7 FAULT DIAGNOSTICS COMPONENTS Appliance stability... 26

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1 REPAIR INSTTRUCTTI I IONS F10-C 1 SAFETY NTC Safety instructions ESD INSTALLATION Aligning the appliance Hose and electric cable lengths Water conection Electrical connection OPERATION Operation in general Programme selector Selection Buttons Start button (optional) Start/Pause button (optional) Led s displays Extra Wash / Super Wash button Audible Signal (optional) Child Safety device (optional) Detergent-solution pump Water flow Grease-resistant seal FUNCTIONS Motor / motor actuation Load detection function Foam detection function REPAIR Diagnosis / Repair aids Removing the door lock Assembly the door lock Spring piston damper - Exchange Heater Outer tub Disassembly of the motor Detergent-solution pump removal FAULT DIAGNOSTICS COMPONENTS Appliance stability Knob Door lock Aqua Stop valve Heater Washing results Time skips Controller TECHNICAL SPECIFICATIONS Consumption rates _ _ARA_EN_C.doc 8902 Page 1 from 29

2 1 SAFETY 1.1 Safety instructions Danger! Attention Comply with the following instructions: Repairs may be carried out by a qualified electrician only! The user may be put at risk and injured by improper repairs! To prevent electric shocks, always comply with the following instructions: If the appliance is faulty, the housing or frame may be live! Electric shock may occur if live components are touched inside the appliance! Before commencing repairs, disconnect the appliance from the power supply! If tests have to be performed while the appliance is live, always use a residual-current-operated circuit-breaker! The protective conductor resistance must never exceed the values specified in the standard! The protective conductor is crucial for personal safety and appliance function. When repairs are complete, perform a test in accordance with VDE 0701 or the corresponding national regulations! When repairs are complete, perform a function and leak test. Conduct the safety test in accordance with VDE 0701 via the connector as follows: Connect the mains plug to the tester Switch electrical bridge between mains terminal and heater board. (See Measuring lead connection). Set upon the appliance and close the door. Conduct the test. The following pictograms are used in the repair instructions: Electrostatic sensitive devices! Please observe handling regulations! Sharp edges: Wear protective gloves. 209_ _ARA_EN_C.doc 8902 Page 2 from 29

3 1.3 ESD Term General Electrostatic Sensitive Devices State of the art electronics achieve economic efficiency, environmental protection, user comfort, high functionality and operating safety in electrical domestic appliances. This high quality technology requires professional handling and competent specialist knowledge. All electronic modules are fitted with components which are at risk from electrostatic voltage. of up to 35,000 volts if you walk across a non-conductive carpet, of up to 12,000 volts if you walk across a non-conductive PVC floor, of up to 1,800 volts if you are sitting on an upholstered chair. The electrostatic voltage on your body is transferred to the electronic components and ESDs you touch which may be damaged as a result. Shot down! A dead component A dead assembly A dead appliance Components which are at risk The following components are at risk from electrostatic voltage: µ processors and ICs Transistors, thyristors and triacs Diodes Wounded! Damaged Debilitated Early failure Causes and effects You are carrying an electrostatic voltage: 209_ _ARA_EN_C.doc 8902 Page 3 from 29

4 1.1.3 ESD instructions All electronic modules and electronic assemblies feature electrostatic sensitive devices. The following measures must be taken in order to protect these electrostatic sensitive devices: Ensure that the assemblies and modules are appropriately identified. Before you touch and measure the ESDs, put on an electrostatic protection system (wrist band with earthing module). Avoid touching ESDs with chargeable plastics (film, etc.). When taking hold of assemblies, modules and printed circuit boards, try not to touch the printed conductors or connections. Keep ESDs away from monitors and television sets. Only use conductive materials or the original packaging for transportation Electrostatic protection system The electrostatic voltage of the body is discharged via the wrist band and the earthing module. For reasons of safety this does not occur directly, but via a combination of resistors. The earthing or protective conductor connection must not be damaged! 209_ _ARA_EN_C.doc 8902 Page 4 from 29

5 2 INSTALLATION 2.1 Aligning the appliance Appliances manufactured after FD8902 To ensure fault-free operation, the appliance must be aligned precisely via the height-adjustable feet. If the appliance is installed on a base, the appliance must be attached with the attachment kit, mat. no for reasons of safety. If the appliance is built under, fit the VDE cover panel instead of the cover plate (mat. no ). 2.2 Hose and electric cable lengths Appliances manufactured until FD Appliances with warm water supply A B C D ca. 100 cm ca. 150 cm ca. 200 cm ca. 145 cm E F G ca. 70 cm ca. 130 cm min. 60 cm - max. 100 cm 209_ _ARA_EN_C.doc 8902 Page 5 from 29

6 Warm water version (optional) Water conection Water supply The warm water appliances feature 2 valves. The warm water connection is red and may be connected to maximum 60 C. For connecting appliances with warm water inlet in one tap, it is The water connection (3/4 inch) requires a conventional water line necessary to install the adapting-pipe Mt. No with a water pressure of at least 1 bar (1 at.) (when the tap is turned on, the water flow rate must be more than 8 l/min.). If the water pressure is more than 10 bar (10 at.), a pressure reducing valve must be installed Aqua Stop version (optional) If appliances feature Aqua Stop, the supply hose can be extended by 250 cm with the Aqua Stop extension or with a longer Aqua Stop hose (available from customer service, hose length 310 cm. Mat No ). The valve may be connected only as illustrated in the diagram. The valve must not be situated in water, but may be connected in protection zone 1 if the appliance is fused with a 30 ma FI circuit-breaker. In this case the socket of the appliance must be in protection zone 3 or higher. 209_ _ARA_EN_C.doc 8902 Page 6 from 29

7 2.3.2 Water outlet The waste water hose may be extended to 4 m ( ,20 m), but only if the hose is lying flat on the floor and has no more than one connection. 2.4 Electrical connection Connect the appliance to a correctly installed earthed socket only. Comply with the specifications on the rating plate. Fuse: 10 A A 3 m long connection cable (incl. earthed plug): mat. no _ _ARA_EN_C.doc 8902 Page 7 from 29

8 3 OPERATION 3.1 Operation in general The appliance features a programme selector, three selection buttons, a Start or Start/Pause button, three Led s which show the programme sequence. 3.2 Programme selector The programme selector with combined main switch has 16 positions. Special programmes, cottons/ coloureds programmes, easy-care programmes, delicates programmes, mix programmes and woollens programmes can be selected. 3.3 Selection Buttons There are three selection buttons: Spin Speed: With the left button under the display you can select the rotation speed. Even without spin drying can be selected. Then an intermediate spin drying cycle runs, but at the end of the program the laundry is left in the last rinsing water. Temperature: With the middle button under the display can be selected the temperature. Start/End time preselection (depending on the appliance): With the right button under the display the start/end time can be delayed up to 24 hours. 3.4 Start button (optional) This button is used to start the programme. 3.5 Start/Pause button (optional) This button is used to start and stop the programme. 209_ _ARA_EN_C.doc 8902 Page 8 from 29

9 3.6 Led s displays 3.8 Audible Signal (optional) The information about the programme sequence is showed throw the three LED s. They can show the following steps: The audible signal indicates the button activation/deactivation, the individual status of the programme (for instance start or end) or errors in operation. End of program: Spin LED flashes. The programme has ended. The washing can be taken out of the washing machine Signal for the extra function and display buttons. Spin: Spin LED illuminates. The washing machine performs Turn the programme selector to ON/OFF the final spin cycle. Press the Start/Pause button and turn the programme Rinse: Rinse LED illuminates. The washing machine performs selector to Cotton. Hold the Start/Pause button down until the rinse cycles. the signal is heard. The selected adjustment is memorised. Wash: Wash LED illuminates. The washing machine washes. Turn the programme selector one more to ON/OFF. Ready: Wash LED flashes. The washing machine has switched on and waits for the start command following actuation of the Start button. When the extra functions start, a long signal is heard. When an extra function is turned off, the audible signal is a short one. This function may be deactivated in the same way as it is started 3.7 Extra Wash / Super Wash button Press this button to run an additional rinse cycle Signal for the programme status and the Start/Pause button. Turn the programme selector to ON/OFF Turn the programme selector to Cotton, press the extra rinse button and wait. You will hear how the audible signal is activated or deactivated. Release the button when the signal comes on. The alarm of the Start/Pause button and the programme status is activated. Turn the programme selector one more to ON/OFF. When the programme is started by pressing the Start/Pause button, a brief audible signal will be heard; when the programme is in pause, no signal will be heard. When the programme has finished, an audible signal will be heard for 10 minutes to warn that it has finished. If any errors or malfunctions should occur in the function, the alarm will give out an alert signal. 209_ _ARA_EN_C.doc 8902 Page 9 from 29

10 To deactivate this function, make sure beforehand that the signal for the extra function and display buttons is deactivated. Turn the programme selector to extra rinse and wait. You will hear how the audible signal is activated and deactivated. Release the button when the signal goes out. The alarm of the Start/Pause button and programme status is deactivated. 3.9 Child Safety device (optional) Turning on the child safety Press the Start/Pause button. The programme starts. Press the Start/Pause button and hold it down (approximately 4 seconds) until the symbol appears, after which Paus appears for a few moments Turning off the child safety Press the Start/Pause button and hold it down (approximately 4 seconds) until the goes out. 209_ _ARA_EN_C.doc 8902 Page 10 from 29

11 4 COMPONENTS 4.2 Door lock 4.1 Knob The knob and the axis are only one part. The door lock is electromechanic, and it consist in a PTC, which is heated when it receives tension and the inside wax is expanded and blocks the door. At the end of the wash, it is necessary to wait for a time before opening the door There are three cases in which the door keeps blocked: It receives signal of movement fo the drum from the tachogenerator. If there is water level N1. If the temperature is higher than 60º 209_ _ARA_EN_C.doc 8902 Page 11 from 29

12 4.3 Aqua Stop valve Function: An electric solenoid valve which is enclosed by a housing is attached to the tap. The housing is connected to the appliance with a double supply hose. The double supply hose contains the water supply hose and electric control cable for the solenoid valve. The safety function is actuated via the float in the base pan. The water flow is then stopped mechanically Technical specifications: Nominal voltage V Frequency 50 Hz Resistance 4.13 kω ± 10 % Flow rate 10 l/min ± 10% Water pressure bar Water inlet temperature max. max. 25 C A Equipment valve B Aqua-stop C Double inlet hose D Leakage water hose E Drip tray F Soil float 209_ _ARA_EN_C.doc 8902 Page 12 from 29

13 4.4 Heater 4.5 NTC Function: Function: The heating element A has two integrated fuses B (boil-dry protection). The fuses cannot be changed. If the NTC value is outside the operating range (e.g. interruption or short-circuit), the programme continues cold without an error display. The test programme displays NTC short circuit or NTC interruption. The NTC is inserted into the heating flange and is sealed with the heater seal Technical data: Operating range: from 5 C to 103 C Temperature in C Resistance in kω A Heating elements B Integrated fuses C NTC (resistance with negative temperature coefficient) Technical data: Nominal power 2000 W Nominal voltage 230 VAC Power tolerance +5 % % Resistance see connection diagram 209_ _ARA_EN_C.doc 8902 Page 13 from 29

14 4.6 Detergent-solution pump Function: The detergent-solution pump features a thermal protection device. If the delivery head of the pump used in the series is not adequate, a customer-service pump (mat. no ) can be used up to a delivery head of 1.5 m Technical specifications: Nominal voltage V Frequency 50 Hz Resistance Ω Delivery head 1.0 m Delivery rate 18 l/min 209_ _ARA_EN_C.doc 8902 Page 14 from 29

15 4.7 Water flow Two-way detergent dispenser The internal supply hoses of the prewash and main wash valves are connected to the two-way detergent dispenser. If both valves are actuated, the water jets hit each other and the water runs into the middle fabric softener dispenser Cascade dispenser (optional) The cascade dispenser dispenses 1/3 of the water, which runs in via the prewash valve, directly as clear water over the seal Container ventilation Container ventilation is required for pressure compensation in the container. If a blockage occurs, the appliance cannot draw in adequate water because the pressure in the transmitter hose is increasing too sharply. A C Two-way detergent dispenser Drainage ventilation B D Return-flow container Cascade dispenser (Optional) Drainage ventilation The internal drainage ventilation prevents the appliance from draining itself (siphon effect) Return-flow container The water volume in the return-flow container ensures that the eco lock in the pump sump closes. 4.8 Grease-resistant seal The grease-resistant seal mat. no.: (with cascade dispenser) and mat. no.: (without cascade dispenser) may be installed only if there is an unusually high grease load. 209_ _ARA_EN_C.doc 8902 Page 15 from 29

16 5 FUNCTIONS 5.1 Motor / motor actuation The motor is controlled (open-loop and closed-loop) by phase control. The actual speed value of the tacho generator signal is compared with the required value of the electronics module. If an unbalanced load is detected, the speed is reduced in the final spin cycle as follows: The drive is synchronous to the line frequency and adjusts itself to a frequency change between Hz. The direction of rotation is changed by two deenergised reversing relays. An integrated protector in the motor winding disconnects the motor in the event of an overload. The control does not disconnect the motor with a tacho generator fault but continues trying to restart the motor. A motor fault is displayed only at the end of the programme. Before each spin speed acceleration, the imbalance is scanned for For spin speeds > 1000 min -1 a field reversal relay is actuated from 20 seconds at 100min-1 A. The imbalance is scanned up to 15x (up to 800 min -1. This clears part of the motor field winding and increases 2x for wool). the speed. By very big imbalance the spinning is aborted by ca. 100 min -1. The following speeds apply to the washing machine with empty drum: Wool: 27 min -1 +/ 5 % Wet: 35 min -1 +/ 3 % Rinse: 50 min -1 +/ 3 % Wash: 50 min -1 +/ 3 % Spin: Spin speeds +/ 2.5 % Measurement speed (unbalanced load): 100 min -1 +/ 1 % The size of the load is detected by reducing the speed to 75 min -1 B (long reduction time = large load, short reduction time = small load). 209_ _ARA_EN_C.doc 8902 Page 16 from 29

17 5.2 Load detection function When the programme has started, the water supply times of the solenoid valves are added. 2 load levels are detected: Water supply times < seg = partial load (it depends on the programm) Water supply times > 65 seg = full load (it depends on the programm) N: Nivel Points of load detection function Water supply times (t1+t2+t3+t4...) 5.3 Foam detection function If during the rinse is reached the level I of the pressure switch, the module understand that there is foam in the drum cause of over dosage of detergent. In this case, the spin will be stopped, will be drained, and there will be an extra rinse. 209_ _ARA_EN_C.doc 8902 Page 17 from 29

18 6 REPAIR Unbalanced load detection 6.1 Diagnosis / Repair aids General Before repairing or testing the appliance, always start the customerservice test programme Test prod Test probe mat. no.: (remove the components from the module before measuring the resistance) The termination of the spin cycle by the unbalanced load scan can be reset with the aid of a water-filled thermal bottle The thermal bottle must be filled with 1250 ml (overall weight: 1,5 kg ) Plastic side cutters Plastic side cutters mat. no.: for repairs to the outer tub Drill bit Drill bit (13.2 mm) mat. no.: for repairs to the friction dampers Protective gloves: Material no.: size 9 = size 10 = _ _ARA_EN_C.doc 8902 Page 18 from 29

19 6.2 Removing the door lock Turn the rear part of the door lock to the inside. Remove the outer bridle of the gasket. Hold the door lock from inside. Press with the pliers in the both fixation points (A). 6.3 Assembly the door lock First, insert the slot in the hole of the front panel. Press until the lock will be fixed. 209_ _ARA_EN_C.doc 8902 Page 19 from 29

20 6.4 Spring piston damper - Exchange Installation The spring piston damper is a friction damper with integrated spring Removal WARNING Possible damage of components. Remove components in the area of the damper support! Required special tool: 13.2 mm drill bit Mat. Nr: The dampers can be replaced without removing the outer tub. 1. Drill plug-in spindle head 30 mm deep. 2. Press out the plug-in spindle towards the rear. 1. Insert bushings into the eye of the damper. 2. Insert damper into the support on the outer tub. 3. From the rear insert a screw with the flattened washer. 4. Insert screw with centring washer and secure with the hex lock nut. 209_ _ARA_EN_C.doc 8902 Page 20 from 29

21 6.5 Heater 1. Remove front panel 2. Loosen the hex nut 3. Release the seal 4. Remove the heating element towards the front. 5. The NTC can be removed after removing the heater. 209_ _ARA_EN_C.doc 8902 Page 21 from 29

22 6.6 Outer tub Dismantling the outer tub (in appliances < 1400 min-1): The tub consists of two glass fibre reinforced plastic shells. These shells are screwed together and also locked in appliances <1400 min Removing the outer tub: 1. Remove plastic clips with special side cutters (mat. no.: ) (Fig. 1). 1. Remove the front panel, fascia and worktop. 2. Remove the two crossbars (a) and remove the detergent dispenser. 3. Disconnect all electrical and mechanical connections on the outer tub. Please use the assembly mat. no if the plastic holder for the motor cable harness breaks. 4. To reduce the weight, dismantle the motor, jacket weight and front weight (b). 5. Loosen the damper on the base plate 6. Lift the complete tub out of the washing machine housing 2. Dismantle the tub 3. Carry out repairs (remove foreign objects, replace bearings) 4. Re-insert seal 5. Re-assemble tub and install with the kit, mat. no.: _ _ARA_EN_C.doc 8902 Page 22 from 29

23 Removing the outer tub (in appliances > 1400 min -1 ): 1. Remove filling and drainage hoses from the tub to prevent damage when drilling 6. Remove old seal, remove 2. Remove screws from the tub (tub is attached by screws only). plastic shavings from the seal groove and insert new seal. 3. Dismantle the tub. 7. Re-assemble tub. 4. Carry out repairs (remove foreign objects, replace bearings). 5. Drill all countersunk holes to mm Ø 8. Insert 17 screws (M5x55) at the front of the tub and tighten in diagonally opposite sequence (torque approx. 3 4 Nm, do not compress plastic). (Fig. 5) 9. Insert and tighten the screw (M5x45) on the filling opening at the back of the tub. (Fig. 6) 209_ _ARA_EN_C.doc 8902 Page 23 from 29

24 6.7 Disassembly of the motor Please use the assembly mat. no (A) if the plastic holder for the motor cable harness breaks. For machines of 600 rpm the motor have 3 supports in the outer tub, the other motors have 4 supports. The spare part tub have always 4 supports. Desmontaje: Remove the rear cover Remove the self-tensioning belt Remove the two bolts (A) Remove the front panel Pull out the motor towards the rear Sharp edges: Wear protective gloves. 209_ _ARA_EN_C.doc 8902 Page 24 from 29

25 6.8 Detergent-solution pump removal 10. Remove the front panel 11. Loosen and remove the hoses 12. Remove the electrical connections 13. Loosen the screw A. 14. Remove detergent-solution pump A B Mounting bolt. Emergency unlocking device (optional) 209_ _ARA_EN_C.doc 8902 Page 25 from 29

26 7 FAULT DIAGNOSTICS 7.1 Appliance stability Fault details Cause Remedial action Appliance is not stable Incorrect installation Advise customer, see Installation chapter 7.2 Washing results Fault details Cause Remedial action Washing is not clean Detergent, load, programme selection, dosage, See general repair instructions pretreatment Does not heat up or insufficiently. Test heating circuit with test programme; if required, replace defective component. Does not wash clean or not clean enough (allergy sufferer) Detergent, load, programme selection, dosage See general repair instructions Time skips Fault details Cause Remedial action Running times and time skips. Adjust the control to the influencing variables Advise customer, see also module / for the wash cycle. remaining running time calculation. 209_ _ARA_EN_C.doc 8902 Page 26 from 29

27 7.4 Controller Running times Fault details Cause Remedial action Adjust the control to the influencing variables Advise customer, see circuit diagrams for the wash cycle. Module is not functioning Partial load detection Heating defect. The NTC doesn t reach the selected temperature in 105 minutes, and go to the next step. Pumping defect. The pressure switch doesn t reach level < N1 in 56 minutes, and go to the next step. Advice customer. Partial load detection. (Water supply times <60-70 seg it depends on the programs) cause of the low load or the low inlet pressure. If the time is longer, it detects full load. The programs time depends on the load (see time diagrams) Do the test program and test the heating Do the test program and test the pumping Electrical component has a short-circuit or earth Remove the component from the module; fault if the module functions, replace the removed component only. The appliance is delayed or disconnected Frequency variations Advice customer. It is necessary to have an stable frecuency, in other case, the appliance can show jumps of time or be disconnected. 209_ _ARA_EN_C.doc 8902 Page 27 from 29

28 8 TECHNICAL SPECIFICATIONS 8.1 Consumption rates kg Appliances until FD8901 Consumption rates** kg Appliances Load Cons. Cons Duration Programme máx. kwh liter min. Consumption rates** Coloureds 40 C 7 kg* Load Cons. Cons Duration Coloureds 60 C 7 kg 1, Programme máx. kwh liter min. Coloureds 60 C ECO 7kg* 1, Coloureds 40 C 6 kg* Cottons 90 C 7 kg 2, Coloureds 60 C 6 kg 1, Coloureds 60 C ECO 6 kg* 1, Cottons 90 C 6 kg 2, Easy care 40 C 3 kg* 0, Delicates 30ºC 2 kg 0, Wool 30 C 2 kg* 0, Easy care 40 C 3 kg* 0, Delicates 30ºC 2 kg 0, Wool 30 C 2 kg* 0, _ _ARA_EN_C.doc 8902 Page 28 from 29

29 kg Appliances after FD8902 Programme Load max. Consumption rates** Cons. kwh Cons litre Duration h Cold Warm water water Cotton cold 7 kg 0,25 0, :36 Cotton 40 C** 7 kg 0,69 0, :36 Cotton 60 C** 7 kg 1,33 0, :39 Cotton 60 C * ECO 7kg 1,05 1, :08 Cotton 90 C 7 kg 2,00 1, :47 Easy care 40 C 3 kg 0,55 0,2 55 1:17 Mix 30ºC 3 kg 0,24 0, :03 Delicate cold 2 kg 0,06 0, :41 Delicate 30ºC 2 kg 0,21 0, :41 Wool cold 2 kg 0,10 0, :40 Wool 30 C 2 kg 0,19 0, :40 * Test programmes in compliance with EN : 1999 and IEC Ed : 02 ** The consumption values and running times will deviate from the specified values depending on the water pressure, softness, inlet temperature, room temperature, type of laundry, quantity and selected additional functions. The consumption values refer to series start-up. The running times are described in the programme overviews (circuit diagrams). 209_ _ARA_EN_C.doc 8902 Page 29 from 29