Kuppersbusch 635 Series User manual

Built-in Dishwashers
Series 635
IGV 699.0 / IGV 699.1
IGV 699.2 / IGV 699.3
IGV 699.4
IGV 6909.0

Service Manual: H7-71-06
Responsible: Dieter Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Email: dieter[email protected]
Phone: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 31.10.2008 45801 Gelsenkirchen

Service Manual 3
For internal use only
Contents
1. Safety...............................................................................................................................5
2. General technical specification.....................................................................................6
3. Installation and connection...........................................................................................6
3.1 Installing................................................................................................................6
3.2 Water connection ..................................................................................................6
3.3 Electric connection ................................................................................................6
4. Features...........................................................................................................................7
4.1 Operation and display module...............................................................................8
4.2 Assembly...............................................................................................................9
5. Components and dismounting....................................................................................10
5.1 Door components................................................................................................10
5.2 Left side wall components...................................................................................11
5.3 Right side wall components.................................................................................11
5.4 Components in the plinth.....................................................................................12
5.5 Pump cavity components ....................................................................................12
5.6 Door lock (servo lock)..........................................................................................13
5.7 Door lock (motor lock) .........................................................................................13
5.8 Rinse water pump ...............................................................................................13
5.9 Circulation pump (SICASYM)..............................................................................14
5.10 Tachometer generator.........................................................................................17
5.11 Recognising / filling up to concentric running......................................................17
5.12 Aqua sensor I and II ............................................................................................18
5.13 Aqua sensor – decisions in the automatic program ............................................19
5.14 Salt and clear rinse agent display .......................................................................20
5.15 Visual clear rinse fill-up sensor............................................................................20
5.16 Info light (optional) ..............................................................................................20
6. Functions ......................................................................................................................21
6.1 Safety function.....................................................................................................21
6.2 3 in 1 detergent recognition.................................................................................21
6.3 Actuator...............................................................................................................21
6.4 Water points ........................................................................................................23
6.5 Aqua Stop System...............................................................................................24
6.6 Door.....................................................................................................................25
6.7 Main switch (IGV 699.0 and IGV 699.1)..............................................................28
6.8 Dispensing device ...............................................................................................29
6.9 Top addition.........................................................................................................30
6.10 Regeneration, drain-off and raw water valves.....................................................31
6.11 Continuous flow heater........................................................................................32
6.12 Water softener.....................................................................................................33
6.13 Optosensor..........................................................................................................34
6.14 Equipotential system with a safety function.........................................................35
6.15 Sieve system.......................................................................................................36
6.16 Rotary spray system............................................................................................37
6.17 Rinsing and pump system...................................................................................38
7. Fill system.....................................................................................................................39
7.1 Regeneration with heat exchanger......................................................................39

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8. Program sequences .....................................................................................................41
8.1 Program selection “Auto-plus rinse”....................................................................41
8.2 Program selection “Automatic rinse” ...................................................................43
8.3 Program selection “Automatic gentle rinse”.........................................................46
9. What do do, if................................................................................................................48
9.1 Controller / module ..............................................................................................48
9.2 Problem (user).....................................................................................................51
9.3 Error message on the customer service program ...............................................63
10. Power module ...............................................................................................................67
11. IGV 699.2 operation ......................................................................................................68
11.1 Function...............................................................................................................68
11.2 Sensor buttons ....................................................................................................68
11.3 Options ................................................................................................................70
11.4 Special programs - IGV 699.2 only......................................................................72
11.5 General instructions on the controls - IGV 699.2.................................................74
12. IGV 699.0 and IGV 699.1 operation..............................................................................78
12.1 Function...............................................................................................................78
12.2 Selecting a program ............................................................................................78
12.3 Options ................................................................................................................79
12.4 Special functions .................................................................................................82
12.5 Special programs - IGV 699.0 and IGV 699.1 only .............................................82
12.6 General instructions on the controls....................................................................85
12.7 Customer service test program ...........................................................................88
13. Technical data...............................................................................................................90
13.1 General technical data.........................................................................................90
13.2 Consumption data IGV 699.0 and IGV 699.1.....................................................91
13.3 Consumption data IGV 699.2 .............................................................................92
13.4 Consumption data IGV 699.3 / 4 and IGV 6909.0..............................................93

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 changing additional devices and the pump pot, 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
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 the IGV
699.0 / IGV 699.1, IGV 699.2 / IGV 699.3, IGV 699.4 and IGV 6909.0.
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.
3. Installation and connection
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. 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.
3.2 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 beexceeded.
3.3 Electric connection
Connect the appliance to a wall socket with earthing in accordance with regulations only. Please observe
the information on the identification plate (see the technical data).
Connection dimensions
for all dishwashers 60 cm
( ) Figures with extensions

Service Manual 7
For internal use only
4. Features
The new fully-automatic dishwashers comprise signif-
icant product innovations in various areas:
• Guaranteed results by means of monitoring soiling
and loading, and fully automatic control of temper-
atures, water quantities and rinsing procedures.
• Easy operation thanks to “single-button operation”
on the upper edge of the inner door and a selec-
tion of all of the functions by means of a clear text
display.
• The appliance is given a new appearance with a
clear text display and menu buttons.
•Fully-automatic controls
For determining soiling and loading with the help
of various sensors and fully-automatic control of
all rinsing parameters: water quantity, temperature
and time.
•Heat exchanger
Economical by means of a transfer of energy,
hygienic through drying without any inflow of outer
air and gentle on dishes through avoiding temperature shocks.
•Glass protection
Targeted control of water hardness in order to avoid damage to the glass surface caused by exces-
sively softened water.
•Clear text display
Simple operation by means of the indication of all functions as well as remote indications in a clear
text (17 languages).
•Aqua sensor II
Water and energy consumption depending on the degree of soiling of the dishes for optimal clean-
liness and economy.
•Speed sensor
Water consumption according to the volume of dishes loaded and offsetting of losses, for example
through pots which have turned over.
•Consumption data
In the test program (Normal Eco) consumption data of only 14 litres and 1.05 kWh.
•Remaining time indication
Information on time remaining until completion of a program, in minutes.
•Fold-over spikesin the bottom basket
Flexible loading of plates and large dishes in the bottom basket and in the top basket.
•Fold-over spikes in the top basket
The spikes in the front part of the two rows (dark grey) can be folded over. Thus this space can be
used for small plates or for bowls and pots, etc., as required.
•Optosensor
Protects glasses and dishes against scaling.
• Filter system with four settings
•Cutlery rack for long items of cutlery
• Aqua-stop optional

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•Types of baskets: Standard baskets and an additional small cutlery basket at the top.
• Normal Eco test program
• Consumption data: 14 litres / 1.05 kWh - Noise level 44 dB
• A-A-A energy label
•Height-adjustable top basket (Rackmatic)
The rackmatic “basket adjustment” is a system which enables the top basket position to be adjusted
easily, even when it is loaded. In order to lower the top basket press both of the handles on the
sides. The basket must only be lifted in order to raise it.
•Multiflex premium baskets
Convenience and flexibility for optimal space utilisation
4.1 Operation and display module
4.1.1 Disassembly
For fully-integrated models, the two decorative panels on the right and left of the door
must be removed prior to dismantling the outer door or the panel.
1. Remove the outer door and the complete panel.

Service Manual 9
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2. Remove the panel cover; to do so, turn the two round white catches on the inside by 90° with a pair
of pointed pliers.
3. Remove the support plate from the panel cover at the four catches (1).
4. Fold the support plate up (2).
5. Remove the front display module (if present).
6. Remove the round lock (3).
lDo not bend the catches on the support plate.
7. Disengage the module from the support plate by the four catches on the module casing (4).
8. Push the module downwards and out.
4.2 Assembly
1. Push the module from below into the support plate until the four catches on the module casing
engage into the support plate.
When installing make sure that
• the catches on the support plate are not bent;
• the sealing on the display is not crushed or damaged;
• the module has engaged properly into the support plate.
2. Insert the round lock (3) into the support plate.
3. Connect the front display module (if present).
4. Engage the support plate into the panel cover.
5. Lock the support plate and the panel cover; to do so use a pair of pointed pliers to turn the two
white catches by 90°.
6. Mount the panel and the outer door.

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5. Components and dismounting
Control panel
Control module
Power module
Door lock
Rinse water pump
Circulating pump
Water diverter
Raw water valve
Aqua-sensor II
Level system
Water inlet
5.1 Door components
ON/OFF switch
Detergent and
dispensing device
Control module with
LCD display
Door lock with a
door switch

Service Manual 11
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5.2 Left side wall components
5.3 Right side wall components
Heat exchanger
Regeneration valve
Level switch
Safety switch
Drain valve
Steam condensation pipe
Power module

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5.4 Components in the plinth
5.5 Pump cavity components
Raw water valve Continuous-flow heater with a water diverter and an aqua sensor
Power module
Circulating pump
with a tachometer
Rinse water pumpWater softener
Level and
safety system
generator
Continuous-flow heater
Water diverter
Aqua sensor
Rinse water pump
NTC with a safety switch
with a pressure switch

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5.6 Door lock (servo lock)
The new “servo lock” in all of the fully-automatic dishwashers is ex-
tremely easy to handle due to smooth-running bearings. The door of
the appliance does not need to be pressed on closing; instead it vir-
tually closes by itself (from an opening angle of approx. 10°, depend-
ing on how the door springs are adjusted).
A Door switch
5.7 Door lock (motor lock)
The door of the dishwasher is motor-locked during the rinsing
process; opening the door will hence require a great deal of force.
AMotor
B Door switch
C Position switch
Opening force:
- locked > 80 N
- open < 40 N
5.8 Rinse water pump
Apart from during the start-up of a program, the pump is
operated on pump for 3 x 5 sec. / 5 sec. circulation.
Alternating pumping results in an improved pumping out
procedure and the micro-sieve is cleaned better.
Remove the base panel and the base sheet. The detergent
water pump is engaged in the pump cavity at the front left.
In order to remove the pump the lever (1) must be disen-
gaged. The pump must then be turned towards the front (2).
After approximately a quarter of a turn it will be possible to
pull the pump off (3).
Technical data
Nominal voltage 230 - 240 V
Frequency 50 Hz
Resistance 110 - 260
Ω
Delivery height 0.9 m
Delivery performance 10 l/min
A

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5.9 Circulation pump (SICASYM)
Single-phase alternating current motor
The circulation pump is operated by means of a single-phase alternator with a tachometer generator.
The tachometer generator registers the number of revolutions of the circulation pump and passes this in-
formation on to the electronics system. The number of revolutions is regulated by means of a phase-con-
trol device generated in the electronics system. Thus the regulation of the circulation pump influences:
1. filling up to a consistent number of revolutions / (load recognition);
2. reduction of the number of revolutions for delicate cycles;
3. reduction of the number of revolutions for alternating rinses (switching from top basket rinses to
bottom basket rinses);
4. the varying number of revolutions for bottom basket and top basket (2200/2800 rev/min).
The control element between the two motor windings and the motor capacitor is either triggered by
means of electronics or a relay on the motor connection or by means of module . During the start-
up phase the two windings (in series with the capacitor) are parallel to one another direct on the power
supply and generate an extremely powerful starting force. After switch-over the two windings will be in
series (behind one another), i.e. the two windings are each supplied with half of the power supply. The
motor will then be optimally adjusted to the pump (in operation) and, besides requiring very little power
- for label AAA – it will also make very little noise, since both windings are supplied with half of the power
supply in operation.
Condenser
Tachometer generator
PTC

Service Manual 15
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Disassembly
1. Remove the side panels and the base sheet.
2. Remove the two screws (at the front and the rear) connect-
ing the stainless steel shell and the plastic base pan on the
right-hand side.
3. Lift up the shell and secure it with an object which is approx.
4 cm thick.
4. The circulation pump is engaged in the pump case. Use a
screwdriver to press the catch on the right-hand side of the
circulation pump to the inside and turn the pump clockwise.
You will then be able to remove the pump.
Assembly is carried out in reverse order. The gasket must be
lubricated with detergent prior to installation.
Technical data
Nominal voltage 230 - 240 V
Frequency 50 Hz
Resistance Ha approx. 44-57 Ω
Hi approx. 50 - -55 Ω
Delivery height 3.9 - 4.1 m
Delivery performance 25 - 30 l/min
Starting current 2.4 A
Operating current 0.31 A
5.9.1 Circulation pump (SIBRUSYM)
The circulation pump is driven with a brushless dc motor (BLDC). The individual coils of the stator wind-
ing (6) are combined in three branches and are star-connected.
The rotor (5) has permanent magnets and operates in the pumping medium with water-lubricated slide
bearings (4) without any rotary seal.
1 Pump housing
2 Pump wheel
3 Panel mount
4 Slide bearing
5 Rotor with a permanent magnet
6 Housing with stator winding

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The motor does not have any thermal winding protection since the motor electronics unit detects faults
and overloading automatically and switches the motor off.
Direct electric current measurement not possible, since the current is distorted (pul-
sating direct currents)
5.9.2 Disassembly
1. Remove the side panels and the base sheet.
2. Remove the screws connecting the stainless steel shell and the plastic base (2 screws at the front
and 2 at the back).
3. Lie the appliance down on the rear wall.
4. Detach the load cables from the door hinges.
5. Bend the base pan downwards.
The circulation pump motor can only be replaced in one unit with the pump housing.
6. Remove the hose clamp at the connection
between the pump housing and the continuous
flow heater (1).
7. Remove the circulation pump and the pump
housing from the pump cavity (2).
8. Remove the circulation pump and the pump
housing from the continuous flow heater (3).
Technical data
Nominal voltage for electronics 230 - 240 V
Frequency for the electronic unit 50 Hz
Resistance across 2 cables, cold 65 - 75 Ω
Delivery pressure 370 mbar
Flow rate (2900 rev./min.) 32 l/min.
(2950 rev./min.) 38 l/min.
Starting current not measurable
Operating current not measurable

Service Manual 17
For internal use only
5.10 Tachometer generator
The number of revolutions and the variations in the number of revolutions of the circulation pump are
gauged by means of a tachometer generator. The speed is controlled by means of an electronic phase
control.
• Fill until a constant number of revolutions has been achieved
• Reduction in the number of revolutions in the gentle-wash cycles
• Reduction in the number of revolutions in the case of alternating rinsing (switching from top basket
rinsing to bottom basket rinsing)
• Differing number of revolutions for the bottom basket and for the top basket (2800 / 2200 rpm)
Moistening with water, hollows or grooves in the dishes or containers which have turned over may result
in losses of rinsing water. In this case air is transported through the pump. This will result in noisier
operation of the dishwasher and in a changed (irregular) operation of the pump.
The tachometer generator will only recognise irregular operation on filling and will reduce the number of
revolutions of the pump. In order for the pump to operate “smoothly” again, water is filled in until the
optimal water level has been reached.
5.11 Recognising / filling up to concentric running
In the filling positions, water is filled in until the tachometer generator signals that the circulation pump is
running concentrically.
On first filling, between 2,8 l and 3,7 l are filled in and 3 enquiries concerning concentrical running are
made:
• a maximum of 200 ml is filled up for the first request;
• another maximum 200 ml is filled up for the second request;
• a maximum of 500 ml is filled up for the third request.
A maximum of up to 900 ml can be filled up during the first filling stage. During an intermediate rinse and
a clear rinse, a maximum of another 500 ml respectively can be filled up.
This means that:
• a fill-up with too little water, due to containers / pots which have turned over, is avoided;
• the noise level of the circulation pump is reduced.

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5.12 Aqua sensor I and II
In addition to an infra-red LED, the aqua sensor II is also equipped with a green LED, which means that
undissolved substances such as tea or spinach can also be recognised. In the automatic program, for
example, the aqua sensor II has the following functions:
1. Aqua-sensor infra-red LED check in the pre-wash cycle
Depending on the result of this check, the water is either exchanged (extremely dirty) or still used
(hardly dirty).
2. Aqua-sensor green LED check in the washing cycle:
Depending on the result of this check, a final temperature of 45°C (little soiling) or 50°C or 55°C
(heavy soiling) is reached during the washing cycle. Should the aqua sensor decide on a change
of water during the pre-rinse cycle, the temperature for the washing cycle will be raised from 50° C
to 55°C. Should the washing cycle be carried out at 50°C or 55°C, the filter will be rinsed through
afterwards.
3. Aqua sensor green LED check in the first intermediate rinse
Depending on the result of this check, an additional intermediate rinse will be carried out after the
first intermediate rinse (heavy soiling) or only the filter will be rinsed through.
Calibrating the aqua sensor II
An additional 400 ml of water is required for the calibration procedure in the first three rinsing cycles.
This step is repeated after 20 rinses.

Service Manual 19
5.13 Aqua sensor – decisions in the automatic program
ZSP = Intermediate rinse
Pre-wash
1.
Aqua sensor
2.
Aqua sensor
2.
Aqua sensor
3. 3.
3.
3.
Aqua sensor
no change of water
51°C; 2 ZSP
no change of water
42°C; 2 ZSP
no change of water
47°C; 2 ZSP
no change of water
42°C; 2 ZSP
no change of water
42°C; 1 ZSP no change of water 47°C; 1 ZSP no change of water
42°C; 1 ZSP no change of water
51°C; 1 ZSP
light soiling
light soiling light soiling
heavy soiling
heavy soilingheavy soiling
little little little little a lota lota lota lot
IR
GN
GN
GN
Aqua sensor
GN Aqua sensor
N Aqua sensor
GN

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5.14 Salt and clear rinse agent display
The reservoir is equipped with a float which has an integrated per-
manent magnet. This uses the magnetic field to activate a reed
switch which is attached to the outside of the reservoir. This switch
in turn activates the lamps of the fill-up displays in the control panel.
A = Permanent magnet
B = Reed switch open
C = Reed switch closed
5.15 Visual clear rinse fill-up sensor
The visual clear rinse fill-up sensor comprises a transmission and
a receiving diode.
The transmission diode sends a light beam to the receiving diode
via a prism. If the reservoir is filled up, the light beam will be dis-
persed in the prism. The receiver signal will therefore be weaker
than the sender signal.
A = Transmission diode
B = Receiver diode
C = Prism
If the reservoir is empty the light beam will be reflected in the
prism. The receiver signal is the same as the sender signal.
The module will evaluate the signal received and will activate the
fill-up LED.
5.16 Info light (optional)
The fully-integratable models are fitted with a program status display
(info light) which is visible from the outside and provides users with addi-
tional information.
The info light comprises an LED (A) and a fibre optic cable (B). The fibre
optic cable focuses the light which is projected as a spot of red light (C)
on the background (D) in front of the dishwasher while the program is in
operation.
The info light is fastened on the hinge plate between the inner door and
the outer door and is regulated by the module.