Smeg GW0160 User manual

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SERIE GW0160 - GW2145 - GW1160 - GW4060 - GW4190
SERIE PW4060
SERIE WD2145 - WD1160 - WD4060 - WD4190
- TECHNICAL MANUAL -
19 490 0015 06 – EN 13/06/2016 Heading, new m dels: GW0160, PW4060
Manual Ed. Date Rev. Note
1 INTROD CTION
This d cument is a c mpendium intended f r the use f auth rised engineers.
It must be used:
1. By the engineers who have been specifically trained by the manufacturer t perf rm maintenance w rk n the pr duct
2. In association with the device’s user manual
3. In association with the latest-version electrical and functional diagrams.
Alth ugh this is n t always necessary, it sh uld be remembered that the “Tracelog” software made available by the manufacturer
all ws c mmunicati n with the instrument/glassware washers c vered and is a useful troubleshooting aid f r technical staff.
F r details f spare parts and the latest-versi n d cumentati n, please visit www.smegtech.c m.
The diagrams sh wn can als be d wnl aded in pdf f rmat fr m the www.smegtech.c m website.
N.B.:
The diagrams sh wn bel w refer t the GW4060 and WD4060 m dels.
F r c mplete technical d cumentati n f r all the m dels in the range, visit www.smegtech.c m
The training f technical staff, pr vided by the main Cust mer Care service, is essential f r the c rrect maintenance r repair f
devices.
2 START- P
The user is responsible for preparing the utility systems required t all w the device t be c nnected and supplied c rrectly and
for positioning the device.
Refer t the user manual and the “INSTALLATION REQUIREMENTS” d cument.
The authorised engineer puts the device into service, checking:
1. that it has been installed correctly:
a. plumbing h kup;
b. electrical h kup;
c. that it is p siti ned in acc rdance with the relative requirements;

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2. That the device is operating and has been set up correctly:
a. date/time setting;
b. mains water hardness setting;
c. demineralised water yes/no setting;
d. setting f the presence of optionals as appr priate f r the m del c ncerned (e.g. P3, Acquast p, “FLSW” fl w
switches, etc).
In additi n t the ab ve checks, the engineer must:
1. Run program “16 SERVICE”, preferably twice in successi n, t prime the detergent intake lines correctly.
2. Run a complete cycle (with drying phase if featured in the m del) and test the device t ensure that it is perating
c rrectly (e.g. test program accessible fr m the device's SETUP menu).
The operations summarised above must be performed and recorded in accordance with the checklist provided by the
manufacturer, using the “IN-SERVICE TEST RECORD” form (“REG STRAT ON OF CORRECT OPERAT ON AT THE USER'S
S TE”) .
The authorised engineer is responsible for training the staff assigned to use the device at the time of installation.
The device may nly be used by specifically trained staff.
The training f the staff resp nsible must include specific inf rmati n n the p ssible risks inv lved in the use f the device, and
training in the safest p ssible way f carrying ut the perating pr cedures.
The installati n engineer is als resp nsible f r notifying the responsible authority of the SER and S PER SER passwords f r
access t the setup parameters.
2.1 TEST PROGRAM
F r firmware versi n pri r t 4.6: the test pr gram c nsists f just 2 phases plus a sh rt drying phase ( nly if the drying system is
installed n the m del.
- PHASE 1: c ld wash
- PHASE 2: thermal disinfecti n at 93 ° C, 10 minutes.
Water intake per phase: 9 litres (sh wn in the illustrati n as “C ld Water: 90”, referring t the value in decilitres. 90 decilitres = 9
litres).
Test program detail, for fw version prior to 4.6
===========================================================================
PHASE 1
Cold Water: 90
P1 DETERGENT (ml/l): 10
P3 DETERGENT (ml/l): 10
TARGET Temperature 1 (°C): 0 Extension (min): 1
=========================
PHASE 2
Demi Water: 90
P2 DETERGENT (ml/l): 10
TARGET Temperature 1 (°C): 93 Extension (min): 10
=========================
DRY NG
Drying temperature (°C): 110
Drying duration (min): 10
From fw version 4.6: the test progr m consists of 2 ph ses plus short drying ph se.
The PHASE 1 h s been modified: T_t rget 93°C, holding time 10 min. The principles for ctiv tion
of the dispenser pump nd drying system (when inst lled) re unch nged.
- PHASE 1: thermal disinfecti n at 93 ° C, 10 minutes, chemicals d sage
- PHASE 2: thermal disinfecti n at 93 ° C, 10 minutes.
The purp se f using tw successive PHASES at 93 ° C is t all w an eventual adjustment with external calibrated pr be, during the
first phase, and t check the pr per maintenance f the calibrati n in the sec nd phase.

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Test program detail, for fw version following the 4.6
===========================================================================
PHASE 1
Cold Water: 90
P1 DETERGENT (ml/l): 10
P3 DETERGENT (ml/l): 10
TARGET Temperature 1 (°C): 93 Extension (min): 10
=========================
PHASE 2
Demi Water: 90
P2 DETERGENT (ml/l): 10
TARGET Temperature 1 (°C): 93 Extension (min): 10
=========================
DRY NG
Drying temperature (°C): 110
Drying duration (min): 10
Test pr gram activati n pr cedure:
1. Access the SET P screen as described in the user manual, by entering the “technician” level passw rd (c ntact the
manufacturer t btain the passw rd if necessary);
2. Scr ll thr ugh the parameters t pti n “ – t”;
3. Use the selecti n butt ns t change the screen setting fr m “--” t “on” and c nfirm;
4. Quit the SETUP m de (h ld d wn the “OPEN DOOR” butt n);
Fig. 1 - contents of Display, test program activation.
On c mpleti n f the pr cedure, the display sh ws “Pr t”.
The nly pr gram available at this p int is the test pr gram; if y u d n t wish t c ntinue, switch the device ff and back n.
WARNING
The test program “Pr t” is intended solely for testing that the inputs and outputs are
activated correctly. It does not constitute w shing progr m nd must never be
considered s such.

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3 F NCTIONAL DIAGRAM
N.B.: The diagrams sh wn bel w refer t the GW4060 and WD4060 m dels. F r c mplete up-t -date digital d cumentati n f r
all the m dels in the range, visit www.smegtech.c m

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4 WIRING DIAGRAM
In revision 04 of the present Technical Manual, the wiring diagram is cancelled from this section
to leave only the official updated reference, on www.smegtech.com, for authorized tecnicians.
F r c mplete up-t -date digital d cumentati n always c nsult www.smegtech.c m
5 KEY TO ABBREVIATIONS
AQS: Acquast p ( pti nal) - micr switch
BPE: Electric l ck
DD: P wder detergent dispenser (GW series nly)
EVCC: C ndenser filling s len id valve
EVD: Demineralised water s len id valve
EVF: C ld water s len id valve
EVR: S ftener resin regenerati n s len id valve
FMD (FLMT_D): demineralised water fl wmeter
FMF (FLMT_F): C ld water fl wmeter
FLSW1, FLSW2, FLSW3: detergent dispensing fl w switches
KR: Chamber heating element c ntr l relay
MA: Dryer m t r
MCM: D r cl sure micr switch
ML: Washing pump
MS: Chamber drain pump
P1, P2, …, P10: PCB c nnect rs
P1, P2, P3: Peristaltic detergent feeder pumps (P3 is always pti nal)
PAP: High pressure switch (f r m nit ring perati n f washing pump ML)
PLA: chamber safety/level anal gue pressure sens r
PLC: C ndenser pressure switch (used as level sens r in the steam c ndenser)
PSC: Steam c ndenser drain pump
R1, R2, R3: Chamber heating elements
RA: Drying System heating element
SF: RFI filter
SL1, SL2, SL3: Detergent jerry can level sens rs
SS: Salt sens r (salt level in integral s ftener tank)
TA: PT1000 pr be f r drying system air temperature
TCL: PT1000 pr be f r m nit ring chamber water temperature
THS1: Safety therm stat f r heating element R1
THS2, THS3: Safety therm stats f r R2, R3
TL1: PT1000 pr be f r chamber water w rking temperature
TS1, TS2: Drying heating element safety therm stats
X1: Main terminal b ard (p wer supply)
XCT: “V ltage change” terminal b ard

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6 TRO BLESHOOTING
6.1 INTROD CING THE ANALOG E PRESS RE SWITCH PLA
PLA: anal gue level sens r, als kn wn as the anal gue pressure switch.
The anal gue pressure switch is a sens r c nnected t the air trap inside the device, used t m nit r the water level in the chamber. Since
it is an anal gue sens r, it all ws c ntinu us c ntr l f the water level present, unlike a c nventi nal pressure switch, which is nly able t
identify 1 r 2 different levels.
The anal gue pressure switch emits a frequency signal f 630/625Hz with the device empty, with n water in the chamber. The device
establishes the actual value f its “zer ” reading each time it resets.
As the water level increases, the PLA signal in Hz decreases.
In this manual, we will refer t relative values (L0, L1, etc.) in relati n t zer rather than abs lute values, since the abs lute zer value is
set each time the device resets.
Signal in Hz with T in chamber < 40 °
[guideline values]
Signal in Hz with T in
chamber > 40 °
[guideline values]
P ssible states
f the PLA
pressure switch
Descripti n f state
GW/WD2145
OTHERS
GW/WD2145
OTHERS
Chamber empty
levels
L0 – Zer Zer Zer Zer Zer
L1 - “Empty” – pressure
switch reset
25 25 18 18
Chamber full
level
L2 - “Full” 31 31 24 24
Limit thresh ld
levels
L3 - Safety level with
washing pump active
ML=ON Limit thresh ld level
60 57 60 57
L4 - Water in Chamber (in
stby).
Standby status by limit
thresh ld level.
60 60 60 60
L5 - Safety level with
washing pump ff ML=OFF.
static c nditi n limit
thresh ld level.
65 63 65 63
F r versi ns pri r t 5.0 fw apply the f ll wing levels
P ssible states f the
PLA pressure switch
Descripti n f state Signal in Hz with T in
chamber < 40 °
[guideline values]
Signal in Hz with T in
chamber > 40 °
[guideline values]
Chamber empty levels L0 – Zer Zer Zer
L1 - “Empty” – pressure switch reset 25 18
Chamber full level L2 - “Full” 31 24
Limit thresh ld levels
L3 - Safety level with washing pump active
ML=ON Limit thresh ld level
57 57
L4 - Water in Chamber (in stby).
Standby status by limit thresh ld level.
60 60
L5 - Safety level with washing pump ff
ML=OFF. static c nditi n limit thresh ld level.
66 66
NOTE the am unt f water entering the machine is measured by the water fl wmeters (FLMT_F, FLMT_D in the diagrams).
The pressure switch PLA is used t intercept any abn rmal situati n.

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THRESHOLD - WATER Q ANTITY – T RBINE FLOW REG LATOR P LSE CORRESPONDENCE
Threshold setting GW/WD2145 OTHERS
Turbine fl w regulat r pulses Water q.ty Turbine fl w regulat r pulses Water q.ty
S0 – washing pump activati n 300 1,5 litres 900 4.5 litres
S1 - prefilling 800 4 litres 1200 6 litres
S2 - fill c mpleti n 200 1 litre 600 3 litres
S3 - tank safety device 1800 9 litres 3000 15 litres
F r versi ns pri r t 5.0 fw apply the f ll wing c rrelati ns
THRESHOLD - WATER Q ANTITY – T RBINE FLOW REG LATOR P LSE CORRESPONDENCE
Threshold setting GW/WD2145 OTHERS
Turbine fl w regulat r pulses Water q.ty Turbine fl w regulat r pulses Water q.ty
S0 – washing pump activati n 300 1,5 litres 900 4.5 litres
S1 - prefilling 800 4 litres 1200 6 litres
S2 - fill c mpleti n 200 1 litre 600 3 litres
S3 - tank safety device 2000 10 litres 3000 15 litres
6.2 DEVICE OPERATING CONDITIONS
F r the sake f clarity, 3 general device perating c nditi ns are defined.
The alarms which may be present depend n the device’s perating c nditi n.
The device’s resp nse if an alarm ccurs als depends n the current perating c nditi n.
OPERATING CONDITIONS
Descripti ns used t identify the device’s perating status
CYCLE IN PROGRESS: washing cycle running STANDBY: device n, n t in “OFF” status,
with n cycle running.
OFF: the PCB is p wered up but in “OFF”
status (the “ON/OFF” butt n has been
pressed). In this c nditi n, nly a small
number f critical inputs are m nit red.
“OFF” appears n the segment display.

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6.3 TRO BLESHOOTING G IDE
The alarms described apply t the vari us m dels as f ll ws:
“WD” (washer disinfect r) series
DRYER SYSTEM PRESENCE (Series 4060 and 4190)
ID DESCRIPTIO
N
EVENT WHICH TRIGGERS
THE ALARM
WHEN THE
ALARM
OCC RS
ALARM MANAGEMENT - DEVICE
RESPONSE TRO BLESHOOTING
AF:01
Water n t
heated
within time
all wed.
1. Three
-
phase device:
tripped if the
temperature d es n t
increase by at least 3°C in
2’.
2. Single-phase device:
tripped if the
temperature d es n t
increase by at least 0.5°C
in 2’.
Cycle in
pr gress,
heating phases.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) f r
45";
if PLA > L1 -> pump- ut (MS=ON) f r
90”.
“pump- ut 45” -> means: the drain
pump is perated f r 45 sec nds t
rest re the device t c nditi ns f
safety.
1.Check that three
-
phase r single
-
phase c nnecti n is set c rrectly in
the device’s parameters.
2.Check whether any safety
therm stats have tripped and reset
them if necessary.
3.Check that the chamber heating
elements and their c ntr l relays are
in g d w rking rder.
Other p ssible causes / checks t be
made:
4. Washing pump jammed;
5. High pressure switch (PAP) c ntact
n t being made;
6. C nnecti n f temperature pr be
TL t the PCB (CONNECTOR P1);
7. C nnect rs t be checked:
- C nnecti n n the heating element
c ntr l relay;
- C nnecti n n the PCB
(CONNECTOR P5-9);
- C nnecti n n the PCB
(CONNECTOR P2-2);
AF:02
The
temperature
difference
between the
tw pr bes,
“TL1” and
“TC”, is
m re than
2°C ( nly
active n
WD series)
In phases which include
thermal disinfecti n
|TL1-TCL| must be < 2°C;
therwise the alarm is
triggered.
The alarm c nditi n must
ccur f r at least 5
sec nds.
During the
cycle, during
the thermal
disinfecti n
time, starting
fr m:
T=T_target
+1°C
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1. Check that the pr bes in the
chamber are clean/in g d w rking
rder.
2. Check n the PCB that P11 and P12
are c rrectly c nnected.
N.B.: The tw pr bes TL and TCL are
c mbined in a single unit, s in the
event f a failure the entire
c mp nent has t be replaced (TCL is
nly installed n WD series devices).
AF:04
Pr be “TL1”
(chamber
temperature
) sh ws a
reading
higher than
the actual
temperature
.
This alarm may be
triggered by a number f
different c nditi ns.
a) F r each heating phase
c ntr lled, the alarm
c nditi n is:
TL1>T target +5°C f r 5
sec
b) Heating c ntr l
failure:
TL1>cycle max T +5°C f r
5 sec
c) Heating c ntr l failure,
if there are n Target Ts
in the cycle:
TL1>T = 60°C + 5°C f r 5
sec. (i.e. Tmax=60°C is
assumed)
With cycle
running.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1.Check that TL1 is perating
c rrectly.
2. Check intake water pressure.
3.Check that the heating element
c ntr l relays are in g d w rking
rder.
4. Check n the PCB that P11 is
c rrectly c nnected.

9
ID DESCRIPTIO
N
EVENT WHICH TRIGGERS
THE ALARM
WHEN THE
ALARM
OCC RS
ALARM MANAGEMENT - DEVICE
RESPONSE TRO BLESHOOTING
AF:05
W rking
temperature
pr be “TL1”
is
generating
an abn rmal
signal
(pr be
“ pen”).
TL1 > 200° f r at least 3
sec.
With cycle
running and in
standby.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
In standby status, the alarm resets
aut matically if its causes are
eliminated.
With cycle running a Manual Reset is
required.
1. The pr blem
may be due t pr be
TL1 (damaged r disc nnected) r
the PCB.
2. Check c nnect r P1 and the cable
as well as the pr be.
AF:07
Drying
temperature
pr be TA1 is
generating
an abn rmal
signal
(pr be
“ pen”).
TA1 > 200° f r at least 3
sec.
With cycle
running and in
standby.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
In standby status, the alarm resets
aut matically if its causes are
eliminated.
With cycle running a Manual Reset is
required.
1. The pr blem may
be due t pr be
TA1 (damaged r disc nnected) r
the PCB.
2. C nnecti n f temperature pr be
TA t the PCB (CONNECTOR P13);
3. Check the c nditi n f the pr be
cable.
AF:10
C ntr l
temperature
pr be TCL is
generating
an abn rmal
signal
(pr be
“ pen”).
( nly active
n WD
series)
TCL > 200° f r at least 3
sec.
With cycle
running and in
standby.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
In standby status, the alarm resets
aut matically if its causes are
eliminated.
With cycle running a Manual Reset is
required.
1. The pr blem may be due t pr be
TCL (damaged r disc nnected) r
the PCB.
AF:11
N c ld
water
during
filling.
(ΔFMF = 0) f r 30” after
activati n f EVF
With cycle
running, during
c ld water
filling phase
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1.Check that the intake tap is pen.
2.Check the water supply pressure.
3.Check that there are n restricti ns
n the h se c nnecting the device t
the tap.
4.Check that the intake s len id
valve EVF is p wered up and pens
c rrectly.
5.Check that the turbine fl w
regulat r FMF is perating c rrectly.
6. C nnecti n n the PCB
(CONNECTOR P2-10).
AF:13
N
demineralis
ed water.
(ΔFMD = 0) f r 30” after
activati n f EVD
With cycle
running, during
demineralised
water filling
phase
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1.Check that the intake tap is pen.
2.Check the water supply pressure.
3.Check that there are n restricti ns
n the h se c nnecting the device t
the tap.
4.Check that the intake s len id
valve EVD is p wered up and pens
c rrectly.
5.Check that the turbine fl w
regulat r FMD is perating c rrectly.
6.If using water fr m a tank, check
that the tank is n t empty r placed
t l w d wn.
7.Check that the display settings
actually c rresp nd t the water
c nnecti ns (demi water present r
n t).
8. C nnecti n n the PCB
(CONNECTOR P2-9).

10
ID DESCRIPTIO
N
EVENT WHICH TRIGGERS
THE ALARM
WHEN THE
ALARM
OCC RS
ALARM MANAGEMENT - DEVICE
RESPONSE TRO BLESHOOTING
AF:17
C ld water
filling time
n t c rrect.
The
setting is split, with 2
filling thresh lds.
First threshold “S1”
c rresp nds t prefilling
Second threshold “S2”
c rresp nds t the
quantity required t
c mplete the fill
• The first thresh ld
FULFILS the f ll wing
equati n:
filling time ut = [Qty f
water t be taken in (dl)
x 10(sec)]
•The sec nd thresh ld is
c nstant at 150 SECONDS
+ Extra Filling Time.
if the Extra Filling Time is
30 sec the time ut f r
the 2nd thresh ld is:
filling time ut =150+ 30=
180 sec
With cycle
running, during
c ld water
filling phase.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1. Check the c ld water filling system
in the same way as f r alarm ID11
(taps, pressure, n restricti ns n
h ses, etc.).
2. Turbine fl w regulat r FLMT_F
3. C nnect r P2-10
AF:19
Demi filling
time t
l ng. The
device is
taking t
l ng t take
in
demineralis
ed water.
As indicated ab ve f r
AF:17
With cycle
running, during
demi filling
phase.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1. Check the demineralised water
filling system in the same way as f r
alarm ID13 (taps, pressure, n
restricti ns n h ses, etc.).
2. turbine fl w regulat r FLMT_D
3. C nnect r P2-9
AF:23
N t en ugh
water.
Chamber
water level
t l w.
Alarm
active at end of
STATIC filling (ML=OFF)
thresh ld “S0”.
Thr ugh ut the phase, if
PLA <”L1” f r 10” an
alarm is triggered; in this
case, pump ML st ps. If
PLA>”L2” the pump
starts up again.
NB: The sequence is
repe ted 10 times , fter
which n l rm is
triggered
Active
thr ugh ut the
cycle.
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1. Check air trap ( bstructed r
f uled);
2. Check pressure switch - air trap
c nnecti n pipe ( bstructed r
f uled);
3. Height f drain pipe, check that
the drain meets the specificati ns
supplied.
4. C nnecti n n the PCB
(CONNECTOR 10) and/ r n pressure
switch PLA;
5. PLA pressure switch malfuncti n;
6. Washing filter f uled;
7.Check that washing pump ML1 is
perating c rrectly.
8.Check that the turbine fl w
regulat rs FMF and FMD are
perating c rrectly.
AF:25
Malfuncti n
related t
washing
pump “ML”.
Washing
pump
pressure t
l w.
PAP=0 with time ut
5
sec.
For fw versions fter
4.6xx, the following rule
lso pplies:
Bef re activati n f the
washing pump (if PAP is
n t at rest- c ntact pen)
and with filling (water)
c mplete and until the
pump- ut phase when
ML is required t
perate.
After filling
with water,
active until
pump-out
phase
Alarm indicati n.
if PLA ≤ L1 -> pump- ut (MS=ON) 45";
if PLA > L1 -> pump- ut (MS=ON) 90”.
1. Washing pump malfuncti ning
(als check starting capacit r);
2. Washing pump c nnecti n n
PCB (CONNECTOR P5-12);
3. Pressure switch (PAP)
malfuncti ning;
4. Pressure switch PAP c nnecti n
n PCB (CONNECTOR P2-2);
5. T much f am in chamber.
Check that the washing chamber
d es n t c ntain material which
generates t much f am
6. Check that the drain meets the
specificati ns supplied.