Garland GIWOK 5.0, GIU 5.0 BI, GIU 1.5, GIU 3.5, GIU 5.0 User Manual
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SERVICE MANUAL
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86037
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INDUCTION COOKERS WITH RTCS TECHNOLOGY
(REAL TIME TEMPERATURE CONTROL SYSTEM
COUNTER TOP/BUILT IN/WOK MODELS
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)
GARLAND COMMERCIAL INDUSTRIES
185 East South Street
Freeland, Pennsylvania 18224
Phone: (570) 636-1000
Fax: (570) 636-3903
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 RANGES, LTD.
1177 Kamato Road, Mississauga, Ontario L4W 1X4
CANADA
Phone: 905-624-0260
Fax: 905-624-5669
Enodis UK LTD.
Swalloweld Way, Hayes, Middlesex UB3 1DQ ENGLAND
Telephone: 081-561-0433
Fax: 081-848-0041
Part # 4521635 (03/04/08) © 2006 Garland Commercial Industries, Inc.
Part # 4521635 (03/04/08) Page 1
TABLE OF CONTENTS
SECTION 1 –SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Description Of Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Personnel Qualication 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
Rectier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 nding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Part # 4521635 (03/04/08)Page 2
SECTION 1 –SAFETY
Description Of Warning Signs
Identies 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
Warning signs mounted directly on the cooker must be
observed at all times and kept in a fully legible condition.
which could result in minor personal
injury or property damage.
Electromagnetic eld.
Personnel Qualication And Training
All persons involved in assembly, installation, commissioning,
operation and maintenance must have the appropriate
qualications. The scope of responsibility, competence and
supervision of the sta must be dened 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 qualied 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 qualied 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 3
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”)
Part # 4521635 (03/04/08)Page 4
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°C to 70°C (-4°F to 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-started as soon as normal working conditions
are reached.
Part # 4521635 (03/04/08) Page 5
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 eld 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., 3.5kW
approx. 140 sec., 5kW ➔ approx. 80 sec., 8kW ➔ approx.
➔
60 sec.). This heat-up time gives you information regarding
the eciency of the pan tested. Bad pans have considerably
longer heating-up times 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 eciency. 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
These tests show whether the induction cooker is operating
correctly when small diameter pans are used and, when
small metallic objects are heated-up on 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”)
hot pan. To avoid injuries (burns) do
not touch the heating area.
Test With Pans
Step Action Level Result
1 Place the pan in
the middle of the
heating area
2 Push the pan
until the edge of
the pan is in the
middle of the
heating area
1...9 (12) Heat, the indicator
lights
1...9 (12) No heating, the
indicator does not
light
Test With Metallic Plates
Step Action Level Result
1 Place the metallic
plate 1 in the
middle of the
heating area
2 Place the metallic
plate 2 in the
middle of the
heating area
1...9 (12) Heat, the indicator
lights
1...9 (12) No heating, the
indicator does not
light
Part # 4521635 (03/04/08)Page 6
Power Rating
Test Of The Components
The heating area is warmed up by the
ATTENTION
Step Action Level Result
1 Place the pan
on the heating
area until water is
boiling
2 Reduce the power
by turning slowly
the control knob
hot pan. To avoid injuries (burns) do
not touch the heating area.
9 (12) Heat, water is
boiling
(12) 9...1 Heat rating
reduces (water
does not boil
anymore), phase
current reduces
continuously
Fan
With this test, the fan observation as well as the degree of
soiling is veried. 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
heating area and
ll it up with 1Liter or (34 oz) of
water
2 Measure the time
until the fan starts
working
3 Go on cooking for
about 30 minutes
4 Stop the induction
cooker
9 (12) Heat
9 (12) The fan should start
working after 6-8
minutes
9 (12) The heating process
may periodically
be interrupted for a
period of 2 seconds.
Unit keeps working.
0 The fan keeps
working.
CAUTION
The power cord must be disconnected
from the power supply.
Rectier
The rectier is xed at the power board with four wires.
Rectier 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
direction A – K, in the opposite direction is “NO” current ow.
If one of the four diodes shows a short circuit or an
interruption, the rectier is defective and must be
replaced.
Part # 4521635 (03/04/08) Page 7
Transistor module (IGBT)
G
E
C
CU (RTCS) Sensors
The IGBT (Insulated Gate Bipolar Transistor) is xed 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-state
voltage of this diode. The forward voltage of this diode is
approximately 0.5VDC.
If the recovery diode shows a short circuit or an
interruption, the IGBT transistor is defective and must be
replaced.
CU Sensor 1 (Center)
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.
CU Sensor 2 (Outer)
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).
Part # 4521635 (03/04/08)Page 8
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