motor
Remove rear panel (5.1.4), rear
drum pulley as you pull the belt off
5.1.8 Heater and NTC
tub spring and drum belt – rotate
the pulley. Disconnect motor wire
harnesses. Remove two motor bolts, then pull motor out toward rear
of washer.
The drum drive motor & tub are grounded through the motor control.
Since the tub is plastic and the motor is isolated from the frame, It’s
critical the ground leads from the tub, drive motor & motor control are
connected properly.
The heater and NTC are located above the drum drive motor and are
rem ved similarly. Remove rear panel (5.1.4) and disconnect heatero
and NTC wire harnesses. Loosen nut and pull heater with NTC out
from tub. Don’t totally unscrew the nut – the nut tightens a rubber
(compression) gasket against the tub to hold the heater in place.
Heater is removed from the back of the
tub – remove rear panel for access.
NTC connector is latched –
carefully pry latch with small
blade screwdriver to remove it.
10mm bolts
Rear tub
spring
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