InformationIndesit Compa

© 2006 Reg. Office: Peterborough PE2 9

Service

5407318 Issue 3 Oct. 2006

HotpointAquariusWashingMachines

WeldedOuter Drum

Models Covered:

WF101WF321WF326WF541WF546

WT540/1PWT540/1G

ny UK LtdJB. Registered in London: 106725

SAFETY NOTES & GENERAL SERVICING ADVICE

1. This manual is NOT intended as a comprehensive repair/maintenance guide to the appliance.2. It should ONLY be used by suitably qualified persons having technical competence applicable

product knowledge and suitable tools and test equipment.3. Servicing of electrical appliances must be undertaken with the appliance disconnected

(unplugged) from the electrical supply.4. Servicing must be preceded by Earth Continuity and Insulation Resistance checks.5. Personal safety precautions must be taken to protect against accidents caused by sharp edges

on metal and plastic parts.6. After servicing the appliance must be rechecked for Electrical Safety. In the case of appliances

which are connected to a water supply (i.e.: Washing Machines, Dishwashers & Food Centres etc.) checks must be made for leaks from seals gaskets and pipe work and rectification carried out where necessary.

7. It can be dangerous to attempt 'DIY' repairs / maintenance on complex equipment and the Company recommends that any problem with the appliance is referred to its own Service Organisation.

8. Whilst the Company has endeavoured to ensure the accuracy of the data within this publication they cannot hold themselves responsible for any inconvenience or loss occasioned by any error within.

2

MANUFACTURING DATE CODE CHART

From 1 May 2006 the appliance date coding changed to include Serial Number and Industrial Code.

SERIAL NUMBER / INDUSTRIAL CODE EXPLANATION

198619942002

198719952003

198819962004

198919972005

199019982006

199119992007

199220002008

199320012009

Jan. 01 13 25 37 49 61 73 85

Feb. 02 14 26 38 50 62 74 86

March 03 15 27 39 51 63 75 87

April 04 16 28 40 52 64 76 88

May 05 17 29 41 53 65 77 89

June 06 18 30 42 54 66 78 90

July 07 19 31 43 55 67 79 91

Aug. 08 20 32 44 56 68 80 92

Sept. 09 21 33 45 57 69 81 93

Oct. 10 22 34 46 58 70 82 94

Nov. 11 23 35 47 59 71 83 95

Dec. 12 24 36 48 60 72 84 96

First 2 digits of the serial number indicate production date

Serial Number Example

3 10 02 0895

Four remaining digits = Build number that day 895th builtThird two digits = Day of manufacture 2nd of monthSecond two digits = Month of manufacture OctoberFirst digit = Year of manufacture 2003

Industrial Code Example

37 24455 0010

Last four digits = 0000 original production.

Second five digits = COMMERCIAL CODE*

First two digits = Factory of origin* Vital for correct model information and system identification

Other numbers denote major production changes

3

INDEX

Safety & Servicing Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Date Code Chart & Serial Number / Industrial Code Details . . . . . . . . . . . . . 3Models Covered & Development History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Connecting to the Water Supply - Cold Fill Only . . . . . . . . . . . . . . . . . . . 6 - 7Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10Console Display, Controls and Programmes . . . . . . . . . . . . . . . . . . . . 11 - 15Wiring Details

Wiring Connection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Wiring Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Power Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Eeproms & Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Dismantling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 - 29

HOTPOINT AQUARIUS WASHING MACHINES

DEVELOPMENT HISTORY

April 2006 Introduction of 2006 welded drum models.Date Code 52

September 2006 Introduction of WT540/1P.Serial No. 60901.0000

November 2006 Introduction of WT540/1GSerial No. 61110.0000

Model Commercial CodeWF101P 40023WF321P 40024WF321G 40025WF326A 40026WF541P 40028WF541G 40029WF546A 40030WT540/1P 45547WT540/1G 46354

4

SPECIFICATIONSModels Covered WF101, WF321, WF326, WF541, WF546, WT540/1P & WT540/1G

Colours P = Polar, G = Graphite, A = Aluminium

Dimensions Height 850 mm Width 595 mmDepth 600 mm Weight 66 kg. Packed approximately 69 kg

Country of Origin Great Britain

Electrical Supply 220/240 Volts AC @ 50Hz Fuse 13 amp

Energy Energy Class: A+ @ 6 kg

Washing Performance Class: A+Spin Efficiency Class: B

Energy Consumption 1.02 kWh / Cycle @ 60°C Cotton

Water Consumption 55 litres @ 60°C CottonWash Load 6 kg CottonsSpin Speed WF101 1000 rpm WF321 1200 rpm WF326 1200 rpm

WF541 1400 rpm WF546 1400 rpm WT540/1P 1400 rpmWT540/1G 1400 rpm

Control PCB 220/240 Volt 50/60Hz Type Merloni EVO 2

Water Supply Cold Valve - Coil Resistance 3.8 KΩMax Pressure = 1 Mpa (10bar)Minimum Pressure = 0.05 Mpa (0.5bar)

Wash Heater 1800 Watts @ 230 voltsResistance 30 Ω approximately

Thermistor NTC Resistance: 20 KΩ @ 20°C

Motor Universal Series Wound 230V 50Hz AC with tapped field

Pump 2 Pole Synchronous 220 / 240 Volt, Resistance = 162 Ω

Door Lock P.T.C. Bimetallic - Time Delay approximately 2 minutes

Torque Settings Upper Balance Weight = 24 NmLower Balance Weight = 24 Nm

Pins Resistances FHP/ACC1-2 Armature Varies with brush-gear 4.8 Ω ± 8%3-5 Full Field 1.6 Ω ± 8%3-4 Tapped Field 0.8 Ω ± 10% 6-7 Tacho 16 Pole (8 pairs) 136 Ω ± 10%

5

CONNECTING TO THE WATER SUPPLYCOLD FILL ONLY

BENEFITS• Removes the requirement to need a hot water supply.• Cold water relaxes fabrics, whilst hot water can seal in stains.• Improved stain removal.• Biological detergents contain enzymes which are active between 30°C and 53°C giving greater

results at lower temperatures.• The most commonly used programme at present is 40°C which will use cold water at present

even when hot and cold are available.• At present only programmes above 60°C use hot water as part of the fill cycle and only

contributes to a very small proportion of the overall water intake.• You only heat the water required to the correct temperature which makes it cheaper to run.

COLD FILL CONNECTION AND HOT SUPPLY REMOVALThe information below is contained in the customers Installation Guide.

Before making the connection to the cold water supply, allow the water to run freely from the tap until it is perfectly clear.

1 Screw the cold water fill hose (blue connector) onto the cold water supply until tight.

2 Fit a 3/4” BSP sealing cap to the hot water supply, to prevent unused supply leakage.

3 Turn on the cold water supply and check for leaks, tighten if necessary.

4 Leave the unused hot water supply turned off.

The 3/4” BSP Sealing Cap required can be ordered under Part Number 1605240.

The cold water pressure should be between 3 and 150 psi (21 - 1034 kPA). Incorrect pressure could lead to flooding. Use the hose supplied with the machine. Do not use an old hose.Electrical connection information can be found on the following page.

All parts affected with this introduction are listed on Partfinder.

HOT WATER SUPPLY(if present)

COLD WATERSUPPLY

Cold water fillhose (BlueConnector)

3/4" SealingCap (notsupplied)

12

34

OFF

ON

OFF

ON

WATERSUPPLY

WATERSUPPLY

6

Connecting to the Water Supply continued

WARNINGS:The water pressure should be between 3 and 150 psi (21 - 1034 kPa). Incorrect pressures could lead to flooding.The water supply tap should be accessible when the machine is installed.Before connecting the fill hose, check that water is running from the water supply tap you will use for the machine.Connect the washing machine to the water supply using the fill hose fitted to the machine.Do not use an old hose.

Cold Fill1 Unclip the fill hose from the back of the

machine.2 Connect the free end of the blue fill hose

to the COLD water supply.3 Turn on the water supply and check for

leaks. If there is a leak, turn off the water supply, remove the connector and check that the sealing washer is in place.Refit the connector and tighten it.Turn on the water supply.

4 When moving the machine into its final position, make sure that the hose is not trapped or kinked.

If the fill hose is too short:A longer fill hose is available. Remove the existing fill hose from the inlet valve on the back of the machine and fit the new longer fill hose as shown above with the angled ends of the hoses connected to the machine(see Fig. 2).

Fig. 1 Fig. 2

Electrical ConnectionsBefore plugging the appliance into the mains socket, make sure that:- the socket is earthed and in compliance with the applicable law.- the supply voltage is included within the values indicated in the Specifications page.- the socket is compatible with the washing machines plug. If this is not the case, replace the socket or the plug.

Location! The washing machine should not be

installed in an outdoor environment, not even when the area is sheltered, because it may be very dangerous to leave it exposed to rain and thunderstorms.

! When the washing machine is installed, the mains socket must be within easy reach.

! Do not use extensions or multiple sockets.! The power supply cable must never be

bent or dangerously compressed.! The power supply cable must only be

replaced by an authorised engineer.

7

INSTALLATION

Unpacking1. Unpack the washing machine.2. Check whether the washing machine has

been damaged during transport. If this is the case, do not install it.

Remove the polystyrene baseThe vertical block part of the base (see below) should have stayed intact when the base was removed. If it has broken off and is still inside the machine, carefully lay the machine on its side, onto the polystyrene top cap and then remove the block.

Warning:Packaging materials are not childrens toys.

Remove the transit fixingsFollow these instructions to remove the TWO transit fixings.

IMPORTANT: Situated one either side of the rear panel, both transit bolts MUST be removed before use.Failure to do so may cause damage to the machine!It is important that the transit bolt and spacer come out intact.

Vertical block

polystyrene base

Repeat steps 1 to 4 to remove the second transit bolt.

LocationWhere the machine is installed will affect its performance:• For your safety and to comply with

electrical regulations, seek professional advice if you want to install your machine in a bath or shower room.

• Make sure that the electrical socket and water taps are easily accessible. You should switch off the machines electrical and water supplies when you are not using it for extended periods.

• Make sure that you allow enough space for the machine. Select a space at least60 cm wide, 60 cm deep and 85 cm high. Also leave enough space to open the door fully, so that you can load and unload it easily.

continued ...

1. Unscrew the bolt using a 13 mm spanner.

2. STOP when 3 threads can be seen.

3. Hold, slide and pull to remove.

4. For safety, insert one of the plastic covers supplied with the machine over the hole.

8

• Where possible, the machine should be positioned on a solid floor to minimise vibration.• Take care when you move the machine not to rip any floor coverings.

LevellingThe machine will be noisy if the two front feet are not adjusted so that the machine stands firm and level.• The machine should be levelled from side to side and from front to back.1. Move the machine into its final location. Take care not to trap or kink the hoses.

- The spring on each foot will stop them coming loose.• If it is placed on a fitted or loose carpet, adjust the feet in such a way as to allow enough room

for ventilation beneath the machine.

2. Turn one or both front feet anti-clockwise by hand until the feet cannot be turned any more. When adjusting the feet, use a spirit level to check the machine stands level, from side to side and from front to back.

9

Drainage ConnectionsTake care when you remove the drain hose from the clips on the back of the machine.All machines are tested with water before they leave the factory so a small amount of water may still be in the hose.Do not remove the hooked end support from the GREY drainage hose when using any of the drainage methods detailed below.You may need to reposition it as required along the drainage hose. For drainage into a standard work top sink, ensure the outlet pipe has a minimum diameter of 32 mm. If the sink is inset, the front edge of the basin must be less than75 mm from the front edge of the worktop, so that the drain hose will hook securely into the sink.Unclip the drainage hose from the back of the machine and hook over into the sink. Make sure that the sink is free of any obstructions and that the sink plug can not fall into the sink, preventing the water from draining away freely. Pumped out water may be very hot.We recommend one of the following drainage methods:

Stand pipe Fig. 1 1 Make sure that the standpipe has a minimum diameter of 38 mm.

2 Remove the drainage hose from the clips on the back of the machine.

3 Make sure that the top of the standpipe is positioned at least 500 mm from the floor (see Fig.1).Use the plumbing indicator line label on the back of the machine as a guide.

4 Place the drainage hose approximately 100 mm into the standpipe.

500 mm

1

WARNING! The company denies all liability if and when these warnings are not respected.

The first wash cycleOnce the appliance has been installed and before you use it for the first time, run a wash cycle without detergent and no laundry, setting the 90°C programme without a pre-wash cycle.

Under Sink Waste System

Fig.2

Fig.3

1 Cut out the membrane, bung or blanking plug (see Fig. 2).

2 Unclip the drainage hose from the back of the machine.

3 Move the hooked end support along the drainage hose as required.

4 Attach the drainage hose securely to the under sink drainage unit, using a hose clip (see Fig. 3).

5 Raise the hooked end support up to at least 800 mm to avoid water being drawn back into the machine.

cutoffend

Hose clip

0

CONSOLE PANELS

WF541 shown with full options

Programme Options - All ModelsWash EnhanceReduced CreasesRinse HoldMini LoadExtra Rinse

WF541, WF546 & WT540/1PVariable Spin Speed

WF321, WF326, WF541, WF546, WT540/1P & WT540/1GVariable Temperature

Spin Speeds1000 rpm - WF1011200 rpm - WF321 & WF3261400 rpm - WF541, WF546, WT540/1P & WT540/1G

11

CONTROLS

On-Off / Selecting a ProgrammeThe machine is switched on by pressing the 'On/Off' button for 2 seconds. All the indicator lights will light up for a few seconds and the 'Door Locked' indicator light will flash once.Turn the programme selector dial to the desired programme. Load the laundry and detergent.Select the options you require.Press the 'Start/Cancel' button for 2 seconds to start the programme.

To Stop or Change a ProgrammePress the 'Start/Cancel' button for 2 seconds.Select 'Pump Out' on the programme selector dial.When the machine has finished emptying, turn the programme selector dial to the new programme. Press the 'Start/Cancel' button to start the programme.If you cancel a hot wash programme, take care when removing the laundry, it might still be very hot.

Progress Indicator LightsThese will light up when you choose a programme, to indicate the progress of the selected programme. When started, the first light in the cycle will stay lit and as the programme progresses, successive lights will come on until the programme finishes.

Door Locked Indicator lightThe 'Door Locked' indicator light will come on two seconds after you press the 'Start/Cancel' button and will stay lit throughout the programme. A short time after the programme has finished the indicator light will go out and you can then open the door.Selected programmes will not start if the door is not closed properly, the 'Door Locked' indicator light will flash to show this. Push the door shut until you hear the catch click.

Button SelectionTo select an option, press the button and you will see a light come on alongside the button.Press again to cancel, and the light will go out.

Reduce CreasesReduces wash action and spin speed, meaning less ironing for delicate clothes.This does not apply to Cotton, Wool or Handwash programmes, except Super Wash and 60°C Fast Wash.

Option Buttons Progress Indicator Lights Start/Cancel On/Off

Programme Selector DialVariable Control(s)(depends on model)

12

Mini LoadFor washing a smaller load.In addition to reducing actual washing time, this option will reduce water and energy consumption by up to 50%.Note: You can reduce the amount of detergent you use with this wash.

Extra RinseFor large wash loads and items for young children or people with sensitive skin.This option adds a rinse.This is not available with Pre-Wash, Wool, Handwash, Silks, Fast Wash or Spin only programmes.

Variable Spin SpeedOnly available on models WF541, WF546, WT540/1P & WT540/1GUse this control to reduce the programme spin speed only.If you leave this dial in the maximum position, the spin speed will be the maximum which is appropriate for whatever wash programme you have chosen.When the programme has finished, return the dial to the original setting.

Rinse HoldClothes will be held in the final rinse water, keeping them fresh until you are ready to complete the programme.Complete the final spin by pressing the Rinse Hold button when the light is flashing.This is not available with Pre-Wash, Wool, Handwash or Spin only programmes.

Variable TemperatureOnly available on models WF321, WF326, WF541, WF546, WT540/1P & WT540/1GUse this control to reduce the wash temperature only.If you leave this dial in the maximum position (95), the actual wash temperature will be the maximum which is appropriate for the wash programme you have chosen.When the programme has finished return the dial to the original setting.

Wash EnhanceSelecting this option on 60°C and 40°C Cotton programmes will give a more intensive wash for heavily soiled items.Selecting this option on 40°C Wool programme will give the Woolmark approved wash cycle.Not selecting this option will give the relevant standard wash cycles.

Cool Wash 30°CA low temperature wash which delivers cleaning results comparable to an intensive 40°C Cotton programme, but at a lower temperature for more colour sensitive garments using less energy.

13

AUTOMATIC FEATURES

Auto Half LoadAuto half load saves you time and money when washing smaller loads. Water levels are automatically adjusted to cater for the different loads.

Unbalanced LoadThe machine has an inbuilt feature to prevent it spinning with an unbalanced load. This will minimise excessive vibration and prolong the life of the machine.Before each spin the machine 'senses' the load within the drum and if the machine considers the load to be unbalanced, it will not automatically spin. Instead the machine will try to redistribute the load to achieve balance by tumbling backwards and forwards.

Out of Balance ProtectionThe machine has an inbuilt feature to prevent spinning with an unbalanced load. A calculation via the motor tacho and control board detects the current drawn by the motor during distribution.These calculations are done very quickly and are unlikely to be detected by the user.Before each spin, the controls senses the load within the drum. If the load is calculated to be out of balance the machine will not automatically spin to the full speed. There are two levels of out of balance, level 1 @ 480 grams and level 2 @ 1030 grams.If the out of balance is below level 1 the machine will spin at full speed. If the out of balance is between level 1 and level 2 the machine will spin at the reduced speed of 800 rpm and above level 2, spin at a reduced speed of 400 rpm. There are 15 attempts at level 1, 39 attempts at level 2 with 54 attempts in total, this being the same for both cotton and synthetic spins.The spin programme will always be completed at a spin speed depending on the balance condition.The wool spin has one level of out of balance @ 1.8 kg. The controls will make three attempts to achieve a balance, if after three attempts a balance is not achieved, the spin is reduced to a speed of 90 rpm.

14

PROGRAMMESCOLD FILL MODELS

WashLabel

Programme Type /Fabric

Description Temp °C

Max Load (kg)

ApproxProg. Time (h:min)

1 PrewashMixed

A cool temperature cycle to loosen stains before selecting a main wash programme

30 6 0:25

2 HygienicWhite Cotton

For hard wearing heat resistant cotton and linen

95 6 2:30

3 Super WashColourfast Cotton

An intensive cleaning programme for heavily soiled hard wearing fabrics

60 5 2:20

4 EverydayColourfast Cotton

For every day cleaning needs for colourfast cotton or linen fabrics

60 5 1:30

5 StandardColourfast Cotton

An intensive cleaning, energy efficient cycle using the maximum load capacity

60 6 2:00

5 Fast WashColourfast Cotton

A fast cycle for lightly soiled heat resistant cotton and linen fabrics

60 5 1:00

6 EverydayNon-Colourfast Cotton

For the every day cleaning needs of cottons and other hard wearing fabrics

40 5 1:15

6 IntensiveNon-Colourfast Cotton

A less energy efficient intensive 40°C cycle for more stubborn soiling

40 6 1:45

7 Man Made FibresColoured Synthetics & Acrylics

A cycle designed to wash a variety of man-made fibres and fibre mixtures

40 3 1:15

8 Cool WashNon Colourfast Cotton

Delivers the same performance as the intensive 40°C cycle but it more energy efficient at the expense of duration

30 4 1:50

9 Machine WashableWool

For machine washable wool and wool mixtures

40 3 1:00

9 Gold Woolmark ApprovedHandwash Wool

A special cycle for Hand Wash wool that will not shrink your garments. Exclusively approved by Woolmark

40 1 0:50

10 Machine WashableSilk

For silk garments labelled as machine washable

30 3 0:55

11 Fast WashMixedNot Wool, Silk/Handwash

A very short refresh programme for lightly soiled mixed fabrics

30 3 0:30

12 HandwashDelicatesNot Wool/Silk

A gentle cycle for delicate items labelled as Hand Wash only

25 4 0:50

R&S Rinse & SpinMixed

This partial programme completes two full rinses and then a slow spin

- 3 0:30

FS Fast SpinCotton

This partial programme completes the maximum speed final spin

- 6 0:15

SS Slow SpinDelicates

This partial programme completes the intermediate speed final spin

- 3 0:12

PO Pump OutAll

This partial programme ensures the appliance is emptied of water

- 6 0:02

15

1

Serial Link160 017 049 00

Earth 160 017 050 00

Solenoid Valves & Heater NTC160 017 048 00

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16

WIRING CONNECTION CHART

9 8 7 6 5 4 3 2

1 2 3 4 5 6 1 2 3 4 5 1 2

Part

No.

12 16

Pressure SwitchBitron or Metalflex

Door Interlock (Hotpoint machines)Metalflex (3 connections)

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1 3

1

2

1

2

12

2 3 4

1234

1C

34679

1

EM

PTY

FULL

CO

MM

ON

GN

D

RX

1 2

3 4 6 7 8

R R

56

D

j5 j1 j3 j8

j10j2j4

12A

12A

10A

10A

8A

10A

10A

1A

10w

10w

1 2

RTN_IP

RTN_PORTA

9

Lav.

1

2

*1 2

1112

j15

WASH VALVES

MAINSINPUTFILTER

WASHTHERMISTOR PUFABRIC COLD

NC

TF

WIRING LEGENDAQS Aquastop solenoid valve N Neutral or Terminal boardB Buzzer or Door lock NC No spin

BF Terminal board contacts, dryer heating element and P Pressure switch

BP Door lock P1 Pressure switch 1st levelC Condenser P2 Pressure switch 2nd levelAC Condenser PA High speed potentiometerDV Switch PB Low speed potentiometerEF/CL Cold water/bleach solenoid valve PL Pure woolEF/L Cold water/wash solenoid valve PM Motor thermoprotectorEF/P Cold water/prewash solenoid valve PR Timer programmer or Pressure switchER Cut-out heater PS Drain pumpET Cut-out thermostat R Heating elementEV Solenoid valve Ras/RA Drying heaterEVA Drying solenoid valve RE RelayEVC Hot water solenoid valve RR Heating elementEVF Cold water solenoid valve RV Speed regulatorEVL Wash solenoid valve S Indicator lightEVP Prewash solenoid valve SL Line indicator lightFA Noise filter SO Door indicator lightFD Delicate drying thermostat SR Heating indicator lightFE Intense drying thermostat ST Temperature selector or Stop with waterFRT Thermofuse resistance SV Spin speed selectorI Reverser T Timer contactsI1..I2..3. Switches/deviators TA Drying timer contactsIA On/Off switch TB Low temperature thermostatIC Switch NC / 1/2 load TC Crosspiece earthID No spin switch TFL Flange earthIE Water-economizer or NC Switch TG Main earthIF Spin decrease switch TH ThermostatIP Door switch TH1 Thermostat 1st temperatureIR Line switch TH2 Thermostat 2nd temperatureIS Water-stop TH3 Thermostat 3rd temperatureL Line or Lamp THF Work thermostatLB Low level THR Adjustable thermostatLN Normal level TM Motor earthLS Indicator light TMB Base cabinet earthM Earth symbol or Dryer motor TMP Motor thermoprotectorMC Spin motor or Spin winding TMS ThermostopMI Induction motor TP Thermoprotector or Pump earthML Wash motor or Wash winding TPS Drain pump earthMO Terminal board TR Heating element earthMP Door microswitch TS Safety thermostat or Support earthMR Microdelay device TT Timer earthMT Timer motor TTH Thermostat earthMV Fan TV Tub earthMV - Ras Dryer fan (RA) ZBN TimerMzbn/M zbn timer motor

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POWER MODULE CONNECTIONS

J11

J8

J10

J13

J14

J15

J9

J2

J1

J4J3

HARDWAREKEY

SOCKET(external)

EEPROM SOCKET

modules only)(Service / spares

J5

19

EEPROMS & DIAGNOSTICS

Three variations of Eeprom can be found or used on Power Boards:

1. Production Power Boards have a soldered Eeprom and is not replaceable.2. Service Power Boards have a socket and the Eeprom is a separate part.3. Blank Eeproms.All types can be programmed or re-programmed via Emit, using a USB lead, Hardware Key and the relevant Eeprom Writer software. Certain models which have a combined Power and Display board also require an Adapter fitted between the Hardware Key and the Power Board.Information can be found in Service Manual 5407177 and Quick Guide 5407200.

The Main Components are shown below.

Fig. A C00115587 Hardware Key Fig. B C00116135 Low End AdapterFig. C 5600261 USB Cable

A Hardware Key Pin Repair Kit is also available which contains five pins. Part Number C00114723.

DIAGNOSTICS

Two versions of a diagnostic programme are available to use after an Eeprom has been replaced or programmed and for general fault finding. Connection to the appliance is the same as for Eeprom Writer.

1. Washing Machine Doctor 1 for Evo 1 based appliances.2. Washing Machine Doctor 2 for Evo 2 based appliances.

Information can be found in Service Manuals 5407180 and 5407182 respectively.

Note: This version of the Hardware Key, Eeprom Writer and Washing Machine Doctor programmes are only available to Indesit Company Engineers.

Pre-programmed Eeproms and Service socket boards are available for repairs and Spare Parts.

Fig. A Fig. B Fig. C

20

ERROR CODES & POSSIBLE CAUSES

Note LCD display codes shown above are found on the Auto Hardware Key Display - not on the machine.

LCD DisplayCode

Console LEDsPossible Causes & ActionsLED 1 LED 2 LED 3 LED 4 LED 5

F01 OFF OFF OFF Flash OFF Motor triac short circuit: check motor & module connections

F02 OFF OFF Flash OFF OFF Motor jammed / tacho detached: check motor & module connections

F03 OFF OFF Flash Flash OFF NTC short/open circuit: check thermistor & module connections

F04 OFF Flash OFF OFF OFF Pressure switch jammed on empty: check switch & module

F05 OFF Flash OFF Flash OFF Pressure switch jammed on full or pump blocked: check pump & switch

F06 OFF Flash Flash OFF OFF N/A

F07 OFF Flash Flash Flash OFF Heater relay stuck: check heater and module connections

F08 Flash OFF OFF OFF OFF Heater relay stuck: check pressure switch, heater & module connections

F09 Flash OFF OFF Flash OFF Setup error: check eeprom

F10 Flash OFF Flash OFF OFF Pressure switch not sensing: check switch & module connections

F11 Flash OFF Flash Flash OFF Pump cannot be activated: check pump, connections & wiring

F12 Flash Flash OFF OFF OFF No communication between cards: check module connections

F13 Flash Flash OFF Flash OFF N/AF14 Flash Flash Flash OFF OFF N/AF15 Flash Flash Flash Flash OFF N/AF16 OFF OFF OFF OFF Flash N/A

F17 OFF OFF OFF Flash Flash Door lock error: check door, door lock & module connections

LED 1

LED 2

LED 3

LED 4

LED 5

When an error occurs,the On/Off LED flashes rapidlyand one or more of the Option LEDs will flash once per second

Refer to the chart below forerror code definitions.

21

DISMANTLING INSTRUCTIONS

SAFETY NOTES1. Ensure that the appliance is disconnected from the electrical supply before dismantling.2. Beware of sharp edges on metal panels, plastic mouldings, and pressed parts.3. Some fixings (especially those into plastic) must be tightened to the correct specification using a

suitable torque wrench.4. Insulation resistance tests must be carried out with the pressure switch set to ensure that the

water heater is 'in-circuit' during the test.

A Table Top1. Remove the two screws at the top rear of cabinet.2. Slide the table top backwards to disengage the location fixings and lift off.

B Lower Rear Access Panel1. Remove 2 screws from the lower rear access panel.2. Pull the top edge of the panel out and disengage it from its location fixings along the bottom.

C Dispenser Drawer1. Open the dispenser drawer fully.2. Press release latch in centre of drawer and pull drawer body and pull drawer away from console.

D Console Panel1. Remove the table top (A) and dispenser drawer (C).2. Remove two top screws securing console to cabinet and two screws securing console to

dispenser.3. Unplug wiring from console PCB - taking note of position.4. Slide dispenser back.5. Unclip two plastic lugs securing console panel to front panel and lift clear.6. Avoid unclipping and handling the control board unless absolutely necessary, as the control

board is susceptible to static electricity.

E Console PCB and Button Assemblies1. Remove the console panel (D).2. Remove wiring plug - taking note of position.3. Remove three securing clips and lift away from the console.

F Pressure Switch1. Remove the table top (A).2. Disconnect the wiring connection block and pressure hose.3. Carefully rotate the pressure switch in a clockwise direction to release from the cabinet.

22

G Door Seal & Restraint:

1. Door Seal to Front Panel FixingThe door seal is fixed to the cabinet front panel by a wire clamp and a small spring. The spring is normally at the bottom of the door.Carefully place a small screwdriver into one of the lugs of the spring and by stretching the spring the wire band can be removed.

2. Drum FixingThe door seal is fixed to the drum with a zipper retainer. After removing the front panel (J), remove the zipper as shown in Fig. 3 below.On refitting place the strap around the door seal and tighten as shown in Fig. 4. Observe correct seal and zipper fixing positions as shown in Fig. 5 and Fig. 6.

H Door Interlock1. Remove the door seal restraint (G).2. Peel the door seal off the front panel, and fold it back into the inner drum.3. Remove two screws from the interlock.4. The interlock can now be eased out, allowing access to the wiring connection block.5. Care must be taken to ensure the correct orientation of the wiring connection plug to prevent

seriously damaging the interlock and / or control board.

Seal to Drum fixing position Correct Seal position at Drum Front

Fig. 3 Fig. 4

Plastic Support (observe position)

Zipper

Fig. 5Fig. 6Fig. 6

Alignment guide

23

J Front Panel1. Remove the table top (A), dispenser drawer (C) and console panel (D).2. Remove the door seal restraint (G) and door interlock (H).3. Grip the appliance kickstrip at both ends tilt forwards, and pull it off in a forward direction.4. Remove 4 front panel fixing screws (2 bottom and 2 top).5. Lift the front panel upwards to disengage the four cabinet fixing pegs, and lift off.

K Drive Belt1. Remove the table top (A).2. Remove the lower rear access panel (B).3. Carefully peel the belt off the motor pulley taking care not to trap fingers and using suitable

protection against sharp edges.4. To refit the belt, place it round the motor pulley first, tie-wrap the belt onto the drum pulley, and

rotate the drum from the door aperture to move the belt into position.5. Ensure any remaining tie-wraps are removed.

It is essential for continued safety that only a genuine spare is fitted. The belt is electrically conductive and provides an electrical earth to prevent static built up on the inner drum assembly.

I Door Assembly1. Open the door through 180° and remove four

screws securing the hinges to the front panel. Ease the hinges from the panel.

2. The door trims can now be split. Lay the door assembly face down on a suitably protected surface and remove 6 screws securing the two halves of the door.

3. Unclip the two halves at the hinge end and separate a sufficient distance to slide out the door glass.

4. When removing the hinges, note the orientation. To remove, fold hinges inward, slide towards each other to release other end. See photo.Reassemble in reverse order.

5. To fully separate the halves, slide the front away from the handle.

6. To remove the handle or latch, slide securing pin out noting the position of the spring and latch.

Top Hinge removal (shown below) - Slide towards lower hinge, twist to the left and slide up to release.Lower Hinge removal - Slide upwards, twist to the right and slide down to release.

24

L Motor1. Remove the lower rear access panel (B) and drive belt (K).2. Disconnect the motor wiring connection plug and earth wire.3. Disconnect the heater and NTC.4. Using a 10 mm socket, remove both motor mount fixing screws. Fig. 7.5. Carefully ease the motor off the drum mountings.6. Slide the motor to the left and lift out of the back of the aperture. Fig. 8.7. When replacing the motor fixing screws ensure that they are tightened to 9 Nm.

M(a) Lower Balance Weight1. Remove the table top (A), dispenser drawer (C) and console panel (D).2. Remove the door seal restraint (G), door interlock (H) and front panel (J).3. Using a 13 mm socket or spanner, remove three balance weight fixing screws.4. Pull the weight forward off its mounting lugs.5. When refitting the balance weight it is essential to ensure that the thread forming screws are

tightened to 24Nm (using a suitable torque-wrench) and that the screws find their original threads, otherwise the thread can be stripped from the plastic drum lug.

M(b) Top Balance Weight1. Remove the table top (A).2. Using a 13 mm socket or spanner, remove three balance weight fixings screws.3. Lift the weight off the drum mountings.4. When refitting the balance weight it is essential to ensure that the thread forming screws are

tightened to 24Nm (using a suitable torque-wrench) and that the screws find their original threads, otherwise the thread can be stripped from the plastic drum lug.

Fig. 7

Fig. 8

25

N Heater / Thermistor1. Remove the rear lower access panel (B).2. Remove the heater wiring and detach the thermistor plug.3. Slacken off the 10 mm heater fixing nut and withdraw the heater from the drum.

O Drum Pulley1. Remove the complete drum assembly (T).2. Carefully peel the belt off the motor pulley taking care not to trap fingers.3. Use the pulley locking tool to prevent rotation of the pulley.4. Use a Torx T40 bit to partially remove the fixing screw in the centre of the pulley, and strike the

head of the screw with a copper mallet to release the pulley from the shaft.5. To ensure adequate pulley security always apply an engineering Nutlock (Part No. 981009) to

the bolt threads.

P(a) Suspension Damper1. Remove two suspension clamp fixing screws.2. Remove the table top (A), dispenser drawer (C) and console panel (D).3. Remove the door seal restraint (G), door interlock (H) and front panel (J).4. Remove the lower balance weight (Ma) if access is required to the left-hand damper.5. Unclip any wiring retained within the integral clip on the bottom damper moulding.6. Remove the plastic peg securing the damper to the outer drum using special tool Part No.

5600198.7. Unclip the suspension clamp from the chassis.

Withdraw the suspension damper. Note: The suspension unit should not be split and is not serviceable.

8. When reassembling, fit a new plastic peg if the locking-tab on it shows signs of damage.

6 kg Welded DrumTorque Setting 24 Nm

Sequence Top Weight 1 2 3Bottom Weight 1 2 3

21

3

Top Block

LEFT

2

1

3

Bottom Block

LEFT

26

P(b) Suspension Spring1. Remove the table top (A).2. Unclip any wiring retained within the integral clip on the spring bearing keeper plate.3. Gently lever out the bearing keeper plate with a small flat bladed screwdriver.4. Unhook the spring from the cabinet top rail bearing.

Q Dispenser1. Remove the table top (A) and dispenser drawer (C).2. Remove two screws around the dispenser recess.3. Remove the screw securing the valve to the valve cover.4. Remove the screw securing the valve cover to the cabinet and remove the cover.5. Ease the dispenser backwards.6. Remove the dispenser inlet and outlet hoses, and any harness retention ties.

R Drain Pump1. Remove the appliance kick strip by gripping it at both ends, tilt it forwards and pull it off towards

you.2. Remove the 2 pump housing fixings screws from the front panel. Rotate the pump to release the

fixing lugs. See Fig. A below. 3. Slide the pump out through the base of the machine. See Fig. B below.4. Detach the sump hose from the pump, using a suitable container to catch any water.5. Disconnect the drain hose from the pump unplug the wiring connection block.

Fig. ARemove screws & rotate clockwise

Fig. BRemove pump through base of cabinet

Screws

27

S Inner Drum Lifter

1. Insert a small screwdriver onto the 3rd lifter hole from the front of the drum.This will depress the drum flap securing the lifter.

2. Slide the lifter to the front of the drum and remove.3. Before refitting, lift the drum locking tab 3 mm above the drum surface.4. Offer the lifter to the holes in the drum, slide lifter to the back of the drum until a click is heard as

the lifter is locked into place.

T Drum Assembly

Note: This sealed drum assembly cannot be split to remove or repair the inner drum, bearing support or bearings.

It must be replaced as a complete unit.

External components such as weights, bolts and hoses, motor and belt etc. will need to be transferred from the faulty drum assembly.

1. Remove the table top (A).2. Remove the top balance weight (Mb).3. Remove the dispenser drawer (C).4. Remove the console panel (D).5. Remove the dispenser (Q).6. Remove the front panel (J).7. Remove the lower balance weight (Ma).8. Remove the lower rear access panel (B).9. Disconnect heater / thermistor wiring and release the wiring harness from the drum clips.10. Detach the drum from the damper units by removing the two plastic pegs using special

tool Part No. 5600198.11. Remove the sump hose fixing clip and detach the sump hose from the sump chamber.12. Unclip any wiring retained within the integral clip on the spring bearing keeper plates.13. Gently lever out the spring bearing keeper plates with a small flat bladed screwdriver.14. Unhook springs from the cabinet top rail bearings.15. Carefully lift the drum assembly out of the cabinet whilst supporting the drum.

3rd hole from the front

28

U Cabinet1. Remove the drum assembly (T).2. Remove the drain pump (R).3. Remove and disconnect wiring harness.4. Unscrew feet and remove hose clips from the rear of the cabinet.

V Power / Control Module1. Remove lower rear access panel (B). 2. Remove screw or screws securing module support to the cabinet.3. Disconnect wiring.

IMPORTANT NOTE - AVOIDING ELECTRICAL DAMAGE TO THE MODULEBefore disconnecting any plugs it is advisable to note their locations.When reconnecting the plugs to the module it is essential that the large WHITE multiway edge connector plug is fitted with the wires from the plug oriented as shown below.Applying power to the machine with the plug fitted in the wrong position WILL CAUSE PERMANENT DAMAGE to the module.

4. Lift module clear.5. When replacing the board an EEProm will also be required.

Service modules are not normally supplied with a programmed EEProm.Note: To remove and fit the EEProm use Insulated Tweezers Part No. C00066292 as shown below. On the original control board, the EEProm may be soldered to the board and cannot be removed.

Wires must exit theplug as shown here

White Multiway Connector Plug

Ensure correct orientation when refitting

IC Removal ToolEEPROM Removal from PCB

29

PARTSand

ACCESSORIESTo order parts and accessories contact our

National Mail Order Parts Hotline

08709 077 077

Monday to Friday 8.00am to 5.30pmSaturday 8.30am to 12.00 noon

or online at :

www.theservicecentre.co.uk

30