Laundrylux CROSSOVER 2.0 Series Installation guide

CROSSOVER 2.0
TRAINING MANUAL

CROSSOVER 2.0
SERIES
W A S H E R SERVICE SCHOOL
DOC. NO. 098017
EDITION 25.2018

Technical Data
Contents
Technical Data
1:1
Machine Overview
2:1
Machine Presentation
2:x
Component Identification
2:x
Display Panel
2:x
Control Board (A1)
2:x
Inverter (U1)
2:x
Drum Motor (M1)
2:x
Doorlock (A111)
2:x
Door Unlock Delay Unit (A31)
2:x
Water Valves (Y11, Y13, & Y21)
2:x
Drain Pump (M2)
2:x
Level Sensor (B1)
2:x
Anti-siphon tube
2:x
Loading door
2:x
Door Bellows-gasket
2:x
Front Panel
2:x
Wash Program Description
3:1
Wash Program Tables
3:x
Coin/Serial Mode Configuration
4:1
Coin Price Programming
4:x
Service Mode
5:1
Real Time Clock Promotion Setup
6:1
Trouble Shooting
7:1
Display Indicators & Error List
7.x
Diagnostic Flowcharts
7:x
Wiring Diagrams
8:1
Bearing Replacement
Appendix
1

Technical Data
Crossover 2.0
Technical Data
Inner drum
volume liters/ft3
diameter mm/inch
98 /3. 5
554/21 13 / 16
Drum speed
wash rpm
extraction max rpm
45
1050
G-factor
Weight, net kg/lbs.
306
136 / 300
Connections
Water valves
connection
DN20
3/4" Garden Hose via included hoses
Rec. water pressure psi
kPa
30-90
200-600
Functioning limits psi
for water valve kPa
8-145
50-1000
Capacity at 45 psi
(300 kPa) gallon/min
liter/min
2 .6
10
Drain hose inch
outer Ø mm
1
25
Draining gallon/min
capacity liter/min
5
20

Technical Data
Crossover 2.0
1 Power Line
2 Air Vent for Safety
3 Cold Water
4 Hot Water
5 Drain Outlet
6 Coin Meter (coin operated models only)
7 Control Panel
8 Detergent Dispenser
9 Door
Fig. 2.2
NOTES:
A 1098mm = 43 1/4 inch
B 584mm = 23 inch
C 310mm = 12 3/16 inch
D 686mm = 27 inch
E 765mm = 30 1/8 inch

Machine Overview
General:
The machine features an electronic control unit (CPU) with wash programs and options that can
be modified in Service Mode by register programming and augmented with hardware options
such as external liquid dosing, “promotion” event discount price programming, or networking.
The drum motor is powered by an inverter that synthesizes three-phase power from a single
phase 120 VAC input. The inverter also provides control and power to the water inlet valves,
drain pump (or valve), the doorlock controller (signaling lock or unlock), and external chemical
injection pumps.
The machine may be set to run for free in OPL mode; or with coin, card, or other central
payment systems.
The machine has built-in self-diagnostic functions which aid in troubleshooting machine faults.
The most recent fault codes are saved.
The machine is soft mount and should be leveled during installation for proper operation.
Metric fasteners are used throughout the construction.
Function Overview:
The drum/motor assembly is suspended by two top-mounted tension springs at the front of the
machine and two bottom-mounted compression springs at the back. Four shock absorbers and
two cast iron counterweights mounted on the front and rear of the outer drum dampen
excessive vibration for out-of-balance load handling. The inner drum is belt driven by a motor
mounted to the rear-outer drum. Belt tension is fixed and does not need to be adjusted.
One hot and two cold water valves flush the detergent, softener, and bleach compartments
while filling the machine. Activating the hot water valve (Y21) or the cold water valve (Y11) fills
the detergent compartment on the left. The center cold water valve (Y13) fills the bleach
compartment on the right. When both cold water valves (Y11 and Y13) are activated the
intersecting streams fill the center softener compartment. Water is drained from the machine via
a pump. Water levels are monitored by a pressure transducer via a level sensor hose
connected to the bottom of the outer drum. Wash cycle temperature setting is enabled by
turning on the cold and/or hot water valves. Water temperature is not monitored by the CPU.
The machine is not fuse protected and should be connected to a breaker as specified in the
installation manual.
During a wash cycle, INTERLOCK voltage L1ʹ and Nʹ must be asserted at the inverter. The
INTERLOCK circuit passes through the doorlock’s door-locked switch (S4) which must be
closed AND locked for the machine’s subsystems to receive power.

The machine has an independent door-unlock delay unit, which will unlock the door 180
seconds after power is removed allowing extracting clothes to come to a compete stop. The
water level is not monitored. If power is reestablished, the door will relock and the cycle will
continue.
IF POWER IS REMOVED WHILE THE MACHINE IS RUNNING A WASH
PROGRAM, WHEN POWER IS RESTORED THE MACHINE WILL RESUME AT
THE POINT ON THE CYCLE WHERE POWER WAS REMOVED.
On Crossover 2, the controller has a built-in real-time clock which is used for activating price
reduction events, time stamping error code logs, and time stamping coin vault access.
On Crossover 1, the top panel is demounted by removing the two T15 Security Torx screws at
the rear of the top panel and them pulling the cover back and up.
On Crossover 2, the top panel is demounted by removing the security bolt behind the payment
area. A service key is required.

Crossover 2.0
Fig 2.4
Crossover 2.0
Machine Presentation
1
Soap dispenser
14
Doorlock (A111)
2
Water inlet valves (Y11, Y13, Y21)
15
Door
3
Anti-siphon Hose
16
Door Closed Switch (S3)
4
Inverter/Power Controller (U1)
17
Display Controller (A1)
5
Drum
18
Pump (M2)
6
Motor (M1)
19
Shock Absorbers (x4)
7
Compression spring (x2)
20
EMI filter
8
Level Sensor (B1)
21
Security bolt (Service key required)
9
Door Unlock Delay Unit (A31)
22
Service Lock
10
Pump (M2) harness interconnect
11
Doorlock (A111) harness
interconnect
12
Tension spring (x2)
13
Service Switch (S2)
NOTE: Removal of the top cover for component access requires removal of the security bolt
#21 behind the Coin/Card faceplate mounting panel.

Component Identification
A1 CPU Circuit Board
A31 Door Unlock Delay Unit
A111 Door Lock
B1 Water Level Sensor
F1 Motor Overheat Switch
M1 Drum Motor
M2 Drain Pump
U1 Power Module / Inverter
S2 Service Switch
S3 Door Closed Switch
S4 Door Locked Switch
Y11 Cold Detergent Valve
Y13 Cold Bleach Valve
Y21 Hot Detergent Valve

Display P a nel
Fig. 2.5 Display Board
The control panel consists of program selection buttons (A), option buttons (B), a start button
(C), and a display (D) Depending on the mode these have different functions.
Operating Mode
Service Mode
A
Program selection buttons
Change register parameter
B
Wash program option buttons
Register navigation
C
Wash program start
Save register parameter changes
D
Display indicating price of programs,
program time remaining, and cycle
completion.
Register parameter values,
machine component status, and
error code display
OPERATING MODE: The display control panel displays the vend price and allows the
selection of the main wash programs. As desired, options can be selected to modify the wash
programs to adjust for load type and soiling. After program start, the time remaining is
displayed until the cycle complete at which point “done” is displayed.
SERVICE MODE: In service mode the display control panel: enables service mode access
via PIN; reading statistics and error coded registers; machine serial/coin mode change;
setting prices and program parameters; machine component activation; and Real Time Clock
promotion events setup. The control board (A1) retains all register value information. In the
event of faults, error codes will be displayed. See the “Error Codes” section of this manual.

Control Board (A1)
Fig 2.6 Control Board (A1)
The CPU control board (A1) is mounted directly behind the display panel. It has: seven switches
activated by the buttons on the display panel; a CPU reset switch on the back; four 7-segment digits;
and an audio chime. Crossover 2 also have a real time clock (RTC) chip on the CPU PC board. The
CPU has a communication port for connection to an optional network module. All register parameters
and machine settings are stored in on-board, non-volatile memory.
The A1 board provides connectivity to the service switch (S2), the optional external price discount
switch (S1), Coin1/Coin2 (pulse) and serial connections, input from the level sensor and power from
and two-way communication with the power board/Inverter (U1). All connectors have a unique pin
count or color to prevent misconnection. The wiring diagram maps the connectors 1-1 with the
physical board layout when looking at the front of the board.
Connections (right-to-left). Connections not required are marked “optional”
CN1: Power Board/Inverter (U1) and Level Sensor (B1)
CN2: COIN1 (Default = 0.25) Connector body color is RED, optional.
CN8: COIN2 (Default 1.00), optional.
CN3: Service Switch (S2)
CN5: External Discount promotion, optional. (S1)
CN7: Network module Crossover 2 only, optional.
CN4: Serial connection for payment system, optional.

The A1 board on some models has a 24-hour Real Time Clock/Calendar. The clock is set up by the
installer and is synchronized to the start-of-minute when time adjustments are made, allowing all
machines to be synchronized. The clock is used to time-stamp error codes, time-stamp coin vault
access, and allow up to four day-of-week and time-specific price promotion events.
The A1 board can be reset to factory “default” register settings by pressing and holding the “reset”
button on the rear of the control board, accessible through a hole in the rear module cover. The board
will give an audible “chime” indicating reset has occurred. Statistics, error logs, and certain other
registers are unaffected by CPU reset. The machine will be set to COIN mode, price = $0.00 and all
configuration registers are loaded with their factory-default values.
If required, a firmware update is accomplished by replacing the A1 board.

Power Controller/Inverter (U1)
`
Fig 2.7 U1 Power Controller/Inverter
The power module/inverter U1 is located on the rear wall of the machine. Connections include:
power and INTERLOCK, display board, drum motor, water valves, pump, doorlock, and
external liquid supply. U1 is secured to the rear of the machine with four screws. U1 is not fuse
protected.
Connectors are unique by size, color or terminal count and are listed below counter-clockwise.
CN1: Motor Overheat Switch located on Drum motor M1 (normally closed)
CN2: INTERLOCK, L1’, N’ (120 vac, when the doorlock is activated)
CN3: Power L1, N (120 vac continuous)
CN4: Cold Detergent Valve Y11 (120 vac, when activated)
CN5: Cold Bleach Valve Y13 and Hot Detergent Valve Y21 (120 vac, when activated)
CN6: External Liquid Supply (120 vac, when activated)
CN7: Pump M2 (120 vac, when activated)
CN13: Door-closed switch S3 and lock and unlock coil all located on doorlock A11
CN22: 12vdc power and communications with CPU Display Board A1
CN17: Tachometer located on Drum Motor M1
CN18: Motor windings (3 phase) drum motor M1 (See wiring diagram for resistance)
INTERLOCK: In order for components (M1, M2, Y11, Y13, Y21, External Liquid Supplies) to
receive power, L1’,N’ INTERLOCK voltage must be present at U1:CN2. This circuit passes
through the two S4 doorlock safety switches on the doorlock A111. Thus, the door must be
closed locked for the machine to operate.
Circuit GROUND: The “logic” ground on the U1 and A! circuit boards is not at earth ground
potential. This means that any machine harness, payment system harness, or component
insulation failure leading to a chassis short, including the circuit ground, can potentially damage
the U1 and / or A1 circuit boards.
CN1
CN2
CN3
CN5
CN4
CN6
CN7
CN13
N.C.
CN22
CN17
CN18

Drum Motor (M1)
The drum motor (M1) is a synchronous 3 phase
motor with tachometer and overheat switch (F1)
that opens at 150 C. These components connect
to the machine’s main harness using a single
seven position connector that in turn, connects to
the U1:CN1, CN17 & CN18 connections on the U1
inverter. The motor connector is physically
attached to the motor frame with snap in pins and
a cable-tie. Dislodging this connector during
machine installation can lead to motor related fault
codes.
The motor drives the washer’s inner a drum via a
belt and pulley. The center of the drum and motor
shafts are fixed, thus and belt adjustment is not
required. The motor is demounted by loosening
the two mounting bolts and pulling the motor out of
the rear access panel of the machine.
The inverter monitors motor current and RPM to
determine load balance and if required (due to
unbalanced loads) reduce extraction speed. There
is no unbalance switch.
Fig 2.8 (M1) Harness connection
Fig 2.9 Pulley and belt

Doorlock (A111)
The electromechanical doorlock (A111) is
secured to the right side of the front panel with
three screws.
A111 has a lock and unlock coil sharing a
COMMON line and is bi-stable in the
unlocked/locked condition when activated with a
24 vdc pulse.
The doorlock engages the door catch to ensure
the door is closed AND locked during operation.
Two independent circuits routed through A111
to the inverter (U1) ensure these two conditions
are met.
1. S3 Door-Closed switch: Normally open
contact. Closing the loading door depresses
the switch plunger and closes the switch
contact.
2. S4 Door-Locked switch: Normally open 2-
pole contact. Locking the loading door closes
the switch contact and energizes the “Interlock”
signal at U1-CN2 (120 VAC).
The doorlock is the primary safety component of
the machine. It MUST always be replaced if
defective, and never repaired. In addition, the
door-closed and door-locked (INTERLOCK)
circuits MUST never be bypassed.
All doorlock signals can be accessed at U1:CN13
and U1:CN2 or at the doorlock interconnect
connector located near the service switch (S2)
S3 Switch
Lock/Unlock
Coil
S4
INTERLOCK
Door
Latch
Manual
Release
Mounting
Screws x3
S3
S4
Fig 2.10 (A111) Doorlock
Fig 2.11 Doorlock
Interconnect
Fig 2.12
Doorlock
Mounting
Screws

Doorlock Unlock Delay Unit (A31)
The Door Unlock Delay Unit (A31) will unlock the
machine approximately 3 minutes after disconnecting
power. A31 has two onboard capacitors that are
charged via the A31’s direct connection to L1 and N.
When power is disconnected from the machine an
onboard timer activates. After 180 seconds, the time it
required for a full load at maximum extract to come to
a stop, the onboard relay discharges the capacitor to
the unlock coil on the Doorlock (A111) allowing the
door to be opened. Care should be used when opening
the door after disconnecting power, as water could spill
from the machine.
If the machine is unattended in the event of a power
failure lasting longer than approximately 3 minutes
followed by power restoration, the CPU will relock the
door and continue the cycle.
The A31 has a connectorized harness with 12 VDC,
250 ma available for optional payment systems.
Fig 2.13 (A31) Doorlock Unlock Delay Unit

Inlet Valves (Y11, Y13, & Y21)
There are two water inlets feeding two cold water
valves (Y11) and (Y13) and hot water valve (Y21). The
valve is METRIC DN20, 20 mm thread. Do not use
standard ¾ in G.H thread as this will damage the valve.
Use the two provided supply hoses included in the
drum kit. The straight end marked “supply” is standard
¾ in Garden Hose thread. The right angle end marked
“machine” is DN20mm must be threaded onto the
machines’ connections. The cold water inlet feeds cold
water valves (Y11) and (Y13) and the hot water inlet
feeds (Y21).
The detergent drawer has three compartments
flushed by various combinations of valves.
1) Detergent: Y11 and/or Y21
2) Softener: Y11+Y13 (both valves on)
3) Bleach: Y13
1 2 3
Fig 2.14 Inlet Valves
Fig 2.15 Detergent Drawer
Fig 2.16

Drain Pump (M2)
The drain pump (M2) is a 120-vac electrical pump
located on the bottom of the machine at the front-left.
The filter basket is accessible from the front of the
machine for cleaning either by removing the plastic
caps on the left side of the kick panel on or demounting
the kick panel depending on model.
The machine can be drained using the bleeder hose to
the left of the filter cap.
The pump is connected to the inverter’s U1:CN7
connector. The pump’s harness has an inline
connector located near the Service Switch (S2) at the
top of the machine. Voltage and pump-motor winding
resistance can be conveniently measured there.
Level Sensor (B1)
The level sensor is mounted to the right side of the
machine and monitors the water level by measuring
the air pressure in the sensor hose connected to the
bottom rear of the outer drum. There are no
adjustments to be made on this component. Water
level adjustments are made through parameter-
entry in the A1 PCB’s service mode.
Anti-siphon hose
The machine has a built-in anti-siphon tube
connecting the drum to the drain hose rear-wall
elbow connection. The tube allows air to fill the drain
hose when the pump is not running, thereby
preventing siphoning of water from the drum.
Fig 2.17 (M2) Pump
Fig 2.18. Pump Motor Interconnect
Fig 2.19 (B1) Level Sensor
Fig 2.20 Anti-siphon hose

Loading Door
The loading door is demounted by removing four
screws and lifting the door up and forward to clear
the mounting hooks. The door can be disassembled
to correct mis-alignment caused by wear and tear or
excessive force applied to the door.
Fig 2.21 Loading Door Mounting
Fig 2.22 Loading Door
Hinge Assembly

Door Bellows-gasket
The door bellows is oriented with its drain holes at
the bottom. The bellows is secured to the outer drum
with a wire ring, tightened by a 7mm hex-head
screw.
The outer, front part of the bellows is secured to the
front panel with a clamp spring.
An outer boot clamp tool is available to assist in
remounting the spring.
Fig 2.23 Bellows-boot drain holes
Fig 2.24 Bellows clamps
Fig 2.25 Bellows clamp tool