Kuppersbusch 450 Series User manual

Service Manual - Series 450/451
IG 448... IGV 449...
IG 458... IGV 459...
IG 459... IG 4408.0
IG 4406.0 IGV 4408.0
IG 4408.1

Service Manual: H7-71-04
Responsible: Dieter Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Email: dieter[email protected]
Phone: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 21.11.2008 45801 Gelsenkirchen

Service Manual 3
For internal use only
Contents
1. Safety...............................................................................................................................5
2. General technical specification - 45cm appliances ....................................................6
3. Assembly.........................................................................................................................7
3.1 Installing................................................................................................................7
3.2 Electric connection ................................................................................................7
3.3 Water connection ..................................................................................................7
4. Functional description of the single groups................................................................ 8
4.1 IGV 4... operation ..................................................................................................8
4.2 IG 4... operation...................................................................................................10
4.3 Initial operation / electronics exchange ...............................................................15
4.4 IG 458.1E operation ............................................................................................17
4.5 Construction components....................................................................................18
4.6 IG 4406.0E operation ..........................................................................................21
4.7 Construction components....................................................................................22
4.8 IGV 4408.0 operation ..........................................................................................25
4.9 Construction components....................................................................................26
5. Explanation of the rinsing instructions......................................................................29
5.1 Coding instructions for an electronics system with G controls IG 4... .................29
5.2 Customer service test program: G controls (with heat exchanger) .....................30
5.3 H controls operation ............................................................................................37
5.4 Coding instructions for an electronics system with H controls ............................41
5.5 Customer service test program: H controls (without heat exchanger) ................42
5.6 Trouble shooting..................................................................................................47
5.7 W controls operation ...........................................................................................48
5.8 Initial operation / electronics exchange ...............................................................51
5.9 Coding instructions for an electronics system with W controls
(IGV 449.2)..........................................................................................................53
5.10 Customer service test program: W controls (IGV 449.2).....................................54
6. Construction components...........................................................................................58
6.1 Actuator...............................................................................................................58
6.2 Aqua sensor........................................................................................................59
6.3 Flow sensor.........................................................................................................59
6.4 Axial flow sensor .................................................................................................60
6.5 Info light (optional) ..............................................................................................60
6.6 Aqua Stop System...............................................................................................61
6.7 Temperature safety system (NTC)......................................................................62
6.8 Salt and clear rinse agent display .......................................................................62
6.9 Hinge...................................................................................................................63
6.10 Dispensing device...............................................................................................64
6.11 Visual clear rinse fill-up sensor............................................................................65
6.12 Water softener.....................................................................................................65
6.13 Sieve system.......................................................................................................66
6.14 Rinse water pump ...............................................................................................67
6.15 Rinsing and pump system...................................................................................68
6.16 Door seal.............................................................................................................68
6.17 Door spring..........................................................................................................69
6.18 Circulation pump (SICASYM)..............................................................................70
6.19 Combined detergents (3 in 1), according to the model ......................................72
6.20 Water points ........................................................................................................73

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6.21 Continuous flow heater........................................................................................74
6.22 Equipotential system with a safety function.........................................................75
6.23 Rotary spray system............................................................................................76
7. Fill system .....................................................................................................................77
7.1 Intake of water with heat exchanger....................................................................77
7.2 Regeneration with heat exchanger......................................................................78
8. Remedying faults for all of the series 45 cm..............................................................81
8.1 Controller / module ..............................................................................................81
8.2 Discharge ............................................................................................................82
8.3 Smell....................................................................................................................83
8.4 Noises..................................................................................................................84
8.5 Food or sandy deposits .......................................................................................85
8.6 Lime deposits ......................................................................................................87
8.7 Starch deposits....................................................................................................87
8.8 Water-soluble or regeneration salt residue on the dishes ...................................88
8.9 Discolouration / residual colour ...........................................................................89
8.10 Residual detergent ..............................................................................................90
8.11 Damage to rinsed dishes.....................................................................................91
8.12 Drying results.......................................................................................................92
8.13 Circulating pump..................................................................................................92
9. Technical data IG 4... and IGV 4... ...............................................................................93
9.1 General technical data.........................................................................................93
9.2 Consumption data IG 459 to .4...........................................................................94
9.3 Consumption data IGV 449. ... and IGV 445. ....................................................95
9.4 Consumption data IGV 459.5 .............................................................................95
9.5 Consumption data IG 448... (G controls)............................................................96
9.6 Consumption data IG 448... (H controls)............................................................97

Service Manual 5
For internal use only
1. Safety
Danger!
Repairs may only be carried out by a qualified electrician!
Improper repairs can be extremely dangerous for the user.
It is essential that you observe the following instructions in order to prevent electric shocks:
• The casing and the frame may be live in the event of faults!
• Touching live components inside the appliance may cause dangerous currents to flow through your
body!
• Disconnect the appliance from the mains prior to carrying out any repair work!
• When inspecting live parts, a residual current circuit breaker must always be used!
• The earthed conductor resistance must not exceed the resistance specified in the standard! It is vital
for ensuring the safety of persons and the functioning of the appliance.
• On completion of repairs, an inspection must be carried out in accordance with VDE 0701
[Association of German Electrical Engineers] or in accordance with the corresponding regulations for
your country!
• On completion of repairs, a function and impermeability inspection must be carried out.
Attention!
It is essential that you observe the following instructions:
• Due to the all-pole disconnection (relay, press switch), when carrying out measurements via the
connector plug in accordance with VDE 0701, a direct measurement must be used to check the
heating (flow heater) for insulation faults or the appliance's differential current must be measured!
• When replacing the dispenser and the pump cavity, beware of sharp edges around the stainless steel
components.
• The appliances must be disconnected from the mains prior to all repairs. If inspections must be
carried out on live appliances, make sure you use a residual current circuit breaker.
Sharp edges: use protective gloves.
Components may be electrostatic!
Observe handling regulations!

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2. General technical specification - 45cm appliances
This service manual serves the purpose of providing customer service technicians who already havethe
know-how required to repair dishwashers with specific information on the operating mode of 45-cm dish-
washers.
This manual deals with all of the appliance specifications relevant to this model.
Descriptions and operating modes of components that are not new have therefore not been included in
this edition.

Service Manual 7
For internal use only
3. Assembly
3.1 Installing
In order to ensure that the lock functions perfectly and to prevent any leakages in the area of the door,
the appliance must be perfectly aligned by means of the adjustable feet. In the case of integrated appli-
ances, it is possible to adjust the middle adjustable foot at the back from the front.
Note: built-under and integrable appliances
Screw the appliance in an upward direction by means of the adjustable feet until the outer casing is at
the same level as the working top.
For integrated and fully-integrated appliances the mounting instructions (drilling stencil) are required for
fastening the front of kitchen units.
The power pull of the door springs of integrated and fully-integrated appliances can be adjusted to suit
the weight of the kitchen unit doors (see item on door springs).
3.2 Electric connection
Connect the appliance to a wall socket with earthing in accordance with regulations only. Please observe
details on the identification plate
3.3 Water connection
If the appliance is installed onto the drain with the standard length of hose, the max. permissible height
above the floor is 90 cm. If the discharge hose is extended, a max. height of 80cm is not to be exceeded.
For the water supply (3/4"), a standard water pipe with water pressure of at least 0.5 bar (0.5 atmosphere
above atmospheric pressure) is required (when the water tap is open more than 8 l/min must flow out).
If the water pressure exceeds 10 bar (10 atmosphere above atmospheric pressure) a pressure reducing
valve will have to be used. The appliances can be connected to a warm water supply of up to 60°C. It is
however recommendable to connect the appliance to a cold water supply (better drying and cleaning
results).
Connection dimensions for all dishwashers 45 cm
a = 1.4 m b = 1.7 m
c = 1.3 m (3.5 m with extension set) d = 1.4 m (3.6 m with extension set)
e = 1.5 m (3.5 m with extension set) f = 1.4 m (3.4 m with extension set)

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4. Functional description of the single groups
4.1 IGV 4... operation
4.1.1 Function
LEDs
• Program selection
• Clear rinse fill-up display
• Salt refill indicator
• End of program
Buttons / program selection
Intensive 70°
The program comprises a pre-rinse at 50°, a washing cycle at 70°, three intermediate rinses, a clear
rinse at 70° and a drying cycle.
Normal 65
The program comprises a pre-rinse cycle, a washing cycle at 65°, two intermediate rinses, a clear rinse
at 69° and a drying cycle.
ECO 50
The program comprises cleaning at 50°, an intermediate rinse, rinsing with a rinsing agent at 65°, and
drying.
Rapid 35
The program comprises cleaning at 35°, an intermediate rinse, rinsing with a rinsing agent at 55°, and
no drying.
Pre-wash
The program only comprises a cold rinse for the dishes.
4.1.2 Program reset
With the appliance switched on, press the S2 button and the S4 button simultaneously for 3 sec. The
water will be pumped off for approx. one minute. The cleaning agent compartment should then be
closed, so that the dispensing device is also reset.

Service Manual 9
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4.1.3 Special functions
Setting the hardness range
Keep the S3 button pressed and switch on the appliance. The LED for fill-up salt will blink. The fault is
indicated by means of the program LEDs (see chart). The setting rises once every time the S3 button is
pressed. If the appliance is switched off, the setting is stored.
Series setting = 2
4.1.4 General instructions on the controls
Tap closed
The appliance stops operating six minutes into the program procedure (filling position interrogation). In
the control, the selected program LED lights up constantly. The controls remain in this position until the
filling level has been reached.
Regeneration electronics system
On comparing the degree of water hardness set in the appliance, the electronics system determines
what quantity of water is possible before the water softener is exhausted. The quantity of water used is
calculated. Regeneration is carried out after the maximum number of rinses possible has been reached.
The discharge behaviour of the regeneration electronics system can be seen in the description under
initial operation / replacing the electronics unit.
Warm water recognition
If the water running in for the rinse with a rinsing agent has a temperature exceeding 45°C, the heat ex-
changer is not filled for the drying stage. In order to guarantee the difference in temperature essential for
condensation, the temperature for the rinse with a rinsing agent is raised to 72°C, thus increasing the
dishes own heat.
Memory electronics system
The electronics system has a memory store which registers the last program selected. Should no other
program be selected on program start-up, the program selected last will operate.
Power cut
The electronics system has a mains cut-off memory which ensures that a rinsing program that has been
commenced when a power failure occurs will be continued.
Sensors
All of the signals leaving the door switch, the level switch, the NTC sensor and the refill switches are
recorded and evaluated by the microprocessor at the respective point in time.
Consumers
Consumers such as valves, detergent and clear rinse dispensers (actuators) are activated by means of
triacs. The circulation and thevacuation pump and the continuous flow heater are activated with relays.
°dH °fH °Clarke mmol / l LEDs
L2 L3 L4
0 0 - 6 0 - 11 0 - 8 0 - 1.1 O O O
1 7 - 16 12 - 29 9 - 20 1.2-2.9 O O
217 - 21 30 - 37 21 - 26 3.0 - 3.7 O
3 22 - 35 38 - 60 27 - 44 3.8 - 6.2

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4.2 IG 4... operation
4.2.1 Function
LEDs
• Program selection
• Clear rinse fill-up display
• Salt refill indicator
• 2½ digit display
4.2.2 Pushbuttons
Pre-set time (ZVW)
The time-setting button enables the starting time to be postponed by up to 19 hours (setting between 0h
and 19h). The button must be pressed for at least one second.
Saving time
The rinsing program operation time can be shortened with the „time saver“ function. The consumption
of water and energy is raised so that the best results can be achieved while at the same time reducing
the operation time.
Display
The display comprises a 2½ digit 7-segment display, which also enables program times of more than
99 minutes to be shown. The remaining duration is recalculated at the end of the heating positions.
Should deviations result due to aqua sensor decisions, the water intake temperature, the quantity of
dishes, etc., the remaining time displayed for these phases will be adjusted. Time differences of up to
60 minutes may hence result at the end of the washing and clear-rinse cycles.

Service Manual 11
For internal use only
4.2.3 Program dial
Intensive 70°
The program comprises a pre-rinse at 50°, a washing cycle at 70°, two intermediate rinses, a clear rinse
at 70° and a drying cycle.
Please ensure that rinsing is only carried out in the bottom basket until the required temperature
has been reached.
Auto 55° - 65° (depending on the model)
In the automatic program the aqua sensor not only decides on a change of water after the pre-rinse
cycle; it also determines the washing temperature and the number of intermediate rinses.
Aquasensor readings are classified into turbidity levels. Readings in the wash cycle decide on the wash-
ing temperature (from 45°C to 65°C) and the time after washing (from 5 to 30 minutes). Readings taken
at the end of the wash cycle decide on the type of intermediate rinse and on how many intermediate
rinses are to be carried out.
Normal 65°
The program comprises a pre-rinse cycle, a washing cycle at 65°, two intermediate rinses, a clear rinse
at 66° and a drying cycle.
ECO 50°
The program comprises cleaning at 50°, an intermediate rinse, rinsing with a rinsing agent at 65°, and
drying. The aqua sensor is not activated in this program. Please ensure that rinsing is only carried out
in the bottom basket until the required temperature has been reached.
Gentle 40°
The program comprises a pre-rinse cycle, a washing cycle at 40°, an intermediate rinse, a clear rinse at
55° and a drying cycle.
Rapid 35°/45°
The program comprises a washing cycle at 35°/45°, one intermediate rinse, a clear rinse at 55° without
a drying cycle. The aqua sensor is not activated in this program.
Pre-wash
The program only comprises a cold rinse for the dishes. The aqua sensor is not activated in this pro-
gram.
4.2.4 Display
The display comprises a 2½ digit 7-segment display, which also enables program times of more than
99 minutes to be shown. The remaining duration is recalculated at the end of the heating positions.
Should deviations result due to aqua sensor decisions, the water intake temperature, the quantity of
dishes, etc., the remaining time displayed for these phases will be adjusted. Time differences of up to
20 minutes may hence result at the end of the washing and clear-rinse cycles.

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4.2.5 Program reset
With the appliance switched on, press the S2 button and the S4 button simultaneously for 3 sec. The
water will be pumped off for approx. one minute. The cleaning agent compartment should then be
closed, so that the dispensing device is also reset.
4.2.6 Special functions
Setting the hardness range
Keep the S3 button pressed and switch on the appliance. The setting will be shown in the display. The
setting rises once every time the S3 button is pressed. Once the setting has reached 7, the indicator re-
turns to 0. When the appliance is switched off, the setting is stored.
Series setting = 4
Setting Intensive drying
Keep the S2 button pressed and switch on the appliance. 0 will appear on the number indicator. By
pressing the S2 button once again, 1 will appear on the display, meaning that the intensive drying pro-
gram is switched on. If the appliance is switched off, the setting is stored. Activating intensive drying rais-
es the temperature by 3K in the rinse program with a rinsing agent.
4.2.7 General instructions on the controls
Tap closed
The appliance stops operating six minutes into the program procedure (filling position interrogation). The
remaining operating period is indicated as before in the display. The controls remain in this position until
the filling level has been reached.
Regeneration electronics system
On comparing the degree of water hardness set in the appliance, the electronics system determines the
number of rinses which are possible until the softeningdevice hasbeenexhausted. The quantityof water
used is calculated. Regeneration is carried out after the maximum number of rinses possible has been
reached.
The discharge behaviour of the regeneration electronics system can be seen in the description under
“Initial operation / electronics exchange”.
°dH °fH °Clarke mmol / l Salt quantity
in g per rinse Setting
0-6 0-11 0-8 0-1.1 --- 0
7-8 12-15 9-10 1.2-1.4 4 1
9-10 16-17 11-12 1.5-1.8 7 2
11-12 18-21 13-15 1.9-2.1 9 3
13-16 22-29 16-20 2.2-2.9 14 4
17-21 30-37 21-26 3.0-3.7 18 5
22-30 38-54 27-38 3.8-5.4 27 6
31-50 55-89 39-62 5.5-8.9 54 7

Service Manual 13
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Warm water recognition
If the water running in for the rinse with a rinsing agent has a temperature exceeding 45°C, the heat ex-
changer is not filled for the drying stage. In order to guarantee the difference in temperature essential for
condensation, the temperature for the rinse with a rinsing agent is raised to 72°C, thus increasing the
dishes own heat.
Memory electronics system
The electronics system has a memory store which registers the last program selected. Should no other
program be selected on program start-up, the program selected last will operate.
Power cut
The electronics system has a mains cut-off store which ensures that a rinsing program that has been
commenced when a power failure occurs will be continued.
Sensors
All of the signals leaving the door switch, the level switch, the NTC sensor and the refill switches are
recorded and evaluated by the microprocessor at the respective point in time.
Consumers
Consumers such as valves, detergent and clear rinse
dispensers (actuators) are activated by means of tri-
acs (see photo). The circulation and the vacuation
pump and the continuous flow heater are activated
with relays.
A* = Filling valve
A* = Dispenser
A* = Water diverter
B = Filling level
C = Drain valve heat exchanger
D = Regeneration valve
E = Filling level
* = Triple triac

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List of triacs
R5 = Filling level
R6 = Filling level
TY6 = Drain valve heat exchanger
TY7 = Dispenser actuator
TY8 = Regeneration valve
TY9 = Filling valve
TY11 = Actuator top basket valve / Water diverter
When a module is replaced due to a defective triac it
is essential to check the component selected too.
Face
Rear

Service Manual 15
For internal use only
4.3 Initial operation / electronics exchange
In the case of initial operation or electronics exchange, the following program procedure is to be ob-
served. (Program counter = 0!)
Procedure for initial start-up - appliances with a heat exchanger
Program counter (PC)
Pump 15 sec.
PC > 0
Salt refill indicator
Lack of salt = Off
Pre-fill heat exchanger
to F1
Pump + drain
70 sec.
Regeneration
60 sec.
Cycle counter
raise by 1
Counter
check
PC => 3
Lack of salt = On
PC < 3
Start of the rinsing program

16 Service Manual
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Procedure for initial start-up - appliances without a heat exchanger
Program counter (PC)
Pump 15 sec.
PC > 0
PC = 0
Salt refill indicator
Lack of salt = Off
Filling valve on,
10 sec.
Regeneration
60 sec.
Cycle counter
raise by 1
Counter
check
PC => 3
Lack of salt = On
PC < 3
Start of the rinsing program

Service Manual 17
For internal use only
4.4 IG 458.1E operation
4.4.1 LEDs
• Tap closed
• Salt refill indicator
• Clear rinse fill-up display
• Additional functions
• 2½ digit display
4.4.2 Main switch
The main switch is located on the left-hand side, separate from the electronic unit.
4.4.3 Pushbuttons / additional functions
Pre-set time (PST)
The time-setting button enables the starting time to be postponed by up to 24 hours.
Soaking (optional)
The button for soaking can be pressed as a supplement to any program. When the button is pressed,
an additional pre-rinse program with heating up to 55° will take place in the lower basket, resulting in an
extension of the program time of approx. 20 min. This function is recommended for washing various
types of dishes (top basket: sensitive dishes / bottom basket extremely dirty robust dishes).
Vario speed (optional)
The Vario speed function reduces the program running time with a higher water and energy consump-
tion. This is achieved by using more water in the rinse cycle and with water points with two-basket func-
tion.
Half load (optional)
The “Half Load” function reduces water consumption and the running time. Basically this is achieved by
passing over the prerinse and the second intermediate rinse cycle.

18 Service Manual
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4.4.4 Deactivating the clear rinse refill display
Press the S1 button and keep it pressed. Switch on the appliance. Thedisplaywill indicate 1. By pressing
the S1 button once again, 0 will appear on the display, meaning that the clear rinse fill-up display is de-
activated.
0 = off
1 = on
If the appliance is switched off, the setting is stored. Deactivating the refill clear rinse display will raise
the temperature for the clear rinse by 3K in order toachieve better drying results (see too 3 in 1detergent
recognition).
4.4.5 Reset
Resetting is done with an additional position of the rotary switch for these dishwashers. This means that
a reset commences 3 seconds after the switch is moved into this position.
Water is drained off for one minute and the electronic system will then be ready for a new program.
4.5 Construction components
4.5.1 Module

Service Manual 19
For internal use only
Mounting the module
If the module is not installed in the proper position, the light conductors in the panel
may be severed.
The brand determines the position of the module in the support plate. There are two positions:
At the bottom of the support plate
The module is fastened at the points shown.
At the top of the support plate
The module is fastened at the points shown.
4.5.2 Water intake
The dishwasher detects that the tap has been closed when the flow sensor receives no signal for
30seconds.
4.5.3 Consumers
Consumers such as valves, detergent and clear rinse dispensers and the circulation pump are activated
by means of triacs (see the list of triacs). The evacuation pump and the continuous flow heater are acti-
vated with relays.

20 Service Manual
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4.5.4 List of triacs
When a module is replaced due to a defective triac it
is essential to check the component selected too.
A = Dispenser actuator
B = Water diverter
C = Filling level
D = Regeneration valve
E = Drain valve heat exchanger
Start up the customer service program before replacing any modules.
Components may be electrostatic!
Instructions on electrostatic hazards are to be observed before a module is replaced.