Garland EFW800 Service Manual

SERVICE/PARTS

MANUAL

GARLAND FONDANT WARMER

MODEL EFW800

FOR YOUR SAFETY:

DO NOT STORE OR USE GASOLINE

OR OTHER FLAMMABLE VAPORS OR

LIQUIDS IN THE VICINITY OF

THIS OR ANY OTHER

APPLIANCE

PLEASE READ ALL SECTIONS OF THIS MANUAL

AND RETAIN FOR FUTURE REFERENCE.

THIS PRODUCT HAS BEEN CERTIFIED AS COMMERCIAL COOKING EQUIPMENT AND MUST BE INSTALLED BY PROFESSIONAL

PERSONNEL AS SPECIFIED.

WARNING:

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY,

OR DEATH. READ THE INSTALLATION,

OPERATING AND MAINTENANCE

INSTRUCTIONS THOROUGHLY

BEFORE INSTALLING OR

SERVICING THIS EQUIPMENT

INSTALLATION AND ELECTRICAL CONNECTION

MUST COMPLY WITH CURRENT CODES:

IN CANADA - THE CANADIAN ELECTRICAL

CODE PART 1 AND / OR LOCAL CODES.

IN USA – THE NATIONAL ELECTRICAL CODE

ANSI / NFPA – CURRENT EDITION.

ENSURE ELECTRICAL SUPPLY CONFORMS WITH ELECTRICAL CHARACTERISTICS SHOWN ON

THE RATING PLATE.

Users are cautioned that maintenance and repairs must be performed by a Garland authorized service agent

using genuine Garland replacement parts. Garland will have no obligation with respect to any product that has been

improperly installed, adjusted, operated or not maintained in accordance with national and local codes or installation

instructions provided with the product, or any product that has its serial number defaced, obliterated or removed,

or which has been modified or repaired using unauthorized parts or by unauthorized service agents.

For a list of authorized service agents, please refer to the Garland web site at http://www.garland-group.com.

The information contained herein, (including design and parts specifications), may be superseded and is subject

to change without notice.

GARLAND COMMERCIAL RANGES LTD.

1177 Kamato Road, Mississauga, Ontario L4W 1X4 CANADA Phone: 905-624-0260 Fax: 905-624-5669

Part # 4521056 Rev 2 (02/21/12) Page 1

IMPORTANT INFORMATION

WARNING: This product contains chemicals known to the state of California to cause cancer and/or birth defects or other reproductive harm. Installation and servicing of this product could expose you to airborne particles of glass wool/ceramic fibers. Inhalation of airborne particles of glass wool/ceramic fibers is known to the state of California to cause cancer.

Part # 4521056 Rev 2(02/21/12)Page 2

TABLE OF CONTENTS

IMPORTANT INFORMATION. . . . . . . . . . . . . 2

DIMENSIONS AND SPECIFICATIONS . . . . . 4

GENERAL INFORMATION . . . . . . . . . . . . . . . 5

Serial Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wall Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OPERATING INSTRUCTIONS. . . . . . . . . . . . . 6

Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SEQUENCE OF OPERATION . . . . . . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 8

SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PARTS REPLACEMENT . . . . . . . . . . . . . . . . . 11

To Access Components . . . . . . . . . . . . . . . . . . . . . . 11

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

High Limit Thermostat . . . . . . . . . . . . . . . . . . . . . . 11

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Thermistor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 12

UPDATING PROGRAMS . . . . . . . . . . . . . . . . 13

MAINTENANCE AND CLEANING. . . . . . . . 13

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . 15

EFW800 PARTS BREAKDOWN . . . . . . . . . .16

EFW800 PARTS LIST . . . . . . . . . . . . . . . . . . . 17

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 9

Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SENSOR DATA . . . . . . . . . . . . . . . . . . . . . . . .10

Temperature - Resistance/Voltage Table . . . . .10

Sensor Diagnostic Procedure . . . . . . . . . . . . . . . . 11

Part # 4521056 Rev 2 (02/21/12) Page 3

DIMENSIONS AND SPECIFICATIONS

20"

[508mm]

12"

[305mm]

5.20"

[132mm]

4.02"

[102mm]

0.50"

[12.7mm]

13.55"

[344mm]

7.42"

[189mm]

8.34" MIN [219mm]

8.78" MAX [223mm]

Voltage Phase kW

120 1 .80 6.7

Clearances

Installation Entry

Sides Rear Crated Uncrated

0” 0"

15.8"

(401mm)

Nominal

Amperes

13.55"

(344mm)

24.11"

[612mm]

21.56"

[548mm]

24.75"

[629mm]

Connection Type

6' cord

w/NEMA 5-15P plug

Shipping

Weight

29 lb

(13.2kg)

Part # 4521056 Rev 2(02/21/12)Page 4

GENERAL INFORMATION

Users are cautioned that maintenance and repairs should be performed by a Garland authorized service agent using genuine Garland replacement parts. Garland will have no obligation with respect to any product that has been improperly installed, adjusted, operated or not maintained in accordance with national and local codes or installation instructions provided with the product, or any product that has its serial number defaced, obliterated or removed, or which has been modi ed or repaired using an authorized parts or by unauthorized service agents. For a list of authorized service agents, please refer to the Garland web site at www.garland-group.com or www.garlandcanada.ca. The information contained herein (including design and parts speci cations) may be superseded and is subject to change without notice.

It is essential that the instructions in this manual be strictly followed for the safe and economical operation of this equipment. If it is known or suspected that a fault exists on an appliance the appliance must not be used until a competent person has recti ed the fault. Service personnel should refer to the service manual supplied with the appliance.

Serial Plate Location

Electrical rating is shown on the serial plate and is readily visible on the rear of the unit next to the power supply cord inlet.

Safety

• DO NOT operate this appliance unless all service and access panels are in place and fastened properly.

• DO NOT attempt to repair or replace any part of this appliance unless all main power supplies have been disconnected.

• DO NOT clean this appliance unless the power supply is disconnected.

• DO NOT immerse appliance in water.

WARNING: To avoid serious personal injury:

• USE EXTREME CAUTION when setting up, operating and cleaning these appliances to avoid coming into contact with hot surfaces. Suitable protective clothing should be worn or proper utensils should be used to prevent the risk of burns.

• NOTE all warning labels and markings on this appliance, which call attention to further dangers and necessary precautions.

Wall Clearances

Back: 0

Sides: 0

Electrical Rating

• A quali ed person must make the installation in accordance with the authority having jurisdiction and local codes.

• This unit must only be operated by a quali ed person. DO NOT operate without reading this manual.

Part # 4521056 Rev 2 (02/21/12) Page 5

Voltage Power Current Power Inlet

120VAC,

60HZ

800

Watts

6.7

Amps

NEMA

5-15P

OPERATING INSTRUCTIONS

This appliance requires water in the tank for even heating. Before  rst use it is recommended that the inside of the tank be cleaned with a detergent soaked cloth, to remove fabricating and protective oils. Rinse with clean water and dry with a clean cloth.

The EFW800 is a full size 12” x 20” (305mm x 508mm) capacity fondant warmer. It is designed to maintain fondant temperature at 115 °F (46 °C). To achieve this, the appliance heats a water bath slightly higher than the required fondant temperature.

Operating Procedure

1. Fill the tank with water so that the level is between the minimum and maximum embossed lines on the inside wall of the tank.

2. Insert pans with a maximum depth not exceeding 4” (102mm).

3. Plug appliance into electrical outlet.

4. Turn on the appliance by pressing the switch marked ON – OFF in the ON position.

5. Lamp Test: After the control has initialized, the amber

WARNING indicator will illuminate for 10 seconds. This lets the operator know the lamp is functioning.

6. The appliance will initially heat the bath of water to a temperature of 145°F (63°C), then maintain it at 122°F, ±3 °F (50°C, ±2 °C). Temperatures are measured with a lid or pans in covering the tank.

Indicators

1. The power switch is illuminated when the switch is in the ON position and power is applied to the appliance.

2. The green READY lamp indicates the water bath has reached its normal operating temperature. Fresh cold fondant may take longer to heat. See the section Fondant Heating Hints for more details in the Operating Manual

4521055.

3. The amber WARNING lamp has multiple functions. A  ashing WARNING lamp indicates a low water condition. If the amber lamp is illuminated continuously it indicates a temperature sensor failure and service personnel should be contacted.

NOTE: Periodic checks should be made during operation to ensure that the water level does not fall below the lower embossed line. Should it do so, top up with fresh cold water. We recommend cleaning the tank and  lling with clean cold water to the embossed line after a low water condition.

IMPORTANT: After a low water condition,  ll with cold water. Only cold water will reset the  ashing lamp. Adding hot water will not reset the low water condition immediately. The lamp will continue to  ash if the water temperature does not drop below 100°F (38°C).

Part # 4521056 Rev 2(02/21/12)Page 6

SEQUENCE OF OPERATION

Turn on Power

Every heat cycle

check for a low water condition

Contol

initializes

(delay)

Warning Lamp

test - illuminates

for 10 seconds

Is Sensor

Yes

Is water

temperature

below

100F

Yes

Timed heater

output and

illuminate

warning

indicator

Keep warning

indicator

ashing

Low Water?

Yes

Set low water condition, ash

warning indicator for 10

minutes; reduce heating power

to 50%. Add cold water

(reduce sensor temperature to

100F) to reset low water

condition or reset if the

condition is corrected after 3

heating cycles.

Low Water condition

reset?

End

Continue normal

Yes

operation

Initiate fast

heating set point water will heat to

145F then go to

normal set point

Is Sensor OK No

Initiate normal set

point (nominal 122F)

(input selects

calibration oset)

Timed heater

output and illuminate

warning indicator

Part # 4521056 Rev 2 (02/21/12) Page 7

TROUBLESHOOTING

DESCRIPTION OF PROBLEM

Warning indicator lamp is  ashing.

Warning indicator lamp  ashes after  lling with water.

Warning indicator lamp is on continuously and water temperature is high.

Warning indicator lamp is on continuously, temperature is normal.

Water temperature and fondant temperature is high by 2 to 4°F (1 to 2.5°C).

Water temperature and fondant temperature is low by 2 to 4°F (1 to 2.5°C).

Heaters are not heating. No indicators come on.

Green indicator does not illuminate but unit works properly.

Amber warning indicator does not illuminate for 10 seconds at power up.

POSSIBLE

CAUSE

Water in tank is low. Fill with cold water.

The water was not cold enough to reset the low water condition.

Sensor could be shorted or the temperature abnormally high.

Sensor could be open or shorted but the control is functioning in a timed heating cycle mode.

Calibration adjustment is required.

Red light on controller. Replace controller.

No lights on power supply. Replace power supply.

Indicator lamp is defective. Replace lamp.

Control relay is defective. Replace controller.

Indicator lamp is defective. Replace lamp.

Control relay is defective. Replace controller.

The lamp will automatically turn o in 10 minutes. Replacing the water in the tank with cold water will reset the low water condition immediately.

Is water bath above 180°F (82°C)? Yes, sensor may be shorted or control relay shorted. Is water bath above 150°F (65°C) but below 180°F (82°C)? Sensor or circuit out of calibration. Check sensor resistance, check control output relay for shorts. Replace sensor or control if necessary.

Check sensor resistance and replace if necessary.

Verify power supply is adjusted to 12.0V DC. Moving jumper may not be necessary. Moving the calibration jumper from input terminal I5 to I4 reduces the temperature by 4°F (2.5°C) or to I3 reduces the temperature by 2°F (1°C).

Verify power supply is adjusted to 12.0V DC. Moving jumper may not be necessary. Moving the calibration jumper from input terminal I5 to I1 increases the temperature by 2°F (1°C) or to I2 increases the temperature by 4°F (2.5°C).

WHAT TO DO

Part # 4521056 Rev 2(02/21/12)Page 8

SERVICING

Introduction

Although this appliance has only an on-off switch and two indicating lamps there is a computerized control to provide accurate temperature control, fault diagnostics and low water detection. In most cases of component failure the control is designed to allow the appliance to continue operating in a service mode. It is important to understand the operation of the control and how it reacts to faults in order to properly diagnose and correct faults.

In order to maintain the safety and accuracy of the appliance it is also important to closely follow the parts replacement procedures and inspection guidelines. For safety and optimum performance use only parts obtained through Garland or an authorized service agency.

System Block Diagram

Power Supply

Tank

Computer

Control

Heater

Indicators

Sensor Input

Heater

Sensor

Service Procedure

When performing any service operations on this equipment it is important to perform the following inspections to maintain the performance and safety of the appliance.

Visual Inspection

1. Unplug the unit.

2. Drain the liquid from the tank.

3. Turn the unit over and remove the bottom.

4. Examine the insulation. It should not be moist or wet. Wet insulation could indicate the unit has been immersed in water. Assess any potential damage.

5. Remove the bottom insulation. Examine the silicon heaters. There should be no staining or delamination from the tank.

6. Examine the high limit thermostats and the position of the high limit bracket. The bracket is positioned so both limit thermostats are over the heaters. There should be no gap between the bracket and the heater. If there is, remove the bracket and bend it slightly so it makes contact with the heaters.

7. Look for any loose or damaged wiring.

8. Check fuse FS1.

System Checks

Check the Following in Powered State.

Warning: before applying power make sure the components are located in a safe manner. Always perform the visual inspection described above before applying power. Do not apply power if there is any damage to heaters, wiring or any components that might compromise safety.

The front control section can be removed from the body by removing the 4 screws on the sides and loosening the 2 nuts that attach the front section to the tank.

• Check for a green indicator on the power supply. If there is no indicator on, check input voltage to the power supply. If there is 120V AC present at the input terminals and no output the power supply must be replaced. There are no serviceable components in the power supply.

• Check the output of the power supply. It should be

12.0V DC ± 0.1V DC. There is a voltage adjustment potentiometer next to the green indicator. If the power supply cannot be adjusted to 12.0V DC ± 0.1V DC, it could indicate there is a problem either with the power supply or the load attached to it (the controller or sensing circuit). Typically if a voltage regulator is defective the voltage error will be greater than 2 volts.

• Check the voltage between 12 volt – terminal and the load side of fuse FS1. 12 volts should be present.

• Check the indicator lamp on the electronic control. In normal conditions it will be green. If it appears red the control has malfunctioned. If the indicator is red the control must be replaced.

Part # 4521056 Rev 2 (02/21/12) Page 9

SENSOR DATA

I6, -12V

VR1

The sensor used on the model is an NTC (negative temperature coe cient) thermistor. This is a sensor whose resistance decreases with an increase in temperature.

The sensing circuit is arranged as a voltage divider circuit shown below. The data chart shows the thermistor resistance out of the circuit, in the circuit and voltage measured at the input if the circuit is energized versus temperature.

+12VDC

11k, 1%

10k

temperature sense

computer

20k 1%

internal resistance 76k ohm

22uf

Temperature - Resistance/Voltage Table

Temperature - Resistance/Voltage

Temperature

°C °F

150 302 187.2 185.01 0.20

145 293 210.3 207.54 0.22

140 284 236.9 233.41 0.25

135 275 267.5 263.06 0.28

Resistance

Out Of Circuit

In-Circuit

Resistance

Voltage

In Circuit

(I8 to -)

Temperature - Resistance/Voltage

Temperature

°C °F

130 266 303.0 297.31 0.32

125 257 344.2 336.88 0.36

120 248 392.2 382.72 0.40

115 239 448.3 435.96 0.46

110 230 514.1 497.93 0.52

105 221 591.6 570.29 0.59

100 212 683.1 654.85 0.67

95 203 791.6 753.91 0.77

90 194 920.9 870.28 0.88

85 185 1075 1006.65 1.01

80 176 1261 1167.98 1.15

75 167 1485 1357.67 1.32

70 158 1756 1580.69 1.51

65 149 2087 1843.95 1.72

63 145 2256 1974.84 1.83

60 140 2491 2152.37 1.96

55 131 2989 2514.34 2.23

50 122 3604 2935.76 2.53

45 113 4369 3424.15 2.85

40 104 5326 3985.40 3.19

35 95 6530 4623.27 3.55

30 86 8056 5339.34 3.92

25 77 10000 6129.03 4.29

20 68 12500 6985.29 4.66

15 59 15720 7888.23 5.01

10 50 19920 8821.56 5.34

5 41 25440 9759.33 5.64

0 32 32740 10672.18 5.91

-5 23 42470 11533.50 6.14

-10 14 55580 12322.86 6.34

-15 5 73390 13023.59 6.51

-20 -4 97820 13627.55 6.64

-25 -13 131700 14134.09 6.75

Resistance

Out Of Circuit

In-Circuit

Resistance

Voltage

In Circuit

(I8 to -)

Part # 4521056 Rev 2(02/21/12)Page 10

SENSOR DATA continued

Sensor Diagnostic Procedure

1. Visual inspection – is sensor mounted correctly? Is there any visible damage to the sensor wires?

2. Check sensor resistance for open or short circuit conditions.

PARTS REPLACEMENT

To Access Components

1. Unplug the unit.

2. Drain the liquid from the tank.

3. Turn the unit over and remove the bottom (10 screws).

4. Access front controls by removing 4 screws from the sides and loosen 2 nuts securing the front section to the tank.

3. Check sensor resistance and compare with the sensor temperature.

4. Check the power supply voltage. It must be 12.0V DC.

5. Check the voltage at the control input. Does it match the above table?

8. Peel the protective liner from the heater. Carefully align the heater making sure it is square and even with one edge of the tank. Start applying the heater from the narrow edge in a slightly curved manner. Press the heater to the tank applying from one side to the other. Applying the heater in this manner will reduce the chance of trapping air between the heater and the tank. Press the heater down across the entire surface of the heater. This helps to set the adhesive.

Heater

1. Remove the High Limit Bracket.

2. Remove the Bracket Spacer.

3. The heater is attached to the tank bottom with a pressure sensitive adhesive. To remove the old heater, disconnect the heater electrical connections. Peel the old heater away from the tank.

4. Scrape as much of the old adhesive from the tank with a sharp blade.

5. Use a 150-200 grit water paper to take o any remaining adhesive. It is important to remove the old adhesive. Installing the new heater without removing the old adhesive will reduce the heat transfer to the tank and reduce the life of the heater.

6. Clean the area with isopropyl alcohol. Clean any lint or  bers from the surface.

7. Replace the Bracket Spacer. This is to ensure the heater is placed so it does not interfere with the bracket.

9. Replace the high limit bracket. If must make contact with both heaters. The bracket may have to be bent slightly toward the heaters.

10. Connect the wires, one to the high limit and the other to the red wire.

11. Test and re-assemble the unit.

High Limit Thermostat

1. Remove the electrical connections.

2. Remove 2, 4-40 nuts from the old thermostat.

3. Verify the part number and temperature value is correct. Component identi cation varies with manufacturer. The Honeywell version is marked L215 (opens at 215°F/102°C). The Selco version is marked OA-220 (open at 220°F/104°C).

4. Install the new thermostat.

5. Replace the 2, 4-40 nuts. Do not over tighten.

6. Replace the electrical connections.

7. Test and re-assemble the unit.

Part # 4521056 Rev 2 (02/21/12) Page 11

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