Kuppersbusch GCM 642.0 ME User manual

GB
Built-in Glass Ceramic Gas Hob
GCM 642.0 ME
Built-in Electronic Control Panel
GES 642.0

Service Manual: H2-120-57-02
Responsible: N. Kirchmair Küppersbusch Vertriebsges. mbH
Phone: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 05.02.1999 45801 Gelsenkirchen

Service Manual GCM 642.0 ME/GES 642.0 3
For internal use only
Contents
1. General technical data ............................................................................4
2. Appliance illustration..............................................................................6
3. Installation/disassembly.........................................................................7
3.1 Installation conditions.......................................................................7
3.2 General notes on the installation......................................................9
3.3 Installing the seal between hob and worktop .................................10
3.4 Making the gas connection.............................................................10
3.5 Installing the hob............................................................................10
3.6 Installing the control panel..............................................................10
4. Description of the appliance.................................................................12
5. Conversion to a different gas type.......................................................14
5.1 Changing the burner injectors........................................................14
6. Appliance operation..............................................................................16
6.1 Switching the cooking zones on and off.........................................16
6.2 The simmering zones.....................................................................17
6.3 Notes on the use of the right saucepans .......................................17
6.4 Setting the digital clock...................................................................18
6.5 Operation........................................................................................19
7. Disassembly of the components..........................................................20
7.1 Disassembly of the hob..................................................................20
7.2 Disassembly of the hob components .............................................21
7.3 Disassembly of the control unit ......................................................23
7.4 Disassembly of the components of the control unit........................24
8. Troubleshooting table...........................................................................26
9. Further technical descriptions
10. Wiring plans...........................................................................................29

4 Service Manual GCM 642.0 ME/GES 642.0
For internal use only
1. General technical data
Appliance dimensions, hob:
♦W x D approx. 584 x 514 mm
♦Installation height 80 mm
♦Recess dimensions, hob:
W x D approx. 560 x 490 mm
♦Recess dimensions, control panel:
W x H approx. 525 x 90 mm
Features:
Built-in glass ceramic gas hob:
♦2 high-speed cooking zones, 2.0 kW each
♦2 residual heat indicators
♦2 additional simmering zones
Electronic ignition device
Built-in electronic control panel:
♦2 energy controllers for cooking zones
♦pilot light for each cooking zone
♦fault light for each cooking zone
♦electronic clock with minute minder without switch-off function
Technical data:
♦Gas connection 4.0 kW
♦Electric connection 0.1 kW (plug-in type)
DIN EN 30 product ident No. CE0085AQ0988
Note:
The appliance may also be operated with LPG (50 mbar).
The LPG injectors are supplied as standard features with the appliance.
Special accessories:
♦Natural gas injector kit
for natural gas G 25 LL-12.4
with high fluctuation range and Wobbe number below the natural gas L quality.
Accessory No. 205
Spare part No. 537551

Service Manual GCM 642.0 ME/GES 642.0 5
For internal use only
Note:
Cannot be combined with GEH, KEH, EEB and EEH
Gas-heated HI-TEC hob:
♦Economical, safe and convenient thanks to advanced microprocessor technology.
♦2 cooking zones
♦2 simmering zones. These zones can be used to cook while saving energy through
the use of the exhaust air heat.
♦The all-electronic, high-precision regulation and control system saves energy and
ensures maximum safety.
♦Reliable, electronic (patented) ignition device
♦Pilot and fault lights for each cooking zone
♦Built-in electronic control panel
♦2 residual heat indicators
The 1/2" gas connection is arranged in the centre of the rear hob bottom section and
points downwards.
If LPG is used, a transition element for 1/2" to 8 mm can be requested if required.
Connected voltage 230 V (min. 180 V).

6 Service Manual GCM 642.0 ME/GES 642.0
For internal use only
2. Appliance illustration
Hob
1 Aeration opening
2 Simmering zones
3 Cooking zones
4 Residual heat indicators
Control panel
5 Pilot light for the cooking zones
6 Digital clock
7 Control knob for left-hand cooking zone
8 Control knob for right-hand cooking zone
9 Fault lights for the cooking zones

Service Manual GCM 642.0 ME/GES 642.0 7
For internal use only
3. Installation/Disassembly
3.1 Installation Conditions
The room where the appliance is installed must have a volume of at least 20 m³ and
offer access for aeration to the outside through a window or a door.
The hob is installed in a worktop recess which is to be made to suit the following
installation dimensions. If the worktop is 600 mm deep, a space of 55 mm remains at
the back.
Distance hob-wall min. 50 mm.
The space at the back increases if the worktop is deeper.
Additional space is required under the hob for the gas connection.
min.

8 Service Manual GCM 642.0 ME/GES 642.0
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If the room where the appliance is installed is limited at the bottom by a horizontal
partition plate, an aeration duct must be created to the surrounding furniture through
an at least 180 cm² (e. g. 10 x 18 cm) large opening in the partition plate.
A space of at least 5 mm must remain between the inside edge of the furniture front
and the worktop recess.
The wall sealing strip must be made of heat-resistant material and must not be
provided with sockets in the hob area. A plastic carrier strip with a cover strip of
aluminium is recommended. The leg length on the worktop must not exceed 30 mm.
As regards protection against overheating of the surrounding areas, the appliance is of
the type Y to VDE 0700/6 and IEC 335-2-6.
The wall above the sealing strip near the appliance must be made of non-flammable
material. Wood, plastic, PVC films etc. do not satisfy this requirement.
In normal use, radiated temperatures of 70°C above room temperature can act on the
surrounding furniture. The furniture must satisfy at least this requirement. In the case
of fitted units the plastic covering or the varnish must be processed with heat-resistant
adhesive (100°C).
The temperature produced at the back of the hob is approx. 300°C. The minimum
distance of wall cupboards and fume extractors above the hob is 650 mm.
Due to the high temperature produced at the back of the hob, the stainless steel grid
becomes bluish. These discolourations can be removed by means of stainless steel
cleaners and are no reason for claims.

Service Manual GCM 642.0 ME/GES 642.0 9
For internal use only
3.2 General notes on the installation
a) Make the worktop and control panel recesses in accordance with the
specified dimensions.
b) Secure the sheet panelling on all four sides in the worktop recess with the
enclosed nails (see Fig.).
The angled part of the shielding sheets rests on the worktop. The notch on
the angled side of the sheets must coincide with the centre of the worktop
recess.
c) In order to fasten the shielding sheets in granite worktops glue them into the
recess by means of heat-resistant silicon adhesive, e. g. Pactan.
d) Secure support angles on the left and right in the switch panel recess with
the enclosed screws in such a way that there is a distance of 502 mm
between the notch points (see Fig.).
502
Support angle
Notch point

10 Service Manual GCM 642.0 ME/GES 642.0
For internal use only
3.3 Installing the seal between hob and worktop
a) Before the appliance is connected to electricity or gas, a seal must be
installed between the hob and the worktop. This seal is glued onto the
underside of the hob frame.
b) Press the self-adhesive sponge rubber seal around the hob frame starting
from the centre at the back (see Fig.).
After installation the seal must be in the position as shown in the illustration.
Do not use additional silicon or similar: Otherwise, when thehob is removed,
the worktop could be damaged.
3.4 Making the gas connection
3.5 Installing the hob
a) Insert the hob into the worktop opening.
b) The pins onthe side panellingsheets must engage the spring catches in the
hob.
c) Press the hob edge by hand lightly.
3.6 Installing the control panel
a) Hold the control panel in front of the prepared opening and insert the two
connection lines with 6 and 9-pole plug into the connection bushes of the
control panel.
Do not use force. The shape and size of the plugs prevent them from being
inserted the wrong way round.
b) Guide the electric cable of the control panel through the opening in the
bottom cupboard to the rear.
Seal
Hob
Glass ceramic top

Service Manual GCM 642.0 ME/GES 642.0 11
For internal use only
c) Carefully press the control panel into the opening. The pins of the control
panel must engage the spring catches of the support angles.
Caution! The all-round gap between the front of the control panel
and the furniture front serves to ventilate the appliance and must
not be sealed.
d) Insert the plug into an earthed shock-proof socket.
If the indicator lights on the control panel glow weakly when the plug is
inserted, insert the plug the other way round.
Prior to commissioning, the appliance must be checked by the fitter for
perfect functioning and any gas leaks. The appliance is then ready for
operation.
Disassembly of the appliance is carried out in reverse sequence.

12 Service Manual GCM 642.0 ME/GES 642.0
For internal use only
4. Description of the appliance
The built-in hob comprises the following five assemblies:
Glass ceramic hob
complete with radiant burners, ignition and monitoring electrodes, ignition
transformer, residual heat indicators, thermal relay with residual heat contacts and
solenoid valves.
Control unit
complete with fascia, energy controller, ignition fuses, control lights, control knobs,
electronic clock with minute minder, terminal, power supply cable and radio
interference suppression capacitor.
Shielding sheets (4 off)
N

Service Manual GCM 642.0 ME/GES 642.0 13
For internal use only
Appliance description
The glass ceramic hob GCM 642.0 ME is a gas-operated, built-in glass ceramic hob for
installation in a worktop, with an operation fascia at the front.
The appliance mainly consists of the following components:
1. the panelling sheets for the worktop recess in the side sections of which the hob
bottom section is suspended by means 4 connectors.
2. the glass ceramic hob is formed from two gas radiant burners at the front, the
insulation mouldings which serve as insulation and heating gas line, the ignition
and monitoring elements, the ignition transformer, thermal relay with residual heat
contact, solenoid valves and residual heat indicators and the assembly box
surrounding the components.
3. the control unit is inserted into two holding angles screwed onto the sides of a
recess in the cabinet front and engaged.
4. the operation fascia with the screwed-on control box comprising the energy
controllers, ignition fuses, control knobs, pilot lights, electronic clock, terminal,
radio interference suppression capacitor and power supply cable.

14 Service Manual GCM 642.0 ME/GES 642.0
For internal use only
5. Conversion to a different gas type
5.1 Changing the burner injectors
a) It is imperative to first disconnect the gas and electricity supply.
b) Pull the control panel forwards out of the holder and disconnect the two plug
connections to the hob.
c) Carefully lift the hob forwards out of the worktop 1.
d) Remove the cover around the gas connection 2.
e) Unscrew clips on the injector pipes.
f) Unscrew the fastening screws and push the valve block to the rear. The
injector holders are pulled out of the injector pipes 3.
g) Remove the injectors using a 9 mm-wrench and insert the new injectors.
Make sure that injectors with the correct diameter are used!
Suitable injectors are indicated on the following page in the table “Diameter
of injectors”.
h) After the injectors have been changed, the injector holders are tobe inserted
again into the injector pipes right to the stop and secured with the clips.
i) Screw the fastening screws of the gas connection back in again and screw
on the cover.
j) First insert the hob back into the worktop.
k) Connect the hob with the control panel and insert the panel back into the
opening.
3
2
4
5
1
1

Service Manual GCM 642.0 ME/GES 642.0 15
For internal use only
Diameter of injectors
The gas suppy pressure is
♦for natural gas H, E, LL 20 mbar
♦for LPG 50 mbar
The appliance must not be put into operation if the gas supply pressure is outside
the specified ranges:
♦natural gas min. 17.0 mbar, max. 25.0 mbar
♦LPG min. 42.5 mbar, max. 57.5 mbar
The specified gas supply pressure applies for the Federal Republic of Germany.
Gas connection values
The injector kits can be ordered for LL natural gas if required.
G20; 2H, 2E, 2E+, 20 mbar setting:
All appliances marked with G20, 2H, 2E+, 20 mbar setting are to be used in the Wobbe
index range of 11.3 to 15.2 kWh/m³ without changing the setting.
Caution: The settings for this appliance are provided on an information sign
(or on the appliance name plate).
Gas type Dia. of injectors for burners
Natural gas G20, 2H, 2E, 2E+
20 mbar 1.15 mm
Natural gas G25, 2LL
20 mbar 1.25 mm
Netherlands (NL):
Natural gas G25, 2L
25 mbar 1.15 mm
LPG G31, 3P Propane
50 mbar 0.72 mm
Pressure couple butane/propane
G30/31
28 - 30/37 mbar 0.74 mm
Gas type Rated load per burner Gas flow per burner
Natural gas G20, 2H, 2E,
2E+
20 mbar 2.2 kW 3.5 l/min.
Natural gas G25, 2LL
20 mbar 2.2 kW 4.0 l/min.
Netherlands (NL):
Natural gas G25, 2L
25 mbar 2.2 kW 4.0 l/min.
LPG G31, 3P Propane
50 mbar 2.2 kW 156 g/h
LPG G30, 3B/P
Butane/propane
50 mbar 2.2 kW 156 g/h

16 Service Manual GCM 642.0 ME/GES 642.0
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6. Appliance operation
6.1 Switching the cooking zones on and off
The appliance has two cooking zones. Each zone has its own control knob. Which
control knob belongs to which cooking zone can be seen from the symbols on the
control panel. The control knobs are each marked with twelve
settings. You should generally start cooking with the
control knob at a high setting and then switch back to
a lower setting to continue.
To switch on a cooking zone turn the control knob to
the right and select the desired setting.
The cooking zone pilot light illuminates. After about
5 seconds the flame will ignite automatically and the
cooking zone will also be supervised automatically.
Combustion is barely visible. After some time (at setting 12 after about 2 minutes), the
radiant burners will glow red.
The burner does not burn continuously during operation, but is permanently switched
on and off by the cooking zone’s energy controller depending on the setting you have
selected.
Caution! There is no such regulation at setting 12.
To switch off the cooking zone, turn the control knob to the left, back to setting “0”.

Service Manual GCM 642.0 ME/GES 642.0 17
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6.2 The simmering zones
The simmering zones on the hob can be used for simmering food until it is done and
for keeping food warm.
Asfromsetting8,thispartof the glassceramic hobheats upsointensely thatadditional
simmering is possible.
Example of an application
Menu:
Beef soup
Roast pork
Vegetables
Potatoes
Cook the beef soup and the roast pork on the two front cooking zones until the food is
3/4 done. Then slide both pans to the simmering zones and cook the vegetables and
the potatoes on the front cooking zones.
If the cooking zones are loaded in this way, all the food will be cooked until it is done.
6.3 Notes on the use of the right saucepans
Using the right saucepans will help you to
reduce cooking times and save energy.
Only use saucepans with a smooth and even
base.
Saucepan and pan bases must contract inwards slightly in the cold condition as they
expand when hot and then rest on the cooking zone. This is the best way for the heat
to be transferred.
The optimum base thickness is 2 – 3 mm for steel enamel and 4 – 6 mm for stainless
steel with a sandwich bottom.
The saucepan bases must be clean and dry in order to avoid scratches on the glass
ceramic hob.
Do not use saucepans made of cast iron or saucepans with electrographic bases.
Never use aluminium dishes or plastic vessels!
Avoid saucepans boiling dry.

18 Service Manual GCM 642.0 ME/GES 642.0
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6.4 Setting the digital clock
You can use the digital clock to remind yourself of the end of the planned cookingtime.
The cooking zones are not switched off automatically.
Setting the time
Briefly press the button with the clock symbol and
then set the time with the buttons + or -.
Setting a cooking time
If you have just set the time:
Wait for about 10 seconds.
Then enterthe desired cooking time with +. Each time
the button is pressed, the cooking time is increased
by 10 seconds (max. 99 minutes can be set). A bell
symbol appears in the display.
The elapsing cooking time is shown in the display and can be changed at any time with
+ or -. The pre-set cooking time is deleted by pressing + and - simultaneously.
Release the button + first as otherwise a new cooking time is set.
Displaying the time while a cooking time is running
Briefly press the button with the clock symbol. The
time is displayed; after a few seconds the cooking
time is automatically shown again.
End of the cooking time
The end of the cooking time is indicated by an acoustic signal.
The alarm is manually switched off with the + button, otherwise it stops automatically
after 7 minutes.
While the signal is sounding, you can change the tone:
Press the button - once or twice to set one of the other three tones.

Service Manual GCM 642.0 ME/GES 642.0 19
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6.5 Operation
♦The gas supplied to the appliance passes in the OFF condition to the two solenoid
valves assigned to each cooking zone.
5 seconds after a cooking zone has been switched on, the electronic safety pilot is
supplied with power through the energy controller; this power then causes the
solenoid valves to open and the gas/air mixture to ignite. The mixture must ignite
within 10 seconds. The electronic safety pilot monitors the operating status on the
radiant burners by means of ionisation.
♦When the cooking zones are in operation, the area above the radiant burners is
heated the most (boiling zone) - max. 600°C.
The gases passed backwards to the heating gas outlet heat the adjacent part of the
cooking zone so much that simmering is possible in this area (simmering zone),
max. 300°C.
♦The energy supply is regulated by means of the control knobs assigned to the
energy controllers.
♦At control setting 12 the cooking zone is not switched off via the energy controller.
♦In case the max. permissible temperature of approx. 600°C is exceeded, the
energy supply can be switched off via the thermal relay assigned to each cooking
zone.
♦If the thermal relay is switched off, the power supply is interrupted by the energy
controller. If the thermal relay is switched on again, the respective cooking zone will
automatically switch on again.
♦The operating status and any critical situations are optically displayed by the lights
on the operation fascia.
♦Should the appliance indicate a fault after being switched on, it can be restarted
after first being switched off and then on again.
♦Combustion is barely visible. After about 2 minutes at setting 12 the radiant burners
glow red.
♦Brief blinking of the fault light during the starting process has no significance.

20 Service Manual GCM 642.0 ME/GES 642.0
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7. Disassembly of the components
7.1 Disassembly of the hob
a) After disassembly of the glass ceramic hob, the ceramic top can be lifted off
from the bottom trough by removing the flat screws 1that have been
screwed into the side panels of the hob frame.
b) The burners 2, ignition monitoring block 3, thermal relays 4, heat
conducting sheets 5and resistant heat indicator 6are now accessible from
the top side of the bottom trough.
c) The large cover sheet 1can be removed by unscrewing the four fastening
screws at the bottom trough underside. The ignition transformer 2and the
solenoid valves 3are now accessible.
d) The small cover sheet 4can be removed after unscrewing the two fastening
screws at the bottom trough underside.
The connections of the thermal relay 5and residual heat indicator 6are
accessible.
3
2
4
5
1
1