Monday, January 18, 2016

Fisher and Paykel SMARTDRIVE WASHING MACHINE – Service Diagnostics - Part-2 of 2

Fault codes – details – remedies – repair procedures - Fisher&Paykel Smartdrive Washing Machine
CONTN: Fault codes
44. (00101100) Phase 2 to 6 - Water in Bowl During Spin
The Motor Control Module has sensed a water level in the bowl during spin. This may be caused by a slow pump out rate due to a partial blockage in the pump hose or pump.
Primary Source: Pump System.
Action: 1. Check that the drain hose is not squashed or kinked.
2. Check the length of the drain hose and try to reduce the length if excessively long. A 1 metre extension hose of the same diameter fitted to the existing drain hose is the maximum allowable length.
3. If the bowl is empty of water, remove the pump from the pump housing and check that it is not blocked. Also check that the drain hose is not blocked.
4. If the bowl contains water, then service the pump from the top of the SmartDrive by removing the top deck and inner bowl. Bail out the water, remove the pump cap and hood and clear the pump of any obstruction.
5. Check that water is not siphoning back into the SmartDrive when the pump turns off when the spin speed reaches 600 rpm.
Secondary Source: Motor Control Module.
Action: Replace Motor Control Module.
45. (00101101) Phase 5 - Display Memory Check Fault
On power up, the display has checked its memory against a known reference and found differences.
Primary Source: Display Module.
Action: Replace Display Module.
46. (00101110) Phase 5 IW - Display EEPROM Check
The Intuitive Display has detected a problem with its internal EEPROM.
Primary Source: IW Display Module.
Action: Replace IW Display Module.
47. (00101111) Phase 2 and 3 - Bowl Dis-engage Fault
While carrying out a bowl check, the Motor Control Module has found that the bowl is not engaged even though the pressure sensor indicates that the bowl is empty. The Motor Control Module continues to check for 2 minutes. During this time the module has not been able to determine a valid bowl status and so displays this fault. This fault differs from fault 40 in that a valid bowl status could not be determined. The first two areas to check are the clutch and the pressure tube. If these two appear correct, then the fault could be with the pressure sensor in the Motor Control Module.
Primary Source: Mechanical.
Action: 1. Check that there are no clothes or other foreign objects preventing the clutch from reengaging.
2. Next check that the pressure tube has not come off and that it is not kinked.
Secondary Source: Motor Control Module.
Action: Replace Motor Control Module, if the above checks out without fault.
48. (00110000) Phase 2 to 6 - Hot and Cold Valve Faulty
The Motor Control Module has measured voltages from the valve diagnostic circuit that indicate both the hot and cold valves are faulty.  The most likely cause is that the valve harnesses have not been connected correctly or the valve is open circuit.
Primary Source: Wiring.
Action: Check the valve harnesses are correctly fastened to the valves or the pins are not bent backwards.
Secondary Source: Water Valves.
Action: Check the valve coils are not faulty (open circuit).
Tertiary Source: Motor Control Module.
49. (00110001) Phase 2 to 6 - Cold Valve Faulty
The Motor Control Module has measured a voltage from the valve diagnostic circuit that indicates the cold valve is faulty. The most likely cause is that the valve harness has not been connected correctly or the valve is open circuit. See fault 48 for service procedure.
50. (00110010) Phase 2 to 6 - Hot Valve Faulty
The Motor Control Module has measured a voltage from the valve diagnostic circuit that indicates the hot valve is faulty. The most likely cause is that the valve harness has not been connected correctly or the valve is open circuit. See fault 48 for service procedure.
Note: Phase 5 can give a fault code 50 when the SmartDrive powers off while spinning. There will actually be no fault if this has happened.
51. (00110011) Phase 5 and 6 Eco - Diverter Valve Fault
Primary Source: The Motor Control Module has registered a drop in water level in the recirculation phase of the wash cycle, water is being drained instead of
recirculated. Or water has been sprayed onto the Valve from an external source and caused the solenoid to blow.
Action: Turn the power off at the SmartDrive but leave the power on at the wall, then measure the voltage across the terminals of the wax actuator.  If a reading of 230V is achieved, the Motor Control Module has failed due to the valve and both will need to be replaced.
Secondary Source: Check for blockage in the valve itself or a broken hinge mechanism.
52. (00110100) Phase 5 and 6 Eco - Diverter Top-up Fault
More than 6 attempts to top-up the water level in the bowl. This then signifies the valve has not closed and is diverting to drain, or the topup was not increasing quickly enough, suggesting the valve has a blockage and is also draining.
Primary Source: Diverter valve.
Action: Remove the diverter valve and check for blockages or broken hinge mechanism.
Secondary Source: Wax Solenoid.n: Replace the Motor Control Module.
Action: Check the resistance of the wax solenoid. Also look for corrosion on the terminals (greenie deposit). Resistance range will be between 0.7kΩ and 2.5kΩ. Values are dependant on ambient temp and when the valve was last actuated. Anything outside of these values and the diverter valve should be automatically replaced.
53. (00110011) Phase 2 to 6 - Rotor Position Sensor Step Fail
The Motor Control Module has attempted a motor step test and has found that the motor has not stepped in the correct direction. It has detected that the motor is connected and that the motor drive is operational. The rotor position sensing system is at fault here.
Primary Source: Wiring.
Action: Check the Rotor Position Harness for continuity and that the connectors are correctly fitted to the Rotor Position Sensor and the Motor Control Module.
Secondary Source: Rotor Position Sensor.
Action: Check the Rotor Position Sensor patterns with a RPS Tester. If faulty, fit a new Rotor Position Sensor.
Tertiary Source: Motor Control Module.
Action: Replace the Motor Control Module, as the sensing circuitry may be faulty.
54. (00110110) Phase 2 to 6 - Motor/Motor Control Module Step Fail
The Motor Control Module has attempted a motor step test and has found that the motor has not stepped in the correct position. The Motor Control Module has detected that there is no current. This indicates that either the motor is not connected or the Motor Control Module motor drive is faulty.
Primary Source: Wiring.
Action: Check the continuity of the motor harness and that the connectors are correctly applied to the motor and Motor Control Module.
Secondary Source: Motor.
Action: Check continuity of motor phases. Check the bridge terminal on the stator is not open circuit or burnt. Replace the stator.
Tertiary Source: Motor Control Module.
Action: Replace Motor Control Module.
55. (00110111) Phase 3 to 6 - System Step Fail
Primary Source: Rotor Position Sensor.
Action: 1. Check Motor and Rotor Position Sensor wiring.
2. Check Rotor Position Sensor with RPS Tester.
56. (00111000) Phase 4 to 6 - Bowl Check No Valid Fault
While carrying out a bowl check, the machine has not been able to determine a valid bowl status and so the Display flags this fault. This fault differs from fault 40 in that a valid bowl status could not be determined.
Phase 4 & 6
Primary Source: Loading.
Action: Remove items until the remaining ones can move freely, or rearrange the load so that the clothes are evenly distributed around the bowl, or select a higher water level. If the load was to one side of the bowl or too heavy it can be possible for the agitator to bind in one direction when trying to sense bowl float.
Secondary Source: Mechanical.
Action: 1. Check the machine is not siphoning.
2. Check that there are no clothes or other foreign objects preventing the clutch from reengaging, and that there aren’t any defects with the clutch mechanism.
3. Check that the pressure tube has not come off and that it is not kinked.
Tertiary Source: Rotor Position Sensor.
Action: Replace the Rotor Position Sensor.
Quaternary Source: Motor Control Module.
Action: Replace the Motor Control Module.
Phase 5
Primary Source: Rotor Position Sensor.
Action: Replace the Rotor Position Sensor.
Secondary Source: Loading.
Action: Remove items until the remaining ones can move freely, or rearrange the load so that the clothes are evenly distributed around the bowl, or select a higher water level. If the load was to one side of the bowl or too heavy it can be possible for the agitator to bind in one direction when trying to sense bowl float.
Tertiary Source: Mechanical.
Action: 1. Check the machine is not syphoning.
2. Check that there are no clothes or other foreign objects preventing the clutch from reengaging, and that there aren’t any defects with the clutch mechanism.
3. Next check that the pressure tube has not come off and that it is not kinked.
Quaternary Source: Motor Control Module.
Action: Replace the Motor Control Module
57. (00111001) Phase 4 to 6 - Brown Out During Display EEPROM Write Fault
The Display has requested the Motor Control Module to perform an EEPROM write. Prior to writing, the Motor Control Module has tested the 15 volt supply and found that it is below the safety level for writing EEPROM and has reported this to the Display. This may be due to transients at the time of writing or due to a faulty Motor Control Module.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
58. (00111010) Phase 4 to 5 - Pressure Transducer at Maximum Adjustment Fault
When the pause or delay start is pressed to start the SmartDrive, the Display Module has checked the memory and found the count greater than expected.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
59. (00111011) Phase 4 to 5 - I D Out of Range Fault
When the pause or delay start is pressed to start the SmartDrive, the Display checked the physical ID and found it was out of range.
Primary Source: Display Module.
Action: Replace Display Module.
60. (00111100) Phase 4 to 6 - Motor Control Module Memory Check Fault
On power up, the Motor Control Module has checked its memory against a known reference and found differences.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
61. (00111101) Phase 4 - Brown Out During Motor Control Module EEPROM Write Fault
The Motor Control Module has been attempting to perform an internal EEPROM write. Prior to writing, the Motor Control Module has tested the 15 volt supply and found that it is below the safety level for writing
EEPROM and has reported this to the display.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
62. (00111110) Phase 5 - Pump Over Current
The Motor Control Module has detected an excessive pump current.
Primary Source: Pump.
Action: Replace Pump.
Secondary Source: Motor Control Module.
Action: Replace Motor Control Module.
63. (00111111) Phase 5 - Pump Comms Error
The Motor Control Module has detected an internal communications problem between its main control system and the pump control system.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
64. (01000000) Phase 5 and 6 - Pressure Transducer (Ptx) Error - Frequency < 66 kHz
The Motor Control Module has received signals from the water level sensor (Ptx) below normal frequency values.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
65. (01000001) Phase 5 and 6 - Pressure Transducer (Ptx) Error - Frequency > 90 kHz
The Motor Control Module has received signals from the water level sensor (Ptx) above normal frequency values.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
66. (01000010) Phase 6 - Pressure Transducer (Ptx) Error - Frequency > 90 kHz
Note: this supersedes Fault code 65 from V41 Motor Control Module code onwards.  The Motor Control Module has received signals from the water level sensor (Ptx) above normal frequency values.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
81. - 95. (0101xxxx) Phase 2 to 3 - Display/ Motor Control Module. See Fault Code 106
104. (01101000) Phase 2 to 6 - See Fault Code 106
105. (01101001) Phase 2 to 6 - Comms Error Time Out
These faults are reported when the Display Module detects an error in the communications between the Display Module and the Motor Control Module.
Note: If the product is an IW, the wrong Motor Control Module may have been fitted. Replace with a compatible part.
Phase 2 to 4 and Phase 6
Primary Source: Display Module.
Action: Replace Display Module.
Secondary Source: Motor Control Module.
Action: Replace Motor Control Module.
Tertiary Source: Rotor Position Sensor (Phase 5 and 6).
Action: Replace Rotor Position Sensor. If this corrects the fault, refit the original Display Module or Motor Control Module.
Phase 5
Primary Source: Pump
Action: Measure resistance of pump. If resistance is less than 33 ohms, replace pump.
Secondary Source: Display Module.
Action: Replace Display Module.
Tertiary Source: Motor Control Module.
Action: Replace Motor Control Module.
Quaternary Source: Rotor Position Sensor.
Action: Replace Rotor Position Sensor. If this corrects the fault, refit the original Display Module or Motor Control Module.
106. (01101010) Phase 2 to 3 and 5 - Display to Motor Control Module Communications Errors (Phase 6 IW Also)
These faults are reported when the Display Module detects an error in the communications between the Display Module and the Motor Control Module.
Phase 2 to 3
Primary Source: Display Module.
Action: Replace Display Module.
Secondary Source: Motor Control Module.
Action: Replace Motor Control Module. If the new Motor Control Module corrects the fault, refit the original Display Module.
Phase 5
Primary Source: Pump
Action: Measure resistance of pump. If resistance is less than 33 ohms, replace pump.
Secondary Source: Display Module.
Action: Replace Display Module.
Tertiary Source: Motor Control Module.
Action: Replace Motor Control Module. If the new Motor Control Module corrects the fault, refit the original Display Module.
107. (01101011) Phase 2 to 6 - Motor Control Module Reset Error
The Display Module has detected that the Motor Control Module has reset when it should not have. This can be due to a Motor Control Module supply disturbance or microprocessor failure.
Primary source: Motor Control Module.
Action: Replace Motor Control Module.
108. (01101100) Phase 6 IW - Coms CRC Error Display.  See Fault Code 106
127. (01111111) Phase 5 - Machine Set up Error
The Display Module has been fitted to the wrong model, size and or phase of SmartDrive, eg. Phase 5 Display Module cannot be fitted to a Phase 4 Motor Control Module. The colour of the module is a good indicator. Part numbers are also very important.
130. (10000010) Phase 1 to 6 - Single Rotor Position Sensor Error
The Motor Control Module has found an error in the pattern received from the Rotor Position Sensor. Likely causes of this fault are a bad connection on the harness between the Rotor Position Sensor and the Motor Control Module, or a faulty Rotor Position Sensor.
Primary Source: Wiring.
Action: 1. Check for corrosion on the edge connector of the Rotor Position Sensor and the Motor Control Module connector.
2. Check the contacts on the rotor positional sensor end of the hall harness to see if any have been damaged. (Each set of contacts in the socket has two wipers. If the distance between these wipers varies between different contacts, replace the rotor positional sensor harness.)
Secondary Source: Rotor Position Sensor.
Action: Check the Rotor Position Sensor with an R.P.S. tester. Replace if faulty.
Tertiary Source: Motor Control Module.
Action: Replace Motor Control Module.
131. (10000011) Phase 1 to 6 - Repetitive Rotor Position Sensor Error
This fault is similar to fault number 130 above but differs slightly in that it is a continuous condition. See fault 130 for service procedure.
132. (10000100) Phase 1 to 4 - Single Current Trip
The Motor Control Module has detected excess current in the motor or electronic switches. This fault has occurred momentarily.
Primary Source: Wiring.
Action: Check the wiring connections from the Motor Control Module to the Stator and the Rotor Position Sensor.
Secondary Source: Motor.
Action: 1. Measure/check the motor harness, connectors and motor for shorts. This can be done by taking a resistance measurement between phases of the motor harness at the Motor Control Module end. Nominal resistance should be approximately 2.6 ohms for Phase 1, 12.2 ohms for Phases 2, 3 and 4, and 32 ohms for Phases 5 and 6.
2. Check the Rotor Positional Sensor, Stator brass bridge terminal point and associated harness for water, mechanical damage or corrosion.
Tertiary Source: Motor Control Module.
Action If all the above show no signs of fault then replace the Motor Control Module. Also check for water leaks from the cooling chamber or valves that could possibly come in contact with the Motor Control Module and fix the leak before replacing with new Motor Control Module.
133. (10000101) Phase 1 to 4 - Repetitive Current Trip
The Motor Control Module has detected excess current in the motor or electronic switches. This fault is a more severe occurrence than fault code 132 but has identical fault sources and fault service procedure.
134. (10000110) Phase 4 - Single Current Trip & Rotor Position Error
The Motor Control Module has detected an excessive motor current AND a Rotor Position Sensor error simultaneously. See fault codes 130 and 132 for service procedure.
136. (10001000) Phase 1 to 6 - Motor Stall
The Motor Control Module has been unable to start the motor.  Possible causes of this fault are: Faulty motor harness, faulty or jammed motor, seized bearings or seals, faulty Motor Control Module, faulty Rotor Position Sensor or harness.
Primary Source: Wiring.
Action: Measure / check the motor harness, connectors and motor for discontinuity. This can be done by taking a resistance measurement between phases of the motor harness at the Motor Control Module end. Nominal resistance should be approximately 2.6 ohms for Phase 1, 12.2 ohms for Phases 2, 3 and 4, and 32 ohms for
Phases 5 and 6.
Secondary Source: Motor.
Action: 1. Check free rotation of the agitator and bowl by rotating by hand. Bearings and seals may be seized.
2. Check the Rotor Position Sensor and associated harness for water, mechanical damage or corrosion.
Tertiary Source: Motor Control Module.
Action: If the primary and secondary checks pass inspection, then replace the Motor Control Module.
144. (10010000) Phase 1 - Motor Control Module Software Trap
The Motor Control Module has developed a fault.
Primary Source: Motor Control Module.
Action: 1. Power off for 5 seconds and try again.
2. Check connections between the Display Module and the Motor Control Module.
3. Replace Motor Control Module.
160. (10100000) Phase 1 to 6 - Bowl Engaged
The bowl has re-engaged itself during agitate. Possible causes for this are a leak in the air bell, the bowl is over-loaded with clothes, the clutch has jammed or is fouled with a foreign object.
Primary Source: Mechanical.
Action: 1. Check that the rotating bowl assembly is not jammed to the agitator with any foreign object that may be caught under the agitator skirt.
2. Check that the clutch teeth are not locked together with dirt, lint, etc.
3. Make sure the bowl is not overloaded with too many clothes.
4. If none of the above appear to be at fault, then check the air bell at the bottom of the inner bowl for leaks.
Secondary Source: Motor Control Module. (Phase 1 to 4 only.)
Action: If the SmartDrive is empty of water at fault it is possible that the pump circuit is faulty and has caused a pump out during wash. This would cause the bowl to re-engage during agitate and the Motor Control Module to display this fault.
Replace Motor Control Module.
161. (10100001) Phase 2 to 6 - Hardware / EEPROM Supply Mismatch
The Motor Control Module checks the hardware configuration (ie. 110v or 230v) against its EEPROM table on power up. Should there be a mismatch, this error is flagged.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
162. (10100010) Phase 3 to 5 - Brake Deceleration Timeout Fault
During the brake mode, the Motor Control Module has detected that the bowl has not come to a stop in the permitted time once dropping below 100rpm. This fault has been installed for software testing only.
163. (10100011) Phase 4 to 6 - Valve Reset Pin Connect Fault
The Motor Control Module has sensed the PCB connection is open circuit. The cold valve cannot operate with this condition.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
164. (10100100) Phase 4 to 5 - Brake Function Time-out Fault
This fault indicates that the Motor Control Module has been attempting to brake for 20 seconds. As all spin loads should come to rest within 10 seconds, something has gone wrong during the brake to prevent the bowl stopping in time.
Primary Fault: Wiring.
Action: Measure / check the motor harness, connectors and motor for continuity. This can be done by taking a resistance measurement between phases of the motor harness at the Motor Control Module end. Nominal resistance should be approximately 2.6 ohms for Phase 1, 12.2 ohms for Phases 2, 3 and 4, and 32 ohms for
Phases 5 and 6.
Secondary Source: Motor Control Module (Phase 4), RPS (Phase 5).
Action: Replace Motor Control Module (Phase 4), or Rotor Position Sensor (Phase 5).
192. (11000000) Phase 4 to 5 - Motor PMW Reset Pin Connect Fault
The Motor Control Module has sensed an open circuit between pins 30 and 31. The motor cannot operate with this condition.
Primary Source: Motor Control Module.
Action: Replace Motor Control Module.
230. (11100110) Phase 6 - EEPROM Value Out of Range
Wrong version detected.
Primary Fault: Motor Control Module is the wrong version.
Action: Change Motor Control Module.
231. (11100111) Phase 6 - MW GW Link Error
Component has failed on the display board.
Primary Fault: Display Module fault.
Action: Replace Display Module.
232. (11101000) Phase 6 - COMMS Timeout 5 Seconds
IW only problem, either the Display or Motor Control Module has not
responded in time.
Primary Fault: Display Module.
Action: Replace Display Module.
Secondary Fault: Motor Control Module.
Action: Replace Motor Control Module.
233. (11101001) Phase 6 - EEPROM Read Error
Problem reading the EEPROM data coming from the Motor Control Module.
Primary Fault: Motor Control Module faulty.
Action: Replace Motor Control Module.
234. (11101010) Phase 6 - Lid Lock Open Circuit
Check Harness to Lid Lock and connections at the Motor Control Module and lid lock ends.
Primary Fault: Connector to the harness. Either end could be at fault.
Action: Replace Harness.
Secondary Source: Lid Lock has failed to be activated.
Action: Replace Lid Lock housing.
Tertiary Source: Motor Control Module has not responded to the Lid Lock being activated.
Action: Check the lid has a Tang and is fitted correctly to activate the Lid Lock. If this is all in order, the Motor Control Module must be at fault and needs to be replaced.
235. (11101011) Phase 6 - Lid Lock Short Circuit
Lid Lock fault, not activated when instructed to by the Motor Control Module.
Primary Fault: Lid Lock mechanism has jammed or failed.
Action: Check resistance across the connections, should be around 73 ohms. If not within 5 ohms, replace the Lid Lock.
236. (11101100) Phase 6 - Incompatible EEPROM Version
Failure to start and fault immediately displayed.
Primary Fault: Motor Control Module is the wrong one.
Action: Replace Motor Control Module.
237. (11101111) Phase 6 - Temperature Sensor Error
The electronics have picked up a continuity problem, same as fault code 10 or 41.
Primary Fault: The sensor has failed either in the harness or connection to the thermistor.
Action: Replace the Thermistor (temperature sensor).
Secondary Source: Motor Control Module has failed to read the temperature. Check connections.
Action: Replace Motor Control Module if connections look fine and the fault still occurs.
238. (11101110) Phase 6 - Lid Lock Fail In-line Test (1)
Final on line tests, final check before going to the field.
239. (11101111) Phase 6 - Lid Lock Fail In-line Test (2)
Final on line tests, final check before going to the field.
240. (11110000) Phase 6 - Hall Out of Order. RPS Fault
Same as previous Hall Error faults, just an extra fault code for Phase 6. See fault codes 130 and 131 for directions.
241. (11110001) Phase 6 - Function Time Out
Display crashed.
Primary Fault: Display has failed.
Action: Replace Display Module.
Secondary Fault: Motor Control Module has failed.
Action: Replace Motor Control Module.
242. (11110010) Phase 6 - OOB Hit Greater Than Max for 5 Seconds
Out Of Balance warning to the user. Additional fault code for Phase 6.
Primary Fault: SmartDrive has detected the bowl movement to be excessive or the Micro switch is permanently on or harness to it is disconnected.
Action: See fault code 43 for details.
243. (11110011) Phase 6 - Stepper Test Failure
Rotor Position Sensor Fault. The Motor Control Module has attempted a motor step test and found the motor has not stepped to the correct position.
Primary Fault: Wiring.
Action: See fault codes 53 and 54.