Kuppersbusch ESW 308.6 Setup guide

j}}|j}ya{
]koKHPFN

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

H1-58-01-02-Ä 3
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”.

H1-58-01-02-Ä 5
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.

H1-58-01-02-Ä 7
For internal use only
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.

8 H1-58-01-02-Ä
For internal use only
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.

H1-58-01-02-Ä 9
For internal use only
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

10 H1-58-01-02-Ä
For internal use only
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

H1-58-01-02-Ä 11
For internal use only
6. 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.
6.1 Calibration mode without changing the electronics
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 10 seconds the key sensor must be pressed. As soon as the key sensor has been
activated, first the lock sensor must be released.
In this way the COMMAND MODE is activated.
6.1.1 Main Reset
The main reset deletes all sensor values stored in a memory module EEPROM 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 EEPROM have been deleted!
6.1.2 Automatic Calibration
Clean the pane. Remove fingerprints and any other soiling with Sidolin or a similar product.
Before switching on the circuit breakers again, the balancing device is positioned on the control with the
light side facing downwards 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 (the electronics unit twice counts up to 60 seconds in the left segment indicator)
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.

12 H1-58-01-02-Ä
For internal use only
6.1.3 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 proce-
dure 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.
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
respective 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 be performed.

H1-58-01-02-Ä 13
For internal use only
6.2 Calibration modus on exchanging the electronics unit
Automatic calibration
Clean the pane.Remove fingerprints and any other soiling with Sidolin or a similar product.
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.
First the current status of the software is indicated in the segment display.
After approx. 2 minutes (the electronics unit twice counts up to 60 seconds in the left segment indicator)
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.
See the operation manual of the honeycomb present.
Balancing aid: product no. 340252

14 H1-58-01-02-Ä
For internal use only
7. Faults
7.1 General notes
The control honeycomb ESW 308.6 is not equipped with an optical fault display.
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:
1. complete failure or
2. a sensory problem.
In most cases, a sensor problem can be remedied as described above without opening the appliance.
master
EEPROMS
slave

H1-58-01-02-Ä 15
For internal use only
7.2 Rectifying faults
7.2.1 The honeycomb is difficult to operate
(The sensors react too sluggishly or not at all)
Measure
Erase the EEPROM modus and re-calibrate (see Manual).
Replace the EEPROM should it not be possible to erase it or should it not be possible to carry out the
process of removal.
On exchanging the EEPROM please ensure that it is positioned correctly.
It is essential that the pre-set dent on the EEPROM be inserted in the direction indicated on the base.
Subsequent to removal or exchange of the EEPROM, the honeycomb is to be re-calibrated as
indicated.
Should the removal of the EEPROM mode or the exchange not be successful and the sensors activate
the input data unreliably even after re-calibration:
Measure
Exchange the electronics unit (see universal electronics unit)
7.2.2 The honeycomb only reacts briefly on being switched on and then
switches off again
Check the power supply.
EEPROM
Base
Power supply for electronics unit: consistent 5 volts
connection
To be gaugedat the connection or on the capacitor
electronics unit

16 H1-58-01-02-Ä
For internal use only
7.2.3 Power supply for the relay platinum: consistent 15 volts at the
connection
Measure
If one of the two voltages is not present or instable:
Exchange the mains connection and/or, if necessary exchange the voltage regulator.
7.2.4 The honeycomb is difficult to operate
(the sensors activate the wrong honeycombs or none at all)
Measure
Exchange the EPROM.
Determine the honeycomb number. Burn the master and the slave again and replace.
Should exchanging the EPROM be unsuccessful, replace the entire electronics unit (see Universal
electronics unit).

H1-58-01-02-Ä 17
For internal use only
8. 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 honeycomb 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!

18 H1-58-01-02-Ä
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-Ä 19
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.