Kuppersbusch GKS 324.0 User manual

GB
Glass Ceramic Gas Hobs
GKS 324.0
GKS 644.0

Technical Manual: H 2-120-59-01
Responsable: Kirchmair
Tel.: [phone]
Fax: [phone]
Date: 26.05.1998
Küppersbusch Vertriebsges.mbH
Kundendienst
Postfach 100132
45801 Gelsenkirchen

For internal use only
Service Manual GKS 324.0 + GKS 644.0 3
Contents
1. 1. General Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Built-In Glass Ceramic Gas Hob GKS 644.0 . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Built-In Glass Ceramic Gas Hob GKS 324.0 . . . . . . . . . . . . . . . . . . . . . . .5
1.3 GKS 644.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.4 GKS 324.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. Installation Conditions and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Notes regarding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 Installation Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 9
3. Technical Components (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . .10
3.1 GKS 644.0J / GKS 644.0M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2 GKS 324.0J / GKS 324.0M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4. Changing of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.1 Disassembly of the Hob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2 Changing of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5. Wiring Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.1 GKS 644.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.2 GKS 324.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6. Conversion to A Different Gas Type – Table of Injectors . . . . . . . . . . . . .15
6.1 Accessory Numbers of the Injector Conversion Kits . . . . . . . . . . . . . . . .15
6.2 Chaning the Main Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.3 Changing the Low Setting Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.4 Funtional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.5 Injector Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7. Gas Connection Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.1 Gas Connection Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.2 Table of Gas Connection Pressure Ranges . . . . . . . . . . . . . . . . . . . . . .17
7.3 Table of Permissible Gas Types and Pressures . . . . . . . . . . . . . . . . . . . .17
8. Power Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9. Further Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9.1 Notes regarding the Correct Pot Sizes . . . . . . . . . . . . . . . . . . . . . . . . . .19

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4 Service Manual GKS 324.0 + GKS 644.0
1. General Technical Data
Features: ”Hardline” design
Built-in glass ceramic gas hob with 4
cooking zones:
• low-emission gas burners, integrated in
the glass ceramic surface
• 1 high speed cooking zone 2.9 kW
• 2 standard cooking zones 1.9 kW, each
• 1 simmering zone 0.9 kW
Full safety.
Electric one-hand spark ignition.
Technical data:
• Gas connection 7.6 kW
• Electric connection 0.1 kW
• Appliance dimensions:
W x D approx. 589 x 519 mm
installation height approx. 42 mm
• Recess dimensions:
W x D approx. 560 x 490 mm
Special accessories:
• LPG injector kit 50 mbar,
accessory no. 192
• gas connection 1/2”
1.1 Built-In Glass Ceramic Gas Hob GKS 644.0
GKS 644.0 M E natural gas
in metallic design (stainless steel look)
GKS 644.0 J E natural gas
in jet black design (black)
The new built-in glass ceramic gas hobs with open burners:
• Modern look thanks to ”hardline” design
• The burners integrated in the glass ceramic surface heat up less which results in a consider-
ably longer life.
• The scratch-resistant glass ceramic surface does not get hot. It is especially easy to clean as
food that might boil over cannot get burnt.
• The electric one-hand spark ignition and the high-precision regulation of the individual coo-
king zones offer maximum user convenience.
• The pot grids can be removed and put in the dishwasher for cleaning.
Note:
This hob can also be operated
with LPG.
An appropriate injector kit can be
supplied as special accessory.

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Service Manual GKS 324.0 + GKS 644.0 5
1.2 Built-In Glass Ceramic Gas Hob GKS 324.0
GKS 324.0 M E natural gas
in metallic design (stainless steel look)
GKS 324.0 J E natural gas
in jet black design (black)
Note:
This hob can also be operated
with LPG.
An appropriate injector kit can be
supplied as special accessory.
Features: ”Hardline” design
Built-in glass ceramic gas hob with 2
cooking zones:
• low-emission gas burners, integrated in
the glass ceramic surface
• 1 high speed cooking zone 1.9 kW
• 1 standard cooking zone 1.9 kW
Full safety.
Electric one-hand spark ignition.
Technical data:
• Gas connection 4.8 kW
• Electric connection 0.1 kW
• Appliance dimensions:
W x D approx. 294 x 519 mm
installation height approx. 42 mm
• Recess dimensions:
W x D approx. 265 x 490 mm
Special accessories:
• LPG injector kit 50 mbar,
accessory no. 190
• gas connection 1/2”

For internal use only
6 Service Manual GKS 324.0 + GKS 644.0
1Standard cooking zone
2Simmering zone
3High-speed cooking zone
4Standard cooking zone
5Pot grids
6Control for high-speed cooking
zone
7Control for left-hand top standard
cooking zone (1
8Control for simmering zone
9Control for right-hand bottom
standard cooking zone (4)
1Standard cooking zone
2High-speed cooking zone
3Pot grid
4Control for high-speed cooking
zone
5Control for standard cooking zone
1.3 Appliance Illustration GKS 644.0
1.4 Appliance Illustration GKS 324.0

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Service Manual GKS 324.0 + GKS 644.0 7
2. Installation Conditions and Assembly
2.1 Notes regarding Installation
• Make sure that the worktop is horizontally aligned and precisely cut out!
• The distances of the hob recess at the front, rear and lateral to the wall must be observed in
accordance with the dimension drawing. In the case of correct minimum distances, wall sealing
strips of solid wood can be used on the worktop behind the cooking zones. The lateral distance
to high cupboards should be at least 300 mm for technical reasons.
• There must be no cross strips below the worktop recess.They have to be cut to at least the
size of the worktop recess.
• In the case of fitted furniture the plastic covering or the varnish must be processed with heat-
resistant adhesive (100 °C).
• The minimum distance of fume exctractors and wall-cupboards above the cooking surface must
be 650 mm.
It is recommended to seal the cutting surface of the worktop recesses for built-in sinks and oven
hobs by water-resistant painting.
2.2 Assembly
KÜPPERSBUSCH built-in hobs can and may be exclusivley combined with KÜPPERSBUSCH
built-in ovens with appliance ventilation. Exception: model series EGS.The use of other brands
excludes any liability by KÜPPERSBUSCH. The granted test marks and approvals become void
in the case of disregarding of this instruction!
In the case of built-under ovens the gas connection bracket located centrally at the rear side
under the appliance has to be twisted to the left-hand or right-hand side.
For this purpose undo the union nut, twist the bracket and tighten the union nut again.
Check for gas tightness.

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8 Service Manual GKS 324.0 + GKS 644.0
2.3 Installation Dimensions
GKS 644.0GKS 324.0
*Appliance height
2.4 Installation
Make the worktop recess in accordance with the specified dimensions (see above drawing
”Installation dimensions”).
Always lift the hob at the sides and not at the front fasica!
Install sealing between cooking zone and worktop:
Prior to connecting the appliance to the power and gas supply install the sealing between coo-
king zone and worktop.To this end fasten the loosely attached, self-adhesive expanded rubber
gasket at the underside of the cooking zone frame starting at the rear middle. After the assembly
the gasket must fit as shown in the drawing below.
Prior to installation and after any disassembly the seal has to be checked for damage and cor-
rect seat and replaced, if required.
Additional sealing with silicon, etc. must not be provided as there is a risk that the coated work-
tops will be damaged when the hob is removed.
The built-in cubboard below the gas hob may be closed by means of an intermediate bottom as
air is supplied to the burner from the top through the knob opening.
1Glass ceramics
2Expanded rubber gasket
3Hob

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Service Manual GKS 324.0 + GKS 644.0 9
Fix the cooking zone:
After installation of the sealing position the cooking zone at the left-hand side of the worktop
recess, align and fasten.
The attached fastening brackets are inserted in the front and rear recesses at the underside of
the cooking hob and screwed down to the worktop (see drawing below).
In case several hobs are
installed next to each other
the minimum distances indi-
cated in the opposite dra-
wing have to be observed.
Top view
Detail

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10 Service Manual GKS 324.0 + GKS 644.0
3.Technical Components (Exploded View)
3.1 GKS 644.0J
GKS 644.0M

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Service Manual GKS 324.0 + GKS 644.0 11
3.2 GKS 324.0J
GKS 324.0M

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12 Service Manual GKS 324.0 + GKS 644.0
4. Changing of Components
4.1 Disassembly of the Hob
• To remove the glass surface, lift out the ribbed plates and burner lid.
• Remove the control knobs.
• Unscrew the circumferential fastening screws of the base trough.
• Then lift out the glass surface with the frame towards the top.
• Now all internal technical components are accessible.
4.2 Changing of Components
1. Ignition device
The ignition transformer is fastened on the left-hand side of the base trough by means of adhesi-
ve tape which is supplied with the ignition transformer.
The spark plugs are fastened from the underside of the burner head by means of 1 screw each.
To remove these spark plugs the gas supply line to the burner head must be loosened and the
burner head screwed off from the underside of the appliance. Disassemble the spark plug by lif-
ting the burner head.
The ignition switches are fastened at the gas tap by means of plastic brackets.
2.Thermoelectric safety pilot
The thermodetectors are fastened at the burner head by means of a union nut 13 mm SW and
at the gas tap by means of a screw 8 mm SW. For disassembly undo both screw connections
and remove the thermoelement.
In order to replace the solenoid inserts remove the thermoelement from the gas tap. Undo the
union nut 13 mm SW at the gas tap. Pull solenoid inserts out of the gas tap.
After reassembly carry out a leakage test.
3. Gas taps
In order to change the gas taps separate the ignition switch by force, remove the fastening
bracket of the gas tap by undoing 2 screws and lift the float rail by loosening the screws at the
underside of the appliance. After reassembly carry out a leakage test.

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Service Manual GKS 324.0 + GKS 644.0 13
5.Wiring Plans
5.1 GKS 644.0
Trough
Ignition device

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14 Service Manual GKS 324.0 + GKS 644.0
5.2 GKS 324.0
Trough
Ignition device

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Service Manual GKS 324.0 + GKS 644.0 15
6. Conversion to a Different Gas Type
The appliance has been factory-set to natural gas G20, 2H, 2E, 2E+.
All appliances marked with G20 are to be operated in the Wobbe index range (Wo) from 11.3
kWh/m3 to 15.2 kWh/m3 without changing the setting.
It the setting is changed, the new setting has to be marked.
6.1 Accessory Numbers of the Injector Conversion Kits
Appliance
Gas type GKS 324.0 GKS 644.0
Natural gas H, E, E+
20 mbar
Pressure pair Natural gas
20/25 mbar
Natural gas LL
20 mbar
LPG Butane/Propane
50 mbar
LPG Butane/Propane
28-30 mbar
Pressure pair Butane/Propane
28-30 mbar / 37 mbar
Factory setting Factory setting
ACC. NO. 186 ACC. NO. 186
ACC. NO. 190* ACC. NO. 192*
ACC. NO. 189 ACC. NO. 191
*Includes burner lid for replacement.
6.2 Changing the Main Injectors
• Close the gas tap!
• Remove the burner lid.
• Disassemble the injectors by means of a 7 mm wrench.
• Install new main injectors for the respective gas type in thh corresponding burner housings.
• Reassemble the burner lid; if required, use the newly supplied burner lids for this purpose (see
table above).

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16 Service Manual GKS 324.0 + GKS 644.0
6.3 Changing the Low Setting Injectors
• Close the gas tap!
• Disassemble the hob from the worktop.
• Pull off the control knobs.
• Undo the screws at the housing side and remove the glass ceramic surface.
• Disassemble the low setting injectors located on the right side of the gas tap axis by means of
a suitable screwdriver.
• Insert new low setting injectors for the corresponding gas type in the respective taps.
• Reassemble the hob in the opposite sequence and re-install. Make sure that the sealing strip
at the underside fully fits.
• The air supply to the burner cannot be adjusted.
6.4 Functional Testing
After the appliance has been completely re-assembled a functional testing is to be perfor-
med!
Put the appliance into service inaccordance with these operating instructions.
Check the appliance for gas leakage (see DVGW working sheet G600) ((DVGW
TRGI/1986)/TRF 1988).
Check burners for overignition and regular flame aspect (also in low setting).
Provide respective nameplates for the newly set gas type in an appropriate location.
6.5 Injector Diameter
Injector marking main injector/low setting injector
Gas type
High-speed burner Standard burner Simmering burner
Natural gas H, E, E+
20 mbar
Pressure pair Natural gas
20/25 mbar
Natural gas LL
20 mbar
LPG Butane/Propane
50 mbar
LPG Butane/Propane
28-30 mbar
Pressure pair Butane/Propane
28-30 mbar / 37 mbar
138/52 102/43 78/34
145/52 112/43 83/34
80/30 63/25 46/23
92/39 71/29 54/24

Gas type Pn/ mbar Pmin / mbar Pmax / mbar
Natural gas 20 17 25
25 20 30
Pressure pair 20 17 25
Natural gas 25 17 30
LPG 28-30 25 35
50 42,5 57,5
Pressure pair 28-30 20 35
LPG 37 25 45
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Service Manual GKS 324.0 + GKS 644.0 17
7. Gas Connection Values
7.1 Gas Connection Values
7.2 Table of Gas Connection Pressure Ranges
7.3 Table of Permissible GasTypes and Pressures
Rated heat load / kW
(Flow)
Gas type
High-speed burner Standard burner Simmering burner
Natural gas H, E, E+
20 mbar
Pressure pair Natural gas
20/25 mbar
Natural gas LL
20 mbar
LPG Butane/Propane
50 mbar
LPG Butane/Propane
28-30 mbar
Pressure pair Butane/Propane
28-30 mbar / 37 mbar
3.20 1.65 1.00
(5.1 l min-1)(2.6 l min-1)(1.6 l min-1)
3.00 1.65 1.10
(5.5 l min-1)(3.0 l min-1)(2.0 l min-1)
3.00 1.65 1.10
(5.5 l min-1)(3.0 l min-1)(2.0 l min-1)
3.00 1.65 1.10
(5.5 l min-1)(3.0 l min-1)(2.0 l min-1)
The flow data refer to the
combustion value and have
been calculated with the test
gases G20 (natural gas H, E)
G25 (natural gas LL) and
G30 (LPG).
The appliance has been
checked in accordance with
the VDE and DVGW guideli-
nes as well as the EC guideli-
ne for gas appliances
(90/396/EWG) and EN 30.
The settings for this applian-
ce are provided on an infor-
mation sign (or on the name-
plate).
Country Cat. Natural gas LPG
(abbreviation acc.
to ISO)
Germany (DE) I2ELL E (G20) 20 mbar Butane/Propane (G30, 3B/P)
I3B/P LL (G25) 20 mbar 50 mbar
Austria (AT) I2H H (G20) 20 mbar
Butane/Propane (G30, 3B/P)
I3B/P 50 mbar
Italy (IT) I2E E (G20) 20 mbar Pressure pair Putane/Propane
I3+ (G30/31) 28-30/37 mbar
Portugal (PT) I2H H (G20) 20 mbar Pressure pair Putane/Propane
Spain (ES) I3+ (G30/31) 28-30/37 mbar
United Kingdom (GB)
Netherlands (NL) I2L L (G25) 25 mbar Butane/Propane (G30, 3B/P)
I3B/P 28-30 mbar
Belgium (BE) I2E+
Pressure pair (G20/25) Pressure pair Putane/Propane
France (FR) I3+ 20/25 mbar (G30/31) 28-30/37 mbar
Luxembourg (LU) I2E E (G20) 20 mbar Butane/Propane (G30, 3B/P)
I3B/P 28-30 mbar
Greece (GR) I3B/P Butane/propane (G30, 3B/P)
Cyprus (CY) 28-30 mbar

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18 Service Manual GKS 324.0 + GKS 644.0
8. Power Table
Power in kW
Country Cat. Pressure (mbar) Simmering burner Standard burner Standard burner High-speed burner
DE I2E 20 1.00 1.65 1.65 3.20
I3B/P 50 0.90 1.60 1.60 2.65
BE I2E+ 20 0.95 1.50 1.50 2.65
I3+ 28-30/37 1.00 1.70 1.70 2.75
I3+ 50/67 0.8/0.95 1.4/1.6 1.4/1.6 2.45/2.85
IT I2E 20 1.00 1.65 1.65 3.20
I3+ 28-30/37 1.00 1.70 1.70 2.75
FR I2E+ 20 1.00 1.65 1.65 3.20
I3+ 28-30/37 1.00 1.70 1.70 2.75
I3B/P 30 1.00 1.70 1.70 2.75
LU I2E 20 1.00 1.65 1.65 3.20
I3B/P 30 1.00 1.70 1.70 2.75
AT I2H 20 1.00 1.65 1.65 3.20
I3B/P 50 50 0.90 1.60 1.60 2.65
NL I2L 25 1.10 1.65 1.65 3.00
I3B/P 30 1.00 1.70 1.70 2.75
ES I2H 20 1.00 1.65 1.65 3.20
I3P 37 1.00 1.60 1.60 2.70
I3+ 28-30/37 1.00 1.70 1.70 2.75
GR I3B/P 30 1.00 1.70 1.70 2.75
GB I2H 20 1.00 1.65 1.65 3.20
I3P 37 1.00 1.60 1.60 2.70
I3+ 28-30/37 1.00 1.70 1.70 2.75
Cy I3B/P 30 1.00 1.70 1.70 2.75
PT I2H 20 1.00 1.65 1.65 3.20
I3P 37 1.00 1.60 1.60 2.70
I3+ 28-30/37 1.00 1.70 1.70 2.75

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Service Manual GKS 324.0 + GKS 644.0 19
9. Further Technical Information
9.1 Notes regarding the Correct Pot Sizes
Using the correct pot sizes saves cooking time and energy.
Select the pot diameter in accordance with the burner size.
• Recommened pot diatmeters:
• High-speed cooking zone 22 - 24 cm
• Standard cooking zone 18 - 20 cm
• Simmering zone (only GKS 644.0) 16 - 18 cm
• For gas-technical reasons it is not allowed to use disks on the burners.
• Using pots with appropriate diameters prevents the pots from getting to near to the control
knobs which could result in heating up or damage of the knobs.
The ribbed plates and burner lids can be cleaned in the dishwasher. After drying provide them
with a thin coating of resin, acid-free grease or oil in order to avoid corrosion.
The built-in gas hobs manufactured until September 1997 have been equipped with thermoele-
ments with a holding/releasing time of approx. 3 seconds. Due to temporary lifting off of the fla-
mes (especially at the high-speed burner) the thermoelement was partially not heated which
resulted in a release of the safety pilot.
In case of problems ”Flame goes out when on high setting” a thermoelement with a longer time-
delay must be installed.This thermoelement is to be ordered under the already published acces-
sory number. In case of problems ”Flame goes out when on low setting” the low setting screw at
the gas tap must be slightly turned out.This is due to a dimensional tolerance of the low setting
injectors.