AEG 88101 Service manual

HOBS

Publ.-Nr.

599 519 523

685

EN

Repair-Instruction for induction hobs

Germany

Fax +49 (0)911 323 1022

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These instructions serve the repairing of autarkic cooking hobs and cooking hobs in combination with an oven with 3 or 4 inductions cooking zones respectively of the type E.G.O.. Also includes hobs with

2 induction zones (Domino, Mixed, Mixed gas) and the Frontline appliance series.

Please search for the corresponding alarm

symptom and then go through the alarm remedy measures from top to bottom.

Information concerning the replacement of parts is to be found in the corresponding replacement instructions or are included with the spare parts.

All work is only to be carried out on the induction modules and the heating elements are only to be carried out after they have been disconnected.

A leak current of 5mA is normal and is therefore much higher than with other appliances.

1.2 Standby

The Standby power consumption amounts to < 1W (Induction plus user interface in the autonomous, exception Frontline up to 2W).

The µprocessor for the measuring of the coil temperature is deactivated in standby, i.e. should the cooking hob be heated up to hot pan being on the zone, no heating display "H“ is displayed when switched off.

In this condition, the ventilator is also not switched on by external heating.

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1.3 Block Diagram/Hob elements

3

Cover plate

Cooling fan

Power mod. Left

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Coils incl. Temperature sensors.

Touch control w. carrier

Coil carrier

PowerMod. Right

Filter pcb

Induction module w. plastic housing incl. mains terminal

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2.1 Appliance not functioning at all, cannot be switched on

References e.g. (1) refer to the illustrations in Chapter 2.8

Alarm Symptom Cooking

Hob

Display

House fuse triggered None

Possible Alarm

Cause

Incorrect connection at the power connection terminal .

Final induction phase defect.

Cooking field cannot be switched on.

Normally no "pips" approx. 4 sec. after mains voltage is applied respectively no quick flashing up of the display in the cooking zone with not selfsufficient cooking zones or front line appliances. longer reacts

No mains voltage or incorrect connection

(1 phase missing ->no control voltage; N not connected to terminal 4 and 5 not connected)

No 5VDC betw. Pin 1 +

3 of the Bus for the

Touch Control

Alarm Remedying

(1) Test the pin assignment and

230VAC between N and the phases on the supply line.

See chapter 3 Testing Power Component using the house fuse, reactivate after approx. 10 sec..

(1) Test the pin assignment and

230VAC between 4 N and the 2 phases on supply line terminals 1 and 2.

Both of the "N“s should be connected to terminals 4 + 5, if appr. jumper.

Connector of the cable to the Touch Control /

Display not inserted.

Fuse strip conductor burnt out and/or final induction phase defect

(2) Test 1+3 5VDC on the underside of the cooking field

(corresponds with the external lines of the bus between filter and Touch

Control), if not applied, replace the

Filterboard.

Caution: this is difficult to test from underneath using normal test probes!

(3) Test connector at the filter and Touch

Control.

Reapply the mains voltage.

See chapter 3 "Check power section'"

Every 5-10 sec "beep" of touch control

None defect.

N not connected to terminal 4 or 5.

Only Frontline appliances: cooking zone can not be activated. Display fully on for more than 5 sec.

All indications

ON

Flat band cable between user interface and glass (touch keyboard) not plugged correctly. replaced: replace Touch Control, ensure that the Touch Control is applied to the glass .

(1) Test the pin assignment and

230VAC between 4 N and the 2 phases on supply line terminals 1 and 2.

Both of the "N“s should be connected to terminals 4 + 5, if appr. jumper.

Check line for seat and correct position

(contact direction), see capter

"References Frontline"

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2.2 Individual cooking zones do not work (partially) or work incorrectly or cannot be used

Alarm Symptom Cooking

Hob

Display

Pan does not heat up.

Normal cooking phase

Display "F" with 2 hobs with all pots

(also 1 hob with 3 hob models)

"F“

Flashing

"F“

Possible Alarm

Cause

Alarm Remedying

Pan in the border area of the pan detection and only works with low power

Use different pot or this pot on a smaller hob. See Chapter 4 Pot Detection

Information

Coil not correctly connected.

Distance between coil and glass ceramic too large.

1 phase missing ; only possible with induction SW.Ver.

0.50.

Check whether the pots or pans are suitable for induction. See 4 Pot Detection

Information

Check whether the coil lines are connected and the torque has been adhered to.

Check whether the coil is applied to the glass ceramic and whether the glass was pushed was pushed down when screwing in position.

(1) Test the pin assignment and

230VAC between 4 N and the 2 phases on supply line terminals 1 and 2.

Both of the "N“s should be connected to terminals 4 + 5, if appr. jumper.

Should the above not succeed, replace the affected power component..

Demo mode activated.

See Chapter 5.2 No power on all hobs Normal cooking phase

Individual buttons cannot be used or cannot always be used.

Cooking hob power too low or not provided for a longer duration.

Normal cooking phase

Touch Control defect. 1) See Chapter 5. Touch Control Autarkic

Cooking Hobs Information..

2) Should this not help, replace Touch

Control.

Incorrectly installed, exhaust not possible to the front.

(4) Change installation situation.

(bottom bent)

Induction coil is not applied to the glass ceramic

Fan does not start.

Check whether the glass ceramic was pushed down when being screwed in position and the coil has been correctly positioned.

1) When setting a cooking phase >0, the fan runs at a slow speed. If not, check the fan for foreign bodies, remove these where appropriate.

2) If necessary, replace fan.

3) Should this not succeed, replace power component.

"H" in display when cooking hob and oven cold and switched off. defect. temperature sensor . Also see Instructions

"E4“.

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2.3 Alarm message "E“

When the appliance is switched on, "E“ / „xx“ Alarm Number is displayed in the timer display. With

Frontline the display of the front zone indicates the error number when switching on. The affected zones are subsequently displayed with an "E" in the cooking phase display and are thereby disabled.

The other zones can still be used. example (left touch control / right indication in the cooking zone):

1) Display alarm number after switching on for 10 sec.

Alarm number

E 5

2) 2 zones are disabled.

0

E

E

0

"E3“

"E4“

Under voltage or over voltage, is only displayed for 10 sec. after voltage has been applied.

Coil temperature sensor defect or not correctly connected.

Alarm

Symptom

Alarm display in the

Touch Control display.

Display in the

Cooking

Hob Timer

"E0“

Possible Alarm

Cause

Incorrect configuration on the Filterboard.

Alarm Remedying

Disconnect cooking hob from mains, wait 10 sec and reconnect the mains supply.

Should alarm still be displayed, replace filterboard..

1) Disconnect cooking hobs from the mains, wait 10 sec. and reconnect the mains.

2) Should alarm still be displayed, test L1 against N (4), test L2 against N (5) at the mains connection (1) .

3) If OK, see

See Chapter 3 Testing Power

Component

1) (5) Inspecting the contacts on the power component.

Is the connector inserted?

2) The resistance at room temperature (25°C) amounts to 1000

Ohm. This corresponds to approx. 3.3

Ohm per +1°C deviation.

If not in this range, replace affected coil including temperature sensor.

3) Should above not succeed, replace power component concerned.

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Alarm

Symptom

Display in the

Cooking

Field

Timer

Alarm display in the

Touch Control

"E5“

Possible Alarm

Causes

1 phase missing

Alarm Remedying

1) Check the house fuse.

2) Check the pin assignment, (1) test L1 against N (4), test L2 against N (5)

3) If ok, see Chapter 3. interference between filter and power component. or temp. Sensor is defective/missing

Note: a norm requirement with regard to new powerboards results in the power supply for the electronics on the powerboard being deactivated in the case of a missing or incorrect temp. sensor value. element.

Is the temp. Sensor connector locked in place or the dummy connector (3 zone appliances, no coil connected) inserted?

2) The resistance at room temperature (25°C) is 1000 Ohm.A deviation of +1°C corresponds to approx. +3.3 Ohm

Replace the corresponding coil incl.

Temperature sensor if not in this zone.

1) Check the cables between the two boards.

(6), Reinsert connector.

Or replace cable.

2) Should all of the zones on the cooking hob be affected (Display "E" in the cooking phase display), replace filter board .

3) Should the above not succeed, replace power component. sensor heat sink power component interference betw. filter and Touch

Control.

Central line at

RAST2.5 connector

/ line defect.

Touch Control. Replace cable or filter and

Touch Control.

Reconnect mains voltage.

2) Should above not succeed, replace Touch

Control.

3) Should above not succeed, replace Filter board. configuration for the

Touch Control on the Filter board.

10 sec. and reconnect to the mains voltage.

Should alarm still be displayed, replace Filter board.

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2.4 Other alarm symptoms

Alarm symptoms

Buzzer defect

Individual display elements do not illuminate or do not do so continuously.

Penetrating aromas from the hob when warm.

Pots cause noises

Display Possible Alarm

Cause

Touch control defect. elements

Alarm Remedying

Replace Touch Control.

Coils subjected to a manufacturing defect.

Unsuitable pots.

The aroma is non-toxic. Replace the affected coils. These also have a slight arom when cold. Clean the glass and aluminium sheet.

See Chapter 4 Pot Detection Information.

Normal sound level Interference noises result from the high working frequency of the induction. This can vary from pan to pan.

When measured in operation pursuant to

EN60335 §11-3 pursuant to EN60704 with 4 pots <47dBA.

A pot with boiling water has approx. 60-

62dBA.

2.5 Cooking zone with electric heating element not functioningt

Alarm symptoms

Cooking zone not functioning.

Possible Alarm Cause Alarm Remedying

No phase 2 power voltage or wrong connection

Electric heating element defect

(1) Check the pin configuration and

230V AC between N (4) and the phases at terminals 1 and 2.

(7) Check whether the electric heating element is open between the connections or whther it has short-circuited. Replace the heating element if defective.

If the above should not succeed. and whether no voltage is applied to the electric heating element. Also refer to the circuit diagram.

Replace the filter module with the relay

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(1)

(7) (8)

2.5.1 Electric heating element relay instructions

• Refer to the wiring diagram xxx.

The electric heating element is pulsed on relay board HOC2000 in the cooker.

• Phase commutation with the cooker/hob combination, refer to Chapter 2.6, special error images for the cooker/hob combination.

2.6 Special error images for the cooker/hob combination

Peculiarities:

• Output

L2 is not continuous and is only connected through when the right zone is switched through

(D37 / D39, Details, refer to the wiring diagram).

• The display in the hob is supplied with 5V DC from the induction module.

• The electronic hob control in the cooker is supplied with 5V DC from the HOC2000 powerboard in the cooker.

•

Mixed with the electric heating element: with the cooker/hob combination, the phases are normally connected to the

L1 left cooking zone

The induction module (front left and right cooking zones) are however connected to the continuous phase L1.

Therear right electric heating element zone is always connected to L2.

L2 is only available however of one of the right cooking zones is switched on.

In order to avoid an overloading of L1, the rear left zone is therefore operated with L1 (D29) or

L2 (D37) if the front right zone is switched on.

The phase commutation is executed with the assistance of relays K501 and K504

A safety conductor strip (9) conductor strip of the K501 which can trigger a relay in case of an error occurring (e.g. contact stuck together).

The output of the 210mm induction cooking zone is set to "P" if none of the right zones are switched on and the rear left zone is fully switched on, without this display being released.

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(9)

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2.6.1 No display or error display on the cooking zone display on the cooker

Alarm symptoms

Error display "E".

Display

"E" if the display exists.

Possible Alarm Cause Alarm Remedying

Errors in the cooking zone display in the cooker concern the hob. I.e. the same error number is displayed as in the hob display. For error displays, refer to Chapter 2.3. Error display "E".

When voltage is applied, the hob display illuminates briefly.

But: no display at the cooker, no display at the hob, no output at the induction zones. hob control in the cooker defective.

Additional instructions and tips concerning cooker problems are to be found in the Competence Service

Manual Doc. No. xxx.

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2.6.2 Cooking zone at the cooker okay, no display at the hob or no output.

Alarm symptoms

The diplay in the hob does not illuminate when voltage is connected.

Cooker display okay.

But: no cooking stage display at the hob, no output at the induction zones.

Display Possible Alarm Cause Alarm Remedying

None. Output connector not inserted..

Check the connector (10) and the cable, check that it is correctly engaged.

No cooker output.

When voltage is applied, the hob display illuminates briefly. Display at cooker is okay.

But: no output at the induction zones

Communication connector not inserted or line damaged.

No 5V DC betweem Pin 1+3 of the display bus

Display defect

Check pin D35 at the output connector to determine whether 230V AC voltage is connected.

1) Checking the connection between cooker / hob (11).

2) Hereby also explicitly check the entrance point of the cable at the hob for damage (14).

3) Check the seat of the connector at the display in the hob (12) to the induction module or (13) to the cooker / external user interface, ditto induction module.

(2) check 5V DC Pin 1+3 on the underside of the hob.

(corresponds to the our lines of the bus line from the filter to the display), if not connected, replace the filterboard. Caution: it is difficult to measure this from below with normal test probe!

Replace display

See normal diagnosis chapter

2.2, individual induction cooking zones do not

(temporarily) work or incorrectly or cannot be operated or see 2.3 chapter error display "E"

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(11)

(10)

(12)

(13)

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(14)

Display in the hob

(14)

4 hobs dep. In comb. With cooker external user Interface

„A“

„E“

„F“

„H“

„L“

„P“

„

∪“

For details, refer to the cooking field instruction manual

„

Symbol Comment

.

“

Intermediate cooking levels („4.“)

„ “ Induction – zone switched off because of over temperature at the coil sensor (empty pot)

Fast heating up function („Ankochstoss“)

Alarm display siehe 2.3 Alarm message "E“

Pot detection – no pot detected

Residual heat indication

Lock – Function or key lock

Power (booster) function for induction

Keeping warm

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(2) Pin 1, 3

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Terminal

1

2

3

4

5

(1)

(5)

(3)

(4)

Air inlet

Min. 5 mm

Min. 20mm

Oven

Remark: if there is no ventilation gap in the front it’s still possible to operate the hob. Only with longer useage ( >15 min. ) the performance will drop. For Mixed hob this is e.g. – 20%, for full induction hobs it’s higher.

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14

2.9 Images control point for 2 zones / Mixed Induction

(1)

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(7)

(6)

(3)

Attention: mains connection for Domino is directly on filter pcb.

(1) Domino

(5)

(3)

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(2)

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3 Testing Power Component

1. When alarm messages and disabled zones exist ("E“ in cooking phase display), please make a note of the power component which is affected.

2. (7) Check whether the lead from the filter board is connected, also check the bus lines (6)

µprocessors filter to power component.

Replace power component

4. (8) Measure resistance at the IGBTs

Pin1-Pin2 or Pin2-Pin3 >50kOhm Æ Okay

<50Ohm

Only replace the affected power component and (9) insert 20A fuse, completely separate the fuse strip conductor.

S12 = right power component

S11 = left power component

5. By a short-circuit and destroyed power component, it is imperative that the coil lines be inspected for signs of damage.

6. Also replace the filterboard should the replacement of the power component not succeed.

(6)

(7)

(9)

(7)

(6)

(8) 8 St. IGBT

Pin 1 2 3

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4 Pot Detection Information

Suitable pot materials:

• Steel

• Stainless steel (with magnet. bottom)

• Aluminium (with magnet. bottom)

Unsuitable materials:

( Æ too much power)

• Copper

• Stainless steel (not magnetic)

• Glass

• Ceramic

The pot detection is designed for the following diameters:

Nominal burner

∅ [mm]

Minimum pot bottom

∅ instruction manual [mm]

Minimum pot bottom

∅ adjusted with steel plate

[mm]

With regard to Ind. G4, the same diameter is stipulated in the instruction manuals as for the previous model. However, the real diameter which still functions is much smaller.

The performance for different pots can very by as much as +/- 10-15%.

• As reference pots, we recommend enamelled steel pots (e.g. Silit).

• 2-3 mm thick round steel plates in various diameters are very suitable for testing the pot detection function.

• Sandwich bottoms can cause very unpleasant noises if they are not correctly pressed. The same is the case with regard to handles which are a little loose.

• The bottom diameter of the pot is decisive and not the exterior diameter.

• With regard to stainless steel pots with sandwich bottoms, the diameter of the magnetic part of the pot bottom is decisive.

• an additional influencing factor is the vertical distance from the coil, i.e. an uneven sandwich bottom has a negative effect on the power consumption. The effect is exactly the same if the induction coil is not pressed on the glass ceramic.

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5 Touch Control Autarkic Cooking Hobs Information

• The Touch Control works on the basis of the infrared principle, i.e. a signal is transmitted with a transmitter which is then reflected by the finger and received once more.

5.1 Instructions on the operation / possible operation errors if the buttons do not function:

• Do not use with the flat finger. Hold the finger relatively upright.

Otherwise 2 buttons can be activated, this is not signalled.

• Please do not approach slowly, especially not from the side, it is better to approach the button faster.

A signal change is above all evaluated.

• Applying excessive pressure to the cooking hob will not make a difference.

It is better to release it for 5 sec. and then press the button again.

•

If the adjustment of the cooking stage/timer does not continue after the button has been released, this is due to the fact that the Touch Control receives a "Button Pressed" signal even from a distance of some mm.

If the user interface is not adjacent to the glass ceramic, the signal for the key evaluation is very much smaller and the keys can not be operated any more, i.e. pay always attention to intact plastic carriers.

• If the appliance switches off without that the glass ceramic has been touched, is this because a key in the extreme case.is switching even in a distance / height of 10 mm. This is the function principle of the touch control and is a normal behaviour. I.e. do not replace the touch control!

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5.2 Demo mode / Self test (Service mode) / Alarm Menu

To enter the self-test/Demo mode, the following sequence of buttons must be pressed:

1. Hob is off. Press main switch continuously until display is going off (without beep).

2. Press the "+" and " -" buttons of the front zones together (->short beep) for about 3 seconds (-> again short beep)

3. Press the timer selection key

Step 1

Step 3 d.

Step 2

4. The display shows a "d" for demo mode.

If you press the timer select key again you switch to “S” for Service mode, another press gets you to “E” the alarm menu.

5. By pressing the button "+" of a cooking zone you activate the menu.

For example, status like above shown in the graphic – hob is in demo mode, press ‘+’ key of zone to deactivate the demo mode.

Demo Mode:

If demo mode is activated the display with the „d“ shows additionally a dot.

After selecting the demo mode, the electronic goes to off. Now it can be used like usual but only without heater activation. The deactivation of the demo mode is done in the same procedure as activating. After deactivating the demo mode the electronic must go off. Now the hob can be used in normal mode.

Service Mode “s”

Routine:

1. Test all LEDs / Displays for 10 Sec.

2. Show Software version Touch control for 10 Sec. in timer display

In the 7-Segment Display for zone right front (zone 4) an “0” is displayed as an indication that it is step 0 – HUI.

3. Software display version power board.

Alarm Mode “E”

The last 5 stored alarm codes (if >o) are displayed like an actual alarm, each for 5 sec., starting with the oldest (read request ‘5’ Alarm code message) to the newest (read request ‘1’).

5.3 Product history

5.3.1 Change from automatic boost to manual boost

This change was done due to customer complaints. It was introduced in series production July2004.

The change is implemented with a modified configuration on the filter board of the induction.

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5.3.2 Error appliance can not be operated, display indicates "0"

This error has been disappeared after a reset.

For that there were 2 fault reasons in the hardware and software, this was removed by SW Vers. 4.2 from Dec. 2004.

6 Frontline self-sufficient hobs

6.1 Special references disassembly/assembly in case of a service:

Î Remove tension clips

2. Open

Î Attention! Before disassembling the glass draw off the connecting line between the user interface at the glass and induction.

3. Replacement of display units

Î By means of a coin loosen plastic carriers by pressing and turning (29)

Î Shift back the plastic carrier until the front edge can be seen.

Î Lay plastic carrier to the bottom side

Î Remove locking bars like (30)

Î Draw off flat band cable

Î Replace electronic board

Î Assemble in the same way. Pay absolute attention to the correct putting and locking of the band cable.

User interface and connection of two electronics at the glass ceramic (58 and 72 cm appliances)

(29) (33)

(33) clamp bradings into the locking clips of the right carrier.

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Assembly of band cable

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(30)

Open locking (black bar)

(31)

Put band cable (silver contacts visible)

Close locking in arrow direction

(32)

Turn down the electronic with displays onto the glass side, press the carrier flatly to the glass lower side and let it lock in. For assembly press the locking slightly to the bottom.

6.2 Demo mode / Self test

To enter the self-test/Demo mode, the following sequence of buttons must be pressed:

1. Hob is off. Press main switch continuously until display is going off.

2. Press the "+" and " -" buttons of the zones together (short beep) for about 3 seconds

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3. Then automatically the software version of the user interface is displayed, for example „2“ „8“ = version 28 and all LEDs / Displays are ON for 10 Sec.

There is no alarm history mode available.

4. Demo mode

By pressing the button "A" / „P“ of one of the rear cooking zone you activate the demo mode, the

LED for Power function active is ON.

With activation of the demo mode the hob can be used like usual but without heater activation.

The deactivation of the demo mode is done in the same procedure as activating. The Led has to be off.

New Demo Mode/ Service Mode/ Alarm menu control philosophy starting with

October 2007 production

To access the self-test/demo mode, press the buttons in the following order:

1. The cooking zone is switched off. Press the main switch until the display goes dark.

2. Press the "+" and "-" buttons of the zones (short beep) simultaneously for about 3 seconds.

3. After 3 seconds, a "d" for demo mode appears in the timer display or in the hot plate display

(depending on the model).

You can change between demo mode "d", service mode "S" and alarm menu "E" using the timer

-

- button or "A" button (depending on the model). if you do not select anything, the unit will switch off.

Demo Mode „d“

Activation: Press the "+" button of the left-hand cooking zone

Indication in the timer display or in the cooking zones display (depending on the model): "do"

You can use the unit as usual, but without heater activation.

To be able to use the unit normally, you have to carry out the following steps:

- Repeat 1. to 3.; after 3 seconds, the timer display or the cooking zones display (depending on the model) indicates a "do".

Deactivation: press the "+" button of the left-hand cooking zone

Indication in the timer display or in the cooking zones display (depending on the model): "d"

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