Garland IN/MO 7000 Service Manual

SERVICE MANUAL

MODUL-LINE

BUILT-IN INDUCTION COOKERS

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86037

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MODEL: IN/MO 7000

GARLAND COMMERCIAL INDUSTRIES

185 East South Street
Freeland, Pennsylvania 18224
Phone: [phone]
Fax: [phone]

Part # 4526029 (02/22/11) © 2008 Garland Commercial Industries, Inc.

Part # 4526029 (02/22/11) Page 1

GARLAND COMMERCIAL RANGES, LTD.

1177 Kamato Road, Mississauga, Ontario L4W 1X4
CANADA
Phone: [phone]
Fax: [phone]

Enodis UK LTD.

5E Langley Business Centre
Station Road, Langley SL3 8DS Great Britain
Phone: [phone]
Fax: [phone]

Part # 4526029 (02/22/11)Page 2

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

Recti er Circuit Board C014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

CPU-Circuit Board C018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

Recti er 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
quali ed 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 service- and maintenance operator must have
knowledge of the following components :

• Diodes

• Z-Diodes (Zener-Diodes)

• Recti ers (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.

Part # 4526029 (02/22/11)Page 4

SECTION 2 – SYSTEM DESCRIPTION

Block Schematic

L1,L2,L3

PE

208VAC

230VAC

heatsink

23VAC

ST5
ST2/3,4

4

ST4

CPU

4

ST6

c014

230VAC

ST1

lter coil

300VDC

8

ST1

24VDC

ST8

c026

1x,2x,3x,4 x

LED
24VDC

5

c014

coil

4

ST7

ST1/1,4

supply
24VDC

ST2/1,2

c018

Relay
24VDC

M

fan
230VAC

Part # 4526029 (02/22/11) Page 5

Voltage Supply

• Coil temperature

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
di erent 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-circuit board (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-recti er,
After the recti er there is a direct voltage of 300V. The
inductance that follows  lters high frequency (EU) current .

• 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 the CPU-Circuit board (C018)

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

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

• Lamp out: Field is cut out

• Lamp  ashes brie y Pan detection (pan is searched)

• Lamp  ashes an error code: Error message (see Error
Messages table)

• Lamp continuously on: Power on

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)

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  elds (for example the surface covering this
induction type) the display can be overwritten from another
 eld. As far as the error code display is concerned, the lower
 eld has priority.

LED5 lead to the outside for an external lamp also. This is the
general error lamp for all  elds 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  eld
and the lower error code have priority.

Part # 4526029 (02/22/11)Page 6

Error Messages

LED 8 LED 7 LED 6 Code Signi cation 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 “o “)

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  ashes 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.

Part # 4526029 (02/22/11)Page 8

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

Compare on another
cooking platform and with
an induction type pan

Replace power circuit

M12

board

1 S01

No coil current
Hardware overcurrent

U10 Non induction type pan M10

U11 Coil defective M11 Check coil L

Power circuit board

U12

defective

E

L

2 S02

3 S03 Temperature heat sink U30

High coil current
Software overcurrent

U10 Non induction type pan M10

U12

U13

U14

U31 Dirty fan/heat sink M31 Clean fan L

U32 Fan defective M32 Check fan L

U33

U34 Sensor Heat sink defective M34

U14

Power circuit board
defective

Error on DIP-Switch­adjustment on CPU

CPU-circuit board
defective

Air entrance/exit
obstructed

Recti er circuite board
defective

CPU-circuit board
defective

Compare on another
cooking platform and with
an induction type pan

Replace power circuit

M12

board

Check DIP-Switch

M13

adjustment

M14 Replace CPU-circuit board L

M30 Clear air transport E/L

Replace recti er circuit

M33

board

Check sensor and heat
sink

M14 Replace CPU-circuit board L

E

L

L

L

L

4 S04

5 S05

Legend: W = Who should complete “Measure” E = End user L = Supplier

Part # 4526029 (02/22/11) Page 9

Temperature cooking
platform

Operational control
Line break

U40 Empty cooking M40 Empty pan E

U41 Interruption of coil sensor M41 Check coil sensor L

Operational control

U50

defective

M50 Check operational control L

Problem Possible Cause Measure

Code No. No No W

No Normal operation

6 S06 Inside temperature U60

U14

Ambient temperature too
high

CPU-circuit board
defective

Check ambient

M60

temperature

M14 Change CPU-circuit board L

L

7 S07

8 S08

9 S09

10 S10

11 S11

12 S12

13 S13

Cooking platform
Sensing element

Communication error
(Serial interface)

Sensing element

U70

Coil temperature
Short circuit

Check coil sensing

M41

element

U100 Line break M100 Check connection L

U101

Operational control
defective

CPU- circuit board

U14

defective

M101 Replace operation L

M14 Replace CPU-circuit board L

L

14 S14

15 S15

Legend: W = Who should complete “Measure” E = End user L = Supplier

Part # 4526029 (02/22/11)Page 10

Additional Errors

Problem Possible Cause Measure

Code No. No No W

No Operation lamp is continuously “ON”

Cooking platform does not

S20

heat enough

U10 Non induction type pan M10

U200 1 phase is missing M200

U12 Power board defective M12

CPU-circuit board

U14

defective

Compare on another
cooking platform and with
an induction type pan

Check mains cable
connection

Replace power circuit
board

M14 Replace CPU-circuit board L

E

L

L

Cooking platform

S21

continuously on
maximum power

Empty cooking platform

S22

switches “on“

Little metallic objects are

S23

heated on the cooking
platform

No. Operation lamp  ashes

Cooking platform does not

S24

heat at all

U220 Pan detection defective M220 Check pan detection L

U220 Pan detection defective M220 Check pan detection L

U240

U200 1 phase is missing M200

U220 Pan detection defective M220 Check pan detection L

U241 Short circuit on generator M241

Operational control

U50

defective

CPU-circuit board

U14

defective

Power circuit board

U12

defective

Pan too small (Diameter
less than 12cm, 4.75”)

M50 Check operational control L

M14 Replace CPU-circuit board L

Replace power circuit

M12

board

M240 Use appropriate pan E

Check connection of
mains cable

Replace or repair
generator

L

L

L

Legend: W = Who should complete “Measure” E = End user L = Supplier

Part # 4526029 (02/22/11) Page 11

Problem Possible Cause Measure

Code No. No No W

No. Operation lamp and error lamp “OFF”

Unit does not heat, no

S25

reaction, contactor does
not work

U250

U251

Building’s power fuses
defective, error on
electrical transmission

Error on operational
control

M201 Check mains supply L

M251 Check operational control L

Building fuses blow when

S26

unit is switched on

Some cooking platforms

S27

do not heat

Unit does not heat, no

S28

reaction, no contactor

Legend: W = Who should complete “Measure” E = End user L = Supplier

U241 Short circuit in generator M241

U271 Generator defective M241

Error on DIP-Switch-

U13

adjustment on CPU

Repair or replace
generator

Repair or replace
generator

Check DIP-Switch

M13

adjustment

Repair Of Problems

Measure Activity Comment

M10 • Compare on another cooking platform and with an induction

type pan

M11 • Check connection of coil

• Check coil on line break

• Coil overheated (brown color change)

M12 • Change power circuit board

M13 • Check DIP-Switch adjustment on CPU-circuit board

M14 • Replace CPU-circuit board

M30 • Clear ventilation system

M31 • Clean fan

M32 • Connect fan directly at 230V

M33 • Change recti er circuit board

M34 • Measure heat-sink temperature sensor resistor

At 25º Celsius (77ºF) resistor will read 20kOhm
At 70º Celsius (158ºF) resistor will read 3,5kOhm

• Check short circuit to case

• For a test: short-out the sensor with a 20kOhm  xed resistor

Check if the pan is appropriate to
induction cooking or not: use a
magnet.

Disconnect temperature sensor

L

L

L

M40 • Switch o unit, cool down and switch on again. Use a pan with

cold water

Switch o  eld!

Part # 4526029 (02/22/11)Page 12

Measure Activity Comment

M41 • Measure the resistance of coil temperature sensor resistor

Disconnect sensing element
at 25º Celsius (77º F) resistor will read 1kOhm
at 180º Celsius (356ºF) resistor will read 3,5kOhm

• Resistor is higher on a higher temperature (PTC-resistor)

• Replace sensor with a value less than 900Ohm

• For a test: Short-out the sensor with a 1kOhm  xed RESISTER

M50 • Measure operational control or main power control switch with

potentiometer: Potentiometer is 10kOhm and linear

Disconnect operational control

(Poti)

• On level “0”: resistor = 0 Ohm

• On maximum level resistance= 10kOhm

• Resistor is proportional (linear) to swing angle

M60 • Measure temperature inside the case

• Admissible ambient temperature: 0°C/32ºF to appr. 70°C/158ºF

• Check point is on the CPU-circuit board

M100 • Check connection cable for serial operational control and

CPU-circuit board

M101 • Change serial operational control

M200 • Check mains cable, perhaps one phase missing

• Check the building fuses

M220 • Disconnect ST2 on CPU-circuit board and measure resistance

between brown and blue,
Measured value: 200Ohm < R < 2kOhm

• Replace recti er circuit board

M240 • Use suitable pan material

• Test with a pan with a diameter of 24cm (4.75”)

M241 • Disconnect mains power supply

• Visually inspect : blackened cables, components or strip
conductors?

• Transistor module: measure internal diodes (UF = 0.4V)

• Recti er: measure internal diodes (UF = 0.5V)

• Control trafo: measure electric voltage

• Check power supply CPU-print +24V
CPU-circuit board ST1/1 and ST1/4 (24V +/- 1V)

M251 • Check power switch on operational control

Part # 4526029 (02/22/11) Page 13

Adjustments

2. Errors can occur after wrong adjustments

This induction unit has been correctly adjusted by the
manufacturer. Any adjustments have to be made with
caution. Please pay attention to the following points:

1. Note the original position of the poti’s: remember the
number of turns you make.

Switch Position

DIP-Switch for

generator type

0

1 ON

2ON

3ONON

4ON

5ONON

6ONON

7 ONONON

8ON

9ON ON

10 ON ON

11 ON ON ON

12 ON ON

13 ON ON ON

14 ON ON ON

15 ON ON ON ON

8765

3. Only small corrections can be made with adjustments

Generator Type

The generator type is adjusted in the binary code with the
DIP-switches 5 to 8 on the CPU-circuit board

Switch Power

Summary: software and generator type

The following list shows the number of types of the various
generators.

Please note the positions of the power switches from the
above table.

Typ e

MO/DU 7000, 208V 6 and 8 on

MO/DU 7000, 400V 5 and 8 on

DIP

Switch setting

Pan detection

The potentiometer on the recti er circuit board is used to
adjust the pan detection:

Turn clockwise: acceptance of smaller pans

Turn counterclockwise: only bigger pans are accepted

Power

Only one potentiometer per  eld is available on the power
circuit board to adjust the power:

Turn clockwise: less power

Turn counterclockwise: more power

Repair by Garland

If the generator has to be repaired by the manufacturer,
please enclose an exact description of the error. If possible,
use the original package for the return. If it isn’t available,
do not use porous material for wrapping (like styropor). This
could enter the unit and the electronic parts and is di cult
to remove.

Part # 4526029 (02/22/11)Page 14

SECTION 5 – APPENDIX

Internal Connections

Recti er Circuit Board C

View solder side

poti for pa n detector

9 10 11 12

230V Venti

Part # 4526029 (02/22/11) Page 15

CPU-Circuit Board C

View components side

eld 4(8
eld 4(7

coil- eld 3(5
sensor eld 2(4
1k eld 2(3

heatsink- eld 3(5
sensor eld
20k eld 2(3

eld 3(6

eld 1(2
eld 1(1

eld 4(8
eld 4(7
eld 3(6

3(4

eld 1(2
eld 1(1

external temp'sensor

optinal

1 2

eld 4(8
eld 4(7

current- eld 3(5
meas. eld 2(4
signal eld 2(3

power- eld 3(5
control eld 2(4
(poti 10k)

RS485 (3
optional (2

3 Poti
optional

eld 3(6

eld 1(2
eld 1(1

eld 4(8
eld 4(7
eld 3(6

eld 2(3

eld 1(2
eld 1(1

DIP-Switch

1)

2)

3)

4) connection

5) to c026

6)

7)

8)

1)

2) connection

(4

(1

3) to c014

4)

1) lamp 1

2) lamp 2

3) lamp 3

4) lamp 4

5) lamp 5

6)

7)

8) +24VDC

Part # 4526029 (02/22/11)Page 16

Power Circuit Board C

p

View components side

IGBT pre

drive

power

adjustment

eld 1

Connection

with

c018 –

logic board

current

measure

signal

POT1-4 und ST5

o

tional

power

adjustment

eld 2

IGBT pre

drive

Coil connection

eld 1

Part # 4526029 (02/22/11) Page 17

Coil connection

eld 2

Tran sf orme r

supply transformer

for logic board

contactor ignition

and fan

Recti er And Transistor Module

-

+

L3

L2

L1

8

230VAC outlet (fan)

7
6

5

230VAC outlet (contactor ignition)

4

mains supply voltage

3

( 208V/ 230V / 400V AC)

2

1

23VAC outlet (logic supply)

+

C2/E1

E2

C1

C2/E1

3

2 1

solder side view
rectier board

C1

­E2

solder side view
power board

Item 2: transistormodul IGBTItem . 1: rectier

Part # 4526029 (02/22/11)Page 18

Part # 4526029 (02/22/11) Page 19