Kuppersbusch 634 Series User manual

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Service Manual: H7-410-02-03
Responsible: D. Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Email: [e-mail]
Tel.: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 22.07.2003 45801 Gelsenkirchen

Service Manual Series 634 3
For internal use only
Contents
1. General technical specification..................................................................................... 5
2. Safety............................................................................................................................... 5
3. Description of operation ................................................................................................ 6
3.1 General.................................................................................................................. 6
3.2 Control panel design ............................................................................................. 6
3.3 Programs............................................................................................................... 7
3.4 Special functions ................................................................................................... 7
4. Installation and connection ........................................................................................... 9
4.1 Installing ................................................................................................................ 9
4.2 Water connection .................................................................................................. 9
4.3 Electric connection ................................................................................................ 9
5. Functions ...................................................................................................................... 10
5.1 Aqua stop system................................................................................................ 10
5.2 Safety function..................................................................................................... 10
5.3 Filling procedures ................................................................................................ 14
6. Technical Data .............................................................................................................. 25
6.1 Consumption ..................................................................................................... I25
6.2 General technical data ........................................................................................ 25
6.3 Component parts: technical data......................................................................... 25
7. Instructions for repair .................................................................................................. 26
7.1 Check list – Pumping off (draining) ..................................................................... 26
7.2 Check list - Noises............................................................................................... 27
7.3 Check list - Odour................................................................................................ 27
7.4 Check list - Control / Modulel .............................................................................. 28
7.5 Calcareous deposits............................................................................................ 28
7.6 Starch deposits.................................................................................................... 28
7.7 Check list –Results after washing ....................................................................... 29
7.8 Water-soluble deposits or deposits of regenerating salt on the dishes .............. 30
7.9 Discolouration / colour deposits .......................................................................... 30
7.10 Residual cleaning agent ...................................................................................... 31
7.11 Damage to the dishes ......................................................................................... 32
7.12 Results after drying ............................................................................................. 33
8. Dismantling the component parts .............................................................................. 34
8.1 Circulation pump ................................................................................................. 34
8.2 Rinse-water pump ............................................................................................... 34
8.3 Working top ......................................................................................................... 34
9. Controls, customer service test routine and circuit diagrams................................. 35
9.1 Coding instructions for an electronics system with H controls (IG 634.2) ........... 37
9.2 Customer service test program: control H (without heat exchanger) .................. 38
9.3 Circuit diagrams IG 634.2.................................................................................... 39
9.4 Coding instructions for an electronics system with G controls (IG 644.2) ........... 41
9.5 Customer service test program: control G (with heat exchanger) ....................... 42
9.6 Circuit diagrams IG 644.2.................................................................................... 43
9.7 Coding instructions for an electronics system with E controls

4 Service Manual Series 634
For internal use only
1. General technical specification
The purpose of this service manual is to provide service technicians who already have the know-how
required to carry out repairs on dishwashers with specific information on the operational mode of the 634/
635 series.
This manual deals with all of the appliance specifications relevant to this series.
Descriptions and operational modes of the component parts that are not new have therefore not been
included in this edition.
Please refer to manual H7-410-02-02 Dishwasher series 630.
2. Safety
ATTENTION!
In the case of a fault, the outer casing and the frame are live!
In order to avoid electric shocks, please observe the following instructions:
• Always disconnect the appliance before commencing with any repair work!
• Should tests under electrical tension be necessary, always use an earth-leakage circuit breaker!
• Always ensure that the protective conducter connection is carried out correctly, since it is vital for
human safety and for the functioning of the appliance.
• On completion of repair work, please carry out a test in accordance with VDE 0701, as well as an
operational test and a leakage test.
• Dangerous voltages inside the appliance!
• Do not touch any component parts in the appliance. The modules too are connected to the mains
voltage. Risk of damage to the appliance or to components!
Please pay close attention to the following points:
• On testing in accordance with VDE 0701 via the wall plug, the heater (continuous flow heater) is
not included.
• Please observe EGB instructions!
•Never attempt to carry out repair work by means of ”a random exchange” of components!
•Always proceed systematically and observe the instructions on fault-finding!

Service Manual Series 634 5
For internal use only
3. Description of operation
3.1 General
The appliances are equipped with an alternating rinse system and a glass protection system. The
alternating rinse system is explained under the sub-title water diverter. The glass protection system
comprises the prewashing program, the natural water valve and the heat exchanger.
3.2 Control panel design
Buttons and indicators are labelled from left to right
Main switch
Double-polar On/Off switch with a mechanical link to the door lock.
Time setting
The time-setting button enables the starting time to be postponed by up to 24 hours.
Remaining time indicator
While the program is operating, the indicator shows in minutes how much time is still likely to be required.
Should the required time exceed 99 min., 2H is indicated on the display. If the time-setting has been set,
the number will appear on the display with a small “h“. The programm duration will automatically be
adjusted in accordance with the type of dishes being washed, the quantity of dishes, the water
temperature and the water pressure. On completion of the programm, the display will indicate “0“.
Soaking
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°C will take place in the lower basket, resulting in
an extension of the program time of approx. 20 min. Recommended for washing various types of dishes
(top basket: sensitive dishes / bottom basket extremely dirty robust dishes).
Time reduction
The time reduction button can be pressed as a supplement to any program. When the button is pressed,
the circulating time and the drying time, and therefore the washing and drying performance, are reduced
(see circuit diagrams and consumption data).

6 Service Manual Series 634
For internal use only
3.3 Programs
Intensive 70°
This program comprises a pre-rinse at 50°, cleaning at 70°, two intermediate rinses, rinsing with a rinsing
agent at 70°, and drying. Please ensure that rinsing is only carried out in the bottom basket until the
required temperature has been reached.
Normal 65°
This program comprises cleaning at 65°, two intermediate rinses, rinsing with a rinsing agent at 69°, 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. Consumption data.
Eco 50°
This program comprises cleaning at 50°, an intermediate rinse, rinsing with a rinsing agent at 66°, 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. Consumption data
Gentle 40°
This program comprises cleaning at 40°, an intermediate rinse, rinsing with a rinsing agent at 55°, and
drying.
Fast
This program comprises cleaning at 35°, an intermediate rinse, rinsing with a rinsing agent at 55°, and
no drying. The aqua sensor is not activated in this program.
Pre-rinse
This program comprises a pre-rinse only. The aqua sensor is not activated in this program.
3.4 Special functions
3.4.1 Adjustment of the water softener
Keep the Eco button pressed and switch on the appliance. The setting will be indicated in the number
indicator. The setting rises once every time the eco button is pressed. Once the setting has reached 7,
the indicator returns to 0.
When the appliance is switched off, the setting is stored.
Recommendation:
At each initial visit the setting of the water hardness level should be checked and, if necessary, adjusted.
Do not apply the maxim "the lower the water hardness setting, the better"

Service Manual Series 634 7
For internal use only
.
3.4.2 Setting intensive drying
Keep the "Normal 65°" button pressed and switch on the appliance. 0 will appear on the number
indicator. By pressing the normal button once again, 1 will appear on the display, meaning that the
intensive drying program is switched on. If the appliance is switched off, the setting is stored. Activating
intensive drying raises the temperature by 3 K in the rinse program with a rinsing agent.
3.4.3 Program interruption (reset)
With the appliance switched on, press the Normal 65° button and the next button but one for 3 sec. A 0
appears on the display and 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.
°dH °fH °Clarke mmol / l Setting
0-3 0-6 0-4 0-0.6 0
4-6 7-11 5-8 0.7-1.1 1
7-9 12-16 9-11 1.2-1.6 2
10-12 17-21 12-15 1.7-2.1 3
13-16 22-29 16-20 2.2-2.9 4
17-21 30-37 21-26 3.0-3.7 5
22-30 38-54 27-38 3.8-5.4 6
31-50 55-89 39-62 5.5-8.9 7

8 Service Manual Series 634
For internal use only
4. Installation and connection
4.1 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
appliances, it is possible to adjust the middle adjustable foot at the back from the front. Please note: for
built-under and integratable 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.
4.2 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 80 cm is not to be exceeded.
4.3 Electric connection
Connect the appliance to a wall socket with earthing in accordance with regulations only. Please observe
details on the identification plate (see technical data).
Connection dimensions
for all dishwashers 60 cm
( ) Figures with lengthening pieces

Service Manual Series 634 9
For internal use only
5. Functions
5.1 Aqua stop system
The valve system comprises two solenoid valves in line, with parallel electric controls, the fill-up valve
and the safety valve. The safety function can be triggered by means of the safety level chamber or
electrically by means of the float in the base pan. The water flow is then stopped mechanically. An
electric solenoid valve, encased, is attached to the tap. From the valve the water supply hose leads to
the integrated water inlet, and the electric control mechanism for the solenoid valve is guided through a
leakage water hose to the inside of the machine where the base pan is located.
5.2 Safety function
Should functional defects in the dishwasher control system or in the structural elements occur, resulting
in an over-filling of the machine, the valve combination will be closed by means of the safety system,
thus blocking off the water supply. The discharge pump is switched on by means of the safety level
switch. Pumping will continue until the filling level has once again been reached. Any leaks occuring
within the machine are collected in the base pan. Leaks in the supply hose are guided to the base pan
by means of the leakage water hose.
Once a set level in the base pan has been reached, the float activates the safety level switch by means
of a switch lever, which then switches off the filling and safety valve electrically. At the same time the
discharge pump is switched on, the rinse water is removed from the rinsing container, and the discharge
pump switches onto continuous operation.
5.2.1 Salt and rinsing agent display
The reservoir is provided with a float and an integrated permanent ma-
gnet. This magnet triggers via the magnetic field a reed switch, which is
fitted on the outside of the reservoir. This switch turns on the lights of the
defect display in the operation panel.
A = Permanent magnet
B = Reed switch open
C = Reed switch closed
5.2.2 Spraying system
The rotor spraying system comprises three spraying levels, the lower and the upper spray arms and a
top sprayer. The water supply to the upper spray arm and the top sprayer comes via a supply pipe
installed on the inside of the back wall of the container. This pipe is connected on one of its two exits by
means of a direct plug connection with the continuous flow heater located under the pump cavity.
The upper spray arm is attached direct onto the upper basket by means of its inlet pipe. The connection
to the supply pipe is carried out by means of a variable attachment. In the case of appliances with a
height-adjustable upper basket, the water supply to the spray arm is adjusted by means of this variable
attachment.
The lower spray arm is mounted to the second outlet of the continuous flow heater directly above the
pump cavity, and has a nozzle on the bottom in order to clean the flat sieve.
Driving the actuator

10 Service Manual Series 634
For internal use only
5.2.3 Continuous flow heater
In the water circulation, the continuous flow heater is used for the spray arms. When rinsing water is
flushed through, a rubber membrane attached to the flange is actuated, and this flange switches on the
safety pressure switch for the heater. When the pressure drops, the heater is switched off. The heating
position is crossed and dry heating is prevented.
5.2.4 Rinsing and pump system
The circulating pump and the discharge pump as well as the continuous flow heater are connected to the
pump cavity by means of plug connections. The continuous flow heater is also screwed to the pump cavity
in such a manner that no pressure can occur. The sieve system comprises a fourfold filter system (a course
filter, fine sieve cylinder, a fine flat sieve and a micro-fine sieve). The pump cavity in which the micro-fine
sieve is positioned, is covered by the flat fine sieve. The flat fine sieve and the combined coarse and fine
sieve cylinder are attached to the bottom of the pump cavity by means of a bayonet catch. The rinse water
which flows into the pump cavity is sucked up by the circulation pump and forced into the continuous flow
heater. If the pressure is sufficient, the push button for the heater is actuated by means of the flange
membrane. Overheating is prevented by means of a temperature control which is connected in series and
switches off at 85°C. This temperature control is combined with an NTC sensing element (negative
temperature coefficient), comprising one component part.
The surface of the sensing element makes direct contact with the rinse water. The aqua sensor is positioned
at the exit of the continuous flow heater and has its sensor in the flow of the rinse water in order to determine
how dirty the rinse water is. The direct fitting of the discharge pump onto the pump cavity means that the
impeller and the non-return flap are accessible when the cover in the rinse cavity is removed.
5.2.5 Actuator
The thermohydraulic system comprises a metal cylinder with a push rod. The cylinder is filled with a
substance which expands greatly on heating.
A PTC (positive temperature coefficient) serves as a source of heat, making direct contact with the metal
cylinder. A strong pressure spring brings the push rod back to its original position subsequent to switch-
off of the heat source.
Construction
After voltage has been applied to the PTC, it heats up and transmits the heat to the metal cylinder which
is filled with wax. The wax expands and presses the push rod out of the cylinder to the outside. The push
rod transfers the mechanical movement to the release mechanism of the cleaning agent and rinsing
agent dispenser. If the source of heat is switched off, cooling reduces the volume of wax. The pressure
spring returns the push rod to its original position.
The release period is approx. 2 min.; the resetting time is approx. 3 min.
Actuator triggered
Push rod path

Service Manual Series 634 11
For internal use only
5.2.6 Water diverter
The water diverter is responsible for alternating the rinsing (the
appliance alternates rinsing in the upper and in the lower
basket, lower basket 60 sec. / upper basket 55 sec., alternation
takes approx. 5 sec.), and comprises a synchronous motor
with a gear transmission, a cam plate, a micro-switch and a
slide. The synchronous motor is controlled by a triac. The
synchronous motor drives the gear transmission, therefore
driving the cam plate and the slide. The slide closes the
respective water channel to the spray arms. Information on the
position of the slide is passed on to the control system by the
micro switches, which are activated by the cam plates. The
water diverter is integrated in the continuous flow heater, and
may only be exchanged as one whole unit.
5.2.7 NTC
The temperature safety switch applied (>85°C) is combined with the NTC sensing element for the
programs. In the case of a defect, the heater is switched off when the water temperature reaches 85°C
(impulse).
5.2.8 Natural water valve / glass protection technology
Irreversible clouding of glass (glass corrosion) is a result of :
a) a low-alkaline cleaning agent
b) excessively soft water (< 3° dH)
c) the quality of the glass
If the degree of water hardness subsequent to recovery is in
the range of below 3°C dH, there is an increased risk that the
water could cause changes in the surface of the glass.
In the case of water hardness below 5° dH, the natural water
valve adds tap water which has not been softened, so that the
water reaches the region of 5° dH, which is gentle on glass.
Attention: The natural water valve is closed without tension! -> Natu-
ral water is filled in !
Since the natural water valve has an ED of 25 - 30%, activation of the valve is limited in time (max.
210 sec.).
Temperature
C° Resistance in ohms Tolerance+/- °C
25 48409 7.9
50 16542 6.2
60 11067 5.6
63 9669 5.5

12 Service Manual Series 634
For internal use only
5.2.9 Glass protection technology (aqua-mix)
By means of a targeted control of the degree of water hardness, the effect of aggressive soft water on
the dishes is avoided. Depending on the degree of hardness set (8 settings, from 0 to 7, setting on the
front panel) and by means of a “bypass,“ fresh tap water is mixed with the softened rinse water, so that
the degree of water hardness in the appliance is always at least 5°dH. The aqua-mix valve is activated
by the electronics system and is located on the water softening device. In the case of naturally soft water,
which has no negative effects on glass, the softening can be set onto “0“, and the glass protection
technology will then not be activated.
Change in degree of hardness of the water in the appliance during several rinses
——–— with glass protection -– – – – –
without glass protection
5.2.10 Alternating pumping procedure
In order to achieve a better cleaning of the fine sieve, the water is circulated and pumped out alternately
3 times for 5 sec. This means that water flows through the sieve in both directions. (Attention: noises).
des
r
s
°dH
Aggressiver
Bereich
2
8
5
°dH
of
r
Aggressive zone

Service Manual Series 634 13
For internal use only
5.3 Filling procedures
5.3.1 Control without setting a time on filling
(Static filling / dynamic filling)

14 Service Manual Series 634
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5.3.2 Control without setting a time on filling
(Static without circulating)
Filling until the filling switch f1 activates the operating mechanism motor m1..
Strompfad

Service Manual Series 634 15
For internal use only
5.3.3 Control without setting a time on filling
(Dynamic without circulation m2)
Filling until the filling switch f1 activates the operating mechanism motor m1.

16 Service Manual Series 634
For internal use only
5.3.4 Control without setting a time on dynamic filling
current path
F = Filling H = Heating R = Rinsing agent added P = Pumping

Service Manual Series 634 17
For internal use only
5.3.5 Control without a time setting on dynamic filling
Time in sec.
Process

18 Service Manual Series 634
For internal use only
5.3.6 Control with a time setting on dynamic filling
(Static filling / dynamic filling)
Strompfad
current path

Service Manual Series 634 19
For internal use only
5.3.7 Control without a time setting on dynamic filling
(Static without circulation)
Filling until the filling switch f1 activates the operating mechanism motor m1.
Strompfad
curent path
current path

20 Service Manual Series 634
For internal use only
5.3.8 Control with a time setting on dynamic filling
(Dynamic with circulation m2)
Filling until the filling switch fl activates the operating mechanism motor m1. Should, however, the filling
switch not switch on, the contact u8 will activate the operating mechanism motor.
current path