Kuppersbusch ESW 308.6 Operating instructions

GB
KÜPPERSBUSCH
CUSTOMER SERVICE
Repair Manual
ESW 308.6

Repair Manual
ESW 308.6
Internal use only 2
VKS-H
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1. Introduction and Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . .3
2. Tools and Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. Functional Description of the Control Honeycomb . . . . . . . . . . . . . .5
4. Components of the Control Honeycomb . . . . . . . . . . . . . . . . . . . . .6
4.1 Power Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.3 Disassembly of the Power Section . . . . . . . . . . . . . . . . . . . . . . . . .9
4.4 Disassembly of the Control System . . . . . . . . . . . . . . . . . . . . . . . .10
5. Adjustment and Balancing of the Sensors . . . . . . . . . . . . . . . . . . .11
5.1 Main Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.2 Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.3 Calibration of Individual Sensors . . . . . . . . . . . . . . . . . . . . . . . . . .12
6. General Notes on Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . .14
7. Instructions for replacing glass ceramic honeycomb units . . . . . . .15
Responsible: Rutz Tel.: [phone] Fax: [phone] Date: 17.10.1998
H1-58-01-02

3Internal use only
Repair Manual
ESW 308.6
VKS-H
1. Introduction and Safety Instructions
The control honeycomb ESW 308.6 is a sensor-controlled cooking honeycomb
which allows controlling of the cooking zones without contacting them.
In contrast to the forerunning model ESW 307.6, the ESW 308.6 is additionally
equipped with a minute minder. From the outside, however, the functions have
remained identical while the internal structure of the control electronics has
completely changed. With the ESW 308.6 manual balancing of the sensors is no
longer required. The control system will be automatically calibrated upon
commissioning (factory-set). If required, calibration may also be repeated at the
customer. However, it is also possible to manually adjust an individual sensor by
means of a special combination of the sensors. The calibration procedure is
dealt with in detail in a separate chapter.
Furthermore, power supply unit and power section of the ESW 308.6 have been
assembled on a joint printed-circuit board mounted on the lid. The connectors
have also been changed.
The appliances are manufactured in accordance with the applicable safety
regulations.
The appliances may only be connected up to the mains, serviced and repaired
by a qualified electrician according to the valid safety regulations. Work carried
out incorrectly will endanger your safety.
When the appliance is connected up to the mains it must be ensured that there
is a device which makes it possible to disconnect it from the mains at all poles
with a contact opening width of at least 3 mm. Line-protecting switches, fuses
and contactors are suitable cut-out devices.
Further general notes are included in the ”Operating and installation instructions
for honeycomb cooking areas with sensor control, series ESW/EKW”.
Before opening the appliance always disconnect it from the power supply!
H1-58-01-02

Repair Manual
ESW 308.6
Internal use only 4
VKS-H
2. Tools and Devices
The following tools are required for a trouble-free performance of a
customer service call:
••digital multimeter incl. measuring leads
••IC extraction tool for 28 poles
••small ratchet box
••5.5 mm socket spanner (type Belzer No. 6400-5.5)
••8.0 mm socket spanner
••side cutting pliers, small
••flat pliers, small
••screwdriver for slotted screws, various sizes (very important: with short handle)
••screwdriver for recessed head screws, various sizes (very important: with
short handle)
••torch, offset
Furthermore the following devices are required:
••setting device for basic calibration of the sensor system
••setting power supply unit
••glass cleansing agent, “Sidolin“ or similar
••cleaning cloths
H1-58-01-02

5Internal use only
Repair Manual
ESW 308.6
VKS-H
3. Functional Description of the Control Honeycomb
See Operating and Installation Instructions ESW, valid: July 1997
H1-58-01-02

Repair Manual
ESW 308.6
Internal use only 6
VKS-H
4. Components of the ESW 308.6
4.1 Power sections
Newly supplied control honeycombs starting with the W-number xxxx will be
equipped with the following combined power supply unit and power section:
power section 2879 - rev. A
electrical connection ESW 308.6
outside view of the lid ESW 308.6
power section mounted on lid
Note:
The power section may
be combined with any
of the forerunning
honeycomb models,
i. e., the control
connection is pin-com-
patible.
H1-58-01-02

7Internal use only
Repair Manual
ESW 308.6
VKS-H
4.2 Control System
The control board is connected to the power section by means of 2 cables.
1. a 4-pole cable for power supply
2. a 14-pole ribbon cable for power section control
H1-58-01-02

Repair Manual
ESW 308.6
Internal use only 8
VKS-H
Before opening the appliance make sure
to observe the safety instructions!
In order to loosen the lid of the cabinet unscrew the 4
screws (marked with an ”X”).
H1-58-01-02

9Internal use only
Repair Manual
ESW 308.6
VKS-H
After the appliance has been DIS-
CONNECTED FROM THE POWER SUPPLY
and the heater cables have been removed,
the 4
screws marked with an ”X” are removed (if
required, the incoming cable must also be
removed).
Then the connecting line to the control
system and the power supply are pulled off.
The pc board ”power section” is fastened by
means of 5 nuts marked with an ”X” in the
illustration below.
After removing the nuts the pc board can be
taken out of the fastening bolts.
Now the connecting cables can be pulled off
from the relays and the pc board be replaced.
Make sure that the terminal assignment at the
relays is the same before and after
replacement of the pc board.
Special terminal assignments will be made
available in the future. Assembly is then
performed in the reverse sequence.
Prior to commissioning the appliance has to
be checked again according to the valid
VDE-regulations!
Aprinted board assembly for all variations is
made available to the Customer Service.
(It may be included in the service box.)
4.3 Disassembly of the Power Section
H1-58-01-02

Repair Manual
ESW 308.6
Internal use only 10
VKS-H
control board
For the diassembly of the control board the
steps ”Removing and loosening the lid with
power section” have already been performed.
Afterwards the 3 fastening screws of the
control board are removed. The pc board is
removed towards the top with the recess
matching one of the top fastening brackets.
The new pc board is inserted and fastened
by means of the 3 screws.
The pc board is now illuminated from the rear
side by means of a torch so that the position
of the display elements can be checked from
above. In case the photo sensors of the
7-segment displays do not match the imprint
on the glass ceramic surface, the pc board
must be loosened again in order to position it
correctly. When the position then matches the
imprint, the 3 screws are tightened.
At this point the balancing procedure of the
sensors has to be performed. (See separate
description on the following pages!)
4.4 Disassembly of the Control System
H1-58-01-02

11 Internal use only
Repair Manual
ESW 308.6
VKS-H
5. Adjustment and Balancing of the Sensors
General
For balancing the sensors of the ESW 308.6 it is no longer required to carry out
manual adjustments via a potentiometer as with the forerunning model ESW
307.6. Sensor balancing of the ESW 308.6 is performed from the control field, i.
e. the cabinet needs no longer to be opened for this purpose.
The following sensors are important for the sensor
adjustment:
In order to enter the calibration mode proceed as follows:
Disconnect the control honeycomb from the power supply via the circuit breaker.
Switch the circuit breaker on again, then press the lock sensor within 5
seconds and keep it depressed. (During this procedure the actual software
version is diplayed in the 7-segment displays from the left to the right.). After
another 7 seconds the key sensor must be pressed. The lock sensor must be
released as soon as the key sensor has been activated. In this way the COM-
MAND MODE is activated, wich allows access to 3 different submodes.
H1-58-01-02

Repair Manual
ESW 308.6
Internal use only 12
VKS-H
5.1 Main Reset
The main reset deletes all sensor values stored in a memory module on the
control electronics. However, this is only required if an automatic calibration
procedure has to be performed afterwards.
When the clock sensor is activated an acoustic signal will sound after expiry
of a certain time. Afterwards the control system can be disconnected from the
power supply via the circuit breaker independently of the time. Now all
memory contents regarding the sensors have been deleted!
5.2 Automatic Calibration
Before switching on the circuit breakers again, the balancing device is positioned
on the control in such a way that no sensor is covered by the spacers. Now the
circuit breakers can be switched on again. After approx. 2 minutes 4 successive
acoustic signals will sound to signal that calibration is completed. In this status
the ESW 308.6 can be operated as usual again. It is recommended, however, to
check each sensor again.
5.3 Calibration of Individual Sensors
Set the appliance to the COMMAND MODE again.
Once again to remember:
Disconnect the control honeycomb from the power supply via the circuit
breakers. Switch the circuit breakers on again, depress the lock sensor within 5
seconds and keep it depressed. (During this procedure the actual software
version will be displayed in the 7-segment displays from the left to the right).
After another 7 seconds the key sensor must be activated. The lock sensor must
be released as soon as the key sensor is activated.
In this way the COMMAND MODE is set.
General notes for the manual adjustment of a sensor:
In the version ”pointed” and ”flat” the sensors are numbered from S00 to S25
each. During manual adjustment the sensors are successively displayed,
independent of whether they are physically existing are not.
H1-58-01-02

13 Internal use only
Repair Manual
ESW 308.6
VKS-H
After having activated the COMMAND MODE the ON/OFF sensor is touched
and a ”1” is displayed. Now sensor 01 can be set. The sensor sensitivity can be
decreased by means of the key sensor and increased by the lock sensor,
respectively. The sensor can be set to a value between 00 and 60. The respec-
tive setting is displayed.
If the ON/OFF sensor is touched again, display ”1” changes to ”2” which
represents sensor S02. In order to store the modified values, the ON/OFF
sensor is kept depressed while it slowly counts up to ”25”. When ”25” is
reached, the sensor is still kept depressed until 4 successive acoustic signals
sound. Now the values have been stored and the ESW 308.6 can be operated
as usual.
Note: If more than 2 sensors have to be reset, automatic calibration has to
H1-58-01-02

Repair Manual
ESW 308.6
Internal use only 14
VKS-H
Three defects may occur:
1. heater is defective
2. control board of the ESW 308.6 is defective
3. power section of the ESW 308.6 is defective
In order to be able to differentiate between
control board and power section, a testing
unit will be available in the near future which
optically displays the power section control.
In case the control board is defective,a
printed board assembly will be made
available to the Customer Service for the
versions ”pointed” and ”flat”. If this board is
used, the slave EEPROM and the master
EEPROM must be removed from the
defective pc board by means of a special tool
(IC extraction tool) and installed on the new
board.
IC extraction and installation tool
A power section assembly will also be made
available to the Customer Service.
Thus faults may be located and remedied
very quickly.
With respect to the control electronics, there
may generally only occur 2 basic faults, i. e. a
complete failure or a sensor problem. In most
cases, a sensor problem can be remedied as
described above without opening the
appliance.
6. General Notes on Possible Faults
The control honeycomb ESW 308.6 is not equipped with an optical fault
display.
H1-58-01-02

H1-58-01-02 15
For internal use only
7. Instructions for replacing glass ceramic honeycomb
units
Replace the ceramic honeycomb as follows:
Parts required:
53 69 25 Glass ceramic honeycomb 53 69 25 Casing section mechanism
53 69 30 Glass ceramic control honeycom 53 69 55 Casing section mechanism
09 15 81 Adhesive cleane
53 58 85 PACTAN primer
09 15 80 PACTAN adhesive
Undo and remove from the casing the casing
cover with power unit and control board and/or
casing cover with radiant heat unit.
Carfully cut the silicone seam between the glass
and worktop with a knife.
The glass ceramic honeycomb and casing can
usually be separated from the worktop by
exerting gentle but constant pressure from
below.
With wood or chipboard worktops, keep the
amount of wooden fragments removed to an
absolute minimum.
If the casing is bonded in firmly and cannot
be released, follow these steps carefully.
Disconnect the appliance from
the mains!

16 H1-58-01-02
For internal use only
Cover the glass ceramic honeycomb to be
replaced with a damp cloth and place a
receptacle underneath to catch any glass
splinters.
Now using a controlled level of force break the
glass and completely remove it.
Remove any remaining welds from the ring and
upper section (by filling).
Using a knife from below, cut the silicon
adhesive between the ring and the worktop.
Remove the ring downwards and then carefully
release the honeycombed upper section from
the worktop with a knife.
Now remove any silicon residues from the
worktop. If any spacers are present, take care
not to damage them. Retain for later.
Danger. Risk of accidents!
Gloves and goggles must be worn!

H1-58-01-02 17
For internal use only
Fit the new glass ceramic honeycomb.
Make sure the surfaces are level and the joints
are of even thickness.
Clean the glass ceramic honeycombs’s
jointing surfaces with adhesive cleaner.
Granite worktops should also be cleaned with
adhesive cleaner.
First coat worktops made from wood or
chipboard with PACTAN primer and leave to
dry.
Dab the corners with PACTAN adhesive
Do not apply too thickly or the ring and the
worktop will stick together again.
Carefully insert the new glass ceramic
honeycomb.
Place a heavy weight on the new control
honeycomb for 24 hours and screw the other
honeycombs to the worktop from below with the
clips.
Mask the glass surface and worktops with tape
and fill the joints with PACTAN, so that the
seals are absolutely watertight.
Smooth off the joints.
Carefully remove the masking tape and
immediately remove any traces of adhesive
from the glass or worktop.
Make clear to the customer that
the hob and joints should not
bear any weight for 24 hours.