Kuppersbusch New Structure ITRONIC HL User manual

GB
Fully Integrated Dishwasher
New Structure
ITRONIC «HL» 60 cm
IGV 689.1

Service Manual: H7-410-03-02-C
Responsible: D. Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Tel.: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 25.11.1999 45801 Gelsenkirchen

Service Manual IGV 689.1 3
For internal use only
Contents
1. General ...........................................................................................................................4
1.1 General features ...................................................................................................4
1.2 Application examples ...........................................................................................4
2. Function features ..........................................................................................................5
2.1 Control panel ........................................................................................................5
2.2 Acoustic signal (buzzer) .......................................................................................8
2.3 Remaining cycle time display ...............................................................................9
2.4 Power failure ........................................................................................................9
2.5 Programme selection - programme execution - programme end........................10
2.7 Setting of the water softening unit ...................................................................... 11
2.8 Washing: with full load/half load .........................................................................14
2.9 Specification of drives and sensors ....................................................................15
2.10 Motor operation ..................................................................................................15
2.11 Water intake .......................................................................................................18
3. Safety/control and alarm systems .............................................................................21
3.1 Description of the safety and alarm systems ......................................................21
3.2 Description of the control systems .....................................................................22
4. Service: Diagnosis programmes and additional functions .....................................25
4.1. Component diagnosis programme .....................................................................25
4.2 Function diagnosis programme ..........................................................................27
4.3 Options for improving the washing result ...........................................................30
4.4 Additional functions for improving the washing result ........................................31
5. Circuit diagrams .......................................................................................................... 32
5.1 Technical data ....................................................................................................34
5.2 Programmme controller ......................................................................................35
5.3 Circuit diagram ...................................................................................................36
5.4 Table of wash programmes ................................................................................37

4 Service Manual IGV 689.1
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1. General
1.1 General features
1.2 Application examples
Electrical supply 220 - 240 V/50 Hz (limit values 187 + 254 V)
Total power consumption 2.300 W (incl. 2.100 W heating element)
Water supply pressure min./max. 5 + 80 N/cm²
Capacity 12 place settings
Consumption data water (in litres) 19 (progr. 4) 17 (progr. 6)
current consumption kWh 1.4 (progr. 4) 1.4 (progr. 6)
Programme duration minutes 90 (progr. 4) 75 (progr. 6)
Noise level dB (A) 33 (sound pressure)
Wash systems alternating
impulse
Water intake level “LMI“ control (dynamical equilibrium)
Water heating built-in heating element
Temperature control temperature sensor
Drying options active
turbo
Safety systems/alarms overall waterproofing system and software
Electronic control module
Printed circuit board main control (via built-in microprocessor)
Display/switch module interface user/appliance

Service Manual IGV 689.1 5
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2. Function features
2.1 Control panel
2.1.1 ON/OFF button (SW0)
◆This button is used for switching the appliance on and off.
◆When the dishwasher is supplied with current, the display (Dgt) lights. If rinse aid
and/or salt is required, the corresponding LEDs “L1“ and “L2“ also light up.
2.1.2 LED “Rinse aid“ (L1) (red)
◆Lights if rinse aid must be refilled.
◆The rinse aid level is controlled during the entire programme sequence. However,
the refill indication LED only lights when the appliance door is open.
2.1.3 LED “Salt“ (L2) (red)
◆Lights if regeneration salt must be refilled.
◆The salt level is controlled during the entire programme sequence. However, the
refill indication LED only lights when the appliance door is open.
◆If the regeneration level has been set to [0] (no regeneration), this LED remains off.
2.1.4 WRD LED (L3) (red)
◆Lights if a wash programme with prewash function has been selected.
◆Indicates that detergent must be filled into the respective WRD detergent dosing
device.

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2.1.5 Display [DGT_1] [DGT_2] [DGT_3] (green)
◆Display by means of letters and digits.
◆Display of the programme number.
◆Display of time down-counting (in hours) in case of preselected start time (1-12).
◆Display of running down-counting timer by means of flashing decimal point.
◆Display of the wash programme end by means of three illuminated (central)
segments.
◆Display of a possible alarm condition.
2.1.6 Programme selection button (SW1)
◆Is used for setting the desired wash programme.
◆The displayed programme number continuously changes with each depression of
the button.
2.1.7 Half load button “Upper/Lower“ (SW2)
◆Enables the optimisation of the wash programme in case of smaller dish quantities.
◆The dishes can optionally be inserted into either of the two dish baskets.
2.1.8 LED Half load “Upper“ (L5) (green)
◆Lights if only the upper dish basket is loaded and thus the wash operation mainly
takes place in the upper basket.
2.1.9 LED Half load “Lower“ (L6) (green)
◆Lights if only the lower dish basket is loaded and thus the wash operation mainly
takes place in the lower basket.
2.1.10 Selector button DRYING (SW3)
◆Enables setting of the desired drying option:
- active
- economic drying
- no drying.
2.1.11 LED “Economic drying“ (L7) (green:
◆Lights if the additional function “economic drying“ has been selected.
2.1.12 LED “No drying“ (L8) (green)
◆Lights if the drying function has been deactivated.

Service Manual IGV 689.1 7
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2.1.13 Standard drying
◆Both LEDs (L7 and L8) have gone off.
◆Dishwashers with ACTIVE drying system execute the active drying cycle.
◆Dishwashers with TURBO drying system execute the ventilated drying cyle.
2.1.14 Preselected start button (SW4)
◆Pressing this button postpones the start of the wash programme.
◆The start of the programme is postponed by one hour each time the button is
depressed (number of hours).
2.1.15 Button CANCEL/REMAINING CYCLE TIME DISPLAY (SW5)
FUNCTION
◆Pressing this button after the wash programme B has started (with the appliance
door open) cancels the previously selected wash programme.
In this case, an acoustic signal (BUZZER) (sequence_F) will sound and three
illuminated segments [ - - - ] indicating the end of the programme will appear in the
display for two seconds. Afterwards the previously selected wash programme with
the corresponding additional functions is displayed again.
◆If this button is pressed during the running time countdown (preselected start), the
timer is reset. All other settings remain stored.
The number of the preselected programme is indicated in the display.
The user may now change the settings, start the wash programme or select a new
programme start time.
REMAINING CYLE TIME DISPLAY
◆If this button is pressed during the programme selection phase, the time is
displayed during the running time of the selected programme.
As soon as the button is released, the number of the selected programme is
indicated in the display.

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2.2 Acoustic signal (buzzer)
The piezoelectric buzzer installed on the printed circuit board sounds at the beginning and end of the
programme and for confirmation each time a button is pressed.
If desired, the user may switch off (deactivate) this acoustic signal by pressing a fixed button
combination.
2.2.1 Deactivation of buzzer
The buzzer function can be deactivated by pressing two determined buttons at the
same time.
Deactivation and reactivation of the buzzer function may only be performed during the
programme selection phase, upon programme start and when the appliance door is
open.
Proceed as follows to deactivate the buzzer:
◆Simultaneously press the buttons “SW1“ and “SW3“ for at least 3 seconds.
Afterwards the buzzer will sound (sequence_A) to indicate the deactivation of this
additional function.
◆When the buzzer has been deactivated, no more acoustic signal will sound upon
pressing of a button, at the start or end of the programme and in case of an alarm
condition.
Proceed as follows to reactivate the buzzer:
◆Simultaneously press the buttons “SW1“ and “SW3“ for at least 3 seconds. During
this time no buzzer signal will sound. Afterwards the buzzer function is activated
again.
The selected setting will be stored when the appliance is switched off.
Standard setting: buzzer activated.
Sequence_A: Depression of the
button Buzzer signal sounds for 80 ms
Sequence_B; Programme start Buzzer signal sounds for 500 ms
Sequence_F: Programme end Intermittent buzzer signal of 2 seconds
(500 ms ON/ 500 ms OFF)
Sequence_E: Alarm Intermittent buzzer signal of 15 seconds
(2 seconds ON/ 3 seconds OFF)

Service Manual IGV 689.1 9
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2.3 Remaining cycle time display
The printed circuit board is programmed with an algorithm calculating the remaining programme time to
be indicated in the display.
This algorithmic system considers:
◆Fixed times for the following programme phases:
◆Draining
◆Washing/cold rinses
◆Programme pauses
◆Drying
◆Variable times for the following programme phases:
◆Water intake
◆Water heating
and for the number of dishes put into the dishwasher
The fixed times are directly determined for each wash programme.
The variable times are changed for each wash programme in accordance with the parameters that have
been measured during the preceding wash programmes. In this way, the duration of the wash
programme can be changed and adapted in accordance with the conditions under which the appliance
is working.
This adaption is made in real time during the execution of the wash programme at the end of each
individual programme phase.
2.4 Power failure
The function “power failure“ ensures that all information concerning the programme sequence and
programme parameters remain stored in case of a sudden power failure so that the wash programme
may be continued from the point where it has been interrupted when the power supply is activated again.
Basic principle of the “power failure“ function:
In case of a power failure, all electric loads are simultanenously deactivated, and the energy stored in
the capacitor is used to store the operational data in the EEPROM.
Therefore the interrupted wash programme can be continued from the point where it has been
interrupted in case of repeated power failure.

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2.5 Programme selection - programme execution - programme end
(without preselected start time)
Programme selection
1. Switch on the dishwasher by pressing the button “SW0“ when the door is open.
◆The programme that has been executed last [P .. ] and the additonal functions that have
been optionally selected by the user are shown in the display.
◆The LEDs “L1“ and/or “L2“ optionally light up.
2. For selecting the desired wash programme press the button “SW1“ several times.
◆The LED “L3“ lights when the programmes 2 and 3 have been selected.
3. Press the buttons “SW2“ and “SW3“ if these additional functions are desired.
◆When the programme No. 1 (soaking) is selected, no further additional function can be
selected.
◆In order to display the programme run time, press the button “SW5“.
Programme execution
4. The selected wash programme automatically starts after closing the appliance door.
◆A brief acoustic signal (sequence_B) confirms the start of the programme.
5. When the programme is started (appliance door closed), the cycle time that remains until the
end of the programme is shown in the display. All LEDs have gone out.
6. When the appliance door is open, the remaining cycle time until the end of the programme is
shown in the display.
◆The LEDs “L1“ and/or “L2“ optionally light up.
◆By pressing the button “SW1“ the running wash programme is displayed.
◆The LEDs “L5“, “L6“, “L7“ or “L8“ light when the respective additional functions have been
selected.
◆All buttons, except for “SW1“ and “SW5“, are deactivated.
7. In order to cancel the running wash programme, press the button “SW5“.

Service Manual IGV 689.1 11
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Programme end
8. At the end of the wash programme a buzzer signal will sound (sequence_F).
◆The end of the wash programme is indicated by 3 illuminated segments [- - -] in the display.
◆All LEDs, except for “L1“ and “L2“ (optional), go out.
◆All buttons, except for the button “SW1“, are deactivated.
9. The dishwasher can be switched off by pressing the button “SW0“ or a new wash programme
can be selected by pressing the button “SW1“ when the dishwasher door is open.
◆If the button “SW1“ is pressed once, the dishwasher returns to the originally set operating
conditions including corresponding additional functions.
2.7 Setting of the water softening unit
The water hardness may only be changed prior to the start of the wash programme.
Proceed as follows to change the water hardness level:
1. Switch on the dishwasher (setting condition).
2. Simultaneously press the buttons “SW2“ and “SW3“ for at least 5 seconds.
[L . . ] is shown in the display:
◆Dgt_1 = [L] (flashes)
◆Dgt_2 = extinguished
◆Dgt_3 = display of the preset water hardness level (between 0 and 9)
Example: Display of the factory-set hardess level.
3. To change the setting, press the button “SW3“, which is marked by the flashing LED “L8“ , within
5 seconds. All other buttons are deactivated.

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◆5 seconds after the button “SW3“ has been pressed for the last time, the dishwasher
stores the set water hardness level and then automatically returns to the original operating
mode.
◆The set water hardness level remains stored when the appliance is switched off.
◆Factory-set water hardness: level 4.
2.7.1 Special regeneration programme
With the new water softening system IWMS the water hardness level for an individual wash programme
can be adjusted as follows (calculation of the cycle intervals starting from a programme with 5 intake
phases per cycle):
◆The cycle counting for the performance of the “special“ regeneration programme is based
on the number of intake phases rather than on the actual cycle number. Therefore, this
process is not dependent on the number and type of the executed programmes.
Water
hardness
level
Autonomous cyles Intake
phases Treated water hardness
°F (TH)
Treated
water hardness
°D (dh)
0no regeneration - 0 - 8 0 - 4
18 cycles: regeneration during
the 9th cycle 40 9 - 14 5 - 8
26 cycles: regeneration during
the 7th cycle 30 15 - 20 9 - 11
34 cycles: regeneration during
the 5th cycle 20 21 - 30 12 - 17
43 cycles: regeneration during
the 4th cycle 15 31 - 40 18 - 22
52 cycles: regeneration during
the 3rd cycle 10 41 - 50 23 - 28
61 cycle: regeneration during
the 2nd cycle 5 51 - 60 29 - 33
70 cycles: regeneration during
each cycle 1 61 - 70 34 - 39
80 cycles: regeneration during
each cycle 1 71 - 80 40 - 45
90 cycles: regeneration during
each cycle 1 81 - 120 46 - 70

Service Manual IGV 689.1 13
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N
◆When the water hardness level is changed, a water softening procedure is automatically
executed for the subsequent program, i. e. independent of the number of inflow phases
that have been performed beforehand.
◆After installation of the new circuit board, a regeneration cycle is automatically performed
during the first wash programme, independent of the preset water hardness level.
Note: The time-out of the solenoid regeneration valve is set to 10 minutes.
◆After a regeneration process, the subsequent water intake is automatically performed
with a static intake phase of 45 seconds (instead of 30 seconds).

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2.8 Washing: with full load/half load
With respect to the distribution of the dishes, the serial settings of the alternating wash phases can be
changed by pressing the button “½ LOAD“ (SW2).
The times of the alternating wash phases are factory-set.
Duration of the alternating wash phases with full and half load
Explanation of symbols:
↑ ↓ = balanced changing function
⇑ ↓ = function mainly in upper dish basket
↑ ⇓ = function mainly in lower dish basket
*) variable changing function (specific variant, see programme table)
When the button “½ LOAD“ is pressed:
♦The prewash cycle is not executed in the programmes 3, 4, 6 and 9.
♦In the programme 2, total drainage of the water during the prewash cycle is replaced by partial
drainage.
♦In all programmes (except for programme 8) one cold rinse cycle is cancelled.
Programme phase Full load ↑ ↓ ½ LOAD ⇑ ↓ ½ LOAD ↑ ⇓
upper
spray arm
t = sec.
lower
spray arm
t = sec.
upper
spray arm
t = sec.
lower
spray arm
t = sec.
upper
spray arm
t = sec.
lower
spray arm
t = sec.
PREWASH 25 25 40 25 25 40
CLEAN 25 25 40 25 25 40
PAUSE 25 25 40252540
COLD RINSE
CYCLES *) 25 / 40 25 40 25 25 40
HOT RINSE CYCLE*) 25 / 40 25 40 25 25 40

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2.9 Specification of drives and sensors
2.9.1 Components
2.9.2 Sensors
2.10 Motor operation
This dishwasher is equipped with an asynchronous single-phase motor with variable speed setting.
A built-in tachometric probe constantly measures the motor speed and transfers it to the electronic
control system.
Component type Power consumption Control type
Circulating pump max. 250 W Triac & Relay
Wash water pump max. 100 W Triac & Relay
Heating element Wash max. 2300 W Relay
Water intake solenoid valve max. 10 W Triac
Reset/fan solenoid valve max. 10 W Triac
Detergent/rinse aid solenoid valve max. 10 W Triac
Regeneration/resin cleaning solenoid valve max. 20 W Triac
Sensor type Type of reading Component type
Salt sensor Digital 5 V Reed
Rinse aid sensor Digital 5 V Reed
Temperature sensor Analog 5 V NTC
Tachometric sensor Frequency 5 V Tacho-generator
Door locking sensor Digital, high voltage Switch
Sensor for protection against leakage Digital, high voltage Switch

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Measurement of the motor speed
♦The motor operation is monitored by the electronic control system which changes the motor speed
for optimisation of the individual wash programmes.
♦The signal transferred from the tachometric sensor to the electronic control system (micro-
processor) indicates the motor speed.
The microprocessor performs a number of calculations via the “supply reduction“ system and then
switches on the Triac in order to generate the respective speed.
♦The following motor speeds are used during the wash programme:
◆1600 rpm: pressure impulse protection routine
◆1900 rpm: mainly during the prewash cycle and
during the water cleaning phases
◆2100 rpm: mainly during the hot rinse cycle
◆2300 rpm mainly during the cold rinse cycles
◆2700 rpm: during the impulse wash cyle
Features
◆Power supply: 220-240V 50Hz
◆Capacitor: 4µF
◆Direction of rotation: bidirectional
◆Cleaning phase: counterclockwise
◆Draining phase: clockwise
Cleaning/draining
The functions CLEANING and DRAINING are activated by alternating supply of the main coil (RM) and
the auxiliary coil (RA).
The control of the motor circuit is realised via the control circuit board. This board:
♦supplies the two coils via TRIAC (TY1) and determines the speed of rotation;
♦determines the alternating supply of the two coils via RELAY (R1).

Service Manual IGV 689.1 17
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Functional priniciple of the motor control circuit:
CLEANING phase
◆RELAY not supplied
DRAINING phase
◆RELAY supplied
Alternating wash cycle
The ALTERNATING WASH FUNCTION is achieved by supplying the motor via a control system, which
provides pauses of a fixed duration when both spray arms are operating.
Impulse wash cycle
In case of the IMPULSE WASH FUNCTION the motor is alternatingly supplied with two rotational speeds
by means of a control system. These phases are interrupted by brief impulses (each interval of (t)
seconds is followed by an interval of (t) seconds).
Impulse wash cycle Upper spray arm Lower spray arm
Motor speed (rpm) 1.900 1.900
Intervals (t) 3 + 5 sec. 4 sec.
Impulses (t)
Motor speed (rpm) 0.6 + 0.9 sec. 2.700 0.8 sec. .,700
sec
sec.
sec.
sec.
IMPULSE
IMPULSE

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2.10.1 Pressure impulse protection
◆When the motor operation is interrupted by opening and repeated closing of the
appliance door during the warm water cleaning phases, pressure impulses may
occur when the motor is started again.
◆A pressure impulse may lead to a leakage of water at the appliance door sealing.
◆The control circuit board performs a special control procedure in order to monitor
the motor operation and to prevent the generation of pressure impulses.
◆This control procedure includes a phase (approx. 20 seconds) in which the motor
runs at a speed of 1600 rpm.
◆This procedure only takes place in the cleaning phases and when the wash
programme is continued after a power failure or when the appliance door has been
opened and closed again.
◆In this phase all power consumers are deactivated.
2.11 Water intake
The latest software permits the control of the water intake by means of a motor speed measuring system
“RVM“ for dishwashers equipped with a motor with tachometric sensor.
The intake phase consists of three subphases:
a) Static intake
b) Dynamic intake
c) Additional intake
a) Static intake phase
◆The intake solenoid valve opens and the water flows into the wash container.
◆The duration of the intake phase is limited to 30 seconds (45 seconds if a regeneration
procedure has been performed during the preceding wash programme). This phase is
followed by a:
b) Dynamic intake phase
◆During the dynamic water intake phase the water volume required for the correct
functioning of the water circuit flows into the water collecting container.
◆The water circuit operates correctly when the water volume in the water collecting
container enables a smooth and continuous pump operation without variations of speed
and generation of cavitation.
◆When this operating condition is reached, the dishwasher is dynamically balanced.
◆In case of a generation of cavitation, the motor speed is increased.

Service Manual IGV 689.1 19
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◆The extent of the generation of cavitation can be measured by comparing the effective
motor speed with a determined objective speed.
This comparison permits the determination of the “speed fault“, i. e. when the motor speed
exceeds the objective speed.
At this point in time the system detects a possible generation of cavitation under consideration of the
following parameters:
1. speed fault
2. duration of the generation of cavitation
1. Speed fault
◆The speed fault must exceed the respective threshold value.
◆In order to determine this condition, the electronic control system adds the objective
speed value to the threshold value.
2. Duration of the generation of cavitation
Test results have shown that a typical generation of cavitation normally lasts approx.
200 msec.
The task of this system is thus to detect a generation of cavitation and to determine the exact
point in time when the water circuit reaches the dynamical equilibrium.
In order to recognise the occurrence of a generation of cavitation, a speed fault to which the
following parameters are applicable, must be detected:
◆higher than the threshold value
◆duration longer than 200 msec.
Detection of the “LMI“ water level
When the water intake control system detects the condition of dynamical equilibrium, a
number of tests are conducted in order to check the stability of this operating condition and to
determine whether the “LMI“ water level has been reached.
Objective speed
rpm Threshold value rpm Speed fault rpm
2300 40 > 2340

20 Service Manual IGV 689.1
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Stability control:
This control phase lasts for a time period of max. 20 seconds during which:
◆the “LMI“ water level is considered as reached when no generation of cavitation has been
recognised for more than 20 seconds. The phase of the dynamic water intake is thus
completed and the additional water intake phase starts.
◆If the generation of cavitation is detected (within the defined time period of 20 seconds
and for a longer duration than 200 msec), the intake solenoid valve opens intermittently
in order to enable the intake of new water.
◆Afterwards the stability tests are repeated.
Intake time
The maximum total intake time amounts to 2.5 minutes. The solenoid valve may be open
during this time period. The time period comprises the following intake phases:
a) static intake phase
b) dynamic intake phase
Besides that, a time of max. 4 minutes has been defined during which a time-out will be
triggered. This time-out puts the appliance in an alarm condition if the “LMI“ equilibrium is not
reached within the dynamic intake phase due to the generation of cavitation.
c) Additional water intake
If the “LMI“ level is reached, an additional water intake phase of variable duration (approx. 3 +
5 sec.), varying from phase to phase, is executed.