Fisher & Paykel CG913T User manual

Gas Cooktops
New Zealand, Australia, Europe
Models
CG913T & CG913TM
599266B

599266B April 2006
Copyright ©Fisher & Paykel Ltd 2006. All Rights Reserved.
3
Manual 599266B Reprint: April 2006
The specifications and servicing procedures outlined in this manual are subject to change
without notice.
The latest version is indicated by the reprint date and letter, and replaces any earlier editions.

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Contents
MODELS COVERED BY THIS MANUAL....................................................................................................................5
SERVICE ASSISTANCE..............................................................................................................................................5
1. SERVICE REQUIREMENTS ...............................................................................................................................6
1.1 HEALTH AND SAFETY..........................................................................................................................................6
1.2 GENERAL WARNING ............................................................................................................................................6
2. SPECIFICATIONS ...............................................................................................................................................7
2.1 PRODUCT OVERVIEW ..........................................................................................................................................7
2.2 MODEL NUMBER.................................................................................................................................................7
2.3 SERIAL NUMBER .................................................................................................................................................8
2.4 ELECTRICAL.......................................................................................................................................................8
3. INSTALLATION REQUIREMENTS, BURNER RATINGS, GAS JET SIZES, GAS CONVERSION AND LOW
FLAME SETTING ADJUSTMENT. ..............................................................................................................................8
4. WIRING DIAGRAM FOR CG913 SERIES COOKTOPS ....................................................................................9
5. IGNITION, FLAME SENSING AND AUTO REIGNITION .................................................................................10
5.1 IGNITION SEQUENCE .........................................................................................................................................10
5.2 FLAME SENSING ...............................................................................................................................................10
5.3 AUTO REIGNITION .............................................................................................................................................11
5.4 FAULT CONDITIONS ..........................................................................................................................................11
6. SERVICING PROCEDURES.............................................................................................................................12
6.1 TO REMOVE THE HOB TOP AND TRAY .................................................................................................................12
6.2 TO REMOVE THE COOKTOP FROM THE BENCH/COUNTERTOP ...............................................................................12
6.3 TO REMOVE AN ELECTRODE ..............................................................................................................................12
6.4 TO REMOVE THE IGNITION BOX ..........................................................................................................................12
6.5 TO REMOVE THE IGNITION SWITCH LOOM ...........................................................................................................13
6.6 TO REMOVE THE TRANSFORMER .......................................................................................................................13
6.7 TO REMOVE A GAS VALVE .................................................................................................................................13
6.8 TO SERVICE A GAS VALVE .................................................................................................................................14
6.9 TO REMOVE THE SOLENOID ...............................................................................................................................14
7. FAULT FINDING................................................................................................................................................15

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Models covered by this manual
MODEL PRODUCT CODE MARKET
CG913T 80034
80033
88379
88380
88381
88382
88829
NZ
AU
EU
GR
DE
DK
GB
CG913TM 80032
80031
NZ
AU
Service assistance
AUSTRALIA Fisher and Paykel Customer Services
POBox798
Cleveland,Queensland4163
Tel[phone]
Fax[phone]
Email:[email protected]
NEW ZEALAND Fisher and Paykel Customer Care
POBox58732
Greenmont, Auckland
Tel0800FPCARE(0800372273)
Fax[phone]
Email:[email protected]
EUROPE Fisher & Paykel Appliances Limited
Pheasant Oak Barn
Hob Lane
Balsall Common CV7 7GX
UNITED KINGDOM
Phone: [phone]
Fax: [phone]
Email: [email protected]

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1. Service requirements
1.1 Health and Safety
When servicing the cooktop, health and safety issues must be considered at all times. Specific
safety issues are listed below with their appropriate icon. They are illustrated in the service
procedures to remind service people of the issues.
Electrical safety. Isolate the cooktop from the electrical supply
before servicing. Failure to do so could result in an electric shock.
Gas leak hazard. Isolate the cooktop from the gas supply if necessary
before servicing and leak test after all gas related repairs.
Sharp metal edges. Take care and use appropriate protection when
handling sharp metal edges to avoid laceration.
Gas fittings are torque sensitive, over tightening could damage them
and cause a gas leak.
Heat hazard. Ensure wiring is correctly routed away from potentially hot
metal parts.
Ensure the work area is clean and tidy at all times to avoid a hazard while
service work is being carried out. Clean the cooktop and tidy the work area
after service work is completed.
1.2 General warning
Qualified gas and electrical service people should only service this product.

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2. Specifications
2.1 Product overview
Model CG913T CG913TM
Supply voltage 220/240 220/240
Flame failure auto reignition 
Brushed stainless steel panels 
Iridium stainless steel panels 
Wok burner 14000 BTU/h 20000 BTU/h
LED burner indicators, innovalves, shut off solenoid 
2.2 Model number
Note: A model and serial number label is located on the underside of the cooktop and on the
cover of the use and care guide supplied with the product. An extra label is provided for the
installer to place in a convenient location.
The model number contains information as shown in the following example:
CG 913 TM
Additional information (T – stainless steel, TM – iridium
stainless steel)
Series
Product length (eg. 91 cm)
Product type (eg. Cooktop, Gas)

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2.3 Serial number
The serial number consists of three letters and six digits and contains the information shown in
the following example:
BR M 123456
Sequential serial number
Manufacturing plant code
FISHERPAYKUL code indicating month of manufacture
CUMBERLAND code indicating year of manufacture
Cumberland code
Letter C U M B E R L A N D
Year 1 2 3 4 5 6 7 8 9 0
Fisherpaykul code
Letter F I S H E R P A Y K U L
Month 1 2 3 4 5 6 7 8 9 10 11 12
Manufacturing plant code
A Laundry – Cleveland, Australia
F Refrigeration – Auckland, New Zealand
M Range and Dishwasher – Dunedin, New Zealand
N Laundry – Auckland, New Zealand
Q Refrigeration – Cleveland, Australia
In the example above, the appliance was manufactured in the sixth month (June) of the fourth
year (2004) at the Range and Dishwasher plant in Dunedin, New Zealand.
2.4 Electrical
Mains powered ignition system - 220/240V 0.6VA
Solenoid - approx. 2.0 Mohms in one direction, infinite in the other.
3. Installation requirements, burner ratings, gas jet sizes,
gas conversion and low flame setting adjustment.
Refer to the installation instructions supplied with the product, or available on the Fisher &
Paykel website - www.fisherpaykel.com

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4. Wiring diagram for CG913 series cooktops

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5. Ignition, flame sensing and auto reignition
5.1 Ignition sequence
5.2 Flame sensing
The ignition box senses when a flame is lit using flame rectification current sensing. The AC
voltage supplied from the ignition box is rectified to a DC current that is monitored at the ignition
box. This is achievable due to the characteristics of the electrical circuit created by the ignition
box, electrode, flame and burner.
Note: There is a cam in each switch in the ignition switch loom and a specific electrode location
at the ignition box for each burner. This identifies to the ignition box which burner to flame
sense. For this reason the electrodes cannot be swapped between burners. (refer to Section 4
or 6.4 for the correct electrode location and the corresponding burner)
AC voltage
DC current flow
Earth
Burner knob is turned on
LED turns on
Ignition box does a self check
Shut off solenoid is energised allowing gas to flo
w
into the manifold and through the gas tube
Ignition starts (all electrodes spark)
Burner is lit
Takes approximately 2 seconds
Takes approximately 2-3
seconds.
If the burner doesn’t light within
approximately 5 seconds a fault
condition will occur.

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5.3 Auto reignition
The ignition box will sense when a flame has gone out (when a burner knob is in the ON
position) and try to reignite the flame. All the electrodes will spark during reignition.
During reignition the ignition box allows a period of approximately five seconds for the burner to
light. If a flame is not sensed in this period a fault condition will occur.
5.4 Fault conditions
There are two fault conditions that will result with the red LEDs flashing. The faults can be
distinguished by the speed at which the LEDs flash. The fault conditions are:
 the burner has failed to light within a five second period during normal use or while trying to
auto reignite. (slow pulse flash)
 there has been an interruption to the power supply during use. (rapid pulse flash)
In both fault conditions all the controls must be reset to the OFF position for the fault to be
cleared.

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6. Servicing Procedures
Refer to the Service requirements before servicing, Section 1 page 6
6.1 To remove the hob top and tray
1. Lift off the trivets and burner components.
2. Remove the knobs.
3. Remove the screws securing each burner.
 To prevent damaging the screw head use a No. 1 Phillip’s head screwdriver.
4. Lift the hob tray out of the hob top.
5. Remove the hob top.
6.2 To remove the cooktop from the bench
Note: It is easier to service the internal components by removing the hob top and tray rather
than removing the product from the bench.
1. Unplug the electrical supply lead.
2. Turn off the gas supply and disconnect the inlet gas pipe.
3. Loosen the cooktop clamping brackets.
4. Lift the cooktop out of the bench.
6.3 To remove an electrode
1. Remove the hob top and tray.
2. Remove the electrode locating clip on the burner bowl.
3. Unplug the electrode lead from the ignition box.
6.4 To remove the ignition box
1. Remove the hob top and tray.
2. Remove the LED bracket by pulling it upwards and unplug the LED harness from the ignition
box.
3. Unplug the electrode leads and the multi-way plugs from the ignition box.
Note: The electrode leads must be plugged into the correct terminals on the ignition box.
Terminal numbers on the ignition box correspond as follows:
S1 Front right burner
S2 Front left burner
S3 Middle burner
S4 Rear left burner
S5 Rear right burner
S6 Not used

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6.5 To remove the ignition switch loom
1. Remove the hob top and tray.
2. Lift the loom switches off the gas valves and unplug from the ignition box.
6.6 To remove the transformer
1. Remove the hob top and tray.
2. Remove the LED bracket by pulling it upwards and unplug the LED harness from the ignition
box.
3. Fold back the lugs holding the transformer to the basepan.
4. Disconnect the wiring from the transformer to the terminal block and ignition box.
Note: The black supply wires are not polarity dependent.
6.7 To remove a gas valve
1. Remove the cooktop from the benchtop.
2. Remove the hob top and tray.
3. Remove the ignition switch loom.
4. Remove the LED bracket by pulling it upwards and unplug the LED harness from the ignition
box.
5. Disconnect all the aluminium tubes from the gas valve outlets.
6. Remove the screws securing :
 the manifold bracket to the base pan.
 the solenoid block to the basepan.
 the manifold support bracket to the basepan.
7. Remove the wires from the solenoid.
8. Remove the manifold.
9. Remove the gas valve from the manifold.
Note: Leak test all gas connections. Block each injector orifice in turn and open the valve to
leak test the gas connections beyond the valve.
 Check and adjust the low flame setting.

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6.8 To service a gas valve
1. Remove the hob top and tray.
2. Remove the ignition switch loom.
3. Remove the screws on the body of the gas valve.
4. Gently lift out the valve cone and clean with solvent.
5. Regrease the cone with high temperature grease.
6. Refit and rotate the cone.
7. Lift out the cone, remove any excess grease and check the holes in the cone and the valve
body are not blocked.
8. Reassemble the valve assembly.
9. Open and close the valve several times.
10. Check the valve for leaks and reassemble the cooktop in reverse order.
6.9 To remove the solenoid
1. Remove the manifold. (refer Section 6.7)
2. Remove the screws from the side of the manifold bracket securing the solenoid.
3. Separate the solenoid from the manifold.
Note: Check the o-ring in the replacement solenoid has a light layer of grease. Take care not
to pinch the o-ring when reinserting the manifold.
 Check for leaks.

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7. Fault finding
NO
YES
YES *
NO NO
YES **
Sparking continuously
Is a burner in
use?
Does the
burner light?
Refer to Burner not lighting flowchart Check for shorted igniton switches in the
loom.
Check the:
electrode/burners are clean and dry
low flame setting is correctly set
electrode is firmly secured on the burner
****electrode leads are firmly connected to their correct location at the
ignition box and are not damaged or twisted
earth to the cooktop and earthing connections in the cooktop are ok.
Is the flame
behaving
normally***?
Check the:
burner components are assembled correctly, are clean and dry
and not distorted
gas jet is the correct size for the gas type and is not blocked
low flame setting is correctly set
cooktop doesn’t require high altitude jets.
Replace the ignition box
These repairs
require gas
qualifications.
Check the gas pressure
NOTES
*The electrode should only spark for approx. 5 seconds before going into a fault condition –
red LED
flashing slowly. If it doesn’t fault after 5 seconds, replace the ignition box.
** This indicates the flame is not being detected.
*** Flame not normal – distorted, too big, yellow, lifting off burner
****
The correct electrode location at the ignition box
-
Terminal Burner
S1 Front right
S2 Front left
S3 Middle
S4 Rear left
S5 Rear right
S6 Not used

599266B – CG913 Gas cooktop
NOTES
*The electrode should only spark for approximately 5 seconds before going into a
fault condition – red LED flashing slowly.
** Indicates there is not enough or too much gas flow at the burner.
*** Flame not normal – distorted, too big, yellow, lifting off burner
These repairs require gas qualifications.
YES
*Does the
problem
electrode spark
now?
NO
Replace the ignition box
Replace the electrode
Replace the solenoid Check the:
gas pressure gas valve for grease blockage gas pipes/connections for gas leak or blockage.
YES
NO
YES
YES
Check the burner components are assembled correctly, are clean and dry and not distorted. Check the electrode: is clean and dry is not damaged is not shorting inside the basepan area lead is connected tightly at the ignition box. Swap the electrode lead at the ignition box with one
that is working ok.
Check the:
ignition switch loom connections at the ignition box continuity, mounting and operation of the ignition switch.
Check the:
power supply up to the ignition box connections at the ignition box continuity of the common wire in the ignition switch loom.
Check the electrode:
is located correctly is clean and dry is not damaged.
YES **
Check the: connections and wiring between the ignition box and the solenoid supply voltage is correct up to the ignition box.
YES
Light another burner
Does it
function ok?
Replace the:
electrode burner cap and spreader.
NO
YES
NO YES*
NO
Burner not lighting properly
NO
Is the
electrode
sparking?
A
re the other
electrodes
sparking?
Does the burner
light with a
match or
manual
i
g
nitor?
NO
Is power
getting to the
solenoid?
NO
Check the:
burner components are assembled correctly, are clean and dry and are not distorted. gas jet is the correct size for the gas type and is not blocked cookto
p
doesn’t re
q
uire hi
g
h altitude
j
ets.
Is the solenoid
opening & gas
turned on?
Is the flame
behaving
normally***?
Check the low
flame setting