Kuppersbusch ESW 308.6 Setup guide

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Service Manual: H1-58-01-02-Ä
Responsible: H. G. Streckert KÜPPERSBUSCH HAUSGERÄTE AG
Email: [e-mail]
Tel.: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 29.04.2003 45801 Gelsenkirchen

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For internal use only
Table of contents
1. Introduction and Safety Instructions ............................................................................ 4
2. The control unit at a glance ........................................................................................... 5
3. Tools and Devices .......................................................................................................... 5
4. Functional Description of the Honeycomb Control Unit............................................. 6
5. Electronics of the ESW 308.6 ........................................................................................ 7
5.1 Universal electronics unit ...................................................................................... 7
5.2 Control System...................................................................................................... 9
5.3 Disassembly of the Control Section ...................................................................... 9
6. Adjustment and Balancing of the Sensors ................................................................ 11
6.1 Calibration mode without changing the electronics ............................................. 11
6.2 Calibration modus on exchanging the electronics unit ........................................ 13
7. Faults ............................................................................................................................. 14
7.1 General notes...................................................................................................... 14
7.2 Rectifying faults ................................................................................................... 15
8. Instructions for replacing glass ceramic honeycomb units..................................... 17

4 H1-58-01-02-Ä
For internal use only
1. Introduction and Safety Instructions
The control honeycomb ESW 308.6 is a sensor-controlled control unit 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´s. 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
zones with sensor control, series ESW/EKW”.

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For internal use only
2. The control unit at a glance
1. Glass ceramic-honeycomb control
unit, layout 05
2. Housing - mechanical system
3. Circuit board flat, shallow
Circuit board pointed
4. Screw M4
5. Power supply
6. Relay board
7. Housing - mechanical system
8. Cable protection sleeve
9. Heat sink
10. Cable duct clip
11. Screw M5
12. Bushing 3-pole
13. Bushing 4-pole
14. Plug, conector 5-pin
3. 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
♦glass cleansing agent, “Sidolin” or similar
♦setting power supply unit
♦cleaning cloths

6 H1-58-01-02-Ä
For internal use only
4. Functional Description of the Honeycomb Control Unit
The honeycomb cooking zone is equipped with a
convenient sensor control unit which is regulated by
means of the control honeycomb.
The markings in the honeycomb control unit repeat
the layout of the cooking zones on the worktop.
With the honeycomb control unit you can also
control
• the cooking with auto parboil
• the minute minder
• the childproof lock
The following control fields are on the honeycomb
control unit:
A and B are control fields for the minute minder with
Plus and Minus sensors
C = Minute Minder
D = Control fields for the cooking zones with Plus
and Minus sensors.
E = Key sensor for childproof lock
F = Lock sensor for childproof lock (Sensor-lock).
G = On / Off sensor
H = This field has no control functions. It simply
indicates the position of the honeycomb control unit.
Switching on and off the appliance
Switching on
Touch the ON-OFF sensor for about 2 seconds. A vertical
bar will light up above the lock sensor.
The appliance is now ready to be put into operation (standby
mode). Each cooking zone can now be controlled
individually.
Switching all functions off
Briefly touch the ON-OFF sensor (for about 0.3 seconds).
The vertical bar will be extinguished. The control honeycomb
unit switches off again automatically, if no further sensor is
touched within 20 seconds, if it is left unused for 10 minutes
after operation or if the sensor of a cooking zone is touched
for longer than 20 seconds.
An acoustic signal already sounds after 10 seconds to warn
you that the appliance will switch off after another
10 seconds.
2 secs.
0.3 sec.

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5. Electronics of the ESW 308.6
5.1 Universal electronics unit
5.1.1 Components
The following spare parts are required when constructing a universal electronics unit:
Spare part no. Quantity Indication
538414 1 Flat universal electronics unit
or
538415 1 Pointed universal electronics unit
538416 1 EEPROM
538417 2 EPROM (master and slave)
In the case of ESW 307.6 honeycombs from honeycomb no. 200 to approx. honeycomb no. 930,
a check is to be made on whether additional components are required.
538418 1 Trip line Electronics relay platinum
538430 1 Power supply Electronics relay platinum
5384xx 1 Lower casing Mains relay platinum
536963 1 Relay platinum essential for 0µ0.1 filters
In the case of ESW 307.6 honeycombs up to approx. honeycomb no. 200, a check is to be made on
whether a complete new unit has to be installed. To be recognised on the stopped (raised) input sensors.
These must always be completely replaced, including the glass pane and on indication of the
honeycomb number.

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5.1.2 Exchanging an universal electronics unit
It is essential to observe the following on exchanging a universal electronics unit:
Attention!
It is essential to carry out a potential adjustment on the exposed conductive part
prior to unpacking and installing the electronics unit!
In the region of the elongated holes for attaching the universal honeycomb it must be ensured that the
areas around the soldering joints are sufficiently covered with tape.
The inversion layer must be clean. If necessary clean with water.
Once installed, the electronics unit must be adjusted so that at the bottom all of the sensors are exactly
in line with the input fields on the glass.
Shine a lamp on from below and if necessary adjust the position.
Then screw all three screws, but not too tightly.
Finally install all of the other components, the mains supply unit and the relay platinum and then close
the lid.
Carry out a VDE 7001 test.
Then calibrate.

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5.2 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.
5.3 Disassembly of the Control Section
Control board
For the diassembly of the control board the steps "Removing and loosening the lid with power section"
have already been performed.
power supply

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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 fastening
brackets. Then it is removed.
The new control electronics is inserted and fastened
by means of the 3 fastening 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 sensors 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.
Assembly
Spare part no. Quantity Indication
538414 1 Flat universal electronics unit
or
538415 1 Pointed universal electronics
unit
538416 1 EEPROM
538417 2 EPROM (master and slave,
indicating the honeycomb
number (W xxxx)
The electronics unit must be re-calibrated subsequent to assembling the lid with the mains
supply unit and the relay platinum.
power supply