Whirlpool GVW9959K-0 manual

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INTRODUCTION This Job Aid, “ELECTRONIC CONTROL WASHER WITH CAL YPSO WASH MOTION ,” (Part No. 8078010), provides specific information on the new features and design elements of Whirlpool Electronic Control washers with Calypso W ash Motion. “ELECTRONIC CONTROL WASHER WITH CAL YPSO W ASH MOTION” has been compiled to pro- vide the most recent [...]

i TABLE OF CONTENTS MODEL/SERIAL PLATE MODEL/SERIAL PLATE MODEL/SERIAL PLATE MODEL/SERIAL PLATE MODEL/SERIAL PLATE DESIGNATOR...............................................ii DESIGNATOR...............................................ii DESIGNATOR...............................................ii DESIGNATOR.............................................[...]

ii MODEL/SERIAL NUMBER PLA TE SERIAL NUMBER DESIGNA TO R SERIAL NUMBER MANUF ACTURING SITE C = Clyde, OH YEAR OF MANUF ACTURE L = 2001 WEEK OF MANUF ACTURE PRODUCT SEQUENCE NUMBER C L 36 50001 Model/Serial Number Plate (Under Lid) MODEL NUMBER DESIGNA TO R SAFETY ! W ARNING ELECTRICAL SHOCK HAZARD Disconnect power before servicing the washing machi[...]

1 SECTION ONE INSTALLATION CONSIDERATIONS INST ALLA TION INSTRUCTIONS Proper installation is your responsibility. You will need A water heater set to deliver a minimum of 120°F (49°C) water to the washer. A grounded electrical outlet located within 4 ft. (1.2 m) of where the power cord is attached to the back of the washer. See “Electrical Requ[...]

2 T ools needed and Parts Supplied Assemble the necessary tools and supplies before beginning the washer installation. Do not re-install into the washer, the styrofoam that contains the supplied parts. To connect the drain hose and water inlet hoses You will need these following tools 1. Flashlight (optional) 2. Pliers (that open to 1 9/16 in (3.95[...]

3 Floor drain system The floor drain system requires a siphon break (purchased separately .) The siphon break must be above the high-water level in the washer , at least 28 in. (71 cm) from the bottom of the washer. Alternate Parts Y ou May Need If You Have You Will Need to Buy Laundry tub or Sump pump system (if not already standpipe taller availa[...]

4 For a laundry tub drain or standpipe Connecting the drain hose “hook” to the corrugated drain hose 1. Open the yellow single-wire clamp and slide over the end of the drain hose about 4 inches. (Pliers optional) 2. Wet the outside end of the drain hose with tap water. Do not use another lubricant. 3. Twist and push the “hook” back and fort[...]

5 4. Attach the hose with the blue coupling to the COLD (left) inlet valve. Screw on coupling by hand. Using the pliers, tighten the coupling an additional two-thirds turn. NOTE: Do not overtighten. Damage to the valve may result. 1. Cold water inlet valve (blue) 2. Hot water inlet valve (red) 5. Attach the hose with the red coupling to the HOT wat[...]

6 Use & Care Information Due to the unique washing action of the CAL YPSO™ washer , it is strongly recommended that the consumer use a High Efficiency detergent. High Efficiency detergents are formulated to control sudsing which may occur with use of regular detergents. If the consumer does not wish to use HE detergent, it is recommended to u[...]

7 SECTION TWO THEORY OF OPERATION CONTROL PANEL NUTATION nu-ta-tion n(y)ü-’ta-shen n The spiral movement of the axis of a rotating body, such as the oscillation of a spinning top. CYCLE DESCRIPTIONS Fig. 2-1 DESCRIPTIONS CYCLES Whitest Whites Heavy Duty Normal Jeans/Darks Bulky Items Quick W ash Delicate/Casual Wool Handwash Rinse & Spin [...]

8 OPTION DESCRIPTIONS Soil Level Soil Level adjusts the amount of nutation or spray wash time in the selected cycle. It is valid for all cycles except Extend Spin and Rinse & Spin stand-alone cycles. Soil Level changes the 7-segment display in 1-minute increments, looping back to the minimum time once the maximum time has been reached. The foll[...]

9 W ater T emp The W A TER TEMP keypad provides for selection of different wash and rinse combinations. W ater fill temperatures can be either HOT (hot water valve only), W ARM (both the hot and cold water valves) or COLD (cold water valve only). Fills during rinses may be COLD until the final rinse/spin interval. The W A TER TEMP can be changed at[...]

10 End of Cycle Signal There are three (3) volume levels for the End of Cycle Signal, HIGH, LOW and OFF . Pressing the END OF CYCLE SIGNAL keypad toggles between these options by lighting one of the LEDs and beeping the corresponding end of cycle signal at the volume level selected. The LED remains lit during program mode and running mode until the[...]

11 MACHINE CONTROLLER The Machine Controller interprets the consumer inputs from the keyswitch pads to operate the cycle selected. The Machine Controller interfaces with the Motor Controller to operate the Drive motor and Pump motor through their vari- ous functions during the cycle. The Machine Controller also directly operates the water fill and [...]

12 NUT A TION The Calypso washer achieves a significant en- ergy savings by utilizing less water than a tradi- tional top loading machine with an agitator . This is made possible by the use of a W ash Plate which provides an undulating motion to toss the wash load. This action is called nutation. The wash plate is tipped at approximately 35 de- gre[...]

13 UNIVERSAL JOINT During Nutation, the W ash Plate is tipped at a 35 degree angle and must be free to undulate to move the clothing properly . The W ash Plate is attached to a Universal Joint that allows the Plate that freedom of movement. The Universal Joint is attached to the basket drive block by a spanner nut and is sealed top and bottom by a [...]

14 INTERLOCK SWITCHES There are two (2) Interlock Switches located behind the front panel and the bottom panel that ground the drive motor circuit when either panel is removed. When the machine is running with both panels in place, the drive motor is electrically isolated from ground. The interlock switches are normally closed and held open when th[...]

15 PRESSURE SWITCHES The washer uses two pressure switches to control the amount of water entering the tub and to protect against an overfill condition. The operating pressure switch, marked OPR, controls the amount of water that enters the tub during normal wash and rinse functions. This switch operates in the same manner as similar pressure switc[...]

16 RECIRCULATION AND DRAIN W ater Pump/Pump Motor The pump is directly driven by a separate reversible 120 V AC 60 Hz motor . By being reversible, the motor provides for two separate operations of the washer . Outer T ub The Outer T ub sump plays a role in the drain and water recirculation function The sump area includes two check balls that direct[...]

17 Changing Cycles and Options Y ou can change Cycles and Options any time before Start is pressed. • A short tone sounds when a change is selected. • Two short tones sound if an unavailable combination is selected. The last selection will not be accepted. Changing Cycles after pressing Start 1. Press STOP/CANCEL twice. 2. Select the desired wa[...]

18 T he follow ing note s appl y to al l cycle she ets wher e indicate d in the NO T ES colum n of the cycle s heet. W hen ther e is a contr adict ion, t he cycle s heet it s elf has pr iori ty. WAT ER F I LL NO T ES A “W AT E R T EM P” of “W A SH” m ea ns t hat th e v alv es are con trol led by t he tem peratur e s elect ion fr om the W A [...]

19 DRI VE MO TO R NOT ES Spin is d efined as a clockwi se ( CW ) M oto r and Bask et rot ati on when loo king dow n from the t op of the m ac hine. N utate is a cou nter-clo ckwise (C C W ) ro tation of the m oto r. 16. S tep Spin. Dri v e m otor r am ps up t o spe ed followi ng spe cific m otor pr ofiles . 17. S uds L ock Detection an d cleanup. S[...]

20 Whitest Whites This cycle introduces liquid chlorine bleach to the load at the proper time for improved whitening of your heavily soiled white fabrics. Use this cycle to get 13 to 17 minutes of medium speed wash action and high speed final spin. For maximum soil and stain removal, liquid chlorine bleach must be used. The preset cycle wash time i[...]

21 Heavy Duty Use this cycle to get 15 to 19 minutes of wash time for loads of sturdy, colorfast fabrics such as work clothes. Cycle combines high speed wash action and high spin speed. The preset cycle wash time is 19 minutes. PH ASE STE P DES CRIPTION OF SEQ UE NCE N OTE S WAT E R TEMP DI SPEN S ER COMMENT PUM P MOTOR ACTI O N DRIVE MOTOR ACTI O [...]

22 Normal Use this cycle to get 12 to 16 minutes of wash time for normally soiled cottons and linens. Cycle combines medium speed wash action and high speed spin. The preset cycle wash time is 14 minutes. PHA SE S TEP DES CRI PTI ON O F SEQUENCE NOT ES WA T E R TE M P D I SP EN SER C OMMEN T PUMP MOTOR ACT I ON DRI V E MOTOR ACT I ON DRI V E MOTOR [...]

23 Jeans/Darks Use this cycle to get 14 to 18 minutes of wash time for dark, colored items that may run or fade. Cycle combines low/medium speed wash action and high spin speed. The preset cycle wash time is 16 minutes. PH ASE STE P DES CRIPTION OF SEQ UE NCE NOTES WA T ER TEM P DISPENS ER COMMENT PUM P MOTOR ACTI O N DRIVE MOTOR ACTI O N DRIVE MOT[...]

24 Bulky Items Use this cycle to get 13 to 17 minutes of wash time for large items like blankets and comforters. Cleaning starts with a spray of water and detergent mixture to thoroughly saturate your large load. This is followed by a low/medium wash action and low/medium spin speed to maintain load balance. The preset cycle wash time is 15 minutes[...]

25 Quick W ash Use this cycle to get 7 to 11 minutes of wash time for small, lightly soiled loads that are needed in a hurry. Fast cleaning starts with a continuous spray of water and detergent mixture as the load is spun at extra-low speed, followed by a brief period of low/medium speed wash action. High spin speed reduces drying time. For fastest[...]

26 Delicate/Casual Use this cycle to get 12 to 16 minutes of low speed wash action for no-iron fabrics and garments indicating “Gentle” cycle on the care label. Low/medium spin is used to reduce wrinkling. The preset cycle wash time is 14 minutes. PH ASE STE P DES CRIPTION OF SEQ UE NCE NOTES WA T ER TEM P DISPENS ER COMMENT PUM P MOTOR ACTI O [...]

27 Wool Use this cycle to get 6 to 10 minutes of wash time for washable items that are normally dry cleaned. Cycle combines extra-low speed spray cleaning and wash action to provide gentle care for delicate items such as wool sweaters and silk blouses. Low spin speed helps garments maintain their shape. The preset wash time is 6 minutes. PH ASE STE[...]

28 Handwash Use this cycle to get 7 to 11 minutes of wash time for garments labeled “Hand Wash” and special care items. Gentle cleaning starts with a continuous spray of water and detergent mixture as the load is spun at an extra-low speed. This lasts for about one minute and is followed by a brief period of extra- low wash action. Low/medium s[...]

29 Soak Cycle Use this option for set-In stains and soil that need extra time for removal. Soaking in this washer is different than in a conventional washer. The washer sprays the load with water and detergent for 4 minutes at extra low spin speed followed by a brief period of wash action at the speed of the selected cycle. Then another 4 minutes o[...]

30 Rinse & Spin Use this option to get a combination of rinses and spins followed by a high-speed spin. The time displayed will include an estimate of how long it will take to fill and drain the washer. Fabric softener can be added to the Fabric Softener dispenser. When to use Rinse & Spin: • For loads that need rinsing only. • For comp[...]

31 SECTION THREE COMPONENT ACCESS COMPONENT LOCATION Machine Control Board Motor Control Board Pressure Switches Line Filter Dome Tub Ring Inner Wash Plate Leveler Outer Wash Plate Universal Joint Pump, Pump Motor and Capacitor Shock Drive Motor Suspension Rod Assembly Log Valve Assembly Lid Switch Interlock Switch Interlock Switch SPECIAL TOOLS/P [...]

32 ACCESSING COMPONENTS IN THE CONSOLE Components accessible inside the console are: • Log Valve Assembly • Machine Control Board Hot Water Inlet Valve • Motor Control Board Cold Water Inlet Valve • Line Filter Fresh Water Outlet Valve • Operating Pressure Switch Bleach Dispenser Valve • Overfill Pressure Switch Fabric Dispenser Valve D[...]

33 Removing the Console 1. Disconnect power from the washing machine. 2. Slide the blade of a putty knife between the bottom of the console and the washer top at each front corner (Arrow in Fig. 3-3) and push the spring clip back far enough to release it from the slot in the washer top. (Fig. 3-3, INSET) Then lift the console up approximately one i[...]

34 Plastic Hoses Harness Connectors NOTE: Although the pressure switches look identi- cal, they are not. When replacing the pres- sure switches, be sure to match part num- ber and connect the correct set of wires to the replacement switch. Fig. 3-6 Removing the Pressure Switches The overfill and operating pressure switches are located next to each [...]

35 ACCESSING COMPONENTS BENEATH THE WASHER TOP Components accessible beneath the washer top are: • Tub Ring • Balance Ring • Inner/Outer Wash Plates • Leveler • Universal Joint • Dispensers • Bleach Venturi • Lid Switch Raising the Washer Top to the Service Position The washer top is hinged at the back edge. It does not have to be c[...]

36 INS ET Removing Components in the Tub 1. Disconnect power from the washing ma- chine. 2. Raise the washer top to the service posi- tion. 3. Disconnect the fresh water inlet hose from the tub ring. (Fig. 3-10) 4. Unsnap the tabs that secure the tub ring to the tub. (Fig. 3-10 - INSET) Lift the tub ring from the tub. 5. Using a flat bladed screwdr[...]

37 1 1. Remove the spanner nut. Once this is done, the universal joint assembly can be lifted from the basket. 12 . The basket can now be lifted from the tub. NOTE: It may be necessary to spread apart one of the drive block sections to loosen the basket from the splines of the spin tube. (Fig. 3-15) NOTE: The U-joint grommets must be re- placed whe[...]

38 6. There is a tab on the underside of the inner wash plate that corresponds to a slot on the universal joint. These should fit together when reassembling the inner wash plate over the universal joint. NOTE: Do not rotate the inner wash plate when reassembling to the universal joint. Rotating the plate may move the leveler to it’s tilted positi[...]

39 ACCESSING COMPONENTS BENEATH THE TUB Components accessible beneath the tub are: • Suspension Assemblies • Pump, Pump Motor and Capacitor • Drive Motor and Drive Pulley Assembly • Drain and Recirculation Hoses • Brake and Drive Tube Assembly Removing the Front Cabinet Panel Access to many of the components beneath the tub can be gained [...]

40 Servicing Components from the Bottom of the W asher Removing the Drive Motor 1. Disconnect the power from the washing machine. 2. Carefully lay the washer on its back. 3. Remove the two screws securing the bottom panel to the washer frame. 4. Disconnect the drive motor wiring harness from the connector block attached to the front bottom frame ra[...]

41 2. Remove the T-40 Torx head bolt securing the drive shaft bearing to the thrust plate. 3. Remove the four (4) T-40 Torx head bolts securing the thrust plate to the posts on the motor mounting plate. NOTE: The two (2) screws at the top of the bracket have ball ends. (Fig. 3-31) Figure 3-32 shows all the components of the thrust plate assembly . [...]

42 Removing the Pump and Pump Motor Refer to Figure 3-34 for these procedures. 1. Disconnect power from the washing machine. 2. Carefully lay the washer on its back. 3. Remove the bottom panel secured to the washer frame. 4. Disconnect the pump motor wiring harness from the connector block attached to the front bottom frame rail. 4. Remove the two [...]

43 SECTION FOUR TROUBLESHOOTING AND DIAGNOSIS TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE SOLUTION Won’t Power Up 120V AC electrical supply . Open AC cord. Line filter open. Machine control board open. Lid Switch failure. Check voltage supply to washer . Check for voltage at the power cord con- nection to the line filter . Check voltage into and[...]

44 PROBLEM POSSIBLE CAUSE SOLUTION Overfills Operating Pressure Switch fail- ure. Pressure Switch tube off at Pressure Switch or tub pressure dome or kink in tubing. Not draining. Check Operating Pressure Switch con- tact and wiring harness connections. Check Pressure Switch tubing for proper connection and check for kinks along length of tubing. C[...]

45 PROBLEM POSSIBLE CAUSE SOLUTION Won’t Drain Foreign material in pump, tub sump or drain hoses. Pump impellar cracked/broken. Pump bound. Pump motor failure. Clear foreign material. Check pump for proper movement and check for impellar problems. Replace pump as needed. Check pump motor windings resis- tances. Check wiring harness connec- tions [...]

46 Long Fill L F If the water fill time exceeds ten (10) minutes, the water valves are turned off and “LF” is flashed. Press STOP/CANCEL to clear the display . PROBLEM POSSIBLE CAUSE SOLUTION Load is Wrinkled Not removing load promptly . Wrong cycle for fabrics being washed. Overloading. Wash water not warm enough to relax wrinkles. Using warm [...]

47 Communications Error If there is any breakdown in communication between the machine controller and the motor controller, “CE” flashes and the unit beeps once. Some common causes of “CE” errors include: • Conformal coating on serial communications pins between the machine controller and motor controller. After disconnecting power to the[...]

48 SELF DIAGNOSTIC ROUTINES Automatic Service Diagnostics Mode STEP 1 2 3 4 5 DESCRIPTION Nutate + Fill Nutate + Recirc Nutate + Fill + Drain Nutate + Fill + Drain Spin + Drain Return to Standby W A TER TEMP Cold Cold W arm Hot Off Off DISPENSER ACTIV A TED Fresh Fab Soft Bleach Detergent Off Off PUMP MOTOR Off Recirc Drain Drain Drain Off DRIVE MO[...]

49 Manual Diagnostic Mode The manual diagnostic mode will enable activation of specific machine functions without having to run a cycle. Each function test will time out in three (3) minutes. T o enter the manual diagnostic mode: 1 . Press: SOAK - CYCLE SIGNAL - SOAK - CYCLE SIGNAL within five (5) seconds while the machine is in Standby Mode. The 7[...]

50 NUT A T E AND REC IRCUL A T E T ES T T his te st se qu ence assu me s the con trol is off . The te st will ti m eout aft er 3 min ute s of u se. PRESS T OUCH PAD DI S PL AY CON TROL A CTI ON 1 SOA K K ey D anc e key pr ess #1 2 CYC LE S IG N A L K ey D anc e key pr ess #2 3 SOA K K ey D anc e key pr ess #3 4C Y C L E S I G N A L K ey D anc e key[...]

51 WATER INLET AND D ISP ENSER V A LVE, OPER A T ING PS T ES T If Oper atin g Pr essur e S wit ch t rip s at any time , all w ater valv e s shou ld t urn off. P ress EXT R A RIN SE t o st art drain ing aft er key pr es s #5 to star t dr ain ing . Pr ess E XT RA R I N SE agai n to tur n of f t he pu mp . PRESS T OUCH PAD DI S PL AY CON TROL ACTION 1[...]

52 Console Switches and Indicators T est The console switches and indicators can be tested by pressing the following touchpads: SOAK - CYCLE SIGNAL - SOAK - CYCLE SIGNAL within five (5) seconds while the machine is in Standby Mode. The 7-segment LED will display “dt”. 1. Press the ST ART pad. Pressing each touchpad will cause a beep to sound an[...]

53 TOUCHP AD + LEAD - LEAD KEY SWITCH MA TRIX • If any switches fail this test, replace the console panel/touchpad assembly . • If all switches are OK, replace the control board. WHITEST WHITES HEA VY DUTY NORMAL JEANS/DARKS BULKY ITEMS QUICK W ASH DELICA TE/CASUAL WOOL HAND W ASH RINSE & SPIN SOIL LEVEL W A TER TEMP SOAK EXTRA RINSE EXTEND[...]

54 RESIST ANCE CHART COMPONENT WINDING RESIST ANCE V ALUE Drive Motor Pump Motor RD to BK YL to WH RD to YL RD to WH YL to WH RD to YL 2 - 4 ohms 2 - 4 ohms 5 - 7 ohms 10 - 12 ohms 10 - 12 ohms 20 - 25 ohms CHECKING DRIVE AND PUMP MOTOR CONTINUITY White Red Y ellow Green Green/ Black Y ellow White Red Black The pump and drive motors can be checked [...]

55 TROUBLESHOOTING TESTS 120VAC Electrical Supply 1. Check for 120VAC on the power cord connection to the line filter. If no AC power is present, replace the power cord. 2. Check for 120VAC on the line filter connection to the machine controller. If no AC power is present, replace line filter. 3. Check for 120VAC to the control board. With the wash[...]

56 Motor and Motor Control System Test These tests check the machine controller power to the motor controller, the motor controller board, the wiring connections between the control board and the drive motor, and the drive motor itself. Machine Control Relay 1. Check for 120VAC on the power cord connection to the line filter. If no AC power is pres[...]

57 Automatic T emperature Control T est This test checks the water inlet solenoids, the temperature sensor and the control board. • Check that the hot and cold water fill valves are working. NOTE: This test MUST be done with the Automatic T emperature Control (A TC) selected. If the fill valves are working properly: → → → → → Press NORM[...]

58 → → → → → Replace the control board. Operating and Over Fill Pressure Switch T est Check the hose connections between each pressure switch in the console and the pressure dome attached to the tub. If hose connections are good, check the Operating Pressure Switch as follows: • Press HEA VY DUTY then ST ART to start a cycle. Let the un[...]

59 • Remove the connector at the motor and take measurements as shown in the following table. Recirc to Neutral 10 - 12 Ω RD to WH Drain to Neutral 10 - 12 Ω YL to WH Recirc to Drain 20 - 25 Ω RD to YL • If the resistance is much higher than shown, replace the pump motor . • If the resistance at the pump motor is correct, there is an op[...]

60 - NOTES -[...]

61 SECTION FIVE TECH TIPS WIRING DIAGRAM Fig. 5-1[...]

62 RESIST ANCE CHART COMPONENT WINDING TEMPERA TURE ° F RESIST ANCE V ALUE Drive Motor Pump Motor Thermistor RD to BK YL to WH RD to YL RD to WH YL to WH RD to YL 2 - 4 ohms 2 - 4 ohms 5 - 7 ohms 10 - 12 ohms 10 - 12 ohms 20 - 25 ohms 126k - 135k ohms 97k - 102k ohms 75k - 78k ohms 58k - 61k ohms 46k - 47k ohms 36k - 37k ohms 28k - 30k ohms 23k - [...]

PRODUCT SPECI F IC ATI ONS AND W A RRANTY INFORM ATION SO URCES I N THE U N I TED STA TES: FOR PRO DUCT SPECIFI CATIO NS AND WARRANTY I NFO RM ATI ON CALL: FOR W HIRLPOO L PRODUCTS : 1- 800-253-1301 FOR KITCHENA I D PRO DUCTS : 1- 800-422-1230 FOR ROP ER PRODUCTS : 1- 800-447- 6737 FOR T ECHNI CAL ASSIST ANCE WHI LE AT T HE CUSTO M ER’S HO M E CA[...]

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