DishDrawerTM 605

Service Summary and Fault Code Descriptions

CAUTION: ALL TERMINALS AND INTERNAL PARTS SHOULD BE TREATED AS LIVE.

This information is intended for use by individuals who have adequate electrical, electronic and mechanical qualifications and experience. Any attempt to repair a major appliance may result in personal injury and property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use. If further help is needed concerning this appliance contact:

Fisher & Paykel Appliances Inc 5800 Skylab Rd, Huntington Beach, CA 92647, USA Telephone: 888 936 7872 E-mail: customer.care@fishpaykel.com

IMPORTANT SAFETY NOTICE

CAUTION: This machine must be electrically grounded through the grounding lead in the 3-prong power cord if plugged into a properly grounded appliance outlet, or through a separate No. 14 AWG or larger wire from the cabinet to an established ground. In all cases the grounding method must comply with any local electrical code requirements. To reduce the risk of shock, disconnect the power supply cord before servicing. CAUTION: ALL TERMINALS AND INTERNAL PARTS SHOULD BE TREATED AS LIVE. IMPORTANT: RECONNECT ALL GROUNDING DEVICES. If grounding wires, screws, straps, clips, nuts or washers are removed for service they must be returned to their original position and properly fastened.

Electronics
The DD605 and DS605 electronic controllers use a 16-bit microcontroller to provide the user interface, motor and ancillary functions. The microcontroller also controls the switchmode power supply. This power supply uses a dropping resistor on the heater plate and phase control of the mains voltage to produce a variable voltage supply to the motors and solenoids of the DishDrawer. A separate 24v dc power supply on the chassis board (located in the lower left corner of the chassis) supplies power to the microcontroller and LEDs in the electronic controllers.

of the porcelain enamelled steel heater plate. A large dropping resistor is also printed onto the heater plate and forms part of the power supply. The heater plate is clamped in place by a lock ring nut and supports the motor at the bottom of the tub. The heater element is only activated during wash cycles. It is not used for drying. The water temperature is sensed by a thermistor on the heater plate pcb. Overheat protection is provided by a thermal fuse on the heater plate itself. The heater plate must be grounded.

The fan runs continuously during the drying phase of a wash cycle and will restart if the tub is opened and closed again. After the drying phase is complete at the end of the wash program the fan continues to run for up to two hours but will not restart if the tub is opened and closed.

Tub Removal
To remove the tub 1. Open the drawer fully. 2. Depress the right-hand tub release clip and push it back about 1.5 inches. Repeat for the left-hand side. 3. Lift the tub up and off the drawer runners. 4. If turning the tub over rotate it counter/anti clockwise. 5. Slide both runners back into the product. 6. Refit in the reverse manner (if the tub was turned over ensure it is rotated clockwise before placing it on the runners).

Tub Home Sensor

The tub home sensor determines when the tub is closed. The tub home sensor consists of an infrared sender and receiver mounted on the right side of electronic controller. When the tub is fully closed infrared light is transmitted from the sender through a light pipe on the side of the tub, through a prism mounted in the chassis trim, then back through the other light pipe to the receiver. If the tub is not fully closed the circuit is not complete and the appliance will not operate.

Dispensing Detergent
The detergent dispenser door is opened manually for detergent loading and then manually closed ready for the detergent to be delivered to the tub with the inlet water. An inlet water diverter valve is controlled by the electronics to dispense detergent from either detergent chamber as required. A positive displacement pump unit and storage tank are incorporated in the dispenser to supply rinse agent. The volume of rinse agent dispensed may be adjusted by the user to suit water conditions. A glowing red light on the rinse agent filler cap indicates an empty tank.

Amount of Water
The tub fills with about 0.8 US gallons of water, almost level with the base of the spray arm. Once this level is reached the wash pump becomes primed and pumps water through the spray arm causing it to rotate. The electronic controller senses when the wash pump becomes primed and stops filling by turning off the water inlet valve. The load on the wash pump is continuously monitored during the cycle and water level increased if necessary.

Drying Cycle
The fan draws air through the rear vent in the tub where it absorbs water from the dish load. The moisture-laden air is then mixed with a large quantity of ambient air (from the kitchen) to minimise the amount of visible vapour exiting from the front of the drawer.

The Element
The water heater element is a thick film resistive circuit printed onto the dry side

Page 1

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

Removal of Drawer Front

To remove the drawer front Warning: Ensure the mains power has been disconnected before servicing the DishDrawer 1. Remove the two retaining pins on either side of the tub at the front using a sharp pair of long nose pliers 2. Pull the drawer front out slightly at the bottom then downwards away from the handle. 3. Carefully remove the grounding wire from the tab on the drawer front. 4. Components on the front of the tub are now accessible. Caution: All terminals and internal parts should be treated as live. 5. Refit the drawer front in the reverse manner. When replacing the retaining pins ensure the web in the centre of the pin is vertical.

DC 24V motor. The actuator assembly is clipped to the side rail. When the appliance is first connected to the power, the lid actuators will raise the lid to the full up position. At the start of a wash cycle both actuators are run for 2 or 3 seconds to pull the lid down onto the tub. The lid remains down for the duration of the wash cycle and is only lifted when the DishDrawer beeps to signal the end of the cycle or the user pauses the cycle to gain access to the tub. If power to the DishDrawer is disconnected or fails with the lid down the drawer may be forced open manually if access is required. However forcing the drawer closed with the lid down is not recommended as it can damage the seal.

A glowing red light on the Salt Reservoir Cap indicates the salt reservoir is empty. Prefinished models with an electronic display will also display a salt symbol.

Filter Plate
To clean the drain filter with the dish rack in place, remove the cutlery basket and open the drain filter access insert. The filter plate can be removed for cleaning after removing dish rack and spray arm and turning the outer lock ring counter/anti clockwise.

Motor
The motor is 80 volt, 60 watt, 3 phase, 6 pole brushless DC device. The electronic controller drives it in a clockwise direction to run the wash pump at 2300 2850rpm depending on the wash cycle selected and in the counter/anti clockwise direction to run the drain pump at about 4200rpm.

Water Softener
Some models are fitted with a Water Softener, which is designed to remove calcium and magnesium ions that cause the water to be hard. The water softener will automatically remove hardness from the water using a salt water solution. It must be set for the local hardness and must always be filled with granular salt made especially for dishwasher water softening systems.

Lid System
The lid is a single piece of polymer plastic with a seal co-injection moulded into it. Each side of the lid is clipped into a yoke which is in turn connected to an actuator assembly consisting of a worm drive gearbox driven by a small brushed

Drain Cycle
The tub is drained by a self-priming centrifugal pump which only pumps when the motor is running in the counter/anti clockwise drain direction. The drain pump outlet has a non return valve to prevent soiled water returning to the tub.

Diagnostics Mode Quick Reference Guide

Diagnostics Mode
Warning: In Diagnostics Mode the element can be turned on with no water in the tub, which can result in damage to the tub and element. While the element should turn off automatically after about 5 seconds to prevent damage it is recommended that the element never be turned on without water in the tub. Diagnostics Mode can only be entered from the Power Off mode. There are four sub modes available: Display/Download, Hardware Output Test, Fast Test Cycle and Continuous Cycle. The power button is used to step through the sub modes. A Temperature and Voltage Display is available in Wash Modes. Display/Download Diagnostic Sub Mode Press and hold down Keylock and Start/Pause buttons for about 5 seconds (ensure Keylock is pressed first). All LEDs and LCD segments except Keylock should display. Press Start/Pause button. This initiates Pen Upload via the lower tub home sensor (sender) light pipe. At the same time the current and then the previous fault code will be displayed on the LCD and the touch switch panel LEDs. Refer to fault code descriptions to translate the LEDs. Press Keylock button. This copies the current fault code and fault log over the previous fault and clears the current fault. Pressing it again will clear the previous fault as well. Successive Keylock presses also turn segments of the LCD wash icon off and on. Press Power button once to step to the Hardware Output Test sub mode, or three times to exit to Power Off mode.

Page 2

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

Hardware Output Test Sub Mode

Enter this sub mode from Display/Download Diagnostic sub mode by pressing the Power Button once. An LCD will display HO and on both Integrated and LCD models the Heavy, Normal, Fast, Delicate and Rinse LEDs will be on. Press Start/Pause button to scroll through the available hardware outputs. Turn the outputs on and off using the Keylock button. The table shows the displays and outputs. Press Power once to step to Fast Test Cycle sub mode, or twice to exit to Power Off mode. Notes: On LCD models the scrubbing brush is displayed when an output is on. On integrated models, the LED above the Start/Pause button is displayed when the output is on. C3 is only used in the factory to empty the water softener before the product is packed. To test the tub home sensor circuit, open and close the tub. This will turn the lock symbol (LCD models) or Lock LED (Integrated models) off (open) and on (closed).
LCD

Dlfjefe Backlight (not fitted to DD605 models) Lefef Element relay (on for only 5 seconds) Fefeodown or up (will run for up to 10 Lid seconds) Efef Detergent diverter Fefef Fill valve Fefefe Wash Efefe motor (only if tub is closed) Drain motor (times out after 255 seconds) Efef Rinse aid pump Fefe

Heavy bL Er Ld dd FV P1 P2 rd dF LE C1 C2 C3 oC oE

Normal

Touch switch panel LEDs Fast Delicate ON ON ON ON ON ON

Rinse ON ON

Eco

ON ON ON ON ON ON ON ON ON ON ON ON

Drying fan Rinse aid and salt tank LEDs Water softener bypass valve Water softener brine pump Water softener brine valve Temperature (only visible on LCD models) PSU voltage (only visible on LCD models)

ON ON ON ON ON ON ON ON

ON ON ON ON

Ffefef

Fast Test Cycle Sub Mode

Enter this sub mode from Hardware Output Test sub mode by pressing the Power button once. FC will be displayed on LCD models and on both Integrated and LCD models the Heavy, Normal, Delicate and Rinse LEDs will be on Press Start/Pause twice to start a short test cycle. This cycle fills the tub, washes for 3 minutes with the element on, drains the tub and runs the drying fan for 1 minute. Total time is about 8 minutes. Efefe Press Keylock to run a self test sequence which turns on all the hardware outputs in succession. Fef Press Power once to step to the Continuous Cycle sub mode or twice to exit to Power Off mode.

Continuous Cycle Sub Mode

Enter this sub mode from Fast Test Cycle sub mode by pressing the Power button once. CC will be displayed on LCD models and on both Integrated and LCD models the Heavy, Normal and Rinse LEDs will be on. Pressing Start/Pause will continuously run the last selected wash cycle. Pressing Keylock before Start/Pause will continuously run all the wash cycles in succession. Press Power to exit to Power Off mode.

Fe

Temperature and Voltage Display Mode

This mode can only be entered from a Wash mode, when a wash cycle is active. Because it uses an LCD for output it is not fefuseful on integrated models unless the badge is temporarily replaced by an LCD. Start a wash cycle Efef Press and hold Keylock for 5 seconds until Keylock is activated Fe Press and hold Start/Pause for 8 seconds. The LCD display alternates between Deg C symbols and the water Ffe temperature. Fe Press Start/Pause. The LCD display alternates between Deg E symbols and the power supply rail voltage. Pressing Ffe Start/Pause again returns to the temperature display. Fe Press Power button to exit to the Keylocked mode. Fef Press and hold Keylock button for 5 seconds to return to the Wash mode. Ef Efe F

Page 3

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

Fault Code Descriptions

F9 Electronics / Power Supply Failure
Yes 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Is previous fault F3, F8 or F9? Fix previous fault. Did fault occur immediately after power on? Are solenoid coils and motor windings damaged or overheated? Replace as necessary. Are solenoid coil resistances about 70 ohm and motor winding resistance about 16 ohm (phase to phase)? Replace as required. Are lid actuators properly connected? Correct if necessary Is controller damaged or overheated or leaking fluid? Replace if so. Is fault on top controller? Does bottom controller work? Are top controller chassis and power harnesses properly connected and undamaged and no wires loose (controller may not be receiving power from bottom controller)? Replace or repair if not. Is bottom controller chassis harness properly connected and undamaged? Replace or repair if not. Are connectors on PCB mains filter properly connected? Replace or repair if not Are heater plate harnesses properly connected and undamaged? Replace or repair if not. Replace controller which is reporting the fault. 2 A 4 A 7 7 A 9 10 12 12 13 14 A

No
3 A 6 5 A A 8 12 12 A A A A A

F8 Ground (Earth) Leakage Fault

Yes
1 2 3 4 5 6 Is a Megger test successful? Are top and bottom harnesses and connectors physically damaged or is there evidence of water damage? Replace if damaged. Are any connectors or grounding (earthing) connectors not properly fitted, including door ground (earth) connectors? Refit if not fitted properly. Are tracks on top or bottom heater plate damaged? Replace heater plate if so. Does replacing PCB mains filter solve problem? Replace top and bottom controllers. 4 A A A A A

No
2 3 4 5 6 A

F7 No Lid Motor Current Detected

Yes
1 2 3 4 5 6 Are lid actuator connectors properly fitted? Refit if not. Is associated controller (top, bottom or single) receiving power (use diagnostics to run drain pump)? Are harnesses undamaged and connectors fitted to controllers? Replace or refit as required. Does replacing PCB mains filter correct problem? Does replacing one or both actuators correct problem? Replace controller. 2 4 4 A A A

No
A 3 A 5 6 A

F6 Lid Motors run but do not reach Stall current

Yes
1 2 3 4 Are yokes connected to actuators and lid and actuators clipped in place? Reconnect if not. Do lid actuators work correctly in diagnostics? Replace actuators. Replace controller. 2 4 A A

No
A 3 A A

F5 Lid Actuator Jammed Up or Down

Yes
1 2 3 4 Are dishes or cutlery preventing lid closing properly? Remind customer of size and loading limitations if so. Do yokes visibly move freely when actuators operated using diagnostics (not jamming at front or rear)? Replace or refit yokes. Replace actuators. A 4 A A

No
2 3 A A

Page 4

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

F4 Element on for more than 3 hours and water has not reached required temperature
Yes
1 2 3 4 5 Are associated controller and heater plate connectors correctly fitted and harnesses undamaged? Refit or replace as required. Is resistance between pins 1 and 2 of heater plate pcb correct? Replace heater plate. Is resistance between pins 1 and 2 of controller power connector about 10K (value depends on ambient temperature)? Replace controller. 2 4 A 5 A

No
A 3 A 3 A

F3 Water Temperature greater than 185 degrees F (85 degrees C)

Yes
1 2 3 4 5 6 7 Is incoming water temperature below 185 degrees F? Is water temperature reading in diagnostics consistent with temperature of water in tub or ambient if tub empty? Is water temperature reading in diagnostics 199? Is power connector on controller and connector on heater plate correctly fitted? Refit if not. Is resistance between pins 1 and 2 of controller power connector about 10K (value depends on ambient temperature)? Replace heater plate. Replace controller. 2 5 4 5 7 A A

No
A 3 5 A 6 A A

F2 Motor Not Starting

Yes
1 2 3 4 5 6 7 8 9 10 Is rotor free to turn? Is power available at controller (do lid actuators run in diagnostics)? Is motor vibrating or turning erratically when using diagnostics? Is hall sensor and its harness correctly fitted and undamaged? Replace damaged items as required. Are connections to stator correct and harnesses undamaged? Is motor moving? Is resistance of stator windings about 16 ohm (phase to phase)? Replace stator if not Are motor and chassis connectors correctly fitted and harnesses undamaged? Refit or replace as required. Is problem corrected by replacing controller? Replace PCB mains filter. 2 3 4 5 7 7 8 9 A A

No
A 8 6 A A 8 A A 10 A

F1 The bottom controller flood detector has activated

Yes
1 2 3 4 5 6 7 8 9 10 11 12 Did a flood occur (any evidence of water in base of chassis)? Are lids on both tubs closing properly and seals undamaged (and no dishes preventing lids closing)? Are spray arms and rotor correctly fitted? Is there any foaming (rinse aid spill or wrong detergent used)? Is there a leaking seal (motor, heater plate, dispenser or water softener) or damage fill or drain hose or failed flapper valve? Replace damaged/failed items as required and mop up water in base of chassis. Is fill valve shutting off (use diagnostics to check)? Is there evidence of corrosion or dirt around flood sensor on mains filter board? Is flood reported by both tubs (double only)? Is problem corrected by replacing mains filter board? Is problem corrected by replacing controllers? Are all connectors and harnesses correctly fitted and undamaged? Refit or replace as required 2 3 4 A 6 A 8 A 10 A A A

No
8 7 A 5 7 A A 9 12 11 12 A

U4 Advisory fault: other tub has disabled power supply

Yes
1 Fix fault on other tub. A

No
A

U3 Filled too quickly or failed to drain

This fault is not displayed to the customer, but it is recorded in the fault history and can be seen by Smart Tool. If the motor senses prime too soon (in less than 20 seconds), the product will drain and refill up to 5 times, then continue the wash program regardless, and log the fault. Yes No 1 Is the product draining completely from the previous fill? Test in diagnostics. 2 3 2 Is the product filling too quickly? 9 3 Is the drain blocked or are the drain hoses kinked? A 4 4 Are the drain sump inlet or outlet pipes blocked? A 5 5 Is the drain filter blocked? A 6 6 Is the rotor fitted correctly, or is it damaged? A 7 7 Are the motor connections and resistances bad? A 8 8 Are the hall sensor or connections faulty? A 9 Is the water pressure too high? A 10 10 Is the water inlet valve faulty? A

Page 5

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

U1 (No Tap symbol on LCD) Fill valve open for 3 minutes and wash pump has not primed
Yes
1 2 3 4 5 6 7 8 9 10 Is there water in the tub? Does turning on water supply correct problem? Is inlet hose or pipe interrupter in water softener (if fitted) blocked? Does fill valve work (use diagnostics)? Is motor operating (use diagnostics)? Replace controller. Is there too much water in tub? Is sprayarm and rotor correctly fitted? Is water pressure sufficient (above 30kPa or 4.3psi)? Is there foaming (spilled rinse aid maybe)? 7 A A 5 6 A 8 10 10 A

No
2 3 4 A A A 9 A A 6

Cause of Problem
Use of liquid detergent or tablets Spray arm has stopped rotating

Poor Wash Performance How to Resolve the Problem

Use only powdered detergent recommended for domestic automatic dishwashers in the detergent dispenser. One of the dishes/cutlery/utensils ahs fallen through the basket and jammed the spray arm. Remove the obstruction. Filter plate, drain filter or filter access panel not installed correctly and is jamming the spray arm. Install correctly. Advise user of correct loading. Advise user about reduced water temperatures and wash times when using Fast and Eco cycles Fill the main wash detergent cup to the top and for best results also fill the pre-wash detergent cup. Run on normal or heavy cycles, not Eco. Advise user of correct loading.

User complains of food particles left on dishes

Product is being overloaded or incorrectly loaded with dishes User is selecting the wrong wash cycle for the soil level on the dishes

User complains of coffee/tea stains left in cups

Not enough detergent being used. To remove these requires a stronger concentration of detergent. More detergent is also required in areas where the water is hard as the minerals reduce the effectiveness of the detergent. The product is being overloaded which is preventing water reaching cups on the upper racks.

User complains dishes have blotchy marks on them which look like water stain marks, not food
Not enough rinse aid being used. The water is not soft enough during the final rinse and hard water droplets containing impurities are drying on the dishes instead of running off during the drying cycle. Confirm the user is using rinse aid. The rinse aid setting may need to be increased (4 or 5 lights) and for optimum drying performance run the DishDrawer on normal or heavy cycles not Eco. Check the rinse aid dispenser is dispensing correctly using diagnostics.

User complains glasses and cutlery have cloudy white film on them and/or plates have a while chalky film on them
Hard water and not enough detergent being used or water softener setting too low (where fitted). Minerals from the water are building up on dishes. Once this film forms on dishes it cannot be removed by normal running in the dishwasher. They need to be cleaned by soaking in an acidic solution such as white vinegar and water. To prevent the build up recurring the user will need to fill both the main and pre-wash detergent cups to the top with powder detergent and we would recommend running on normal or heavy cycles. On water softener models modify the setting. In problem areas with very hard water the user may need to use a detergent additive designed for use in hard water areas or fit a water softener to the incoming supply or purchase a Water Softener model.

Page 6

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

DD605 Power Distribution Concept

Page 7

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.

DD605 Wiring Diagram (Lower drawer only shown)

Page 8

Part no: 522145 C Published: 01/2009

For more help, see Samurai Appliance Repair Man at www.FixitNow.com.