Kuppersbusch EKDG 6800.0-75 Service Manual
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Kuppersbusch EKDG 6800.0-75 Service Manual

Combi-steam cooker
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  • Page 1 [‡…zDkŒ}y… [‡‡ƒ}Š ]c\_ NPHHFHDOM ]c\_ NPHHFHDOM...
  • Page 2 Service Manual: H3-72-01 Responsible: D. Rutz KÜPPERSBUSCH HAUSGERÄTE AG Email: dieter.rutz@kueppersbusch.de Tel.: (0209) 401-733 Kundendienst Fax: (0209) 401-743 Postfach 100 132 Date: 20.10.2003 45801 Gelsenkirchen...

  • Page 3: Table Of Contents

    Overview of reference messages................ 37 Overview of the F-fault messages (procedure faults).......... 38 Overview of information, alarm and error signals for the EKDG 6800.0-75 ..39 Overview of the U-fault messages (power supply faults) ........41 Wrong behaviour ....................41 Circuit diagrams ......................

  • Page 4: Safety

    H3-72-01 Safety Danger! Repairs may only be carried out by a qualified electrician! Inexpert repairs may lead to risks and damages for the user! To prevent electric shocks, please observe the following tips: • In the event of faults, housing and frame may be live! •...

  • Page 5: General

    H3-72-01 General Depressurised steam cooking involves cooking food with a combination of steam and hot air. Gentle steam cooking at temperatures of between 40°C – 100°C optimally preserves vitamins and minerals as well as maintaining colours and natural aromas. Food does not dry out and nor will it burn or stick. Since only a relatively small amount of water needs to be heated, steam cooking means that a great deal of time and energy can be saved.

  • Page 6: Technical Features

    H3-72-01 Heating power Hot air power: 2.2 kW Steam generator: 1.4 kW Floor heater: 0.14 kW Technical features • Clear text display for indicating programs • Climatic sensor • Limestone sensor • Permanent regulation of oven air conditions • External steam generator •...

  • Page 7: Installation

    H3-72-01 Installation Safety instructions for technicians • Local electricity suppliers’ statutory regulations and conditions for connection are to be fully observed. • The appliance must be disconnected on being connected, on carrying out repairs and when changing a bulb. Disconnect the shock-proof plug or switch off the safety fuse. •...
  • Page 8 H3-72-01 in a standard niche (with a levelling panel, ZUB. 736 (in preparation)) Installation in kitchen units Installing the appliance • Put the plug into the socket. • If “U2” is indicated on the display, the plug must be turned. Should this not be possible, a qualified electrician must exchange the zero conductor and the terminal wire in the socket.

  • Page 9: Fittings And Operation Of The Ekdg 6800.0

    H3-72-01 Fittings and operation of the EKDG 6800.0 Appliance structure Emptying Induction water tank limestone sensor swivel arm hot air steam generator oven steam climatic sensor Display and control elements For internal use only...

  • Page 10: Acoustic Signals

    H3-72-01 Controls A ok K appliance off B oven lighting button for setting C time M clear text display D timer N operation time / timer E switch-off time O time / switch-off time operation time P oven display G oven temperature Q core temperature H core temperature R operational mode symbol...

  • Page 11: User Settings

    H3-72-01 User settings Language: select the required language (German, French, Italian or English) Childproof lock: on - off Utilisation of residual heat: on - off Time: visible - not visible Acoustic signal: soft - medium - loud Switch-off time: short - medium - long Oven lighting: with button only - automatic with door Display indicates “please wait, water is being pumped off”...

  • Page 12: Steaming

    H3-72-01 Operational modes The five operational modes (steaming, regenerating, baking like professionals, hot air and hot air with steam vapours) are divided into five different procedures. Each procedure comprises several steps, during which the functions are activated by means of one or more commands. The operational modes are distinguished as follows: Baking like Hot air with...
  • Page 13 H3-72-01 Filling in water The filling procedure is carried out in the following steps: On commencement of the operational mode, the presence of the water tank is monitored by means of a Reed switch. If the Reed switch is not activated, operation is discontinued, an acoustic signal sounds and “insert water tank and press OK”...
  • Page 14 H3-72-01 Continued steam heating Once a slight degree of excessive pressure has been reached, the surplus steam exits the oven in a controlled manner through an opening. The temperature at the exit opening is measured with a climatic sensor (ceramic NTC temperature sensor). The production of steam is interrupted if the temperature of escaping steam exceeds an empirically deducted threshold value.
  • Page 15 H3-72-01 4.5.2 Sequence diagram: Steaming Temperature Steam Hot air Time Operating time Hot air Altitude adjustment finished heater Initial actuation climatic sensor Evaporator heater Temperature Floor heater Time Supply air and vent flap open closed Time Speed of ventilator fan Hot air fan Time For internal use only...

  • Page 16: Regenerating

    H3-72-01 Regenerating Recommended oven temperature: 130°C Area of application: 100°C to 130°C On regeneration, the oven is heated with steam and hot air. This ensures fast, consistent heating up of the food without any drying out. The regeneration operational mode is suitable for: •...
  • Page 17 H3-72-01 4.6.2 Sequence diagram: Regenerating Temperature Steam Hot air Time Altitude adjustment finished Initial actuation climatic sensor Hot air heater Operating time Evaporator heater Temperature Floor heater Time Supply air and vent flap open closed Time Speed of ventilator fan Hot air fan Time For internal use only...

  • Page 18: Baking Like Professionals

    H3-72-01 Baking like professionals Recommended oven temperature: 210°C Area of application: 100°C to 230°C During the baking like professionals mode the food is firstly vaporised in an initial phase and operation is then automatically adjusted for the second “hot air phase” subsequent to a steaming period which depends on the quantity of food in the oven.
  • Page 19 H3-72-01 Continued heating with hot air (hot air phase) The hot air phase commences after the steam phase. The heater in the evaporator is switched off. The heater remains switched on at full power until the T pre-set oven temperature or given oven temperature is reached.
  • Page 20 H3-72-01 4.7.2 Sequence diagram: Baking like professionalsi Steam Hot air Time Altitude adjustment finished Initial actuation climatic sensor Operating time Hot air heater Evaporator heater Temperature Floor heater Cutoff time lag Time Supply air and vent flap open closed Time Speed of ventilator Hot air fan Time...

  • Page 21: Hot Air

    H3-72-01 Hot air Recommended oven temperature: 180°C Area of application: 30°C to 230°C On heating with hot air, the air in the oven is heated up by a heater located behind the back wall of the oven and is then circulated evenly throughout the oven by means of the hot air fan. The baked products are therefore heated up from all sides, enabling simultaneous baking at two or three levels.
  • Page 22 H3-72-01 Filling and heating with hot air See “1. Filling in water” on page 13 and then as follows: simultaneously with activating the supply pump, the hot air fan and the ventilator fan are switched on at a certain setting and the hot-air heater is activated at full power.

  • Page 23: Structure - Subassembly - Structural Components

    H3-72-01 Structure – subassembly – structural components Limestone sensor Limestone sensor and heat protection NTC 25°C/10 k ! Heater installed Heater with limestone Heater dismounted The amount of scaling is determined as two measured variables, namely the temperature of the heating spiral and the conductance of the level sensor.

  • Page 24: Descale

    H3-72-01 Since soft water or a domestic descaling device may result in the limestone sensor not actuating, after a certain number of hours of operation and for reasons of hygiene the clear text display will require the user to descale the system. In order to be able to recognise the water level in the evaporator by means of the level sensor, the average result of 80 readings during a period of 2 sec.
  • Page 25 H3-72-01 • Subsequent to circulation the rinsing liquid is heated up to a certain temperature [105°C] for a certain period [120 sec.] (time-controlled heating up!). • After having been heated up the rinsing liquid is cooled down to a certain temperature at the same time as emptying takes place (see Descale on page 24).

  • Page 26: Water System

    H3-72-01 Water system Water tank, 1.25 litres Ignition solenoid For internal use only...
  • Page 27 H3-72-01 5.4.1 Water inlet If, during a certain period, no water is recognised in the evaporator on filling, the supply of water is discontinued and the clear text display will indicate “Fill up with water”. The following may be the cause of a faulty water supply: •...

  • Page 28: Automatic Altitude Adjustment

    H3-72-01 Automatic altitude adjustment Sensor for altitude adjustment and water NTC 25°C/100 k ! Altitude adjustment is carried out automatically for the steaming, regenerating, baking like professionals and hot air with steam vapour modes. Automatic altitude adjustment enables the hot air temperature to be regulated with some difference in temperature below the maximum possible steaming temperature.

  • Page 29: Floor Heater 140 W With Protection Against An Excessive Rise In Temperature

    H3-72-01 Floor heater 140 W with protection against an excessive rise in temperature Rise in temperature Rise in temperature Rise in temperature Floor heater The floor heater serves the purpose of reducing the quantity of condensate on the floor of the oven. The quantity of water required during the cooking process can also be reduced by means of repeated evaporation.

  • Page 30: Recognising A Steam Leak With The Climatic Sensor

    H3-72-01 Recognising a steam leak with the climatic sensor climatic sensor Leaks, such as those caused by damaged or dirty door sealing, insufficient sealing of the hot air motor shaft, open vent flaps, blocked steam emissions, climatic sensors which are full of water or anything similar, will distort the temperature reading of the climatic sensor.

  • Page 31: Slide With A Magnetic Lifting Cylinder

    H3-72-01 Slide with a magnetic lifting cylinder Please note! On steaming, inlet air and outgoing air of the oven are closed. Protection against an excessive rise in oven temperature PT 500 12 V transformer for the water pump (return) Transformer print K2.8310 Excessive rise in temperature Drain pump...

  • Page 32: Electric Connecting Box

    H3-72-01 5.10 Electric connecting box Breakdown In the event of a breakdown, for example, on opening the door, settings such as operational mode, oven temperature and core temperature, operating time and switch-off time are maintained. Timing comes to a halt. Baking like Hot air with Breakdown...

  • Page 33: Removing The Guide Rack

    H3-72-01 Termination of operation Terminating operation with the OFF button immediately results in the operating mode, oven temperature and core temperature, operating time and switch-off time settings being deleted and the emptying of the evaporator being indicated on the clear text display and being carried out, should it have been possible to reduce the water temperature down to a certain level.

  • Page 34: Modifications To The Electronic Packaged Circuits

    H3-72-01 Modifications to the electronic packaged circuits General The following is a brief description of the most important modifications. Identification Electronic packaged circuits are indicated by means of an article no. and an additional version index which is separated by a hyphen. (Identification example: W1.2345-6, i.e. the version or the latest modification = 6).
  • Page 35 H3-72-01 Calculator in the customer service model: K2.84601 (for V-ZUG service), K2.84602 (for partner service), K2.84603, K2.84604 Available as of approx. Jan. 2002 Series comprises software version -0 and process version -1. (Note: calculators as of Feb. 2003 supply 110mA of electricity for the slider motor, while older versions only supply 80mA).

  • Page 36: Error And Alarm Messages

    H3-72-01 Error and alarm messages Should the control system have recognized a fault, it will firstly switch off all of the consumers and indicate a corresponding A-alarm message or F or U-fault message. There are four groups of fault messages which, depending on the reason for the fault, can be rectified by users themselves or by skilled customer service staff only: •...

  • Page 37: Overview Of Reference Messages

    H3-72-01 Depending on the cause of the fault, there are two principle possibilities to reset: resetable: Users can acknowledge the fault message by pressing a button. If there is still reason for the fault, there will be a renewed fault indication, either immediately or during the next program.

  • Page 38: Overview Of The F-Fault Messages (Procedure Faults)

    Heating spiral temperature gauge defect (NTC) Data security (EEPROM) defect Boiler heater defect Emptying defect Steam leakage monitor actuated 7.2.2 EKDG 6800.0-75 Fault Description Oven temperature gauge defect (Pt500) Food temperature gauge defect (NTC) Water temperature gauge defect (NTC) Air temperature gauge defect (NTC)

  • Page 39: Overview Of Information, Alarm And Error Signals For The Ekdg 6800.0-75

    H3-72-01 Overview of information, alarm and error signals for the EKDG 6800.0-75 Signal Faulty diagnosis of the Possible causes of the fault micro-controller Add water Water resistance remains Besides a lack of water in the tank, the following high although the pump is...
  • Page 40 H3-72-01 Signal Faulty diagnosis of the Possible causes of the fault micro-controller Resistance of the air Air temperature sensor short circuit, temperature gauge (NTC) interruption beyond the permissible range Faulty wiring (interruption, short-circuit, loose contact, etc.) Calculator defect, possibly as a result of moisture Motor current of the exhaust The motor exhaust air slider races,...

  • Page 41: Overview Of The U-Fault Messages (Power Supply Faults)

    H3-72-01 Signal Faulty diagnosis of the Possible causes of the fault micro-controller No signal Heater for hot air does not There is no supply on the L2 terminal of the heat up. calculator (instructions for installation observed?) Heater defect, interruption Thermostat F6 activated (manual resetting) Faulty wiring (interruption, short-circuit, loose contact, etc.)
  • Page 42 H3-72-01 Fault mechanisms of the power supply monitoring system The power supply monitoring system checks the following power supply criteria: • is the PE earthed conductor connected? • has a terminal wire been connected instead of the N zero conductor (excessive voltage on N)? •...
  • Page 43 H3-72-01 Oven temperature PT 500 RESISTANCE DEPENDING ON THE TEMPERATURE Resistance ( ! ) Temperature (°C) 539.7 579.2 696.15 886.4 979.35 1034.45 1422.45 Fault mechanisms A meter is incremented every 200 ! s in order to calculate the discharge time. If the time for discharging the reference resistance is lower than 400* 200 ! s (metre reading 400 is an indication of a resistance short circuit) or if it is higher than 1500* 200 ! s (metre reading...
  • Page 44 H3-72-01 Possible causes of faults • PT500 or reference resistance defect (short circuit, interruption) • Discharge capacitor defect (short circuit, discontinuity) • Wiring defect (plug connections, cable discontinuity, cable short circuit). • Wiring on the control device defect (filter capacitor defect, strip conductors excessively resistant). 7.5.3 Food temperature sensor RESISTANCE SEQUENCE...
  • Page 45 H3-72-01 Technical data Sensor element resistance NTC 50k ! Resistance at + 25°C Temperature gauging range +40°C... + 100°C Accuracy of measurement see table Temperature stability -10°C... +250°C for the sensor element (up to +260°C short-term) -10°C... +270°C for cables and handles (distance to the infrared heater 100 mm) Electric strength between...
  • Page 46 H3-72-01 Possible causes of faults • NTC temperature sensor defect (short circuit, discontinuity) • Wiring defect (plug connections, cable discontinuity, cable short circuit) • Wiring on the control device defect (filter capacitor defect, strip conductors excessively resistant) 7.5.5 Heating spiral sensor and steam temperature sensor The gauging of the heating spiral temperature and the steam temperature is monitored for sensor short cuts and sensor interruptions respectively.
  • Page 47 H3-72-01 7.5.6 Water level pin The water level pin is only indirectly monitored for short circuits. If, on emptying the boiler (see chapter «Emptying» beginning page 27), the level pin still detects water after pumping has been carried out several times (e.g. short circuit), a fault message will appear. An interruption of the level pin will be recognised indirectly on filling up the boiler.
  • Page 48 H3-72-01 7.5.7 Boiler heater When the boiler heater is switched on the water temperature is monitored during the process of altitude adjustment. A fault is indicated if the water temperature no longer rises and if it has not reached a certain level within a stipulated period of time.
  • Page 49 H3-72-01 7.5.8 Emptying The maximum pumping off time during the process of emptying is monitored. If, after a certain period of time, the water level pin still detects water, a fault will be indicated. Fault mechanisms The pumping-off procedure will be repeated if the water level pin still recognises water (EEPROM parameter) subsequent to the emptying time (EEPROM parameter) during the process of emptying.
  • Page 50 H3-72-01 7.5.9 Steam leak Fault mechanisms A fault will be indicated if, during a stipulated period of time, a certain degree of lifting in the case of the steam temperature is not reached. The steam leakage monitoring system is active if the boiler is switched on and the operating mode “hot air with vaporisation”...

  • Page 51: Circuit Diagrams

    H3-72-01 7.5.10 Boiler and water level pin scaled Fault mechanism Scaling of the boiler is detected during the process of altitude adjustment. If the difference between the temperatures of the heating spiral and the water, taken with several measurements, is too great, or if the water level pin has been recognized as being scaled several times, an alarm message will be indicated.

  • Page 52: Ekdg 6800.0

    EKDG 6800.0 Display VFD Control unit K2.8300 Calculator K2.8320...
  • Page 53 H3-72-01 For internal use only...
  • Page 54 H3-72-01 Circuit diagram legend Anschlusskasten Connecting box VFD-Display VFD display Netzfilter Power filter Bedienteil Control Prog. Gerät Prog. appliance Rechner Calculator Treiber Drive Drehgeber Shaft encoder ZUG Auge Sender ZUG eye transmitter ZUG Auge Empfänger ZUG eye receiver Tasteneingang Key input Heizung Boiler Boiler heater Trafoprint...

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