Kuppersbusch 640 Series User manual

_ìáäíJáå=~ìíçã~íáÅ=ÇáëÜï~ëÜÉêë
pÉêáÉë=SQM
IG 6507.1E - IG 6506.0E
IGS 6507.1E - IGS 6609.1E
IGV 6506.1 - IGVS 6506.1
IGV 6509.1 - IGV 6610.1
IGV 6508.1 - IGVS 6610.1
IGV 6509.1 - IGVS 6509.1
IGV 6609.1 - IGVS 6609.1

Service Manual: H7-71-07
Responsible: Dieter Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Email: dieter[email protected]
Phone: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 20.11.2009
1) Repair instructions 58300000 132031 zeolite Date 15.12.2008
2) Repair instructions 58300000 131150 zeolite Date 15.12.2008
3) Repair instructions 58300000 131186 zeolite Date 15.12.2008
4) Repair instructions 58300000 132037 zeolite Date 15.12.2008

GV 640 Service Manual 3
For internal use only
Contents
1. Safety ............................................................................................................................... 7
2. General technical specification..................................................................................... 8
2.1 General features.................................................................................................... 8
3. Installation and connection ........................................................................................... 9
3.1 Assembly............................................................................................................... 9
3.2 Water connection ................................................................................................ 10
3.3 Electric connection .............................................................................................. 10
3.4 Disassembly ........................................................................................................ 11
4. Control panel ................................................................................................................ 12
4.1 Control panel ....................................................................................................... 12
4.1.1 On/Off button (A)..................................................................................... 12
4.2 Control module Piezo keys.................................................................................. 13
4.2.1 Piezo electric principles........................................................................... 13
4.3 Setting options - appliance with a display ........................................................... 13
4.3.1 Programme selection .............................................................................. 13
4.3.2 Water hardness....................................................................................... 14
4.3.3 Storing..................................................................................................... 14
4.4 Setting options - appliance without a display ...................................................... 15
4.4.1 Programme selection .............................................................................. 15
4.4.2 Water hardness....................................................................................... 15
4.4.3 Amount of rinse aid ................................................................................. 15
4.4.4 Intensive drying ....................................................................................... 15
4.4.5 Storing..................................................................................................... 15
4.5 Setting options - appliance fully integrated without a display .............................. 16
4.5.1 Programme selection .............................................................................. 16
4.5.2 Water hardness....................................................................................... 16
4.5.3 Amount of rinse aid ................................................................................. 16
4.5.4 Intensive drying ....................................................................................... 16
4.5.5 Storing..................................................................................................... 16
4.6 Setting options – appliance with a zeolite drying system .................................... 17
4.6.1 Key layout ............................................................................................... 17
4.6.2 Selecting the customer settings .............................................................. 17
4.6.3 Settings ................................................................................................... 17
4.6.4 Setting options ........................................................................................ 17
4.7 Removing the control panel................................................................................. 18
5. Appliance components ................................................................................................ 19
5.1 Side panels.......................................................................................................... 19
5.1.1 Installation ............................................................................................... 19
5.1.2 Removing ................................................................................................ 20
5.2 Outer door ........................................................................................................... 20
5.2.1 Installation ............................................................................................... 20
5.2.2 Removing ................................................................................................ 21
5.3 Base panel .......................................................................................................... 21
5.3.1 Removing ................................................................................................ 21
5.3.2 Installation ............................................................................................... 21

4 GV 640 Service Manual
For internal use only
5.4 Door section ........................................................................................................ 22
5.4.1 Transparent door.....................................................................................22
5.4.2 Door springs ............................................................................................ 22
5.4.3 Door lock .................................................................................................24
5.4.4 Door lock / child safety lock.....................................................................25
5.4.5 Installing the child safety lock..................................................................26
5.5 Door sensor .........................................................................................................26
5.5.1 Functioning of the door sensor................................................................ 27
5.5.2 Checking the door sensor .......................................................................27
5.5.3 Removing the door sensor ...................................................................... 27
5.6 Replacing the supply hose ..................................................................................28
5.7 Replacing the discharge hose .............................................................................29
5.8 Basket system ..................................................................................................... 29
5.8.1 Cutlery drawer .........................................................................................30
5.8.2 Top basket...............................................................................................30
5.8.3 Removing the smooth running top basket glide-out ................................ 31
5.8.4 Bottom basket .........................................................................................32
6. Appliance functions and components........................................................................ 33
6.1 Zeolite drying system in the GV640.....................................................................34
6.1.1 Zeolite container structure.......................................................................34
6.1.2 Full system structure ............................................................................... 34
6.1.3 Zeolite properties..................................................................................... 35
6.1.4 Cleaning phase and desorption...............................................................35
6.1.5 Drying phase and adsorption .................................................................. 36
6.1.6 Temperatures during the course of the program..................................... 36
6.1.7 Electrical connection ...............................................................................36
6.1.8 Checking the zeolite auxiliary heater....................................................... 37
6.1.9 Replacing the fan motor of the zeolite auxiliary heater ........................... 38
6.1.10 Replacing the zeolite container ...............................................................39
6.1.11 Installing the zeolite container when the rinsing cavity is installed..........41
6.1.12 Replacing the zeolite auxiliary module ....................................................41
6.2 Power module...................................................................................................... 43
6.3 Connections......................................................................................................... 43
6.4 Removing the power module............................................................................... 44
6.5 Opening the rinsing cavity ................................................................................... 44
6.5.1 Rinsing cavity Klixon ...............................................................................44
6.5.2 Removing the flow-off channel ................................................................ 45
6.5.3 Removing the discharge hose................................................................. 45
6.5.4 Removing the float switch safety system ................................................ 45
6.5.5 Opening the duct for the supply hose...................................................... 46
6.5.6 Releasing the container catch ................................................................. 46
6.6 Opening up the rinsing cavity ..............................................................................47
6.6.1 Mounting the fan motor ...........................................................................48
6.6.2 Positioning the rinsing cavity ...................................................................48
6.6.3 Removing the duct ..................................................................................51
6.6.4 Installing the duct .................................................................................... 51
6.6.5 Installing the zeolite auxiliary module...................................................... 52

GV 640 Service Manual 5
For internal use only
6.7 Heater pump........................................................................................................ 53
6.7.1 Structure of the heater pump .................................................................. 53
6.7.2 Structure of the pump casing .................................................................. 53
6.7.3 Structure of the circulation pump ............................................................ 53
6.7.4 Functioning of the circulation pump ........................................................ 54
6.7.5 Structure of the heater ............................................................................ 54
6.7.6 Functioning of the heater / NTCs ............................................................ 54
6.7.7 Checking the heater pump...................................................................... 55
6.7.8 Heating capacity insufficient.................................................................... 56
6.7.9 Removing the heater pump..................................................................... 56
6.7.10 Installing the heater pump....................................................................... 57
6.7.11 Cleaning the heater pump....................................................................... 57
6.8 Discharge pump .................................................................................................. 58
6.8.1 Checking the discharge pump................................................................. 58
6.8.2 Removing the discharge pump ............................................................... 59
6.9 Sieve system....................................................................................................... 59
6.9.1 Fine sieve cylinder .................................................................................. 59
6.10 Pump cavity ......................................................................................................... 60
6.10.1 Removing the pump cavity ...................................................................... 61
7. Functions ...................................................................................................................... 62
7.1 Safety system...................................................................................................... 62
7.1.1 Safety system components ..................................................................... 62
7.2 Aquastop valve.................................................................................................... 63
7.2.1 Functioning.............................................................................................. 64
7.2.2 Checking the aquastop valve electrically ................................................ 64
7.3 Float system ........................................................................................................ 65
7.3.1 Functioning.............................................................................................. 65
7.4 Dispensing device ............................................................................................... 66
7.4.1 Functioning.............................................................................................. 66
7.4.2 Checking the dispenser electrically......................................................... 67
7.4.3 Replacing the dispenser.......................................................................... 68
7.4.4 Mounting the detergent cover ................................................................. 68
7.4.5 Dispensing assistant ............................................................................... 69
7.5 Aqua sensor (optional) ........................................................................................ 69
7.5.1 Replacing the aqua sensor ..................................................................... 70
7.6 Salt refill identification.......................................................................................... 71
7.7 Visual clear rinse fill-up sensor............................................................................ 71
7.8 Status display lights............................................................................................. 72
7.8.1 Info light (optional)................................................................................... 72
7.8.2 Emotion light (optional) ........................................................................... 72
7.8.3 Checking the emotion light...................................................................... 73
7.8.4 Replacing an emotion light...................................................................... 73
7.9 Flow sensor ......................................................................................................... 74
7.9.1 Functioning.............................................................................................. 74
7.9.2 Structure of the mechanical reed contact................................................ 75
7.9.3 Replacing the flow sensor ....................................................................... 75
8. Water cycle.................................................................................................................... 76
8.1 Water inlet ........................................................................................................... 76
8.2 Free flow section ................................................................................................. 77

6 GV 640 Service Manual
For internal use only
8.3 Water softening equipment..................................................................................78
8.3.1 Softening ................................................................................................. 78
8.3.2 Regeneration...........................................................................................78
8.3.3 Regeneration valve .................................................................................79
8.3.4 Flow of water in the softening equipment................................................ 79
8.3.5 Replacing a regeneration valve............................................................... 80
8.4 Water diverter ......................................................................................................81
8.4.1 Checking the water diverter electrically ...................................................82
8.4.2 Water diverter pulse generator................................................................ 82
8.4.3 Replacing the water diverter....................................................................83
8.5 Rotary spray system............................................................................................ 83
8.6 Feed pipe.............................................................................................................84
8.7 Heat exchanger ................................................................................................... 85
8.7.1 Replacing the sealing washer .................................................................85
8.7.2 Emptying the heat exchanger.................................................................. 86
8.7.3 Replacing the heat exchanger.................................................................86
8.8 Expansion opening .............................................................................................. 87
8.9 Water discharge ..................................................................................................88
8.10 Discharge ventilation ...........................................................................................88
8.11 Non-return valve ..................................................................................................89
8.11.1 Removing the non-return valve ............................................................... 90
8.11.2 Installing the non-return valve .................................................................90
9. Error diagnosis ............................................................................................................. 91
9.1 Malfunctions ........................................................................................................ 91
9.2 Result errors ........................................................................................................91
9.3 Noises..................................................................................................................92
9.4 Electrical errors....................................................................................................92
9.5 Mechanical errors ................................................................................................ 92
9.6 Error codes ..........................................................................................................93
9.6.1 Customer settings ................................................................................... 93
9.6.2 Customer settings, selection (e.g. piezo electronics).............................. 94
9.6.3 Customer service program - structure..................................................... 95
9.6.4 Error code chart - structure ..................................................................... 96
9.6.5 Error codes ............................................................................................. 97
9.7 Checking water hardness in the dishwasher
when error messages are displayed.................................................................. 100
9.7.1 Check for active softening equipment ...................................................100
9.7.2 Operation with the softening equipment switched off............................ 100

GV 640 Service Manual 7
For internal use only
1. Safety
Danger!
Repairs may only be carried out by a qualified electrician!
Repairs that are not carried out properly may lead to risks and injuries 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 [Associ-
ation of German Electrical Engineers] regulations or 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 cavity, beware of sharp edges around the stain-
less steel components.
• The appliances must be disconnected from the mains prior to all repairs. If inspections must be car-
ried out on live appliances, make sure you use a residual current circuit breaker.
Cuts on sharp edges: use protective gloves.
Components may be electrostatic!
Observe handling regulations!

8 GV 640 Service Manual
For internal use only
2. General technical specification
This service manual serves the purpose of providing customer service technicians who already have
the know-how required to repair dishwashers with specific information on the operating mode of the
GV 640 series.
This manual deals with all of the appliance specifications relevant to this model.
2.1 General features
Mains voltage 220-240V / 50Hz
Power consumption in the stand-by mode
- Panel with push-buttons:
- Panel with a piezo electronic unit:

< 0.1 W
< 0.8 W
Filling capacity 12 place settings
Overall dimensions:
- Width
- Height
- Depth



59.6 cm
81.8 - 87.8 cm
55.5 cm
Control elements
- Switching on/off
- Programme selection / additional function



Horizontal / vertical
Bipolar switch, separated from the electronic unit
By buttons (min. 3, max. 6)
Display 2.5 numbers and LEDs
Washing system Combined / pulse
Water intake level Pressure control + software
Heating up water Encased heating element (2100 W)
Temperature control NTC temperature sensor
Drying system Activated / turbo
Safety systems / alarms Full water protection / total protection of electronic
components and software
Please note!
Work on electrical appliances may only be carried out by suitably qualified staff.
Always disconnect the mains plug before touching components inside the appliance.

GV 640 Service Manual 9
For internal use only
3. Installation and connection
3.1 Assembly
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 with the adjustable feet. The middle adjustable foot of integrated
appliances, located at the back of the dishwasher, can be adjusted from the front. Screw the adjustable
feet to lift the appliance until the outer casing is at the same level as the worktop.
The appliances have 3 or 4 feet, depending on the design.
The adjustable heights vary.
Free-standing appliance
Integrated/ fully integrated

10 GV 640 Service Manual
For internal use only
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 be exceeded.
3.3 Electric connection
Only connect the appliance to a wall socket with earthing
in accordance with regulations. Please observe the in-
formation on the identification plate (see the technical
data).
The mains supply line is fitted with a low-heat system
connection and is supplied with the appliance. The cable
must be connected to the back of the dishwasher when
it is put into operation.
Two strong catches on the sides prevent the plug from
accidently becoming loose or coming off the appliance.
Extension cables
Customer service has extension cables of 3 metres in
length on offer.
Spare part No.: 436993
Connection dimensions
for all dishwashers 60 cm
( ) dimensions with extensions

GV 640 Service Manual 11
For internal use only
3.4 Disassembly
Tools required
Special tools for the ring nut on the salt box; cover of the
expansion opening; exhaust air duct; water intake bolts.
1. Drain off water.
• Start up any programme and close the water
tap in order to empty the heat exchanger. The
heat exchanger is emptied.
• Then reset to pump off the rest of the water.
• Remove the remaining water in the pump cavity
with a suction syringe.
2. Remove the mains cable from the appliance
plug by moving it carefully up and down and
pulling it at the same time (do not move it side-
ways!).

12 GV 640 Service Manual
For internal use only
4. Control panel
4.1 Control panel
The structure of the control panels are different; they come with a display or without.
• 9 programmes operated with a rotary swich
• Number of LEDs
Control panel with a display
Control panel without a display
Control panel fully integrated, no display
4.1.1 On/Off button (A)
The models are all fitted with this button which is used to switch the dishwasher on and off. Switching
the button off does not delete a programme in operation.

GV 640 Service Manual 13
For internal use only
4.2 Control module Piezo keys
Appliances with Piezo keys have a flat control panel. The stainless steel control interface reacts to even
the slightest touch. This is because of a control button fitted with minute crystal elements that has been
applied with glue. The electrical impulses are generated according to the principle of Piezo technology.
4.2.1 Piezo electric principles
Mechanical pressure generates an electrical charge on certain crystals, also called Piezoelectric ceram-
ics. Natural crystals only show this effect to a very limited extent, e.g. Turmalin. Lead zirconate titanate
as a natural crystal is doped by foreign atoms. This enhances the Piezo effect.
This crystalline property was discovered by the physicists Pierre and Marie Curie in 1880. The name
“Piezo” has its origins in the Greek language and means “pressure” or “press”. Electrical voltages can
be determined on two crystal surfaces when pressure changes. This change in pressure may result from
bending, turning or pressing. The electrical voltage is proportionate to the power exerted.
A hexagonal crystal structural cell is shown here. This cell is externally neutralised elec-
trically, since all the charges have been equalised.
The centre of gravity of the positive and negative charges are forced against one another
under pressure.
A difference in charge will result. This is tapped as a charge or voltage and utilised.
Applying electric voltage will reverse the effect and crystals are stimulated to change
their structure (expansion, vibration).
4.3 Setting options - appliance with a display
4.3.1 Programme selection
1. Close the door and switch the dishwasher on.
2. Press button B and keep it pressed.
3. Turn control knob C until the chosen setting range is shown in the display.
4. Release button B.
5. Turn control knob C until the chosen setting is shown in the display.

14 GV 640 Service Manual
For internal use only
4.3.2 Water hardness
1. Keep start button B pressed.
2. Turn the programme selection knob C until the salt refill indicator blinks.
3. Release start button B. The current setting is shown, see chart.
4. To change the setting turn the programme selection knob until the right setting is shown.
4.3.3 Storing
1. Keep start button B pressed.
°dH Hardness
range mmol/l Setting
0 - 6 Soft 0 – 1.1 0 (off) 0 0 0
7 - 16 Medium 1.2 – 2.9 1 0 0 X
17 – 21 Hard 3.0 – 3.7 2 0 X X
22 - 35 Hard 3.8 – 6.2 3 X X X

GV 640 Service Manual 15
For internal use only
4.4 Setting options - appliance without a display
4.4.1 Programme selection
1. Close the door and switch the dishwasher on.
2. Press button B and keep it pressed.
3. Turn control knob C until the chosen setting range is shown in the display.
4. Release button B.
5. Turn control knob C until the chosen setting is shown in the display.
4.4.2 Water hardness
1. Keep start button B pressed.
2. Turn the programme selection knob C until the salt refill indicator blinks.
3. Release start button B. The current setting is shown, see chart.
4. To change the setting turn the programme selection knob until the right setting is shown.
4.4.3 Amount of rinse aid
1. Keep start button B pressed.
2. Turn the programme selection knob C until the rinse aid refill indicator blinks.
3. Release start button B. The current setting is shown, see chart.
4. To change the setting turn the programme selection knob until the right setting is shown.
4.4.4 Intensive drying
1. Keep start button B pressed.
2. Turn the programme selection knob C until the “water intake display”
blinks.
3. Release start button B. The current setting will be shown.
4. To change the setting turn the programme selection knob until the right
setting is shown.
4.4.5 Storing
1. Keep start button B pressed.
Range Display Selection
Hardness range H:00 – H:07 8 ranges, factory setting: H:04
Intensive drying d:00 – d:01 Switching on and off, factory setting: d:00 - off
Rinse aid r:00 – r:06 6 ranges, factory setting: r:05
ON 0
OFF X

16 GV 640 Service Manual
For internal use only
4.5 Setting options - appliance fully integrated without a display
4.5.1 Programme selection
1. Open the door and switch the dishwasher on.
2. Press button B and keep it pressed.
3. Turn control knob C until the chosen setting range is shown in the display.
4. Release button B and turn control knob C until the chosen setting is shown in the display.
4.5.2 Water hardness
1. Keep button C pressed.
2. Press button D as well until the finish display and the salt refill display blink.
3. Release the buttons. The salt refill display will blink and the current setting will be shown, see
chart. To change the setting press button B until the right setting is shown.
4.5.3 Amount of rinse aid
1. Keep button C pressed.
2. Press button D as well until the finish display and the salt refill display blink.
3. Release the buttons. Press button C repeatedly until the rinse aid display blinks; the current setting
will be shown. To change the setting press button B until the right setting is shown.
4.5.4 Intensive drying
1. Keep button C pressed.
2. Press button D as well until the finish display and the salt refill display
blink.
3. Release the buttons. Press button C repeatedly until the salt refill display
and the water intake display blink; the current setting will be shown, see
chart.
4. Release the buttons. To change the setting turn the programme selection knob until the right
setting is shown.
4.5.5 Storing
1. Press the start button.
°dH Hardness
range mmol/l Setting LED 1 LED 2 LED 3
0 - 6 Soft 0 – 1.1 0 (off) 0 0 0
7 - 16 Medium 1.2 – 2.9 1 X 0 0
17 – 21 Hard 3.0 – 3.7 2 X X 0
22 - 35 Hard 3.8 – 6.2 3 X X X
1
ON 0
OFF X

GV 640 Service Manual 17
For internal use only
4.6 Setting options – appliance with a zeolite drying system
This will only be possible when the appliance is switched on.
4.6.1 Key layout
4.6.2 Selecting the customer settings
Press key A and the “Start” key simultaneously
4.6.3 Settings
• Press key A to select the setting range.
• Press key C for selecting a program to adjust the setting.
4.6.4 Setting options
Press the START key to save the setting.
Range Display Selection
Hardness range H:00 – H:07 8 ranges set in the factory: H:04
Intensive drying d:00 – d:01 Switching on and off, factory setting: d:00 - Off
Rinse aid r:00 – r:06 6 ranges + Off, factory setting: r:05
Buzzer b:00 – b:03 3 ranges + Off, factory setting: b:02
Select language L:01 – L:19 19 languages, factory setting: L:01, German
Auto Power OFF P:00 – P-01 On – Off, factory setting: AU options: P:01 On EU options: P:00 Off
Emotion Light E:00 – E:01 On – Off, factory setting: E:01 On
Board Computer C:00 – C:01 On – Off, factory setting: C:01 On
Info Light I:00 – I:01 On – Off, factory setting: P:01 On
Partially optional functions

18 GV 640 Service Manual
For internal use only
4.7 Removing the control panel
This is only possible if the outer door (if present) is removed.
Preparation
1. Remove the cables on the left and right
from their sockets.
2. Remove the cable for the rinse aid refill
sensor.
3. Remove the earth cable.
Removal
1. Open the door.
2. Remove the top 6 screws.
3. Remove the control panel.
Installation
1. Fix the control panel onto the inner door
and then fasten the 6 screws.
2. Reconnect the plug connections.
Please note!
Hold the control panel with one
hand when you take out the last
screw. The panel is not secured
by more than the screws and may
fall down. Use 4x16 mm screws.

GV 640 Service Manual 19
For internal use only
5. Appliance components
The dishwasher can be divided up as follows:
• Modular conversion structure, in the following designs:
free-standing, integratable, fully integratable.
• Monobloc load-bearing base in a sound-absorbing plastic
material.
• Two removable side panels.
• Styling variable to meet the various configurations
requested.
• Simpler installation and mounting.
• The rear foot of built-in models can be adjusted from the front.
5.1 Side panels
5.1.1 Installation
1. Hang the side panel into the catches on
the underside of the dishwasher.
2. Press them evenly into the dishwasher
and
3. screw them at the front.

20 GV 640 Service Manual
For internal use only
5.1.2 Removing
1. Remove the 2 screws on the front of the side
panel.
2. Fold the top of the side panel outwards.
3. Push the side panels downwards and
remove them from the retaining clips of the
base pan.
5.2 Outer door
5.2.1 Installation
Position the insulation mats and the force trans-
ducer.
Close the inner door but do not engage it.
1. Push the outer door under the control panel
with the top at an angle
2. Press the outer door onto the inner door.
Screw from the inside with the door slightly
open.
Please note!
Use 4x11mm screws.