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
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
For internal use only 2

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
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
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
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
For internal use only 4

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
IW 1409 H6-400-02-01
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
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
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
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
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
IW 1409 H6-400-02-01
Responsible: Rutz Phone: [phone] Fax: [phone] ate: 21.04.1998
For internal use only 8

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