Fisher & paykel Titan ce901 User manual

CERAMIC COOKTOP

MODELS CE901 AND CE901M

599098

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599098 Issue A - April 2003

MODELS COVERED BY THIS MANUAL

Fisher and Paykel CE901 Titan Ceramic Cooktop

MODEL CODE MARKET

CE901 SS FP 88414 US United States of America/Canada

CE901M SM FP 88418 US United States of America/Canada

CE901M SM FP 87815 NZ New Zealand

CE901M SM FP 87825 AU Australia

CE901 SS FP 88773 GB, IE Great Britain, Ireland

CE901M SM FP 88774 GB, IE Great Britain, Ireland

SERVICE ASSISTANCE

USA Toll Free 1 888 9 FNP USA (1 888 936 7872)

Fisher and Paykel Appliances Inc.

27 Hubble, Irvine CA 92618

Website: http://usa.fisherpaykel.com

GB Fisher and Paykel Appliances Ltd

Broxell Close, Wedgnock Industrial Estate, Warwick

Warwickshire, CV34 5QF.

Tel 01 926 626700

Fax 01 926 626701

IRELAND C & F Quadrant, Unit 4

40 Cherry Orchard Industrial Estate

Dublin 10

Tel 01 630 5757

Fax 01 630 5706

AUSTRALIA Fisher and Paykel Customer Services

PO Box 798

Cleveland, Queensland 4163

Tel 07 3826 9122

Fax 07 3826 9164

Email: customer.care@fp.com.au

NEW ZEALAND Fisher and Paykel Customer Care

PO Box 58732

Greenmont, Auckland

Tel 0800 FP CARE (0800 372273)

Fax 09 273 0656

Email: customer.care@fp.co.nz

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CONTENTS

MODELS COVERED BY THIS MANUAL ............................................................................3

SERVICE ASSISTANCE .....................................................................................................3

1. SERVICING & SAFETY PRECAUTIONS.....................................................................5

1.1 WARNINGS ..............................................................................................................5

2. SPECIFICATIONS........................................................................................................6

2.1 DIMENSIONS ...........................................................................................................6

2.2 COUNTERTOP CUTOUT DIMENSIONS .................................................................6

2.3 ELECTRICAL SPECIFICATIONS .............................................................................7

2.4 LOCATION OF SERIAL NUMBER AND PRODUCT INFORMATION ......................7

3. SERVICING INSTRUCTIONS ......................................................................................8

3.1 REMOVAL FROM THE COUNTERTOP...................................................................8

3.2 REPLACING ELEMENTS .........................................................................................9

3.3 REPLACING ENERGY REGULATORS..................................................................12

3.4 REPLACING HOT/ON LIGHTS ..............................................................................15

3.5 INTERNAL WIRE RESTRAINT...............................................................................18

3.6 WIRING DIAGRAM – STANDARD MODELS .........................................................20

3.7 WIRING DIAGRAM – IRIDIUM MODELS ...............................................................21

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1. SERVICING & SAFETY PRECAUTIONS

1.1 WARNINGS

The following icons will appear in the left margin when the precaution they illustrate is

particularly relevant. Safe and tidy work practices must be adhered to at all times when

servicing appliances.

Electrical shock hazard. Isolate the cooktop from the electrical supply

before servicing. Failure to do so could result in death or electric shock.

Cut hazard. Take care when handling as the stainless steel may have sharp

edges. Failure to do so could result in injury or cuts.

Make sure all the screws and covers are refitted after servicing, as some are

vital to maintaining the earth path.

The plastic standoffs that hold the main cover are required to maintain safe

clearances between the cooktop and the surrounding joinery. Ensure they

are always refitted.

Wiring is to be gathered and taped so it cannot reach the element cases.

The tape is to be a glass cloth type, rated to at least 200°C. For USA the

wiring in the control box must also be gathered and taped so it cannot reach

live terminals and the tape must be UL rated for 200°C. See section 3.5

Internal wire restraint.

Carry out an earth continuity test between the earth conductor and exposed

metal parts.

Carry out a high potential electric strength test (megger test) with the phase

and neutral conductors (L1 and L2 in the US) connected together to protect

the electronics.

The CE901 cooktop contains electronic components that can be damaged

by electrostatic discharge from your fingers. A grounded wrist strap must be

worn when handling electronic components or wiring connected to electronic

components.

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2. SPECIFICATIONS

2.1 DIMENSIONS

Width Depth Height HM Height HCMarket

mm inch mm inch mm inch mm inch

US 914 36 546 21

1/2

80 3 1/8 80 3 1/8

AU, NZ, GB, IE 914 36 546 21

1/2

70 2 3/4 83 3 1/4

2.2 COUNTERTOP CUTOUT DIMENSIONS

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2.3 ELECTRICAL SPECIFICATIONS

Market Voltage Frequency

Power

Current

Max. Amps

Approvals

US 240

208

8.5

6.4

35.4

UL858

NZ, GB, IE 230 50 7.8 34 IEC 60335

AU 240 50 8.2 35.4 IEC 60335

ELEMENTS

Size F&P Part NumberPosition

mm inches

Power

Kw CE901 CE901M

Right Rear 200 8 1800 355747 355747

Left Rear 165 6 1/2 1200 355746 355746

Centre 255 10 2500 531148 531148

Right Front 165 6 1/2 1200 355746 531143

Left Front 200 8 1800 355747 355747

2.4 LOCATION OF SERIAL NUMBER AND PRODUCT

INFORMATION

NOTE: Ratings and Test stickers also show

the cooktop serial number.

Serial number and bar code

Wiring Diagram

Service Summary – US Models only

Ratin

and Approvals Sticke

Electrical Test Sticke

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3. SERVICING INSTRUCTIONS

3.1 REMOVAL FROM THE COUNTERTOP

Isolate the unit from the power supply by turning off the main switch and

removing the fuse or fuses where more than one phase is used. Check that

the circuit is dead by

attempting to operate the appliance.

qRemove the clamping brackets from the

underside of the cooktop. Take note of their

positions.

qPlace a protective covering on the countertop adjacent to the cooktop or another

surface suitable for placing the cooktop on. Check that there is sufficient length of cable

/ conduit to allow the cooktop to be removed and turned over. In some situations, the

cable / conduit may need to be disconnected with the cooktop in the counter top. On

models sold in AU, NZ, GB and IE the cable can be disconnected at the cooktop

terminal block.

Push the unit up from below and place

blocks under the corners of the hob.

This will allow the cooktop to be lifted

out from above.

qIn some situations it may not be possible to reach

the underside of the cooktop to push it up. In this

case, use a smooth edge tool to raise the cooktop

at the corners to place the blocks. Take care not

to mark the counter top.

qLift the cooktop out of the countertop and place it face down on the protective covering.

qDisconnect the conduit from the junction box (US models) or cable from the cooktop

terminal block (AU, NZ, GB and IE). The cooktop is now free to be removed for service.

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3.2 REPLACING ELEMENTS

Isolate the cooktop from the power supply and remove it

from the countertop as described in 3.1.

qRemove the three self tapping screws between the

main cover and the 45°end panel.

qRemove the eight screws and plastic standoffs that

hold the main cover. US models are fitted with a heat

shield which is attached to the main cover. This can

remain attached to the cover.

Disconnect the wiring from the element to be

replaced, taking note of the terminal

positions.

qRemove the element screws from the case of the

element to be replaced. Withdraw the bushes from the

holes in the supporting cross-member(s). Note that the

screw holes in the element case are numbered. See

the table on page 10.

qRemove the screws that attach the cross-member(s) to the cooktop frame. The cross-

member(s) will ride up on the element springs.

qLift up the cross-member as required to allow the

removal of the element springs and the element body.

Unless it is the dual element being replaced, there will

be another element still attached to the cross-member.

Try to minimise the movement and handling of the

remaining element as the insulation material is easily

damaged.

qReplace the element. Position the new element as near as possible to the original

location and orientation.

qSit the cross-member(s) back in position and start the screws into the frame.

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qSlide the element springs between the cross-member and element case so they are

positioned centrally over the screw holes in the element case and beneath the holes in

the cross-member.

Element Element Case Screw Hole Numbers

Dual Element 6, 30, 42 and 66.

1800W Element 21 and 57.

1200W Element 24 and 60.

Tighten the screws between the cross-member(s) and the frame. Maximum

screw torque 1.3 Nm (11.5 lb-in).

qRefit the element bushes and screws in the correctly numbered holes. Maximum screw

torque 1.3 Nm (11.5 lb-in). Make sure that the bush seats squarely on the element

case surface and that the spring does not get caught between the bush and the

element case.

Reconnect the element wiring and check that the wiring is restrained so that

it cannot contact the element cases or sheet metal edges. The wiring must

be taped as shown in 3.5, using a glass cloth tape rated for at least 200°C.

For US models, this tape must be UL rated for 200°C (F&P part 556339 TP

3M 69 GLASS CLOTH SI 19x33M).

Refit the main cover, screws and standoffs. Maximum screw torque 1.3 Nm

(11.5 lb-in).

Refit the screws between the main cover and the 45°end panel. Screw

torque 1.3 Nm (11.5 lb-in).

Test the earth continuity between the main cover and the conduit earth

conductor (US models) or terminal block earth connection.

Carryout a high potential electric strength test, (megger test) between the

phase and neutral conductors (L1 and L2 in the US) and the earth conductor.

Use a jumper lead to connect the phase and neutral conductors together.

They must remain connected together during the test to protect the electronic

circuitry. Test the cooktop with all the energy regulators set in the HI position.

Test potential to be between 500 and 1000 volts. See pictures on the

following page.

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Conduit Equipped Models (US).

Terminal Block models (AU, NZ, GB and IE).

Once back in the counter top and reconnected to the supply, check the

function of each element by switching to a medium setting and observing its

operation. Look for the cycling of the energy regulator by observing the glow

of the element as it heats and cools. Check the operation of the “on” light

under the knob.

qTurn to HI and wait for the element to cycle on the temperature limiter.

qTurn the element off and check that the “hot” light is operating. Watch for this to go out

as the element cools.

Earth

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3.3 REPLACING ENERGY REGULATORS

Isolate the cooktop from the power supply and remove it from

the countertop as described in 3.1.

qRemove the energy regulator knobs and support the cooktop so that it is not resting on

the energy regulator shafts.

qRemove the eight screws and plastic standoffs that

hold the main cover. US models are fitted with a heat

shield which is attached to the main cover. This can

remain attached to the cover.

qRemove the three screws that retain the 45°end cover

and remove the cover.

qRemove the four screws that retain the regulator box

cover and remove the cover.

qModels in Aust, NZ, GB and IE, will have wires

attached to the inside of the cover through the terminal

block. These can remain attached during this

procedure.

qOn US models, remove the tape wraps that hold the

wiring to the to the wire restraint rod in the regulator

box.

qRemove the two screws that retain the wiring duct

(raceway) cover. Remove the cover. The cover part

number and name is, 531180 Bracket cover wire clamp

CE901.

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qRemove the two screws that hold the duct (raceway) to

the frame.

Remove the wiring from the regulator that is

to be replaced, taking note of the position of

each wire.

qRemove the four fine thread screws that retain the

regulator mounting panel.

qLift the regulator mounting panel straight up until the

regulator shafts are clear of the light bezels. Once the

shafts are clear, the regulator panel can be tipped

slightly to allow access to the nuts.

qThere are seals between each light bezel and regulator

boss. These may come out on the shaft. Place the

seals back in the bezels as soon as possible so they

are not lost. The seal part number and name is

531159 Seal bezel.

qReplace the energy regulator, taking note of its orientation. Maximum nut torque

0.5 Nm (4.4 lb-in).

qLower the regulator panel back into position. Make sure that the bezel seals stay in

position and are not damaged by the regulator shafts. Check that the LED wires are not

trapped under the panel or damaged by sharp edges.

Refit the four fine thread screws that retain the regulator mounting panel.

Some downward pressure will be required to compress the bezel seals and

line up the screw holes. Screw torque 1.3 Nm (11.5 lb-in).

qLift the cooktop slightly, refit the knobs and check that they turn freely and are clear of

the hob surface. Check the push to turn function on US models. Over tightening of the

energy regulator nut may cause the shaft to bind.

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Refit the wiring to the regulator(s). On US models, the wiring in the regulator

box must be restrained so it cannot contact live terminals of other circuits.

The wiring is to be bunched and taped to the wiring restraint rod with glass

cloth insulation tape as shown in 3.5. On US models this tape must be UL

rated for 200°C. (F&P part 556339 TP 3M 69 GLASS CLOTH SI 19x33M).

Refit the screws that hold the raceway to the frame. Screw torque 1.3 Nm

(11.5 lb-in).

Refit the raceway cover. Screw torque 1.3 Nm (11.5 lb-in).

Refit the terminal box cover. Screw torque 1.3 Nm (11.5 lb-in).

Refit the 45°end cover. Screw torque 1.3 Nm (11.5 lb-in).

Refit the main cover, screws and standoffs. Maximum screw torque 1.3 Nm

(11.5 lb-in).

Test the earth continuity between the main cover, raceway cover, regulator

box cover and the conduit earth conductor (US models) or terminal block

earth connection.

Carryout a high potential electric strength test, (megger test) between the

phase and neutral conductors (L1 and L2 in the US) and the earth conductor.

Use a jumper lead to connect the phase and neutral conductors together.

They must remain connected together during the test to protect the electronic

circuitry. Test the cooktop with all the energy regulators set in the HI position.

Test potential to be between 500 and 1000 volts. See pictures page 11.

Once back in the counter top and reconnected to the supply, check the

function of each element by switching to a medium setting and observing its

operation. Look for the cycling of the energy regulator by observing the glow

of the element as it heats and cools. Check the operation of the “on” light

under the knob.

qTurn to HI and wait for the element to cycle on the temperature limiter.

qTurn the element off and check that the “hot” light is operating. Watch for this to go out

as the element cools.

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3.4 REPLACING HOT/ON LIGHTS

Isolate the cooktop from the power supply and remove it from

the countertop as described in 3.1.

qRemove the four screws that retain the regulator box

cover and remove the cover.

qModels in Aust, NZ, GB and IE, will have wires

attached to the inside of the cover through the terminal

block. These can remain attached during this

procedure.

qOn US models, remove the tape wraps that hold the

wiring to the to the wire restraint rod in the regulator

box.

The PCB has five identical circuits for controlling the “hot” and on lights. At

this stage you can confirm that it is the light that is faulty rather than the PCB

by swapping the board connector for a malfunctioning light with one that is

operating correctly. Refit the regulator box cover, turn the cooktop over and

reconnect the power supply. Operate the cooktop only briefly to check the

lights as it will need to cool before servicing can continue. Do not leave the

cooktop unattended. Determine from this test if it is the light or the control

circuit that is faulty.

Disconnect the power supply immediately following the test and allow the

cooktop to cool before turning it over again.

qRemove the three self tapping screws between the

main cover and the 45°end panel.

qRemove the regulator box cover.

qRemove the eight screws and plastic standoffs that

hold the main cover. US models are fitted with a heat

shield which is attached to the main cover. This can

remain attached to the cover.

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qIf the light is faulty, remove the two screws that retain

the wiring duct (raceway) cover. Remove the cover.

The cover part number and name is 531180 Bracket

cover wire clamp CE901.

qRemove the wiring tape wraps as required to free the

white PTFE coated hot light switch wire between the

faulty LED light harness plug and the element.

Remove the harness plug from the PCB. Disconnect the hot light switch wire

from the element and disconnect the on light switch wire from the pilot

terminal on the energy regulator.

qRemove the LEDs from the light bezel by pushing the plastic hooks aside with a fine

screw driver and maneuvering the LED wires out. It may be necessary to remove the

PCB mounting screws and gently move the PCB to one side to improve access. The

other harness plugs can remain in place.

qThe LED harnesses are supplied complete. There are two short and three long

harnesses per cooktop. The part names and numbers are as follows:

Iridium Short 531162 Harness LED Short White CE901M

Iridium Long 531163 Harness LED Long White CE901M

Standard Short 531104 Harness LED Short CE901

Standard Long 531105 Harness LED Long CE901

qPush the new harnesses LEDs into the light bezel with its head firmly against the end

of its cavity. Take care that the wire insulation is not damaged during this operation.

Check that the LED wires are trapped by the plastic hooks.

Reconnect the harness wires to the element and the energy regulator. Refit

the harness plug to the PCB.

Replace the wiring tape wraps. The wiring must be restrained so that it

cannot contact the element cases or sheet metal edges. The wiring must be

taped as shown in 3.5, using a glass cloth tape rated for at least 200°C. For

US models, this tape must be UL rated for 200°C (F&P part 556339 TP 3M

69 GLASS CLOTH SI 19x33M).

If the control circuit is faulty, remove the harness plugs from the edge of the

PCB and remove the two screws that retain the PCB.

Replace the PCB. Part number and name is, 531094 Indicator PCB assy.

Screw torque 1.3 Nm (11.5 lb-in).

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qOn US models, the wiring in the regulator box must be restrained so it cannot contact

live terminals of other circuits. The wiring is to be bunched and taped to the wiring

restraint rod with glass cloth insulation tape as shown in 3.5.