Garland GIU 2.5 BI (BH-IN 2500) User Manual

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SERVICE MANUAL

INDUCTION COOKERS WITH RTCS TECHNOLOGY

(REAL TIME TEMPERATURE CONTROL SYSTEM

COUNTER TOP/BUILT IN/WOK MODELS

C

86037

ANITATIO

S

N

LISTED

CM

IMPORTANT NOTE:

INDUCTION COOKERS MANUFACTURED WITH RTCS TECHNOLOGY WILL HAVE

FIVE DIGITS IN THE CENTER OF THE SERIAL NUMBER: EXAMPLE: BA06.00001.0505

MODELS

GIU 1.5 (BH/BA 1500)

GIU 1.8 (BH/BA 1800)

GIU 2.5 (BH/BA 2500)

GIU 3.5 (SH/BA 3500)

GIU 5.0 (SH/BA 5000)

GIU 2.5 BI (BH/IN 2500)

GIU 3.5 BI (SH/IN 3500)

GIU 5.0 BI (SH/IN 5000)

GIWOK 3.5 (SH/WO 3500)

GIWOK 5.0 (SH/WO 5000)

GIWOK 3.5 BI (SH/WO/IN 3500)

GIWOK 5.0 BI (SH/WO/IN 5000)

GARLAND COMMERCIAL INDUSTRIES

GARLAND COMMERCIAL RANGES, LTD.

Enodis UK LTD.

185 East South Street

1177 Kamato Road, Mississauga, Ontario L4W 1X4

Swallowfield Way, Hayes, Middlesex UB3 1DQ ENGLAND

Freeland, Pennsylvania 18224

CANADA

Telephone: 081-561-0433

Phone: (570) 636-1000

Phone: 905-624-0260

Fax: 081-848-0041

Fax: (570) 636-3903

Fax: 905-624-5669

 

Part # 4521635 (03/04/08)

© 2006 Garland Commercial Industries, Inc.

Part # 4521635 (03/04/08)

Page

TABLE OF CONTENTS

SECTION 1 –SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Description Of Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Personnel Qualification And Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Information, Installation And Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unauthorized Reconstruction And Use Of Spare Parts. . . . . . . . . . . . . . . . . . . . . . . 3 Improper Operating Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 2 – TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . .4

SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Adjusting The Performance Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Temperature Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Protection Overload Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 4 – TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

.6

Pan Material For Induction Cookers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

6

Pan Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

6

Test With Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

. 6

Test With Metallic Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

. 6

Power Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

. 7

Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

. 7

Test Of The Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Transistor module (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

8

CU (RTCS) Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

8

SECTION 5 – MAINTENANCE/SERVICE . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 6 – FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . .12

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 12

Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 12

Flow chart to fault finding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 7 – EXCHANGE OF SPARE PARTS . . . . . . . . . . . . . . . . . . .

 

.15

To Open The Induction Unit (Counter Top Models). . . . . . . . . . . . . . . . . . . . . . .

.

15

To Open The Induction Unit (Built In Models) . . . . . . . . . . . . . . . . . . . . . . . . .

.

. 15

SECTION 8 – ADJUSTMENT OF PROCESS PARAMETERS . . . . . . . . . . . . .

 

.15

Initializing CU Sensors By The Short Circuit Plug. . . . . . . . . . . . . . . . . . . . . . . .

.

. 15

Initializing The Induction Unit By PC Or Laptop . . . . . . . . . . . . . . . . . . . . . . . .

.

. 16

Change Of The Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Parameters For (Mains) Power Current And Pan Detector. . . . . . . . . . . . . . . . . . . .

.

18

SECTION 9 – IR (INFRARED) INTERFACE . . . . . . . . . . . . . . . . . . . .

. 19

SECTION 10 – WIRING BLOCK SCHEMATIC . . . . . . . . . . . . . . . . . . .

 

22

Page

Part # 4521635 (03/04/08)

SECTION 1 –SAFETY

Description Of Warning Signs

Identifies safety information about dangers which may cause serious personal injury if equipment is not operated properly.

Dangerous voltage warning symbol, indicates a risk of electric shock and hazards from dangerous voltage.

Indicates a hazard or unsafe practice CAUTION which could result in minor personal

injury or property damage.

Electromagnetic field.

Warning signs mounted directly on the cooker must be observed at all times and kept in a fully legible condition.

Personnel Qualification And Training

All persons involved in assembly, installation, commissioning, operation and maintenance must have the appropriate qualifications. The scope of responsibility, competence and supervision of the staff must be defined and controlled.

Safety Information, Installation And Service

Operators of the equipment must ensure that all installation, service and as well as all inspections, are performed by authorized and qualified personnel. Before attempting to operate the equipment carefully read the information and instructions outlined in the ”Installations and Operating” manual. For all installations, service, maintenance, repair and or overhaul of the induction cookers, personnel must be specially qualified and must have attended a technical training course authorized by Garland.

Do not attempt to perform any repairs or replace any part of the induction cooker unless, all power supply to the cooker has been disconnected.

Unauthorized Reconstruction And

Use Of Spare Parts

Reconstruction of the 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 only genuine OEM spare parts and accessories, authorized by the manufacturer. Garland will not be held liable for any damage or injury caused by used of other components.

Improper Operating Methods

The operating reliability of the cookers can only be guaranteed when the cooker is used appropriately. The limit values stated in this manual must not be exceeded.

Part # 4521635 (03/04/08)

Page

SECTION 2 – TECHNICAL INFORMATION

Model BH/BA (Counter models)

120 V/1 Ph

208 V/1 Ph

240 V/1 Ph

 

 

 

 

Wattage kW

1.5/1.8 kW

2.5/3.5 kW

2.5/3.5 kW

 

 

 

 

Current A

12.5/15

12/14.5/17

10/12.5/14.5

Power factor Cos ϕ

>0.95

>0.95

>0.95

 

 

 

 

Discharge rate mA

4

4

4

 

 

 

 

Coil mm

190 (7.5”)

190 (7.5”)

190 (7.5”)

Model BH/IN (Counter Models)

208 V/1 Ph

240 V/1 Ph

Wattage kW

2.5 kW

2.5 kW

 

 

 

Current A

12

10

Power factor Cos ϕ

>0.95

>0.95

Discharge rate mA

4

4

 

 

 

Coil mm

190 (7.5”)

190 (7.5”)

Model SH/BA (Counter Models)

208 V/1 Ph

240 V/1 Ph

208 V/3 Ph

Wattage kW

3.5 kW

3.5 kW

5 kW

 

 

 

 

Current A

max. 16

14.5

max. 16

 

 

 

 

Power factor Cos ϕ

>0.95

>0.95

>0.95

Discharge rate mA

4

4

4

 

 

 

 

Coil mm

190 (7.5”)

190 (7.5”)

190 (7.5”)

 

 

 

 

Model SH/IN (Built in Models)

208 V/1 Ph

240 V/1 Ph

208 V/3 Ph

 

 

 

 

Wattage kW

3.5 kW

3.5 kW

5 kW

Current A

max. 16

14.5

max. 16

 

 

 

 

Power factor Cos ϕ

>0.95

>0.95

>0.95

 

 

 

 

Discharge rate mA

4

4

4

Coil mm

190 (7.5”)

190 (7.5”)

190 (7.5”)

 

 

 

 

Model SH/WO (Counter Wok Models)

208 V/1 Ph

240 V/1 Ph

208 V/3 Ph

 

 

 

 

Wattage kW

3.5 kW

3.5 kW

5 kW

 

 

 

 

Current A

max. 16

14.5

max. 16

Power factor Cos ϕ

>0.95

>0.95

>0.95

Discharge rate mA

4

4

4

 

 

 

 

Coil mm

190 (7.5”)

190 (7.5”)

190 (7.5”)

Model SH/WO/IN (Built in Wok Models)

208 V/1 Ph

240 V/1 Ph

208 V/3 Ph

 

 

 

 

Wattage kW

3.5 kW

3.5 kW

5 kW

Current A

max. 16

14.5

max. 16

 

 

 

 

Power factor Cos ϕ

>0.95

>0.95

>0.95

 

 

 

 

Discharge rate mA

4

4

4

Coil mm

190 (7.5”)

190 (7.5”)

190 (7.5”)

 

 

 

 

Page

Part # 4521635 (03/04/08)

Maximum tolerance of power supply

Nominal voltage +6/-10%

Frequency

50/60 Hz

Protection class

IP X0

Min. diameter of pans

Approx. 12 cm ( 4.7” )

Max. ambient temperature: stockage

-20°Cto 70°C(-4°Fto 158°F)

Max. ambient temperature: function

-5°C to 40°C (23°F to 104 °F)

Max. relative humidity of air: stockage

10 to 90 %

Max. relative humidity of air: function

30 to 90 %

SECTION 3 – OPERATION

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) = maximum power.

Temperature Check

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 stops. As soon as the coil has cooled down, the Induction unit can be re-started.Turn the position of the control knob to “0” and then to the required power level (See Error Message, Section 6).

Power board

The temperature of the power board is checked by a temperature sensor. As soon as the heat sink is heated over 70°C (158°F), a cooling fan starts. A heat sink temperature of more than 80°C (176°F) automatically reduces 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 is reduced by 50% if the temperature reaches 75°C (167°F). As soon as the temperature reaches 90°C (194°F) the unit stops working and shows the error code “E06” (See Error message, Section 6).

Protection Overload Current

When inappropriate pan material or magnetic objects are detected on the heating area, the current in the induction coil may raise excessively. In order to protect the power board, the coil current is checked and as soon as the current in the coil exceeds the maximum tolerance, the generator stops and there is no further active energy exchange. The unit can be re-startedas soon as normal working conditions are reached.

Part # 4521635 (03/04/08)

Page

SECTION 4 – TESTS

Pan Material For Induction Cookers

When cooking with induction it is very important to use the appropriate pan material. The bottom of the pan is the element that closes the magnetic field generated by the induction coil. We highly recommend only appropriate induction pans be used with this equipment.

A quick test can be performed to determine if a pan is appropriate. For this test you will need 1- Liter (34 ounces) of water at a temperature of 20°C (68°F). Heat up the pan with the cooker set to maximum power and measure the time it takes for the water to boil. Compare your time that referenced by Garland: (2.5kW approx. 240 sec., 3.5kWapprox. 140 sec., 5kW approx. 80 sec., 8kW approx. 60 sec.). This heat-uptime gives you information regarding

the efficiency of the pan tested. Bad pans have considerably longer heating-uptimes for the same quantity of water.

A magnet can be used to determine whether the pan material is appropriate for induction cooking. The magnet must attach its self to the bottom of the pan. Please note, this magnet test will not determine the material structure of the pan or its efficiency. In some cases the magnet will attach itself to the bottom of the pan however, the pan may not

be suitable for use with induction cooking. Always use pans which are suitable and designed for induction cooking.

Pan Detection

The heating area is warmed up by the ATTENTION hot pan. To avoid injuries (burns) do

not touch the heating area.

These tests show whether the induction cooker is operating correctly when small diameter pans are used and, when small metallic objects are heated-upon the heating area.

This test will require 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”)

Test With Pans

Step

Action

Level

Result

 

 

 

 

1

Place the pan in

1...9 (12)

Heat, the indicator

 

the middle of the

 

lights

 

heating area

 

 

 

 

 

 

2

Push the pan

1...9 (12)

No heating, the

 

until the edge of

 

indicator does not

 

the pan is in the

 

light

 

middle of the

 

 

 

heating area

 

 

 

 

 

 

Test With Metallic Plates

 

Step

Action

Level

Result

1

Place the metallic

1...9 (12)

Heat, the indicator

 

plate 1 in the

 

lights

 

middle of the

 

 

 

heating area

 

 

2

Place the metallic

1...9 (12)

No heating, the

 

plate 2 in the

 

indicator does not

 

middle of the

 

light

 

heating area

 

 

 

 

 

 

Page

Part # 4521635 (03/04/08)

Power Rating

ATTENTION

The heating area is warmed up by the

hot pan. To avoid injuries (burns) do

 

 

not touch the heating area.

 

 

 

 

 

Step

Action

 

Level

Result

 

 

 

 

1

Place the pan

9 (12)

Heat, water is

 

on the heating

 

boiling

 

area until water is

 

 

 

boiling

 

 

 

 

 

 

 

2

Reduce the power

(12) 9...1

Heat rating

 

by turning slowly

 

reduces (water

 

the control knob

 

does not boil

 

 

 

 

anymore), phase

 

 

 

 

current reduces

 

 

 

 

continuously

Fan

With this test, the fan observation as well as the degree of soiling is verified. At the beginning of the test, the induction cooker should be cold. You need a pan with a bottom diameter of 28 cm (11”).

Step

Action

Level

Result

 

 

 

 

1

Place a pan on the

9 (12)

Heat

 

heating area and

 

 

 

fill it up with 1-

 

 

 

Liter or (34 oz) of

 

 

 

water

 

 

 

 

 

 

2

Measure the time

9 (12)

The fan should start

 

until the fan starts

 

working after 6-8

 

working

 

minutes

3

Go on cooking for

9 (12)

The heating process

 

about 30 minutes

 

may periodically

 

 

 

be interrupted for a

 

 

 

period of 2 seconds.

 

 

 

Unit keeps working.

 

 

 

 

4

Stop the induction

0

The fan keeps

 

cooker

 

working.

 

 

 

 

Test Of The Components

CAUTION

The power cord must be disconnected

from the power supply.

 

 

 

Rectifier

The rectifier is fixed at the power board with four wires. Rectifier connections must be unsoldered for correct test results To begin, you have to measure the forward 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 of about 0.5VDC in directionA – K, in the opposite direction is “NO” current flow.

If one of the four diodes shows a short circuit or an interruption, the rectifier is defective and must be replaced.

Part # 4521635 (03/04/08)

Page

Transistor module (IGBT)

G E

C

The IGBT (Insulated Gate Bipolar Transistor) is fixed onto the power print (board) with three solder connections.

The IGBT Transistor has as a supplementary protection an integrated recovery diode. To begin, measure the on-statevoltage of this diode. The forward voltage of this diode is approximately0.5VDC.

If the recovery diode shows a short circuit or an interruption, the IGBT transistor is defective and must be replaced.

CU (RTCS) Sensors

CU Sensor 1 (Center)

CU Sensor 2 (Outer)

4 – 5.5 Ohms

4 – 5.5 Ohms

The two CU sensors are mounted directly on top of the coil for base-line,(counter top) cookers. Both the center and outer sensors, will measure approximately 4 - 5.5 Ohms.

Potentiometer

The potentiometer is mounted onto the main power switch. On setting “0” the reading will be 0 - Ohms and on the maximum level, the resistor will read 10kOhm (10,000 Ohms). Resistor is proportional (linear) to swing angle. (see following photo for measurement points).

Page

Part # 4521635 (03/04/08)

Measurements taken across points shown.

SECTION 5 – MAINTENANCE/SERVICE

Maintenance work must only be completed by authorized personnel. Before beginning any maintenance work, ensure that all power supply is disconnected and the appliance has had an opportunity, to cool down. It is important that the following maintenance procedures be performed as recommended. Such preventative maintenance measures will extend the life of this equipment and will provide trouble free operation. The length of time used each and the use frequency will determine how often maintenance is required. Every cooker must be checked at least once a

year. The following routine maintenance should and must be completed periodically.

Fan

Function of the cooker can only be guaranteed if all electronic components are operated within their normal working conditions (temperatures).

The air inlet and air outlet slots must not be blocked.

The air filter must not be blocked by dirt or grease.

The airducts must be free of dirt.

The air must circulate unhindered through the heat sink (no hindrance).

The fan is correctly installed and in good operation.

The heat sinks are installed correctly and in place.

Check Induction coil

Mechanical, screw mountings (screws all tightened)?

Coil adhesive (coil wire in place o.k.)?

Ferrites (all mounted and in place o.k.)?

Copper coil (wire in place o.k.)?

Coil connections to power board ok? (Refer to the following Figures #1 and #2 for correct and incorrect, coil connections).

Part # 4521635 (03/04/08)

Page

General Checks

Protection connection grounded?

Screwed connections all tight?

Isolations of cables?

Any kind of liquids that have entered the cooker?

Dirt in the cooker?

Figure # 1 - Correct Coil (Spoil) Connection

This connection must be well insulated and slightly bent upwards so the terminal end, does not make contact with the high voltage section on the power board.

Coil wires must be tightly twisted together and precisely placed.

Page 10

Coil terminals must be connected in the direction shown in photo.

Part # 4521635 (03/04/08)