Kuppersbusch IW 1409 Operating instructions

KÜPPERSBUSCH
AFTER-SALES SERVICE
Repair Manual
Washing machine
IW 1409
GB

Contents
1. Safety Notes .......................................................................................................... 2
Connect the water supply.................................................................................... 2
2. Operation ............................................................................................................... 3
3. Consumption/energy requirements ........................................................................ 4
3.1 Consumption values...................................................................................... 4
4. Function description/Technical Notes .................................................................... 5
4.1 General ......................................................................................................... 5
4.2 Motor control ................................................................................................. 7
4.3 Washing ........................................................................................................ 8
4.4 Fuzzy logic quantity sensing ......................................................................... 8
4.5 Fuzzy logic in the spin cycle.......................................................................... 9
5. Maintenance ........................................................................................................ 10
5.1 Variant coding: Service module .................................................................. 10
5.2 Variant coding: Control and power module ................................................. 12
6. Supplement ........................................................................................................ 13
7. Activate test program............................................................................................ 13
8. Select test program .............................................................................................. 14
8.1 Test program - motor .................................................................................. 14
8.2 Test program - solenoids, W-regulator, heater............................................ 15
8.3 Test program keys, speed and program selector........................................ 16
8.4 Test program - variant display..................................................................... 18
8.5 Test program - safety elements .................................................................. 19
8.6 Test program - consumer ............................................................................ 20
8.7 Safety-check ............................................................................................... 20
8.8 DEMO-Program .......................................................................................... 21
8.9 HES - Coupling module............................................................................... 21
9. Circuit digrams...................................................................................................... 21
10. Fault display ......................................................................................................... 32
VKS-H Repair Manual
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
1For internal use only

1. Safety Notes
Disconnect the device from the mains before attempting any repairs.
When performing tests which must be done under power, a fault current
protection switch must be used.
Before beginning troubleshooting, perform a safety check per VDE 0701.
Observe EGB notes!
After repairs are complete, a function and seal test as well as the safety
test per VDE 0701 must be performed.
Connect the water supply.
Activate the test program:
•Set program select switch to new selection.
•Turn on the mains switch while pressing the PREWASH and START buttons.
•If test program is activated, the START button flashes.
•Activate the safety test program (Easy-care 60°C). Water fills to Level 1.
•When heating current flows, perform safety test.
•After completing the safety test, check whether the window is still lok-
ked. If not, repeat test procedure!
VKS-H Repair Manual
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2. Operation
1. On/Off button
•For turning the appliance on and off (2-pole main switch).
2. Window button (optional)
•With Bowden cable for opening the fill window through a PTC locking relay.
3. Program selector
•The program selector is a rotary switch with 24 positions for dividing the
cycles into Boil/Colours, Easy-Care, Delicate, Wool and special cycles
with varying wash temperatures.
4. Speed selector
•The speed selector is an 8-position rotary switch. Six speeds, IVS (interval
spin) and rinse stop can be selected.
5. Pre-wash
•Pre-wash can be selected optionally. For wool, pre-wash is not carried out
even if it is selected.
6. Time save
•The wash time is reduced om the main wash cycle.
7. Water plus
•For increasing the water level when washing and activating an additional
rinse cycle.
•Spin rinse with reduced speed for boil-fast/coloured wash.
•No spin rinse with wool.
8. Heavy
•For extending the active wash time for heavily soiled laundry. For adding
the powdered bleach/spot remover at the optimum time. Functions only
with no pre-wash!
VKS-H Repair Manual
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3For internal use only

9. Start time and time remaining (optional)
•The program time can be delayed up to 19 hours. Time remaining display
in minutes.
10. Start
•For program start.
11. Program display
•LED’s are used to display the corresponding program status.
3. Consumption/Energy Requirements
3.1 Consumption values
Wash
program
Load
capacity
(kg)
Energy
consumption
(kwh)
Water
consumption
(l)
Maximum
program
duration
(min.)
Boil-fast
90°C
5.0 1.7 59 137
Boil-fast 60°C
Eco
5.0 1.3 55 140
Colours
40°C
5.0 0.6 55 115
Easy-care
40°C
2.0 0.4 50 83
Delicates
30°C
2.0 0.5 65 64
Wool
30°C
2.0 0.5 55 58
The consumption values are derived by the test program in accordance
with IEC456/IEC59(CO)37. The indicated times are based on an average
load. They may, depending on local conditions, vary (e.g., water inlet
temperature, batch size, etc.).
VKS-H Repair Manual
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4. Function Description/Technical Notes
4.1 General
The ME2/ME3 control is based on a simple electronic controller. The control
consists of:
•control and display module, mounted in the panel,
•control and power module, ounted on a sheet metal panel beneath the
sill plate.
4.1.1 Control and display module N1
Located on the control and display module are the program selector, the
speed selector, as well as various button switches and the associated
LEDs. Jumpers are used to code the variants.
Optionally available is a start and time remaining display.
4.1.2 Control and power module N7
The control and power module contains all the important components like
the microcontroller and the required switching elements for controlling and
sensing the motor, pump, valves temperature sensor, etc.
Along with the drive functions, the control/power module assumes complex
functions such as wash sequences, rinse and spin functions, temperature
and speed regulating, safety functions, keypad monitoring, determining
parameters (load size, misbalance, etc.), and jumper-determined variant
coding.
VKS-H Repair Manual
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Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
5For internal use only

The electronic functions can be divided into the following groups:
•Reading and processing incoming signals (speed, temperature, mains
voltage, frequency, phase, control elements, etc.).
•Logical relating of all the information provided with the help of the stored
program.
•Speed control of the motor.
•Load sensing for various load sizes with the help of fuzzy logic functions
for washing, rinsing and spinning.
•Fault detection (short-circuit in motor triac, tacho fail, NTC fault,
synchronisation failure).
•Sensing excessive times (pumping, heating, water fill).
•Currentless reversing using two relays, triac short-circuit for power-off.
•Field reversing of the motor using a relay (optionally available).
•Temperature regulation.
•Serial interface for testing and checking purposes.
•Integrated test program for function and customer service checks.
•Reading the RAM and EEPROM for diagnostic purposes.
4.1.3 Power failure
When power is lost the selected program stays in memory. When power is
restored, the program is resumed from that point. However, all wash times
are set to zero, full load is recognized, and the suds detector is reset.
VKS-H Repair Manual
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For internal use only 6

4.2 Motor Control
The motor is controlled by means of triac phase-control. A speed signal
makes speed control possible. The actual speed value is compared with
the setpoint in the electronics.
Direction changing is currentless, using two reversing relays controlled by
the electronics.
An integrated protector in the motor winding shuts the motor off upon
overload.
The control does not switch off based on a speed signal fault, but rather
keeps trying to restart the motor.
A motor fault is only displayed at the end of the program.
Optionally, for spin speed 800 rpm, a field reversing relay is actuated
above 600 rpm. This switches off a part of the motor field winding and
thus increases the rpm.
The following speeds apply to a washing machine with empty drum:
Wool 27 rpm
+/-5%
Wetting: 35 rpm
+/- 3%
Rinsing: 50 rpm
+/- 3%
Washing: 50 rpm
+/- 3%
Spin: all spin numbers
+/- 2.5%
Measuring rpm (imbalance): 100 rpm
+/-1%
VKS-H Repair Manual
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7For internal use only

4.3 Washing technique
Through use of asymmetrical catches together with fuzzy logic control,
delicate or powerful washing can be selected depending on the type of
clothing and the program chosen.
This is controlled through the up to 16 different reversing rhythms and the
turning direction of the washing drum. For this reason the left- and right-
handed rotation times of the wash drum are different.
Clockwise rotation: The water runs later out of the catches, the
wash rather slides off, i.e., the clothes are
washed delicately.
Counter-clockwise rotation: The water runs out of the catches sooner,
the wash is raised higher, i.e., the clothes
are washed with more force.
4.4 Fuzzy logic quantity sensing
Flow quantity measurement Time after program start until level 1
is reached
Load sensing Valve opening times until level 1
is added
VKS-H Repair Manual
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4.5 Fuzzy logic in the spin cycle
** Imbalance sensing The measurement is made at 100 rpm.
If the imbalance is too great, the cycle is interrupted
and restarted up to 11 times.
* Load sensing If the 100 rpm can be held without large fluctuations
in speed, the speed is reduced to 75 rpm and the
load quantity is detected.
The ramping and the final spin speed is determined by the degree of imbalance:
High imbalance steep ramp low rpm
Low imbalance flat ramp high rpm
VKS-H Repair Manual
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
9For internal use only

5. Maintenance
5.1 Variant coding: Service modules
Sectional view
For the service modules used in series production models, the variant coding
is done by punching out certain conductor paths.
For customer service there is a special service module where the conductor
paths are replaced by wire jumpers (Jumpers J1-J6). In addition, the CS service
module is equipped with a beeper.
When repairs are done, the service module must be correctly set by the
CS technician according to the model/type.
This means wire jumpers (Jumpers J1-J6) must be removed according to the
diagram.
VKS-H Repair Manual
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Variant coding
x Jumper set
•Open jumper or cut through!
J1 J2 J3 Max. speed/deselect steps (rpm)
X - X 1400, 1200, 1000, 800, 600, 400 Motor with 7
connections
- X X 1300, 1200, 1000, 800, 600, 400
X X X 1200, 1100, 1000, 800, 600, 400
- - X 1100, 900, 800, 600, 500, 400
XX -
1200, 1000, 1000, 800, 600, 400 Motor with 6
connections
---
1100, 900, 800, 600, 500, 400
-X-
1000, 900, 800, 600, 500, 400
X- -
900, 800, 700, 600, 500, 400
For models without field reversal
J4 Warm water
X without
-with
J5 Time remaining
X without
-with
J6 Wash type
X Standard
- Export
Setting the beeper signal
The signal sounds at the end of the program, at the end of a rinse cycle, or
when there are operating faults. The volume may be varied.
•Turn on appliance.
•Hold down PREWASH button.
•The signal goes from loud, medium, soft, to off.
•Release the PREWASH button when the desired
volume level is reached.
VKS-H Repair Manual
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
11 For internal use only

5.2 Variant coding: Control and power module
There is only one wire jumper (Jumper 1) on the control and power module
which needs to be noted.
Wire jumper J1 remains in only for warm water variants.
Note: Remove wire jumpers carefully in order to avoid short-circuits
with adjacent jumpers or components.
Use side-cutters designed for electronics!
If a jumper is advertently cut, it may be soldered in again.
For soldering, use a small gas soldering appliance with solder
wick or vacuum solder remover. Only in this way can the electronics
be protected from damage.
VKS-H Repair Manual
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6. Supplement
Grease-resistant window seal
A grease-resistant window seal is available under spare parts number 29
61 40.
For use only when unusually high amounts of grease or oil are present,
e.g., children’s ward (salves) in a hospital.
7. Activate test program
Activate
test program: •Program select switch to New
Selection
•Press PREWASH + START
keys,
•and turn the unit on
Display:
•Start LED flashes
•optional, 7-segment
display:
- Level (e.g. n0) or
- Last stored error
(only at 1st activation)
Set test program: •Set progam switch
to test program
•Start LED flashes
Start test
program:
•Press START button •Start LED stays on
•Error display neutral
Abort test
program:
•Press START button or
•change program selector
•Start LED flashes
Test program
ended:
•Start LED flashes
Error in
test program:
•Error number in test sequence
VKS-H Repair Manual
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13 For internal use only

8. Select test program
Note program select switch function!
Function: Test program
Whites/Colours 30°Motor
Whites/Colours 40°Solenoids, W-regulator, heater
Whites/Colours 60°Keys, speed selector, program selector
Whites/Colours 60°e Model display (LED’s sequence)
Whites/Colours 90°Display elements (LED’s and 7-segment display)
Whites/Colours Consumer test (for CS and Rep test)
Easy-Care 60°Safety test
Wool 40°Demo program
Wool For HES appliances: coupling module
8.1 Test program - motor
"Whites/Colours 30°C"
Test: Sequence: Time:
Reverse •CW at 50 min-1
•Pause
•CCW at 50 min-1
•Pause
5 sec.
5 sec.
5 sec.
5 sec.
Spin/
pump
•continuous rise to nmax
after imbalance (100 min-1)
•Catastrophe check only
•Field reversal (Relay K7) at 600 min-1
depending on model
•Spin at nmax 10 sec.
VKS-H Repair Manual
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8.2 Test program - solenoids, W-regulator, heater
"Whites/Colours 40°C"
For warm water variant through warm water valve, pulsed
Heater raises temperature by approx. 3°C (for heating to 60°C, press
WATER PLUS)
VKS-H Repair Manual
IW 1409 H6-400-02-01
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15 For internal use only

8.3 Test program - keys, speed and program selector
"Whites/Colours 60°C"
(Window optionally locked)
Exit the program by pressing the START button
LED over
On/Off
button*
Buttons Pre-wash X
Time save X
Water plus X
Heavy X
Start time X**
* Switching state changes as long as held
** Here the 7-segment display shows 1.8.8
Option
7-segm.
display
LED keys Sequence display
Pre-
wash
Time
save
Water
plus
Wash Rinse Spin
Speed selector 0X X
1X X
2X XX
3X X
4X X X
5X XX
6X XXX
7X X
In this position the buzzer (option) is also activated
VKS-H Repair Manual
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Set volume (in normal mode):
The buzzer sounds at the end of a cycle, at rinse stop or under fault conditions.
Its volume can be set.
•Turn appliance on.
•Hold down PRE-WASH key.
•The volume changes from loud to medium to soft to off.
•Release PRE-WASH key when desired level is reached.
option
7-segm.
display
LED keys Sequence display
Pre-
wash
Time
save
Water
plus
Wash Rinse Spin
Program
selector
Whites/
Colours 90 1 X X
eco 60 2 X X
60 3 X X X
40 4 X X
30 5 X X X
6 XXX
Easy-Care 607 XXXX
50 8 X X
40 9 X X
30 10 X X
cold 11 X X X
12 X X
Delicates 40 13 X X X
30 14 X X X
cold15 X XXX
16 X X
Wool 40 17 X X X
30 18 X X X
cold19 XX XX
20 XXX
Extra rinse 21 XXX X
Add
softener 22 XXXX
Drain 23 XXXXX
New
selection 24 X (X) (X) (X) (X)
(X) Display status depends on respective setting of speed selector
VKS-H Repair Manual
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8.4 Test program - variant display
"Whites/Colours 60°e"
(Window optionally locked)
LED Drain LED flashes, if jumper (J...)
is open
Key Water plus J6
Time save J5
Pre-Wash J4
Heavy Frequency sensor 60 Hz
Program Wash J3
Rinse J2
Spin J1
Variant coding
x Jumper in
- Jumper out or cut
J1 J2 J3 Max. speed/deselect steps (min-1)
X - X 1400, 1200, 1000, 800, 600, 400
- X X 1300, 1200, 1000, 800, 600, 400
X X X 1200, 1100, 1000, 800, 600, 400
- - X 1100, 900, 800, 600, 500, 400
XX -
1200, 1000, 1000, 800, 600, 400
---
1100, 900, 800, 600, 500, 400
-X-
1000, 900, 800, 600, 500, 400
X- -
900, 800, 700, 600, 500, 400
For models without field reversal
VKS-H Repair Manual
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For internal use only 18

J4 Warm water
X without
-with
J5 Time remaining
X without
-with
J6 Wash type
X Standard
- Export
8.5 Test program - Display elements
"Whites/Colours 90°C"
(Window optionally locked)
Check display elements by:
•LED flashing
in half-second intervals
LEDs 7-segment
display
LEDs program Wash
Rinse
Spin
1.1.
2.2.
3.3.
LEDs keys Start
Pre-Wash
Time save
Water plus
Heavy
Start time
4.4.
5.5.
6.6.
7.7.
8.8.
1.8.8.
VKS-H Repair Manual
IW 1409 H6-400-02-01
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19 For internal use only