Induction
Induction
Induction
TECHNICAL EDUCATION
INDUCTION COOKTOP
Models: Kitchen Aid KICU500X KICU509X KICU569X Jenn-Air JIC4430X JIC4536X Whirlpool GIC3051X
FORWARD
This Induction Cooktop Job Aid (W10346831), provides the In-Home Service Professional with information on the installation, operation, and service of the Induction Cooktop. For specific information on the model being serviced, refer to the Use and Care Guide, or Wiring Diagram provided with the cooktop. The Wiring Diagrams used in this Job Aid are typical and should be used for training purposes only. Always use the Wiring Diagram supplied with the product when servicing the cooktop.
WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on our products by anyone other than authorized In-Home Service Professionals.
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GENERAL ............................................................................................................................... 1-1 Cooktop Safety................................................................................................................... 1-1 Model & Serial Number Designations................................................................................. 1-2 Model & Serial Number Label And Tech Sheet Locations. .................................................. 1-3 Specifications...................................................................................................................... 1-4 Induction Cooktop Components. ......................................................................................... 1-6 INSTALLATION INFORMATION ............................................................................................ 2-1 Installation Instructions....................................................................................................... 2-1 PRODUCT OPERATION ....................................................................................................... 3-1 Theory of Induction Cooking............................................................................................... 3-1 Advantages Of Induction Cooking...................................................................................... 3-3 Faster Cycle Time............................................................................................................... 3-2 High Thermal Efficiency And Increased Profitability........................................................... 3-2 Cool Stove Top. ................................................................................................................... 3-3 Environmentally Sound....................................................................................................... 3-3 User-Friendly. ...................................................................................................................... 3-4 Pinpoint Accuracy............................................................................................................... 3-4 Maximum Repeatability. ...................................................................................................... 3-4 Noises that are Common to the Normal Operation of Induction Cooktops......................... 3-4 Overview of Induction Cookware........................................................................................ 3-5 Pots and Pans good for Induction Cooking. ........................................................................ 3-5 Pots and Pans not good for Induction Cooking. .................................................................. 3-5 COMPONENT ACCESS ......................................................................................................... 4-1 Component Locations......................................................................................................... 4-1 Removing The Cooktop Glass............................................................................................ 4-2 Removing the User Interface.............................................................................................. 4-3 Removing An Induction Element......................................................................................... 4-4 Removing a Cooling Fan.................................................................................................... 4-5 Removing, Power Control Board, Fuses and EMI Board. ................................................... 4-6 Terminal Block, Capacitor, Shunt Clip and Thermofuses.................................................... 4-7 COMPONENT TESTING ........................................................................................................ 5-1 Component Testing Chart................................................................................................... 5-2 Coil Burner.......................................................................................................................... 5-3 Coil Sensor (S1). ................................................................................................................. 5-3 Strip Circuit. ......................................................................................................................... 5-4 TROUBLESHOOTING ............................................................................................................ 6-1 Failure/Effor Codes............................................................................................................. 6-2 Type 1................................................................................................................................. 6-3 Type 2................................................................................................................................. 6-3 Type 3................................................................................................................................. 6-3 Control Board Indicator Light.............................................................................................. 6-7 WIRING DIAGRAM ................................................................................................................ 7-1 30 Cooktop. ........................................................................................................................ 7-1
TABLE OF CONTENTS
Page
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NOTES
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GENERAL
Cooktop Safety
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word DANGER or WARNING. These words mean:
DANGER WARNING
You can be killed or seriously injured if you don't immediately follow instructions. You can be killed or seriously injured if you don't follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed.
1-1
SERIAL NUMBER DP DIVISION RESPONSIBILITY DP = CLEVELAND YEAR OF PRODUCTION 0 = 2010 WEEK OF PRODUCTION 24 = 24TH WEEK PRODUCT SEQUENCE NUMBER
0 24
01234
1-2
The Model/Serial Number label and Tech Sheet locations are shown below.
1-3
Specifications
New Model Color Cooktop Width Cooktop Material Number of Elements Left Front Type Left Front Power Left Rear Type Left Rear Power Right Front Type Right Front Power Right Rear Type Right Rear Power Central Front Type Central Rear Power Control Type Control Location Knob Features KICU500X BL/SS (BL has beveled edge) 30" Ceran 4 6" Single 1800 W 9" Single (10" Graphic) 3200 W 7" Single 2500 W 8" Single (9" Graphic) 3000 W KICU509X BL/SS (BL has beveled edge) 30" Ceran 4 7" Bridge 2500 W 7" Bridge 10/8" Dual (11/9" Graphic) 3700 W KICU569X BL/SS (BL has beveled edge) 36" Ceran 5 7" Bridge 2500 W 7" Bridge 7" Bridge 2500 W 7" Bridge 11/8" Dual (12/9" Graphic) 5000 W Power Boost G8 touch Cluster in Central Front N/A One Timer Boosters on each element (except 7" bridge) Quick Function Key: Melting Quick Function Key: Simmering Control Lockout Pause Function Control Lockout All. Extruded frame
6" Single 1800 W G8 Touch G8 Touch Center Front Cluster in Right Front N/A N/A One Timer One Timer Booster on All Elements Boosters on each element Pause Function (except 7" bridge) Control Lockout Quick Function Key: Melting Quick Function Key: Melting Quick Function Key: Quick Function Key: Simmering Simmering Control Lockout Pause Function Control Lockout All. Extruded frame
1-4
Specifications (continued)
New Model Color Cooktop Width Cooktop Material Number of Elements Left Front Type Left Front Power Left Rear Type Left Rear Power Right Front Type Right Front Power Right Rear Type Right Rear Power Central Front Type Central Rear Power Control Type Control Location Knob Features JIC4430X 30" Ceran 4 7" Bridge 2500 W 7" Bridge 10/8" Dual (11/9" Graphic) 3700 W JIC4536X B/S (Black has beveled edge) 36" Ceran 5 7" Bridge 2500 W 7" Bridge 7" Bridge 2500 W 7" Bridge 11/8" Dual (12/9" Graphic) 5000 W Power Boost G8 Touch Cluster in Right Front N/A Timers for all elements Boosters on each element (except 7" bridge) 6th Sense Control Lockout Pause Function Multi Function Key: Simmer, Melting, Keeping Warm All. Extruded frame GIC1306X B 30" Ceran 4 6" Single 1800 W 9" Single (10" Graphic) 3200 W 7" Single 2500 W 8" Single (9" Graphic) 3000 W
6" Single 1800 W G8 Touch Cluster in Right Front N/A Timers for all elements Boosters on each element (except 7" bridge) 6th Sense Control Lockout Pause Function Multi Function Key: Simmer, Melting, Keeping Warm All. Extruded frame
G8 Touch Center Front N/A One Timer Booster on One Element Control Lockout Pause Function Quick Function Key: Simmering
1-5
L K M
J I H G O P Q R N
F E D
S C B T U V
A W
A. Cooktop base B. Power control board right C. Power control board left D. Plastic housing E. User interface harness F. Fan
G. User interface H. Aluminum plate I. Coil (6" [15.2 cm]) J. Coil (9" [22.9 cm]) K. Mounting bracket L. Mounting clips (4)
M. Assembly glass N. Frame O. Coil (8" [20.3 cm]) P. Coil (6" [15.2 cm]) Q. EMI - Filter board R. Fuse
S. Harness fixing T. Fan U. User Interface harness V. Thermofuse harness (250F [121C]) - one on yellow cable and one on black cable W. Power cord
1-6
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. Disconnect power or unplug the cooktop. NOTE: Kit Part Number W10310006 is required for installing the cooktop into a marble countertop. See the Assistance or Service section of the Use and Care Guide for information on ordering. To Install Brackets into Marble Countertop: 2. Clean the brackets and cooktop cutout of any dust and debris.
5. Position brackets in the center of the vertical centerline and align the upper edge of the brackets so that they are flush with the countertop.
A B
A. Bracket B. Screw
6. Push the brackets firmly onto each side of the cooktop cutout and wait 1-hour for adhesive to dry.
3. Measure the center line of the vertical sides of the cooktop cutout..
Center line
2-1
WARNING
Install Cooktop
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. Disconnect power or unplug the cooktop. 2. Measure the center line of the vertical sides of the cooktop cutout.
Center line
1. Using 2 or more people, lower the cook top into the cutout making sure the clips on each side of the cooktop line up with the brackets in the cutout.
A. Clip 2. Push down on cooktop to snap the cook top clips onto the brackets installed in the cutout.
A
3. Position brackets in the center of the vertical centerline and align the upper edge of the brackets so that they are flush with the countertop.
2-2
WARNING
4-Wire Cable from Home Power Supply IMPORTANT: Use the 4-wire cable from home power supply in the U.S. where local codes do not allow grounding through neutral, New Branch circuit installations (1996 NEC), mobile homes and recreational vehicles, new construction, and in Canada.
A B E F G
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. This cooktop is manufactured with a frameconnected, green (or bare) ground wire. 1. Disconnect power. 2. Remove junction box cover if it is present. 3. Connect the flexible cable conduit from the cooktop to the junction box using a UL listed or CSA approved conduit connector.
A
C D
H I
A. Cable from home power supply B. Red wires C. Green (or bare) ground wires D. 3-Wire cable from cooktop E. Junction box
F. White wire (from home power supply) G. UL listed wire connector H. Black wires I. UL listed or CSA approved conduit connector with wire bushing
4. Tighten screws on conduit connector if present. 5. See Electrical Connection Options Chart to complete installation for your type of electrical connection. Make Electrical Connection If your home has: Go to Section: 4-Wire Cable from 4-wire Home Power Supply
" (1.3 cm)
1. Connect the 2 red wires (B) together using a UL listed wire connector. 2. Connect the green (or bare) ground wire (C) from the cooktop cable to the green (or bare) ground wire (in the junction box) us ing a UL listed wire connector. 3. Put a UL listed wire connector on the end of the white wire (F). NOTE: Do not connect the green (or bare) ground wire to the neutral (white) wire in the junction box. 4. Connect the 2 black wires (H) together us ing a UL listed wire connector. 5. Install junction box cover.
3-wire
" (1.3 cm)
2-3
A B
E F G H
C D
A. Cable from home power supply B. Red wires C. Green (or bare) ground wire from cooktop D. 3-wire cable (from cooktop) E. Junction box
F. White wire (from home power supply) G. UL listed wire connector H. Black wires I. UL listed or CSA approved conduit connector with wire bushing
1. Connect the 2 red wires (B) together using a UL listed wire connector. 2. Connect the green (or bare) cooktop cable wire (C) to the white (neutral) wire (F) in the junction box using a UL listed wire connector. 3. Connect the 2 black wires (H) together using a UL listed wire connector. 4. Install junction box cover.
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PRODUCT OPERATION
Theory Of Induction Cooking
Understanding The Makeup Of A Magnet Metals are available to us in many different shapes and make-up. Copper, Cast Iron, Tin, Aluminum, Stainless steel and so on. They are all made up of positive and negatively charged electrons that distinguish metals from each other. In some materials it is possible for the positive and negatively charged electrons to end up more or less aligned. These electrons tend to separate into distinct areas of the material, called "domains". So, in some metals, all the positively charged electrons are grouped together and the negatively charged electrons are in another domain, separated from the each other. This is the makeup of a magnet. Because the metal has defined positive and negative domains, it is possible to make the two metals attract each other. This is done by using the positively charged electrons of one metal and placing them in contact with the negatively charged electrons of another piece of metal. Let's remember, at one time in science class, we were taught that opposites attract. On the other hand, if you try to stick the metals together by using the positively charged side of one metal and the positive side of a second piece of metal, they will resist each other and make it impossible to put them together. Try it with two magnets, in one direction the magnets stick together because the negative electrons of one magnet are attracted to the positive charged electrons in the other magnet. But if you try to put the magnets together with the positive side of one magnet and the positive side of another magnet, it cant be done. This is the theory behind induction cooking. We need to use the electrons in metals to create movement, friction and resistance causing heat. We talk about using ferromagnetic pots and pans to cook with induction. What is ferromagnetic metal? Metals with randomly arranged positive and negatively charged electrons in no particular order (as shown below), providing the characteristic of a magnet but have no net magnetic ability. Because of that make-up, a ferromagnetic metal will attract to both the positive and the negative sides of a magnetic, meaning a magnet will attract or stick to ferromagnetic metal, but the ferromagnetic material will not attract other metals by itself. If we provide a stimulus to ferromagnetic metals, and arrange the electrons so that they form domains, ferromagnetic pots and pans have the potential to work very well within a magnetic field. Let's look at the set-up. The system will include a glass cooktop, Induction coils, a frequency converter, an insulator between the coils and glass cooktop and a ferromagnetic piece of cookware. You can see in the ferromagnetic pan the positive and negative electrons move around freely. By providing a very strong electrical stimulus into the system (240 VAC), we can arrange the electrons in the pan to have the characteristics of a magnet. Remember, opposites attract and by providing voltage, the positive and negative charges in the induction coil create a tremendous magnetic field.
Figure 1 By providing a very strong electrical stimulus into the system (240 VAC), we can arrange the electrons in the pan to have the characteristics of a magnet.
3-1
20 THOUSAND times per second. What do you think the electrons in the pan are doing? (creating heat very quickly). Induction cooking and the movement created in the cookware performs better at the lower frequency of 20KHz. Changing the frequency upwards to 60KHz reduces the efficiency of induction operation. This is how we regulate the performance between a high, medium and low setting at the cooktop. By speeding up the alternating current in the induction coil, the electrons in the pan will move very quickly and provide instant heat to cook food. This magnetic field that we produced works in the 2-3cm of the bottom of the cookware, creating heat in just the bottom of the cookware. You always see the dollar bill trick where they put a dollar bill between the cooktop glass and the pan being heated, well now you know how it works. The paper money does not contain the electrons (like in metal) to stimulate and will not provide any heat. Same thing with the glass cooktop, the glass doesn't get hot (except from the heat provided from the hot cookware) because it doesn't contain the material makeup that the metals do to stimulate movement and friction in the glass.
Remember, opposites attract and by providing voltage, the positive and negative charges in the induction coil create a tremendous magnetic field. The electrical circuit from our house supply is 240 VAC and 60 Hz. Meaning the positive and negative electrons, of a sine wave, shift back and forth 60 times a second. Now how do we make this movement happen quicker? We use a frequency converter to step up the 60 Hz frequency from our home power supply to between 20 and 60 THOUSAND Hz . Meaning now the positive and negative electrons in the coil alternate back and forth
Figure 2
The range of the frequency converter is 20 to 60 kHz. Induction cooking reacts better with a lower frequency, so 20 kHz produces the most energy.
60 KHz is not as efficient an operation as 20 KHz, so as the frequency rises the efficiency of the induction operation decreases.
3-2
Cooler kitchens: Of course the cooking vessel and the food itself will radiate some of their heat into the cooking areabut compared to gas or other forms of electrically powered cooking, induction makes for a much cooler kitchen. Cool stove top: The stove top itself barely gets warm except directly under the pan (and that only from such heat as the pan bottom transfers). No more burned fingers, no more baked-on spills, no more danger with children around. Environmentally Sound Induction heating is a clean, non-polluting process. It produces much less smoke or waste heat to alter the surrounding environment. It is an obvious but still very important fact that induction cooktops are powered by electricity. Not every home actually has a gas pipeline available to itfor many, the only gas option is propane, with the huge propane tank and regular truck visits. But everyone has clean, silent, ever-present electricity. Burning gas has byproducts that are vaporized, but eventually condense on a surface somewhere in the vicinity of the cooktop. Electrical cooking of any kind eliminates such byproducts.
3-3
User-Friendly Working conditions are improved with the absence of smoke and heat produced by heating equipment. You can touch the outer casing without getting burned. If the electricity supply to your home is interrupted, you will be unable to cook; gas supplies can be interrupted, too, but such interruptions are normally somewhat less likely than electricity interruptions. If the electricity where you are frequently goes out for hours at a time, the loss of cooking ability may be an issue for you. Pinpoint Accuracy Power input is precisely controlled to achieve the exact temperature required for heating. Heat is developed directly inside the pot or kettle or cooktop. With gas, when you adjust the element setting, the energy flow adjusts instantly. But with induction cooking the heat level is every bit as instantaneous, and as exact, as with gas, yet with none of the many drawbacks of gas. Induction elements can be adjusted to increments as fine as the cooker maker cares to supply, just like gas, andagain very important to serious cookssuch elements can run at as low a cooking-heat level as wanted for gentle simmering and melting (something even gas is not always good at). Moreover, gasinductions only real competitionhas special risks of its own, not all of which are as well known as they perhaps should be. While the risk of a gas flame, even a pilot light, blowing out and allowing gas to escape into the house is relatively small, it does exist. Maximum Repeatability With modern induction heating equipment, the heating pattern is always the same for a given set-up, cycle after cycle and day after day.
Noises that are Common to the Normal Operation of Induction Cooktops Induction heating technology is based on the capacity that certain metal materials have to vibrate when they are subject to high frequency waves. Under certain circumstances, these vibrations may make certain sounds of a low volume due to the following: Low tone noise, similar to that of a transformer: It occurs when cooking at high power levels. It is due to the enormous amount of energy that the cook top is supplying to the container. It disap pears or attenuates as the power level used is reduced. Soft whistling: They occur when the container is empty. They disappear or weaken when water or the food to be cooked is added. Crackling: This kind of noise may occur in containers composed of layers of different materials. The noise is due to the vibration in the separation zones between the various layers of material. This noise is proper to the container. It can change ac cording to the quantity and type of food that is cooked. Sharp whistling (beeps): They occur basically with containers composed of different layers of materials when two adjacent cooking zones are started up at the same time and at maximum power. They disappear or weaken when the power is reduced. Intermittent clicks: They are noises caused by the commutations of the control electronics, above all when low power levels are selected. Fan noise: In order to control the correct operation of the electronics, they must work at a controlled temperature. To achieve this, the cooktop is equipped with fans that work to cool the cooktop whenever it is in operation. The fan can also continue operating when the cooktop is
3-4
turned off after being used if the detected temperature continues to be high. NOTE: All these noises are normal and inherent to induction technology, and they are not a sign of any breakdown. The noises that occur with greatest frequency are those with containers that have a sandwich type base.
3-5
NOTES
3-6
COMPONENT ACCESS
Component Locations
Coil Sensor (1 For Each Element) Left Rear Induction Element Assembly Right Rear Induction Element Assembly
User Interface
Burner Box
4-1
WARNING
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
1. Unplug cooktop or disconnect power. 2. Remove the cooktop from its mounting location, (see Installation Instructions in Section 2). Position the cooktop so that you can access the bracket screws below the cooktop glass. 3. Remove the (6) T-20 Torx head screws from the front, and side ceramic glass brackets. 4. Lift and remove the ceramic glass from the cooktop base
Cooktop Base
4-2
WARNING
3. Gently pull up on edges of User Interface board to release holder tabs, raise the user interface, and remove the board from the tab locations, see figure 1.
User Interface (back side) Holder Tabs
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. Unplug cooktop or disconnect power. 2. Remove the cooktop glass from the cooktop (see page 4-2 for the procedure).
Tab Locations
Figure 1 4. Remove the two edge connectors from the top of the User Interface.
Holder Tab
Figure 2 5. When replacing the User Interface, be sure to engage the holder tabs into the tab location positions, see figure 1. Holder tabs are held in place by the pressure of the glass top and isolated by the springs surrounding each tab, see figure 2.
User Interface
4-3
WARNING
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. Unplug cooktop or disconnect power. 2. Remove the cooktop glass from the cooktop (see page 4-2 for the procedure).
Left Rear Induction 9 inch Element Right Rear Induction 8 inch Element
Figure 2
Connector Screws
U connectors
Sensor Connector
Figure 3 4. Slip the U connector out. Disconnect the sensor connection from the P.C. board, and remove the element, see figure 3.
Element Base
Openings
Figure 1 3. The elements are connected to the right and left power boards by means of two centrally located openings in the aluminum cover plate, see figure 2. To remove an element, loosen the connector screw for each of the 2 leads on the element.
Figure 4 5. The elements are located on the cooktop by a series of tabs that engage corresponding openings in the element base. Remove the element by lifting the element up off of the tabs, see figure 4.
4-4
WARNING
5. a) Disconnect the 3-wire fan connector from power control board, see figure 3. b) Remove two screws from the cooling fan and lift the fan from the power control board, see figure 4.
Left Cooling Fan Right Cooling Fan
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. 3. 4. Unplug cooktop or disconnect power. Remove the cooktop glass. Remove elements. Remove 11 screws that mount the aluminum plate, and 1 ground screw. Be sure to replace the ground screw when reassembling, see figure 1.
1 Ground Screw Left Fan Connector
Figure 3
2 Screws
Figure 4
Figure 1
Figure 2
4-5
WARNING
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. To remove a Power Control board: 1. a) Unplug cooktop or disconnect power. b) Remove the cooktop from installation. c) Remove cooktop glass. d) Remove the aluminum plate. e) Disconnect the wires from the power control board terminals. f) Remove 2 screws. g) Slide the board from under the two tabs on the interior side of the board and lift the power control board from its holder, see figure 1. (left board shown).
To replace the fuses on the Filter (EMI) board: 1. a) Unplug cooktop or disconnect power. b) Remove the cooktop from installation. c) Remove cooktop glass. d) Remove the elements. e) Remove the aluminum plate. f) Remove and replace fuses as needed, see figure 2.
Fuses
Figure 2 To remove the EMI (Filter) Board: 1. a) Unplug cooktop or disconnect power. b) Remove the cooktop from installation. c) Remove cooktop glass. d) Remove the elements. e) Remove the aluminum plate. f) Disconnect the wires from the EMI (filter) board terminals, see figure 1. g) Remove 5 screws. h) Lift the EMI (filter) board from its holder, see figure 3.
Disconnect Wires
4-6
WARNING
Thermofuse
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. To access the terminal block, shunt clip and thermofuses: 1. Unplug cooktop or disconnect power. a) Remove the cooktop from installation. b) Remove cooktop glass. c) Remove the elements d) Remove screws and lift the aluminum plate. e) The terminal block, shunt clip and thermofuses are now accessible, see figure 1.
Electrical connection to EMI (Filter) Board
Terminal Block
Thermofuses Capacitor
Shunt
Figure 1
4-7
NOTES
4-8
COMPONENT TESTING
Before testing any of the components, perform the following checks: The most common cause for control failure is corrosion on connectors. Therefore, disconnecting and reconnecting wires will be necessary throughout test procedures. All tests/checks should be made with a VOM or DVM having a sensitivity of 20,000 ohms-per-volt DC, or greater. Check all connections before replacing components, looking for broken or loose wires, failed terminals, or wires not pressed into connectors far enough. Resistance checks must be made with wiring harness or connectors disconnected.
DANGER
WARNING
Electrical Shock Hazard Only authorized technicians should perform diagnostic voltage measurements. After performing voltage measurements, disconnect power before servicing. Failure to follow these instructions can result in death or electrical shock.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
5-1
WARNING
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Component Testing Chart
L o c at i o n o n t h e c o o k t o p EM I filt er b oard Power control board (PC) from Filter (EMI) Board Left and right Power control board (PC) to blower fan Left and right Power control board (PC) to coil sensor Left and right Power control board (PC) to the User Interface Ch ec k p o i n t s J1 - (L) (N) J1 - (L) (N) J205 - (00) - (22) J205 - (00) - (60) J604 - (1) - (2) J605 - (1) - (2) J806 - 99 J806 - 00 J806 - 88 J806 - 22 [0VDC, Neutral pin]) J806 - 44 J806 - 99 Resul t s Vo l t ag e From 208VAC to 240 VAC - 60Hz From 208VAC to 240 VAC - 60Hz From 0VDC to 12VDC +5VDC 0V +10.5V 0VDC From 0VDC to 12VDC
To Enter Manual Configuration Mode: NOTE: This menu is accessible only during the first minutes after the cooktop is plugged in. 1. Remove the key-lock functionality by pressing the Control Lock button. 2. Press the following keys sequentially (a beep will sound after each key press): Timer -, Timer +, Timer-, Timer+, Control Lock. After the key stroke combination is pressed, a CO will appear on the display. 3. Press the Control Lock button. A OO will appear on the display. 4. Configure the cooktop by choosing one of the following numbers, see chart. 5. Press the Control Lock button to confirm the configuration. The configuration will then be downloaded into the cooktop. This process will last a few seconds. The configuration number chosen will blink on the display. 6. The cooktop is ready to use.
Use the Timer buttons to scroll between the numbers on the display, moving sequentially and beginning at 00. The Timer+ button will increase the number by 1, and the Timer- will decrease the number by one. Reconfiguration Chart
Configuration Number Cooktop Model
5-2
The resistance of the coil differs according to the size of the coil.
Coil Sensor
This sensor reduces power output from the burner before it completely fails. Coil Sensor: begins at 400F (210C) to gradually reduce the power output of the element, reduces the power output down to zero power at 440F (226C), sensor opens and completely fails at 482F (250C).
5-3
This is a simplified strip circuit of the operation of a typical burner. You can see what components are working during the operation of a burner.
5-4
TROUBLESHOOTING
Before testing any of the components, perform the following checks: The most common cause for control failure is corrosion on connectors. Therefore, disconnecting and reconnecting wires will be necessary throughout test procedures. All tests/checks should be made with a VOM or DVM having a sensitivity of 20,000 ohms-per-volt DC, or greater.
Check all connections before replacing components, looking for broken or loose wires, failed terminals, or wires not pressed into connectors far enough. Resistance checks must be made with power cord unplugged from outlet, and with wiring harness or connectors disconnected.
DANGER
WARNING
Electrical Shock Hazard Only authorized technicians should perform diagnostic voltage measurements. After performing voltage measurements, disconnect power before servicing. Failure to follow these instructions can result in death or electrical shock.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
6-1
6-2
Troubleshooting (continued)
Failure Codes
Failure/Error Code Types There are 3 types of failures associated with the cooktop. The description of these failures and the impact they will have on the rest of the cooktop are listed in the following: Type 1
This is showing a TYPE 1 failure code. Only one burner affected. In this case Burner (coil) sensor is not working. Only the left rear burner is affected. All other burners can be used. Type 2
Type 2 failure codes come from the control board, there could be some exceptions. This failure affects both burners associated with that power control board. Customer can use the burners on the other power control board. Type 3
Type 3 failure codes come from the user interface. This failure disables the entire cooktop, all burners are switched off by the user interface.
6-3
Troubleshooting (continued)
WARNING
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
Failure/Error Codes
Service Code Shown on Display F-12 Failure Description Coil under current Type of Failure Type 1 1. Repair Suggestions Check for the correct connections at T2A - T2B or T3A - T3B on the power control board (whichever connection the burner is plugged into) by completing the following steps. 2. Disconnect power. 3. Replace the burner coil. 4. Replace all parts and panels before operating. 5. Reconnect power. 6. Reconfigure the cooktop following the directions in Manual Configuration Mode. 7. Check for proper operation. 8. If everything operates, end service. If error code still appears, disconnect power and go to Step 9. 9. Replace the power control board. 10. Replace all parts and panels before operating. 11. Reconnect power. 12. Reconfigure the cooktop following the directions in Manual Configuration Mode. 1. 2. 3. 4. 5. 6. F-25 Stuck fan on power control board (Right or left side fan, depending on which side of the display the failure is on.) Type 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Disconnect power. Replace the power control board. Replace all parts and panels before operating. Reconnect power. Reconfigure the cooktop following the directions in Manual Configuration Mode. If the issue is not fixed, contact a qualified electrician to verify the frequency of the home power supply is 60 Hz. Disconnect power. Check that the cooling fan connector is firmly plugged in. Replace all parts and panels before operating. Reconnect power. If the issue is not fixed, disconnect power. Replace the cooling fan. Replace all parts and panels before operating. Reconnect the power. If the issue is not fixed, disconnect power. Replace the power control board. Replace all parts and panels before operating. Reconnect power. Reconfigure the cooktop following the directions in Manual Configuration Mode.
F-21
Type 2
6-4
Failure Description
Troubleshooting (continued)
Type of Failure Type 1 Repair Suggestions 1. 2. Disconnect power. Check that the temperature sensor is between 184,000 - 292,000 at room temperature and is firmly plugged in. If the sensor is not between 184,000 - 292,000 , replace the coil and go to Step 5. If the sensor is between 184,000 - 292,000 and the electrical connection is good, go to Step 3. Replace all parts and panels before operating. Reconnect power and check that the coil is working. If it is not working, disconnect power and replace the non-working coil and the control board. Replace all parts and panels before operating. Reconnect power. If the control was replaced in Step 4, reconfigure the cooktop following the directions in Manual Configuration Mode. Disconnect power. Check that the cable between the User Interface and the power control board is good and properly connected. If the cable needs repair, fix it. Replace all parts and panels before operating. Reconnect power. Verify if error is still present. If yes, disconnect power. Replace the power control board. Replace all parts and panels before operating. Reconnect power. Reconfigure the cooktop following the directions in Manual Configuration Mode. Check for 240 volts AC at the main incoming power supply connection by completing the following steps. Disconnect power. Connect voltage measurement equipment. Reconnect power and check for 240 volts at J1 L to N, and then J2 L to N at the EMI filter board, and then J1 L to N at both power control boards. If voltage is correct, disconnect power, replace the power control board and go to Step 5. If voltage is not correct, disconnect power and check for an open fuse on the EMI filter board. If there is not an open fuse, have a qualified electrician check the home power supply. Replace all parts and panels before operating Reconnect power. Reconfigure the cooktop following the directions in Manual Configuration Mode. Disconnect power. Check that the cables between the User Interface and the power control board are not damaged and are firmly plugged in. Replace all parts and panels before operating. Reconnect power and check that it is working. If it is not working, disconnect power and replace the cables between the User Interface and the power control board. Replace all parts and panels before operating. Reconnect power and check that it is working. If it is not working, go to Step 7. Disconnect power. Check the continuity between black luge at the terminal block and both L2 terminals on the EMI board. If there is not continuity on one or both of these lines, replace the thermofuse harness. Replace all parts and panels before operating. Reconnect power and check that it is working. If it is not working, go to Step 11. Disconnect power. Check the continuity of the fuses on the EMI board. If either of the fuses is blown, replace with a new one. Replace all parts and panels before operating. Reconnect power and check that it is working. If it is not working, go to Step 15. Disconnect power. Change both control boards. Replace all parts and panels before operating. Reconnect power and reconfigure the cooktop following the directions in Manual Configuration Mode. Check that it is working. If it is not working, go to Step 19. Disconnect power. Change the User Interface. Replace all parts and panels before operating. Reconnect power and reconfigure the cooktop following the directions in Manual Configuration Mode.
3. 4. 5. 6. 7. F-40 Power control board failure Type 1 or Type 2 1. 2. 3. 4. 5. 6. 7. 8. 9. F-42 P ower s upply Type 2 1. 2. 3. 4.
5. 6. 7. F-47 Power supply from power control board to User Interface is missing or WIDE communication error between UI and power control board or an open fuse on the filter board Type 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
6-5
Troubleshooting (continued)
Service Code Shown on Display F-56 Failure Description Wrong or invalid configuration. Type of Failure Type 3
F-58
Type 2
F-58
Type 2
F-60
Type 3
F-60 F-61
Type 3 Type 2
F-61
Type 2
C-81, C-82
Over temperature
Type 2
go to Step 11. 11. Disconnect power. 12. Check the continuity of the fuses on the EMI board. If either of the fuses is blown, replace with a new one. 13. Replace all parts and panels before operating. 14. Reconnect power and check that it is working. If it is not working, go to Step 15. 15. Disconnect power. 16. Change both control boards. 17. Replace all parts and panels before operating. Suggestions 18.Repair Reconnect power and reconfigure the cooktop following the directions in Manual Configuration Mode. Check that it is working. If it is not working, go to Step 19. 1. Disconnect power. 19. Disconnect power. 2. Reconnect power. 20. Change the User Interface. 3. Reconfigure the cooktop following the directions in Manual 21. Configuration Replace all parts and panels before operating. Mode. 22. Reconnect power and reconfigure the cooktop following the Repair Suggestions 4. If the issue is not fixed, disconnect power. directions in Manual Configuration Mode. 5. Replace the User Interface. 6. all parts and panels before operating. 1. Replace Disconnect power. 7. 2. Reconnect power. 8. 3. Reconfigure the cooktop following the directions in Manual Configuration Mode. 4. If the issue is not fixed, disconnect power. 1. Disconnect power. 5. Replace the User Interface. 2. Reconnect power. 6. Replace all parts and panels before operating. 3. Reconfigure the cooktop following the directions in Manual 7. Configuration Reconnect power. mode. 8. If Reconfigure followingpower. the directions in Manual 4. the issue isthe notcooktop fixed, disconnect Configuration Mode. 5. Replace the power control board. 6. all parts and panels before operating. 1. Replace Disconnect power. 7. 2. Reconnect power. 8. 3. Reconfigure the cooktop following the directions in Manual Configuration Mode. mode. 4. If the issue is not fixed, disconnect power. 1. Disconnect power. 5. Replace the power control board. 2. Replace the User Interface. 6. Replace all parts and panels before operating. 3. Replace all parts and panels before operating. 7. Reconnect power. 4. Reconnect the power. 8. Reconfigure the cooktop following the directions in Manual 5. Reconfigure the cooktop following the directions in Manual Configuration Mode. Configuration Mode. 1. Disconnect power. 1. Disconnect power. 2. Replace the User Interface. 2. Check that the cables between the User Interface and the power 3. control Replaceboard all parts before areand notpanels damaged andoperating. are firmly plugged in. 4. Check Reconnect theVolts power. 3. for 240 AC at the J1 connector on the power control 5. board Reconfigure the cooktop directions in Manual by completing the following the steps. Configuration Mode. 4. Connect voltage measurement equipment. 5. 1. Reconnect Disconnectpower power.and confirm voltage reading. If voltage is not correct, disconnect power and have a qualified electrician check 2. the Check that the cables between the User Interface and the power home power supply. control board are not damaged and are firmly plugged in. 6. If voltage is correct, disconnect power and replace the cable 3. between Check forthe 240User Volts AC at the J1 connector the power control Interface and the power on control board. board by completing the following steps. 7. Replace all parts and panels before operating. 4. Connect voltage measurement equipment. 8. Reconnect power. 5. Reconnect power and confirm voltage reading. If voltage is not 9. Reconfigure the cooktop following directions in Manual correct, disconnect power and havethe a qualified electrician check Configuration Mode. the home power supply. 6. enough If voltage is correct, disconnect powerinstallation and replace the cableto Not ventilation: Check the cooktop according between the User Interface and the power control board. the Installation Instructions. In particular, check the blower intakes. 7. Replace all parts and panels before operating. 8. Reconnect power. 9. Reconfigure the cooktop following the directions in Manual Configuration Mode. Not enough ventilation: Check the cooktop installation according to the Installation Instructions. In particular, check the blower intakes.
C-81, C-82
Over temperature
Type 2
6-6
Troubleshooting (continued)
Control Board Indicator Light
Red Green
240VAC connection with top of insulator open These LEDs are mainly used in the labs and for engineering evaluations. However, the technician should consider a blinking red light as something not properly working inside the system. The green light always blinks whenever power is supplied to the power control board. You can also see the 240 VAC + connection with insulated terminal connections --- the top of the insulator is open in this picture.
6-7
NOTES
6-8
WIRING DIAGRAM
30 COOKTOP
208 - 240V
Main Connection 2 L1 L1 L1 G L2 L2 L2
Power Cord
L1
L2
L1
W1
Cx2 Cx1
L2
TF2
TF1
L2
240V
J1 F1 fuse 1
W EMI F2 fuse 2
J2
BR I1
S1
I1
S1
Y BK 66
BK Mo. Mo. 1
11 L J1
J803 J802
00 22 66 _ + S J205
2 1 2
GF801
J801
Mo.A Mo.B
J806 1 2 3 4 5 00 88 99 22 44
IPC
J806 1 2 3 4 5 00 88 99 22 44
I1 I1
W BK
S1
W BK
10.5VDC 5VDC
1 2 345
00 8899 22 44
1 2 345
00 8899 22 44
J008
J004
J003
J002
UI
J005
J007
10.5VDC 5VDC
CONNECTOR NOTE:
7
J003 - WIDE 2 connector from IPC2 J004 - WIDE 1 connector from IPC1
6 5 4
J803 - Jumper connector with jumper for IPC board in right position (ref. pos. B in assembly module.) No jumper for IPC board in left position (ref. pos. A in assembly module)
7-1
NOTES
7-2
FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMERS HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-488-4791 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL