080417_Service manual Base, Wok- and Install-Line E
Contents
1. 3 192 3 amaach e 23 Ee CAE mam 5000 mam Faas ovac nsw mme baam za nr base an 1 3 amp 6 8 3 3 3 6 6 080417 Service manual Base Wok and Install Line E 23 ER 080417 Service manual Base Wok and Install Line E 24 9 IR Interface 9 1 Build up of IR communication To build up the IR communication you need the software Hyper Terminal which is usually already available in Windows under Start gt Program gt lt Accessories gt Hyperterminal Prior to the first use Hyperterminal should be configurated properly INDUCS service needs the following settings Connect the IR box and bring it into line to the IR sensor on the generator Start Hyperterminal and give an access name e g IR2400 ht Beschreibung der Verbindung RIES Neue Verbindung Geben Sie den Namen fur die neue Verbindung ein und weisen Sie ihr ein Symbol zu Name E Symbol Select the communication via COMI or where your IR box has been connected Verbinden mit i2 x IR2400 Geben Sie die Rufnummer ein de gewahlt werden soll Landeskennzahl Dirtskennzahl 3100 Rufnummer Verbinden ber z ve 080417 Service manual Base Wok and Install Line E 25 Select the following settings 2400 Bits sec 8 Databits no parity 1 Stop bit Hardwa2. The indicator lamp flashes for an interval of 0 6 sec The following short flashes need to be counted This gives information about the error corresponding to the above mentioned code system 080417 Service manual Base Wok and Install Line E 15 6 3 Flow chart to fault finding Unit does not work Check mains supply Replace fuse Short circuit Check connection Poti connection Poti Check fuse of installation Connection 0 k and mains supply Defect pud Replace LED O k Connect Dismount Replace plug and socket Unit unit power board Defect Defect Defect Contact Check Check fuse SS rectifier T10A electrician Is there any LED indication Check electric voltage DC ns fuse Error code in Is there any IR mode error code Check circuit board visually Utilize error code and go ahead accor ding to list Check wiring Check IGBT transistors It works It does not work Unit works Continuous test for Correct Replace power Replace power s board about 10 min necessary board wiring 080417 Service manual Base Wok and Install Line E 16 7 Exchange of spare parts Caution All spare parts ano accessories may only be changed by authorized personnel In order to guarantee safety use only genuine spare parts and accessories from INDUCS Ltd If other components are used no liability is accepted
3. voltage Indicates a hazard or unsafe practice which CAUTION could result in minor personal injury or property damage Electromagnetic field Information signs mounted directly on the cooker must be observed at all times and kept in a fully legible condition 12 Qualification and training of personnel The staff for assembly installation commissioning operation and maintenance must have the appropriate qualification The field of responsibility competence and supervision of the staff must be defined and controlled 13 Safety prescriptions for installation and service The operating personnel has to make sure that installation and service as well as all inspection is done by authorized and qualified personnel This personnel must have read very carefully the Instructions for use in order to meet the requirements For installation service maintenance repair and overhaul of the induction cookers the personnel has to be specially qualified and must have attended a special training authorized by the manufacturer In principle such work at induction appliances must only be carried out when it is under no electrical tension The cookers must be switched off and disconnected from the electric 080417 Service manual Base Wok and Install Line E connection The installation of safety and protection must be re installed after finishing the work 1 4 Unauthorized reconstruction and use of spare parts Reconstruction of th
4. voltage between anode cathode by means of the multimeter please use only multimeters with diode check as an additional function The forward voltage for this diode is about 0 5V in the direction A C in the opposite direction there is no current flow 080417 Service manual Base Wok and Install Line E 10 In case one of the four diodes shows a short circuit or an interruption the rectifier is defective and has to be exchanged y N N A K 4 8 2 Transistor module IGBT The IGBT Insulated Gate Bipolar Transistor is fixed on the circuit board with three solder connections The IGBT Transistor has as a supplementary protection an integrated recovery diode At first we have to measure the on state voltage of this diode The forward voltage of this diode should be about 0 5V In case the recovery diode shows a short circuit or an interruption the IGBT transistor is defective and has to be exchanged E 080417 Service manual Base Wok and Install Line E 1 5 Maintenance Service Maintenance work may only be done by authorized personnel Before starting the maintenance work the power supply must be turned off and the appliance must have cooled down The following maintenance works need to be carried out periodically The longer and more frequently the cooker is used the more often the maintenance works have to be don
5. Caution The mains cable must be disconnected 7 1 To open the induction unit base Caution Turn the induction unit over upside down Remove M4x8 screws Turn induction unit back to normal position e Lift cover tip to the right side stand it on its side e Remove coil carrier remove the 2 stop nuts on the left Remove screws Remove screws Al and A2 e Turn away coil carrier at the left 7 2 To open the induction unit install Remove 4 screws on the right side Lift cover with the glass Remove M4 screws remove coil carrier e Remove PT sensor and coil connections 080417 Service manual Base Wok and Install Line E 17 73 Repair of spare parts Repair of spare parts and of whole units may only be effected by INDUCS Ltd Therefore check and replace only parts described in this service manual In case you should repair parts please describe exactly the faults and give information about the history of the unit for example new installation changements done next to the induction cooker or to other units supplied by the same network In order to save transport charges do not return defective parts such as temperature sensors rectifier transistor modules interrupters Such parts can be disposed correctly on place 080417 Service manual Base Wok and Install Line E 18 8 Adjustment of process parameters The induction unit excluding WOK units with new Cu sensors can be adju
6. SERVICE MANUAL INDUCTION COOKERS BASE LINE INSTALL LINE WOK LINE BH BA 1500 BH BA 1800 BH BA 2300 BH BA 2500 BH BA 3000 BH BA 3500 BH IN 2500 SH BA 3500 SH BA 5000 SH IN 3500 SH IN 5000 SH WO 3500 SH WO 5000 SH WO 8000 SH WO IN 3500 SH WO IN 5000 SH WO IN 8000 ICE p Freecall 1800 998 125 OVE www iceandoven com Ice And Oven 1312 Inducs Service Manual Version 13 Aug 14 CONTENT Te RU 2 Deseriptiom of EE EE 2 1 2 Qualification and training of personnel 2 1 3 Safety prescriptions for installation and 1 2 1 4 Unauthorized reconstruction and use of spare parts 3 1 5 Improper Operating een codi seid eegen e 3 2 Te bnical information ee 4 Meunier 6 3 1 Adjusting the performance HE SI ea reine ea Eee aX FER EUREN ARES 6 3 2 Check or the temperature sacas d OR RE EE 6 9 2 CO verload current protection oss obe on E Io Oen ded n EO BE dade E 6 MM Cc 7 4 Pan material for induction cookers nennen 7 e Parise ve CHM EE 7 43 Test With pais Sucesos de E Hodie ied a ese ibd eodein 8 44 eat eid estt n dins 8 LINE AM gasientnelaya 8 4 6 oett coetu 8 OR ES e ME ia E drca e cuc Lt Mc 9 46 Test of the Compo
7. a Take pan off until cooking area has temperature of cooking cooled down surface 2 b Wait until it has cooled down CU sensor 1 c Check coil Warning temperature 17 CU sensor 1 a Temperature of the cooking field too overtemperature high b Check CU sensor 1 index value 5Ohm at 25 C 18 CU sensor 2 a Temperature of the cooking field too overtemperature high b Check CU sensor 2 index value 5Ohm at 25 19 CU sensor 2 a Temperature of the cooking field too warntemperature high b Turn the power down 20 Power reduction generator a Check for heat sources around the inside temperature generator and remove them b Check air circulation 21 Heat sink sensor error a Contact Inducs AG 24 Board temperatur sensor a Exchange power unit error 25 CU sensor 1 error a Check CU sensor 1 for short circuit or discontinuation index value 5Ohm at 25 26 CU Sensor 2 error a Check CU sensor 2 for short circuit or discontinuation index value 5Ohm at 23 27 Empty cooking detector CU a Check cooking material in the pan sensor 1 28 Empty cooking detector CU a Check cooking material in the pan sensor 2 P 080417 Service manual Base Wok and Install Line E 14 D The induction unit can only be restarted when the fault has been rectified turn power rotary knob oft The induction unit continues working 3 The induction unit does not heat Order of error message for error code 1 8
8. aterial is appropriate for induction use a magnet This has to stick to the bottom of the pan This test says nothing about the efficiency or the material structure of the pan it can be a bad induction pan 4 2 Pan detection The heating area is warmed up by the hot pan ATTENTION avoid injuries burnings do not touch the heating area This test shows whether the induction cooker is working well when pans with a small diameter are used and if small metallic objects are heated up on the heating area To do this test you need the following material An appropriate pan with a bottom diameter of 12cm 4 7 or two untreated round iron plates approximately 4mm 0 16 thick iron plate 1 diameter d 12 cm 4 7 iron plate 2 diameter d 7 cm 2 75 080417 Service manual Base Wok and Install Line E 43 Test with pans Step Action Level Result _ Put the pan in the middle of the heating 2 9 12 Heat the indicator lights area 2 Push pan until the edge ofthe 15 1 9 12 No heating the indicator in the middle of the heating area does not light 44 Test with metallic plates Step Action Level Result Put the metallic plate 1 inthe middle of 1 9 12 Heat the indicator lights the heating area 2 Put the metallic plate 2 in the middle of 1 9 12 No heating the indicator the heating area doe
9. charge rate mA 4 4 4 Coil mm 190 190 190 Modell SH IN 208 V 1 Ph 230 V 1 Ph 240 V 1 Ph Wattage kW 3 5 3 5 3 5 Current A max 16 15 14 5 Power factor Cos 20 95 20 95 20 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Modell SH IN 208 V 3 Ph 400 V 3 Ph 440 V 3 Ph Wattage kW 5 5 5 Current A 13 9 7 2 6 6 Power factor Cos 20 95 20 95 20 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 080417 Service manual Base Wok and Install Line E Modell SH WO 208 V 1 Ph 230 V 1 Ph 240 V 1 Ph Wattage kW 3 5 3 5 3 5 Current A max 16 15 14 5 Power factor Cos 20 95 0 95 50 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Modell SH WO 208 V 3 Ph 400 V 3 Ph 440 V 3 Ph Wattage kW 5 5 8 5 Current A 13 9 7 2 11 6 6 6 Power factor Cos 20 95 20 95 20 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Modell SH WO IN 208 V 1 Ph 230 V 1 Ph 240 V 1 Ph Wattage kW 3 5 3 5 3 5 Current max 16 15 14 5 Power factor Cos 20 95 0 95 20 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Modell SH WO IN 208 V 3 Ph 400 V 3 Ph 440 V 3 Ph Wattage kW 2 5 8 5 Current A 13 9 7 2 11 6 6 6 Power factor Cos 50 95 0 95 0 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Max tolerance of power supply Nominal voltage 6 10 96 Frequency 50 60 Hz Protection class IP X0 Min diameter of pans Ap
10. e Every cooker should be checked at least once a year Fan The proper function of the cooker can only be guaranteed if the electronic unit is kept at normal working temperature The air inlet and outlet slots must not be blocked or covered The air filter must not be blocked by dirt or grease e The airducts must be free of dirt The air must circulate freely through the heat sink The fan is properly mounted The heat sinks are properly mounted Check Induction coil Mechanical fixing screws tightened Coil adhesive mounting o k e Ferrite mounting e Copper coil mounting o k General check e Earth protection e Screwed connections Cable insulation Any kind of dirt or liquids that have entered the cooker must be cleaned out Remove insects if present 080417 Service manual Base Wok and Install Line E 2125 6 Fault finding 6 1 Generally 2 Do not open the cooker while the power is Caution connected Dangerous tension The induction cooker may only be serviced by authorized personnel Stop any work if the heating area Ceran Glass is broken The induction cooker must be switched off and the mains cable disconnected Do not touch any parts inside the cooker Before replacing a part check the wiring Give special attention to the following faults Broken cables e Squeezed cables e Defective insolations of cables e soldering joints You must n
11. e cooker or changes to the cooker are not allowed Contact the manufacturer if you intend to do any changes to the cooker To guarantee safety use genuine spare parts and accessories authorized by the manufacturer The use of other components will cancel any liability for the resulting consequences 1 5 Improper operating methods The operating reliability of the cookers can only be guaranteed with appropriate use of the cooker The limit values may be exceeded on no account 080417 Service manual Base Wok and Install Line E 2 Technical information Modell BH BA 120 V 1 Ph 208 V 1 Ph 230 V 1 Ph 240 V 1 Ph Wattage kW 1 5 1 8 2 5 3 3 5 2 3 2 5 3 3 5 2 5 3 3 5 12 5 15 12 14 5 17 10 11 13 15 10 12 5 14 5 Power factor Cos 20 95 20 95 20 95 20 95 Discharge rate mA 4 4 4 4 Coil mm 190 190 190 190 Modell BH IN 208 V1Ph 230 V 1Ph 240 V 1 Ph Wattage kW 2 5 2 3 2 5 Current A 12 11 10 Power factor Cos 20 95 20 95 0 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Modell SH BA 208 V 1 Ph 230 V 1 Ph 240 V 1 Ph Wattage kW 3 5 3 5 3 5 Current max 16 15 14 5 Power factor Cos 20 95 20 95 20 95 Discharge rate mA 4 4 4 Coil mm 190 190 190 Modell SH BA 208 V 3 Ph 400 V 3 Ph 440 V 3 Ph Wattage kW 5 5 5 Current A 13 9 T2 6 6 Power factor Cos 20 95 20 95 20 95 Dis
12. eaches 70 C 158 F As soon as the temperature reaches 80 C 176 F the unit will stop working and show the error code E06 see chapter 7 2 33 Overload current protection When inappropriate pan material or magnetic objects are detected on the heating area the current in the induction coil may rise substantially In order to protect the power board the coil current is checked As soon as the current in the coil exceeds the tolerance the generator will cut out and there is no further active energy exchange The unit can be re started as soon as normal working conditions are reached 080417 Service manual Base Wok and Install Line E 4 Tests 4 1 Pan material for induction cookers When cooking with induction it is most important to use appropriate pan material The bottom of the pan is the element that closes the magnetic field generated by the induction coil We recommend to use only appropriate pan material In order to check your pan make a test You will need water of about 20 C 68 F Heat up the pan with maximum power and measure the time it takes until the water is boiling Refer and compare to the reference time given by INDUCS Ltd 2 5kW approx 240 sec 3 5kW approx 140 sec SKW approx 80 sec SKW approx 60 sec This heating up time gives you information about the efficiency of the pan Bad pans have considerably longer heating up times for the same quantity of water In order to find out whether the pan m
13. he initialization of the CU sensors as well as the adjustments of pan detection and performance can be done by means of the hyperterminal program You will find exact information for the handling of the hyperterminal program in chapter 9 interface IMPORTANT Pay special attention whether you receive feedback signal from the PC Laptop after every changement This will be the sign that the changement has been accepted 12345 Entry to the mode of adjustment password Initialize Cu sensor temperature of the coil ca 25 C excluding WOK Increase the mains current limit Decrease the mains current limit Save the limit of the mains current Increment pan detection Decrement pan detection Save pan detection Leave the mode of adjustment State software version 83 Change of the parameters 1 Connect the RS232 connection cable to the PC Laptop and straighten the IR box to the left lower corner of the ceran glass 2 Start HT2400 see chapter 9 and turn unit on 3 By input of 12345 the mode of adjustment is started The following message appears the hyperterminal program IR On WELCOME REPAIRMEN 4 Not valid for WOK The parameters on the CPU can now be changed The unit temperature and the surrounding temperature have to be 25 C 4 C Press the key On the console appears the message please confirm Press the key again The CU sensor will now be init
14. herwise you have to start at the beginning 080417 Service manual Base Wok and Install Line E 21 Different information about the unit is shown in the adjusting mode The following parameters can be read Output on the hyperterminal program 1 KK 58 CU1 22 CU2 22 B 33 F 20080 1 KK 58 CU1 22 CU2 24 B 33 F 20080 1 KK 57 CU1 22 CU2 24 B 33 F 20080 1 KK 57 CUI 22 CU2 24 B 33 F 20080 Meaning CU sensor 2 outside temperature of the coil Heat sink temperature Error message KK 58 CU1 22 CU2 22 B 33 F 20080 Active Board temperature field CU sensor 1 inside Status message temperature of the coil The fan will be activated at a heat sink temperature of 60 C 080417_Service manual Base Wok and Install Line E 22 8 4 Parameters for mains current and pan detector Article Nr Pan detector BaBa isoo ovac Naw wo O 27 140 99560105 2500 240VAC IN 2 5kW 7 __ ___ 99560106 3000 208VAC 1N 3kW 130 26 99560107 BH BA 3000 230VAC IN 3kW 99560108 3000 240V AC IN 3kW 2 2 2 1 160 H 187 0 153 99560109 3500 208VAC IN 3 5kW 99560110 BH BA 3500 230VAC IN 3 5kW 99560111 3500 240VAC IN 35kW 99560112 BH BA 2300 230VAC IN 23kW 10 27 980000 BH IN1500 120VAC IN 1 5kW 162 E 187 IN 2 153 s 140 IN
15. ialized to 25 C The following message appears on the hyperterminal program save CU sensor 25 C 080417_Service manual Base Wok and Install Line E 20 Set the limit of the mains current see mains current parameters in chapter 8 2 N increase the limit of the mains current N decrease the limit of the mains current The following message appears on the hyperterminal program linecurrent limit Save the limit of the mains current with the key On the console appears the message please confirm Press the key again The following message appears on the monitor save linecurrent limit Set the pan detector see pan detector parameters in chapter 8 2 T increase pan detector T decrease pan detector The following message appears on the monitor pan detection limit Save the pan detector with the key 2 On the console appears the message please confirm Press the key again The following message appears on the monitor save pan detection limit By input gt the mode of adjustment will be left The following message appears on the monitor see you again 10 The mode of adjustment has a time out function After 10 minutes the mode of adjustment will be left automatically The adjustments are now finished and it is not possible to make any other adjustments Ot
16. nents cese iS Ha Ree AE NIU ORE HERE E E 9 4 5 e H H 9 Transistor module IGBE e decocto io eoe ee ud e e E epe Que Deep EO an E IM age 10 Ne EE E 11 6 Fault ege EE 12 PH SG emer ay e Mae bd intend bd te m tedio e dune dt EM MEE 12 EE Dn e EE 12 6 3 Flow chart to Tault finding 15 T Exchange of spare EE 16 7 1 To open the induction unit base ee m dee oe amne De e o e e due vn 16 7 2 To open the induction unit Install 16 T Repair Of Spare e cenae eroe E E R ER RR R 17 8 Adjustment of process parameters ssssssccocccesssssscoceceseesssocococccesessoococcecesesssssooseesees 18 8 1 How to initialize CU sensors by the short circuit plug 18 8 2 Initialisation of the induction unit by PC Laptop 19 8 3 Change of the etd PR rrt HER RU wei ce NR 19 8 4 Parameters for mains current and pan detector 22 KU Wl spe ec 24 9 1 Build up of IR communication coeno tan 24 080417_Service manual Base Wok and Install Line E 1 Safety 1 1 Description of danger signs This symbol identifies the safety information which may cause danger personal injury for people at non observance of proper operation This dangerous voltage warning symbol indicates a risk of electric shock and hazards from dangerous
17. ot do any repair on the circuit boards The appropriate maintenance work should be carried out after each repair see Maintenance and Service 6 2 Error messages Number of Significance Measures to take flashing signals Error code 3 Temperature heat sink a Heat sink temperature too high wait eme until the temperature has cooled down under 80 C 176 F b Check supply of cooling air perhaps blocked check function of fan c Check temperature of heat sink replace power circuit 4 Temperature cooking a Temperature of the cooking surface too SURE surface 3 high b Check CU measure coil index value at 20 C 68 F approx 5Ohm 080417 Service manual Base Wok and Install Line E 13 Number of Signification Measure to take flashing signals Error code 5 Error on power switch 2 a Check connection b Check power switch 6 Temperature inside the unit c Check whether the unit is next to a eee too high source of heat as e g friteuse d Check whether hot air is taken in generator has no air exhaust system 7 Empty cooking sensor a Check cooking material in the pan 8 Sensor error 7 a Check Cu sensor ZU UE E b Check heat sink sensor c Check RTCS sensor d Check board sensor 12 Power reduction heat sink a Turn the power down temperature b Check fan I5 Power reduction
18. prox 12 cm approx 4 7 Max ambient temperature stockage 20 to 70 C 4 to 158 F Max ambient temperature function 5 to 40 C 41 to 104 F Max relative humidity of air stockage 10 to 90 Max relative humidity of air function 30 to 90 080417_Service manual Base Wok and Install Line E 3 Functioning 3 1 Adjusting the performance rate The performance rate is adjusted by the potentiometer control knob The inductive performance depends on the position of the potentiometer Position 1 minimum power Position 9 resp Position 12 2 maximum power 32 Check of the temperature Induction coil The temperature of the induction coil is checked by a temperature sensor If the coil is heated over the maximum temperature the heating process is stopped As soon as the coil has cooled down the Induction unit can be re started Turn the position of the kontrol knob on and then on the required power level see chapter 7 2 Error Messages Power board The temperature of the heat sink is checked by a temperature sensor As soon as the heat sink is heated over 60 C 140 F a cooling fan is started A temperature of the heat sink of more than 75 C 167 F will reduce automatically the power in order to keep the induction cooker working under normal conditions The internal temperature of the unit is supervised as well The power will be reduced when the temperature r
19. re protocol Eigenschaften von 1 Vestes These adjustments will be saved under the access name IR2400 ht 080417 Service manual Base Wok and Install Line E
20. s not light 4 5 Power rating The heating area is warmed up by the hot pan ATTENTION To avoid injuries burnings do not touch the heating area Step Action Level Result Put the pan on the heating area until the 9 12 Heat water is boiling water boils 2 Reduce the power by turning the control 12 9 Heat rating reduces water knob down slowly does not boil anymore phase current reduces 4 6 Maximum rating The heating area is warmed up by the hot pan ATTENTION avoid injuries burnings do not touch the heating area 080417 Service manual Base Wok and Install Line E 4 7 Fan With this test fan fan controller as well as the degree of soiling are verified At the beginning of the test the induction cooker should be cold You need a pan with a bottom diameter of 228 11 Step Action Level Result 1 Pur a pan on the heating area and fill a 9 12 Heat few litres of water in it 2 Measure the time until the fan starts 9 12 The fan should start working working in 6 8 minutes 3 Goon cooking for about 30 minutes 9 12 4 Vum off the induction cooker 0 The fan keeps working 4 8 Test of the components CAUTION mains cable must be switched off 4 8 1 Rectifier The rectifier is fixed at the power board with four wires These rectifier connections have to be unsoldered for correct test results At first you have to measure the forward
21. sted This can be done either by means of the short circuit plug Poti LED art nr 94900096 or by PC Laptop In addition the pan detection and the performance can be adjusted by the hyperterminal program of the PC Laptop Exact information to the use of the hyperterminal program is given in chapter 9 IR interface 8 1 How to initialize CU sensors by the short circuit plug If only the CU sensor is exchanged the new CU sensor can be initialized by means of the short circuit plug Poti LED For this you will not need the PC Laptop The pan detection and the performance will not have to be changed Prozedure of initialization The cooking area has to be devoid of any items Surrounding temperature 25 C 3 Disconnect the induction unit from the mains supply Put short circuit plug Poti LED into the power print Connect the induction unit to the mains supply The CU sensors will now be initialized automatically After successful initialization the green LED on the CPU print will illuminate In case the system will find an error during initialization the red LED will illuminate Disconnect the induction unit from the mains supply Check the CU sensors at the plug by means of the Ohmmeter Re start the procedure of initialization Disconnect the unit from the mains supply Remove the short circuit plug Poti LED 080417 Service manual Base Wok and Install Line E 19 8 2 Initialisation of the induction unit by PC Laptop T
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