BSH HBG633BS1 Setup guide

Repair Instructions – Cooking
2017-03-23 / DIS 184_58300000197442_ARA_EN_A Copyright by BSH Hausgeräte GmbH Page 1 of 101
1 Concerning this document 3
1.1 Purpose and target group.............................................................................. 3
1.2 Other applicable documents...........................................................................3
2 Safety 4
2.1 Qualification.................................................................................................... 4
2.2 Information in warning messages...................................................................4
2.3 Basic safety instructions................................................................................. 6
2.4 Grouped safety messages..............................................................................7
3 Design and function 8
3.1 Brushless direct current motor....................................................................... 8
3.2 EcoClean Direct............................................................................................11
3.3 Cooking compartment temperature sensor (Pt500 / Pt1000)....................... 12
3.4 Fold-down door.............................................................................................13
3.5 Temperature regulation in the various operating modes (60 cm wide)......... 14
3.6 Temperature regulation in the various operating modes (45 cm wide)......... 19
3.7 Clock............................................................................................................. 24
3.8 Vapour extraction system............................................................................. 25
4 Fault diagnosis 28
4.1 Result faults................................................................................................ 28
Food is not cooked.......................................................................................28
Food is heated too slowly............................................................................ 28
Cleaning action is inadequate...................................................................... 28
Pieces of dough form a skin........................................................................ 28
Food dries out.............................................................................................. 29
4.2 Malfunctions................................................................................................ 30
A short acoustic signal can be heard every 11 minutes, when the appliance
is switched off...............................................................................................30
Display is mirrored........................................................................................30
Rails - Sloping down at the back/askew...................................................... 30
Rails - Jam/become caught..........................................................................30
Baking tray/universal pan warped, bent, bounces ...................................... 31
Operating ring can be rotated easily / no change on the display................. 31
Operating ring does not respond / no display.............................................. 31
Operating ring is hard to turn / remains stuck in a specific position............. 31
Operation is not interrupted when the door is opened................................. 32
Display background white/display hard to read............................................32
Fault code is displayed.................................................................................32
Floor of cooking compartment becomes deformed during or after the drying
phase............................................................................................................ 32
Appliance does not generate any steam......................................................33
Appliance continues to heat although the setpoint temperature has been
attained......................................................................................................... 33
Brightness of microwave differs from that of the oven................................. 33
Cooling fan overruns for too long.................................................................33
Reset during operation in main menu "MyProfile"........................................34
Door (fold-down door) does not open 90°....................................................34
Clock gains > 1 minute every day................................................................34
Time - is fast / slow...................................................................................... 34
Clock loses several minutes a day.............................................................. 35
Time jumps back when switching on the appliance..................................... 35
4.3 Noise............................................................................................................ 36
Rails squeaking............................................................................................ 36
High-frequency whistling sound....................................................................36
Cooling fan motor makes a high-frequency noise........................................36
Cooling fan motor whistles at a high frequency at certain speeds............... 36
Cooling fan overrun too loud........................................................................36
Door closes loudly........................................................................................ 37
4.4 Other faults (surface defects, cracks, breaks)........................................ 38
Rails discoloured after pyrolysis...................................................................38
Baking tray/universal pan do not fit on the rails........................................... 38
Control panel and/or door askew................................................................. 38
Difference in display colour/brightness.........................................................38
Difference in colour of microwave/oven turning handle................................38
Gap between panel and door varies............................................................ 39
Connecting sleeve of the cooking compartment seal is becoming frayed
...................................................................................................................... 39
4.5 Leaks............................................................................................................ 40
Steam escapes in the top right-hand corner................................................ 40
Water drips onto the floor or furniture when the door is opened.................. 41

Repair Instructions – Cooking
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Vapour/condensation escapes......................................................................41
5 Test 42
5.1 Measure the distance between the front glass panel and the cabinet
cavity............................................................................................................. 42
5.2 Checking the alignment of the panel with the door...................................... 43
5.3 Checking the cooking sensor (Lambda sensor)...........................................45
5.4 Check the ventilation of the appliance in the furniture................................. 46
5.5 Check the meat temperature probe (NTC)...................................................48
5.6 Checking the lighting in the cooking compartment.......................................51
5.7 Check the cooking compartment temperature sensor (PT1000)..................53
5.8 Check the cooking compartment temperature sensor (PT500)....................56
5.9 Checking condensation................................................................................ 59
5.10 Checking the position of the wall socket......................................................61
5.11 Checking the socket of the meat temperature sensor..................................62
5.12 Check the heat-resistance of the fitted units................................................63
5.13 Measuring the temperature of the operating surfaces for hot air at
220 °C........................................................................................................... 64
5.14 Measuring the temperature of the operating surfaces for grilling level 3...... 66
5.15 Measuring the temperature of the appliance surfaces for hot air at
200 °C........................................................................................................... 68
5.16 Measuring the temperature of the furniture surfaces for hot air at
220 °C........................................................................................................... 71
5.17 Measuring the temperature in the cooking compartment for hot air at
200 °C........................................................................................................... 73
5.18 Time - check clock accuracy........................................................................ 75
5.19 Checking the vapour system........................................................................76
6 Repairs 78
6.1 Remove the Lambda sensor on the Lambda module.................................. 78
6.2 Removing and installing the baking sensor module (Lambda module)........ 79
6.3 Installing and removing the control panel.................................................... 80
6.4 Removing and installing the control power module......................................81
6.5 Flashing and coding..................................................................................... 82
6.6 Removing and installing the interior light (roof)............................................84
6.7 Install and remove cabinet upper section.................................................... 85
6.8 Installing and removing the cabinet back panel........................................... 86
6.9 Installing and removing the cabinet side panel (left).................................... 87
6.10 Installing and removing the cabinet side panel (right)..................................88
6.11 Remove and install the appliance................................................................ 89
6.12 Dismantling and assembling the fold-down door......................................... 90
6.13 Removing and installing the cooling fan motor............................................ 93
6.14 Removing and installing the power module................................................. 94
6.15 Remove and connect the mains cable.........................................................95
6.16 Removing and installing the deflector.......................................................... 96
6.17 Removing and installing the PT500............................................................. 97
6.18 Removing and installing the meat temperature probe socket...................... 98
6.19 Removing and installing the door hinge.......................................................99
6.20 Removing and installing the vapour valve..................................................100
6.21 Removing and installing the vapour valve motor....................................... 101

Concerning this document
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1.1 Purpose and target group
These repair instructions include information on troubleshooting and repairs.
This information supports the following employees in customer service:
• Service technicians who repair domestic appliances
• Technical storemen in the spare-parts warehouse who determine the required
spare parts
• Call centre employees who take orders
1.2 Other applicable documents
The following documents include additional relevant repair information:
• Documents “Design and function” and “Customer advice”
• Test programmes
• Circuit diagrams
• Exploded drawings
• Parts lists
• Repair videos

Safety
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2.1 Qualification
In Germany repair work may be performed only by electrical engineers who have
been trained by BSH or a centre authorised by BSH.
In all other countries repair work may be performed by comparably trained
technicians only.
2.2 Information in warning messages
2.2.1 Danger levels and warning symbols
Warning messages are provided with danger levels and warning symbols in this
document.
The warning levels consist of a symbol and a warning word. The warning word
indicates the severity of the danger.
Warning level Description
Non-observance of the warning message will result in death or
serious injuries.
Non-observance of the warning message could result in death
or serious injuries.
Non-observance of the warning message could result in minor
injuries.
Non-observance of the warning message could result in dam-
age to property.
Table 1: Danger levels
Warning symbols are symbolic representations which give an indication of the kind
of danger.
Symbol Description
General warning message
Danger from electrical voltage
Risk of explosion
Danger of cuts

Safety
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Symbol Description
Danger of crushing
Danger from hot surfaces
Danger from strong magnetic field
Danger from non-ionizing radiation
Table 2: Warning symbols
2.2.2 Structure
Warning messages in this document have a standardized appearance and a
standardized structure.
Type and source of danger!
Consequences of ignoring the warning.
► Actions to protect from danger.
The following example shows a warning message that warns against electric
shock:
High voltage!
Death by electric shock.
► Disconnect appliance from grid.
► Discharge high-voltage capacitor.

Safety
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2.3 Basic safety instructions
These repair instructions form the basis for a systematic and
safety-conscious procedure for the repair of domestic appliances.
2.3.1 Measures to be taken for each repair
The following dangers are associated with the repair of domestic appliances:
• Danger of electric shock from exposed, live wires and components
• Risk of cut injuries from sharp edges
• Risk of destruction of electronic components by electrostatic discharge
Specific measures prevent injuries and damage. Service technicians are obliged to
take these measures for each repair.
Preventive measures
... against electric shock When carrying out repairs:
• Disconnect appliance from power
supply.
When running tests with power supply
on:
• Use a residual-current-operated cir-
cuit-breaker.
• Select protective conductor connec-
tion less than standard value.
... to prevent cut injuries • wear protective gloves.
... electronic components • wear earthing wrist strap.
• Discharge capacitors.
Table 3: Measures to be taken for each repair
2.3.2 Measures to be taken after each repair
State of the appliance Measures
Appliance has been repaired and is
functionally reliable. • Run tests in accordance with VDE
0701 or comparable national regula-
tions.
• Conduct a performance test.
• Document repair work, tests, mea-
sured values and functional reliabili-
ty.
Appliance is still defective and not func-
tionally reliable. • Clearly identify appliance as "not
functionally reliable".
• Inform customer in writing about the
lack of functional safety.
Table 4: Measures to be taken after each repair

Safety
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2.4 Grouped safety messages
Exposed, live components!
Death from electric shock.
► Disconnect the appliance from the power supply.
► Do not touch housing, frame or components.
► If running tests while the power is on, always use a residual
current circuit-breaker.
► Ensure that the resistance of the protective conductor does not
exceed the standardised value.
Discharge current of charged capacitors!
Death from electric shock. Risk of injury from startle response.
► Disconnect the appliance from the power supply.
► Discharge capacitors.
Exposed, defective components live!
Death from electric shock.
► Disconnect the appliance from the power supply.
► Do not touch housing, frame or components.
► If running tests while the power is on, always use a residual
current circuit-breaker.
► Ensure that the resistance of the protective conductor does not
exceed the standardised value.
Sharp edges!
Cut injuries.
► Wear protective gloves.
Touching electrostatically sensitive components!
Destruction of components.
► Use a system offering electrostatic discharge protection.
► Observe measures to protect components susceptible to electrical
discharge.
Unnecessary replacement of sensitive components!
Destruction of components.
► Systematically check components before replacement.
► Do not replace components without reason.
► Observe technical documentation.

Design and function
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3.1 Brushless direct current motor
A BrushLess Direct Current motor (= BLDC motor) is an Electronically
Commutated motor (= EC motor).
3.1.1 Structure
In a BLDC motor there is no electrical contact for between the movable rotor and
the fixed stator.
The movable rotor consists of permanent magnets. The fixed stator consists of
coils that are controlled in sequence by the motor electronics. This creates a rotary
field.
Fig. 1: An external rotor motor assembly
1 Motor electronics 3 Magnets (rotor)
2 Coils (stator) 4 Motor housing (rotor)
A distinction is made between internal and external rotor motors. For internal rotor
motors, the movable rotor with the magnets is on the inside and the fixed stator is
on the outside. For external rotor motors, the movable rotor with the magnets is on
the outside and the fixed stator is on the inside.
Internal rotor motors are more efficient than external ones, but external rotor
motors have a higher torque than internal ones.
The motor electronics is made up of the power electronics and the control
electronics. The motor electronics generates the voltage with which the individual
coils are controlled.
Power transistors, for example power MOSFETs (Metal Oxide Semiconductor Field
Effect Transistors) are used for this circuit.
3.1.2 Function and model variant
The motor is operated with direct current. Contrary to their name, the functional
principle is not based on that of a direct current motor, but on that of a three-phase
synchronous motor with excitation by means of a permanent magnet. The coils
create a rotating magnetic field, which pulls the permanent magnets with it.
There are motors with at least two or with many coils. Depending on the number of
the coils, the coils are controlled single-phase, two-phase or three-phase.
The efficiency is greater for three-phase controls than for single-phase controls.
The torque is greater for twelve coils than for four.
Fig. 2: BLDC motor, 4-pole, single-phase, for appliances without pyrolytic self-
clean systems
Fig. 3: BLDC motor, 12-pole, three-phase, for appliances with pyrolytic self-
clean systems

Design and function
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3.1.3 Commutation
Commutation is the process in which a current flow passes from one path to
another. There is natural and forced commutation.
Natural commutation is present if the feed voltage originates from an alternating
current or three-phase mains and the current path switching occurs due to its
polarity reversal.
Forced commutation is present if the feed voltage does not originate from an
alternating current or three-phase mains and the current path switching occurs by
means of a control.
EC motors use forced commutation.
Fig. 4: Basic circuit electronic commutation
red coil = north pole / green coil = south pole / grey coil = countervoltage
The big advantage of an EC motor is that the electronic commutation can be
made dependent on the rotor position, rotor speed and torque. The electronic
commutation thus becomes a controller. The way in which the rotary field is
generated determines the characteristic of the EC motor.
Fig. 5: Basic curve showing the torque and (positive/negative) currents in
phases L1, L2 and L3, depending on the rotation angle 0° to 360° for a
block commutation
Fig. 6: Rotary field
red coil = north pole / green coil = south pole / grey coil = countervoltage

Design and function
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There are different ways of measuring the rotor position and speed:
•Sensor-controlled commutation
- Hall or optical sensors are used to determine the position of the rotor. The
advantage of the sensor-controlled commutation is that it also works for
very low torques or when stationary.
•Sensorless commutation
- The countervoltage in the coils, analysed by the motor electronics, is
used to determine the position of the rotor. A minimum rotational speed is
required in order to analyse the countervoltage. For this reason, EC motors
are switched idle until the minimum rotational speed is reached.
New procedures allow precise control even below the minimum speed by using
targeted brief current pulses, which do not move the motor but are influenced by
the rotor’s magnetic field.