Garland 7000 User Manual

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SERVICE MANUAL

MODUL-LINE

BUILT-ININDUCTION COOKERS

ITAT

IO

AN

S

N

C

86037

L

I

S

TED

CM

MODEL: IN/MO 7000

GARLAND COMMERCIAL INDUSTRIES

GARLAND COMMERCIAL RANGES, LTD.

Enodis UK LTD.

185 East South Street

1177 Kamato Road, Mississauga, Ontario L4W 1X4

5E Langley Business Centre

Freeland, Pennsylvania 18224

CANADA

Station Road, Langley SL3 8DS Great Britain

Phone: (570) 636-1000

Phone: 905-624-0260

Phone: 01753 485900

Fax: (570) 636-3903

Fax: 905-624-5669

Fax: 01753 485901

Part # 4526029 (02/22/11)

© 2008 Garland Commercial Industries, Inc.

Part # 4526029 (02/22/11)

Page 1

Page 2

Part # 4526029 (02/22/11)

TABLE OF CONTENTS

SECTION 1 – REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Authorized Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

“Operation Instructions“ Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Knowledge Of Electronic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 – SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Block Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Voltage Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 3 – INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pan Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 4 – TROUBLE SHOOTING AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Error-Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Additional Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Repair Of Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Generator Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pan detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Repair by Garland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 5 – APPENDIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Rectifier Circuit Board C014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

CPU-CircuitBoard C018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power Circuit Board C026 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Rectifier And Transistor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Part # 4526029 (02/22/11)

Page 3

SECTION 1 – REQUIREMENTS

Authorized Personnel

The operator has to insure that all installation, maintenance and inspection work is carried out by authorized and qualified personnel who has done a training course at Inducs Ltd.

“Operation Instructions“ Knowledge

In order to do service work on an induction generator, the operator must have an extended knowledge of the “Operating Instructions“.

Knowledge Of Electronic Systems

The serviceand maintenance operator must have knowledge of the following components :

Diodes

Z-Diodes(Zener-Diodes)

Rectifiers (2phases and 3phases)

Power transistor (IGBT)

The operator must know how to measure the electric potential, current and resistors by means of a digital multimeter. He also has to know how to check diodes with a diodes tester.

Page 4

Part # 4526029 (02/22/11)

SECTION 2 – SYSTEM DESCRIPTION

Block Schematic

 

230VAC

24VDC

 

 

23VAC

 

ST1

 

 

208VAC

 

300VDC

L1,L2,L3

 

 

 

 

c014

filter coil

 

 

230VAC

 

 

PE

 

 

 

ST5

 

ST1

 

 

 

 

ST2/3,4

 

 

 

4

 

 

 

ST4

8

 

 

CPU

ST8

 

 

heatsink

4

 

 

 

ST6

 

 

coil

4

 

ST2/1,2

 

ST7

 

 

 

ST1/1,4

 

c018

 

 

 

 

supply

 

 

 

24VDC

 

 

c026

1x,2x,3x,4 x

LED 24VDC

5

c014

M

Relay

 

fan

24VDC

 

230VAC

 

 

 

 

 

 

Part # 4526029 (02/22/11)

Page 5

Voltage Supply

The power board voltage supply is wired with the power contactor. On starting the generator, voltage is supplied to the power board. The transformer is connected directly at the entrance of the power supply. The transformer supplies two different voltages: 230VAC for the power contactor and the fan as well as 23VAC for the low voltage supply. The 23VAC are changed on the circuit board C026 to 24VDC.

The following components are supplied with 24VDC:

CPU-circuitboard (C018)

IGBT (C026)

Fan relay (C014)

External lamps

Power Board

As already stated, the power board is supplied by the power contactor. The mains current is measured by a current transformer, directly at the entrance of the 3-phases-rectifier,After the rectifier there is a direct voltage of 300V. The inductance that follows filters high frequency (EU) current .

At the following power switch (IGBT) an alternating current of approximately 20kHz is generated. This alternating current (coil current) is transferred to the induction coil. At the exit of the circuit board (C026), the coil current is measured by a current transformer.

Control unit

The control unit is the heart of the generator. This is the CPUcircuit board (C018) with an integrated microprocessor which manages the whole control system.

The following data are measured:

Coil current

Phases current

Performance rate (Poti)

Heat sink temperature (IGBT)

Coil temperature

Ambient temperature

The power switch (IGBT), the fan as well as the display are managed in response to these factors.

Display

Two elements are used for this display:

1.LED-group(LED1 - LED8) on theCPU-Circuitboard (C018)

2.External lamps (24V), maximum 5 pieces

The five external lamps are connected with the five LED’s (LED1-LED5).Please distinguish between operation lamps and error lamps. The operation lamp shows what kind of operation for the respective field:

• Lamp out: Field is cut out

Lamp flashes briefly Pan detection (pan is searched)

Lamp flashes an error code:

Error message (see Error

 

Messages table)

 

Lamp continuously on:

Power on

The error lamp indicates an error function.

LED1 to LED4 lead to external lamps on the outside, they are used as operational lamps or as error lamps, depending on the generator type. If an operation lamp or an error lamp is shared by two fields (for example the surface covering this induction type) the display can be overwritten from another field. As far as the error code display is concerned, the lower field has priority.

LED5 lead to the outside for an external lamp also. This is the general error lamp for all fields all the time.

In an error, LED6 to LED8 show the error code, but only until error code 7. If this happens in some errors, the lower field and the lower error code have priority.

Page 6

Part # 4526029 (02/22/11)

Error Messages

LED 8

LED 7

LED 6

Code

Signification

NOTE

No error, normal function

 

On

01

No coil current, overdrive caused by non induction pan

 

On

02

High coil current, overdrive by non induction pan

 

On

On

03

Temperature heat sink too high

 

On

04

Temperature heating area (coil) too high

1

On

On

05

Potentiometer defected , wiring disconnected

 

On

On

06

Temperature inside the unit too high

 

On

On

On

07

Heating area – coil sensor short circuit

2

08

 

 

09

 

 

10

Communication error (serial interface)

 

11

 

 

12

 

 

13

 

 

14

 

 

15

 

 

 

 

 

 

 

 

1.The induction unit can only be started again if the fault has been acknowledged (turn power rotary knob “off“)

2.The induction unit continues working but the temperature of the cooking platform is not controlled anymore.

Part # 4526029 (02/22/11)

Page 7

SECTION 3 – INITIAL OPERATION

Function control

To check the function controls, the induction generator must be totally connected.

Display

1.The external lamps must be checked.

2.The operation lamp flashes if a coil is not used (Searching function).

3.This procedure must be repeated for every coil.

Pan Detection

To check the pan detection, two pans are needed: one with a diameter of 8cm (3”) and the other with a diameter of 12cm (4.75”) .Only the pan with a diameter of 12cm (4.75”) should be detected. A coil should not start operation when it is not being used.

This procedure must be repeated for every coil.

Power

Place an “induction ready” pan with a diameter of 22-24cm(8.5”-9.5”)onto the coil. Measure the generator power

at maximum level. This should be at the nominal power (tolerance +/- 10%). This procedure must be repeated for every coil.

Fan

Place various pans on the coils and start the generator on the highest level. After a few minutes the fan should start. The fan is controlled by the temperature and starts when the heat sink temperature is about 50ºC/122ºF.

Page 8

Part # 4526029 (02/22/11)

SECTION 4 – TROUBLE SHOOTING AND REPAIRS

This section includes a list of the main errors, their causes and the respective steps to correct.

Trouble Shooting

Error-Code

 

 

Problem

 

Possible Cause

 

 

Measure

 

Code

No.

 

No

 

 

No

 

W

 

 

 

 

 

 

 

 

 

No

 

 

 

Normal operation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No coil current

 

 

 

 

Compare on another

 

1

S01

U10

Non induction type pan

 

M10

cooking platform and with

E

Hardware overcurrent

 

 

 

 

 

 

 

 

an induction type pan

 

 

 

 

U11

Coil defective

 

M11

Check coil

L

 

 

 

 

 

 

 

 

 

 

 

 

U12

Power circuit board

 

M12

Replace power circuit

L

 

 

 

defective

 

board

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

High coil current

 

 

 

 

Compare on another

 

2

S02

U10

Non induction type pan

 

M10

cooking platform and with

E

Software overcurrent

 

 

 

 

 

 

 

 

an induction type pan

 

 

 

 

U12

Power circuit board

 

M12

Replace power circuit

L

 

 

 

defective

 

board

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U13

Error on DIP-Switch-

 

M13

Check DIP-Switch

L

 

 

 

adjustment on CPU

 

adjustment

 

 

 

 

 

 

 

 

 

 

U14

CPU-circuitboard

 

M14

Replace CPU-circuitboard

L

 

 

 

defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

S03

Temperature heat sink

U30

Air entrance/exit

 

M30

Clear air transport

E/L

obstructed

 

 

 

 

 

 

 

 

 

 

 

 

U31

Dirty fan/heat sink

 

M31

Clean fan

L

 

 

 

 

 

 

 

 

 

 

 

 

U32

Fan defective

 

M32

Check fan

L

 

 

 

 

 

 

 

 

 

 

 

 

U33

Rectifier circuite board

 

M33

Replace rectifier circuit

L

 

 

 

defective

 

board

 

 

 

 

 

 

 

 

 

 

U34

Sensor Heat sink defective

 

M34

Check sensor and heat

L

 

 

 

 

sink

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U14

CPU-circuitboard

 

M14

Replace CPU-circuitboard

L

 

 

 

defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

S04

Temperature cooking

U40

Empty cooking

 

M40

Empty pan

E

platform

 

 

 

 

 

 

 

 

 

 

 

 

 

U41

Interruption of coil sensor

 

M41

Check coil sensor

L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

S05

Operational control

U50

Operational control

 

M50

Check operational control

L

Line break

defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Legend: W = Who should complete“Measure”

E = End user L = Supplier

 

 

 

Part # 4526029 (02/22/11)

Page 9

 

 

Problem

 

Possible Cause

 

 

Measure

 

 

 

 

 

 

 

 

 

 

Code

No.

 

No

 

 

No

 

W

No

 

 

 

Normal operation

 

 

 

 

 

 

 

 

 

 

 

6

S06

Inside temperature

U60

Ambient temperature too

 

M60

Check ambient

L

high

 

temperature

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U14

CPU-circuitboard

 

M14

Change CPU-circuitboard

L

 

 

 

defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cooking platform

 

Sensing element

 

 

Check coil sensing

 

7

S07

U70

Coil temperature

 

M41

L

Sensing element

 

element

 

 

 

 

Short circuit

 

 

 

 

 

 

 

 

 

 

 

 

 

8

S08

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

S09

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

S10

Communication error

U100

Line break

 

M100

Check connection

L

(Serial interface)

 

 

 

 

 

 

 

 

 

 

 

 

 

U101

Operational control

 

M101

Replace operation

L

 

 

 

defective

 

 

 

 

U14

CPUcircuit board

 

M14

Replace CPU-circuitboard

L

 

 

 

defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

S11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12

S12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13

S13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

S14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15

S15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Legend: W = Who should complete“Measure”

E = End user L = Supplier

 

 

 

Page 10

Part # 4526029 (02/22/11)