Gas Oven Repair Guide

Transcription

1 - /6 - Gas Oven Repair Guide [ FX70*, FX50*] Ver. Aug-0 Ignition Failure Cooktop ignition Oven ignition Heating defect Oven Cooktop Abnormal Flame Button, Motors Lamp Others Smell, Smoke, Noise No Display, Key Panel Error Code Sensors Temperature control

2 #. Symptom : Ignition Defect (Cooktop) -. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Tip Check- Cause Check- Code Electrode defect Crack & clip fastening Wire damage Connection check - Block # # # Electrode Clip Spark module defect Check for normal voltage Connection check - Spark Module Electrode Switch Ignition Switch ignition defect Crack & wire damage Connection check Switch Ignition Spark Module - Cooktop Ignition Defect Burner / Cap defect Burner, Cap mounting inspection Burner, Cap check for debris -4 Burner Cap Orifice defect Orifice Diameter inspection Orifice check for debris -5 Nozzle Gas leak / Regulator defect Gas main pipe connection leak check Gas line and manifold crack & leak GBR Shut-off operation check NG/LP condition check -6 Regulator Gas Line - /6 - Next Page

3 - /6 - #. Symptom : Ignition Defect (Oven) Repair -. Repair 계통도 Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Tip Check- Cause Check- Code HSI defect HSI Crack inspection HSI connection inspection - Block # # # HSI Wire Harness Temp. Sens. defect Sensor Inspection Connection check - Temp. Sensor Wire Harness Assy PCB defect PCB inspection (Components/Pattern damage, connection, Relay inspection) - Assy PCB Oven Ignition Defect Safety valve defect Current measurement check Safety Valve -4 Gas leak / Regulator defect Gas main pipe connection area leakage check Gas line and manifold crack & leak GBR Shut-off operation check NG/LP condition check -6 Regulator Gas Line

4 #. Symptom : Heating Defect (Oven) -. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Check- Cause Check- Temp. Selection defect Temp. Selection inspection Tip Code - Block # # # Program Temp. Sens. defect Sensor inspection Connection check - Temp. Sensor Wire Harness Assy PCB defect PCB inspection (Components/Pattern damage, connection, Relay inspection) - Assy PCB Oven Heating Defect Orifice defect Gas leak / Regulator defect Orifice Diameter inspection Orifice check for debris Gas main pipe connection area leakage check Gas line and manifold crack & leak GBR Shut-off operation check LNG/LPG condition check -5-6 Nozzle Regulator Gas Line Door Open/Close defect Door assembly condition check Gasket check - Door Gasket - 4/6 - Next Page

5 - 5/6 - #4. Symptom : Heating Defect (Cooktop) 4-. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Check- Cause Check- Orifice defect Orifice Diameter inspection Orifice check for debris Tip Code -5 Block # # # Nozzle Cooktop Heating Defect Gas leak / Regulator defect Gas main pipe connection area leakage check Gas line and manifold crack & leak GBR Shut-off operation check NG/LP condition check -6 Regulator Gas Line

6 - 6/6 - #5. Symptom : Flame Defect (Cooktop) 5-. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Check- Cause Check- Cooktop Flame Defect Burner/Cap defect Burner, Cap mounting inspection Burner, Cap check for debris Tip Code -4 Block # # # Burner Cap. Yellow tip Orifice defect Orifice Diameter check Check Orifice for debris -5 Nozzle. Lifting. Flame-Out Gas leak / Regulator defect Gas main pipe connection area leakage check Gas line and manifold crack & leak GBR Shut-off operation check NG/LPGcondition check -6 Regulator Gas Line Flame-out defect Valve inspection Valve 5-

7 #6. Symptom : Other Defects 6-. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Check- Cause Check- Gas Leak Gas main pipe connection area leakage check Gas line and manifold crack & leak Tip Code -6 Block # # # Gas Line Smell, Smoke Defect Burner/Cap defect Burner, Cap mounting inspection Burner, Cap check for debris -4 Burner Cap Air shutter defect Air shutter opening area inspection 6- Oven Burner Air Shutter Open/Close Defect Assy Door / Drawer Part and Open/Close check Hinge inspection Open/Close interference check Drawer assembly condition check Drawer part check 6- Hinge Assy Door Cooktop noise defect Burner, Cap mounting inspection Check if Spark noise, or Gas noise Orifice spec check 6- NDF Nozzle Burner Noise Defect Convection Fan noise defect Fan cover casing check Fan operation check Fan Motor Cover Casing /6 - Next Page

8 - 8/6 - #6. Symptom : Other Defects 6-. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Check- Cause Check- Breaker / Power cord defect Wire harness coating condition check Tip Code Block # # # Power cord Breaker Spec defect 6-5 No Power Wire connection issue Wire connection inspection (P/cord, PCB connector, Main relay terminal) 6-6 PCB defect PCB inspection (Components/Pattern damage, connection, Relay inspection) - PCB Button Operation Defect Membrane panel Key issue Panel key operation and ribbon cable connection defect 6-7 Membrane Membrane Switch Deformation Defect Membrane Switch Customer usage : Too Deformation defect large of a pot or using pot too close to Key panel 6-8 Membrane

9 - 9/6 - #7. Symptom : Error Code 7-. Repair Schematic Chassis Project Basic Model Type Gas Oven Vulcan FX70 FX50 Check- Cause Check- SE E-7 Key panel (Membrane switch) Temperature Sensor Open Key panel surface damage Ribbon cable insert condition check (Tilted) Tail pattern corrosion and short Tip Code 7- Sensor wire disconnect Sensor resistance value check 7- Block # # # Key Panel Wire Harness Main PBA Sensor E-8 Temperature Sensor Short Sensor resistance value check Main PBA short and other abnormality 7- Sensor Main PBA E-08 Preheat Fail Gas supply defect (not reach preheat HSI ignition defect target temperature) Safety valve defect 7- HSI Safety Valve Main PBA E-0A Over Temperature Excessive gas supply Temp. Sensor defect PCB defect 7-4 Main PBA Temp. Sensor E-0E Door Locking defect Connection Door switch defect Door lock motor Latch assembly condition 7-5 Door Switch Door Lock Motor Door Latch

10 - 0/6 - Tip -. Electrode Inspection Electrode wire and fastening Clip conditions inspection. Step Check if power comes on. Check if any Sparks are coming from the Electrode. Step 4 If there are no Sparks, Check the Electrode & Spark module wiring. Check the Electrode wire for signs of melting or other damage. Check the Electrode fastening clip and Electrode fixed state. Make sure there are no movements of the Electrode (In the case of Wire melting, sparks will come out of the melted area and it will fail to ignite)

11 - /6 - Tip -. Spark Module Inspection Spark module state and Wire connection state inspection. Step Check if power comes on. Check if any Sparks are coming from the Electrode. Step If there are no Sparks, Check the Electrode & Spark module wiring. Switch ignition & Spark module connection state check. Check the Spark module input voltage. (0V) (Take measurements while Knob is at LITE position)

12 - /6 - Tip -. Switch Ignition Inspection Switch ignition state and Wire connection state inspection. Step Check if power comes on. Check if any Sparks are coming from the Electrode. Step 4 If there are no Sparks, Check the Switch Ignition & Spark module wiring. Check the switch ignition & each valve s assembly state. Check if Switch ignition has any damage in the mold. Check for any damage on Switch ignition wire. Tip -. Spark module

13 Tip -4. Burner, Cap Inspection Burner, Cap debris and mounting state inspection. Step Check if any Sparks are coming from the Electrode. Check if the gas supply valve is opened completely. Step Check the Burner, Cap for any foreign debris. (Food particles or Aluminum tip) Check the Assy Cooktop to see if screws are assembled completely. Check that the Burner and Cap are mounted properly. 4 Check if Sparks are sparking towards the Burner cap. (If the gap between Electrode and Cap is larger than.5~4mm, Spark will go towards the burner instead of the cap and will not ignite).5~4mm If the Burner / Cap mounting is unstable, it might still ignite but the flame will be unstable and the incomplete combustion has a high chance of producing smoke. Return to Abnormal - /6 - Return to Other

14 Tip -5. Nozzle Inspection Orifice debris and Orifice Diameter inspection. Step Check if Cooktop / Oven is operating properly. Check if the gas supply valve is opened completely. Step 4 Check that the gas pressure is not above 7 WC. Check if GBR is appropriately selected with NG / LP mode. Check for any debris on the Orifice. Check the Orifice Diameter (Oven has same diameter) (Cooktop has different Diameter per product) 5 Use the appropriate valves according to specs, then check for proper operation. Refer to next page for Gas Oven Cooktop orifice spec per product Return to Abnormal Return to Oven Heating - 4/6 - Next Page

15 - 5/6 - Tip -5. Nozzle Inspection Orifice debris and Orifice Diameter inspection. Cooktop Orifice Diameter Spec Sheet per Product NG LP.0.0.9

16 Tip -6. Regulator, Gas Leak Inspection Regulator damage, Shut-off lever, Gas leak inspection. Step Check if any Sparks are coming from the Electrode. Check if the gas supply valve is opened completely. Step Check if GBR s Shut-off lever is in open state. Check if supplied gas pressure is 7 (NG), (LP). Check for proper NG / LP setting. Check for Regulator damage. (Check if gas is being supplied through Regulator, Lubber clogged) 4 With Main gas line connected, check for any gas leakage at each Gas line, Manifold. -> Main Leak point (Install Error: Most likely leakage cause) Return to Abnormal - 6/6 - Return to Other

17 - 7/6 - Tip -. HSI Inspection HSI damage and ignition state inspection. Step Check if power comes on. Check if the gas supply valve is opened completely. Check if HSI ignites properly when Oven starts. Step Check to see if Bake, Broil burner s HSI is properly connected. Check the HSI resistance value (normal : 40~400Ω)

18 - 8/6 - Tip -. Temperature Sensor Inspection Temp. Sensor connection and resistance value inspection. Step Check if power comes on. Check if the gas supply valve is opened completely. Check the Temp. Sensor connection. Step Check the Temp. Sensor resistance value (normal : ~080Ω at room temp.) (Short : ~0Ω, Open : ~ Ω) Check the PCB Wire connection (if not connected, E7 error will occur. Must be connected) Return to Oven Heating

19 Tip -. Assy PCB Inspection Temp. Sensor connection and resistance value inspection. Step Check the PCB terminal s input voltage. Check connection on each PCB terminal. Step Check the PCB input voltage (normal : 0V). Check for any change in Relay resistance at unit start. (With power connected, at unit start, normal: ~0VAC, : ~VDC) Bake : T60-T605, Broil : T60-T604 Check for any Relay operating noise at Oven start. 4 Disassemble the PCB and check for any component or pattern damage. If any problems are found, replace the PCB and check for proper operation. Return to Oven Heating - 9/6 - Return to Other

20 - 0/6 - Tip -4. Safety Valve Inspection Safety valve connection and resistance value inspection. Step Check the Safety valve connection. Check if HSI ignites properly when Oven starts. Step Check the Safety valve terminal current value at Oven start. (normal :.~.6A) If problems are found, replace the Safety valve and check for proper operation. (Measurement method when Broil operates) Replace the Safety valve and check for proper operation.

21 - /6 - Tip -. Temperature Selection Inspection Conversion on / off state inspection. Step Verify with the customer the difference between actual temperature and the product s Temp. sensor temperature. Step Press the Convection bake + 0 keys and check if Conversion is on/off. Select Off and delete the Convection -5 drop function. Press the Bake + 0 keys and reduce the temperature range using Temp. Adjust function.

22 - /6 - Tip -. Door Close Inspection Conversion on / off state inspection. Step Check if the Door closes properly. Step 4 Check the Display while the oven is operating for the word Door. Check if any heat is leaking excessively around the unit during Oven operating. While the door is closed, check the gap between door and Gasket. Inspect the Gasket for any tearing or damage, and assembly conditions. Gasket Check

23 - /6 - Tip 5-. Cooktop Flame-Out / Low Flame is Large Orifice debris and Orifice Diameter inspection. Step Check if the gas supply valve is open completely. Check if the unit is igniting when Cooktop start. Step 4 5 Check the gas pressure (normal : 7 WC(NG), WC(LP). When using High selection, check if flame is normal. Check if the flame goes out when knob is turned from High -> Low. Check if the flame is large at Low selection. Adjust the inner Valve Screw to calibrate the flame size when the burner is set to it s lowest setting.

24 - 4/6 - Tip 6-. Smell / Smoke Inspection Air shutter opening area inspection. Step Check if the gas supply valve is open completely. Check if Self Clean was used at least once before first time use. Step 4 Check the supplied gas pressure. (normal - 7 WC(NG), WC(LP) Check if flames are normal during Oven operation. (To check in Bake mode, first remove the Cavity floor) If the flame shows signs of lifting during Broil or Bake, reduce the Air Shutter s opening area. If the flame shows signs of yellow tip or if the flame is abnormally large, increase the Air shutter s opening area. (Reducing Opening) (Increasing Opening)

25 - 5/6 - Tip 6-. Door / Drawer Open/Close Defect Door / Drawer Assy and Open/Close interference inspection. Step Check the Door / Drawer for any assembly issues. Step 4 5 Check the Hinge for any stuck debris or deformations. After removing debris, apply Grease. When Door Opening/Closing, check interference with Side Panel. When Drawer Opening/Closing, check the rail for any stuck debris or deformations. After removing debris, apply Grease. When Drawer Opening/Closing, check to see if Drawer stays on railing. Check the Drawer s inner walls for any deformations.

26 - 6/6 - Tip 6-. Cooktop Abnormal Noise Orifice debris and orifice Diameter inspection. Step Check if it s a Spark operating noise, or gas flow noise. Step 4 Check that there is no gas pressure above 7 WC. Check if GBR is appropriately selected with NG / LP mode. Check for any debris on the orifice. Check the orifice Diameter (Oven has same diameter) (Cooktop has different Diameter per product) Check that the Burner / Cap is mounted properly. For Spark noise, check if knob dial has LITE position selected. (Explain to the customer that if only one burner is operating but there are Sparks at all burners, this is normal operation and not a defect) Explain to the customer that gas flow noise is normal during operation, and not a defect. Cooktop orifice Diameter Spec Sheet per Product : See Tip -5

27 - 7/6 - Tip 6-4. Convection Operation Inspection Convection operation and abnormal noise inspection. Step 4 5 Check if the Conv. Fan motor is connected properly. Check for any abnormal noise during Conv. Mode operation. Check if Blade is rotating properly during Conv. Mode operation. Check if the Assy Cover Casing Set Screw is tightened properly. Check if Wire harness is connected properly without any issues. Step Disassemble the Assy casing and check the Blade for deformation and interference with nearby parts. Check the input voltage at Conv. Fan motor (normal : 0VAC). If voltage value isn t normal, replace the Main PCB. Check the resistance between the Conv. Fan motor terminals. (normal Resistance = 0~0Ω)

28 - 8/6 - Tip 6-5. Circuit Breaker Inspection Wire harness coating condition inspection. Step Check if the Breaker Spec is appropriate for product use (Allowable Current >0A). Check if the Extension cord is appropriate for product use (Allowable Current > 0A). Step Check that the Power cord terminal insulation resistance is normal. Ground and Live, Neutral resistances should be >0MΩ. Disassemble the unit and check the Wire insulation condition. If any damage to the Wire is found, tape and repair the wire, re-assemble the unit, and check for proper operation.

29 - 9/6 - Tip 6-6. Wire Harness Connection Inspection Wire harness coating condition inspection. Step Check that the Power cord is connected properly. Step Check that the PCB is connected properly.. PCB power input terminal : check if not connected properly, or Pin disconnected

30 - 0/6 - Tip 6-7. Membrane Key Operation Inspection Key operating conditions inspection. Step Check if Keys operating properly. Step Check if the Membrane ribbon cable is properly connected. If issue persists after reconnecting the ribbon cable, inspect the Membrane ribbon cable. If issue persists after Membrane replacement, replace the Assy PCB and check for proper operation.

31 - /6 - Tip 6-8. Membrane Switch Deformation Key operating conditions inspection. Step Check if Keys operating properly. Step Check if Membrane Switches are deformed or damaged. Explain to the customer that if an excessively large pot is used, or if pot is used too closely to the Control Panel, the heat from the Oven vent and burner can cause damage to the Membrane Switch. Oven vent heat Gas cooktop heat Oven vent If problem persists after Membrane replacement, replace the Assy PCB and check for proper operation.

32 - /6 - Tip 7-. Key Panel Short (-SE-) Check Key panel appearance inspection. Step Check for any imprints or dents on the Key Panel. Step Check if Key Panel ribbon cable connector is inserted properly. over-insert, moisture intrusion Connection status Moisture Check if there s any corrosion or damage to the ribbon cable pattern.

33 - /6 - Tip 7-. Temperature Sensor Open(E-7), Short(E-8) Check Temperature Sensor assembly and component inspection. Step If E-7 error is displayed, check that the Temp. Sensor is connected properly. Step Measure temperature Sensor resistance value ( normal - at room temp : ~080Ω ) Step If E-8 error is displayed, and E-8 still displays after disconnecting the connector, assume PBA short and replace the PBA. If E-7 error is displayed after disconnecting the connector, assume Sensor short and replace the Sensor.

34 - 4/6 - Tip 7-. E-08 (Preheat fail) Inspection Gas supply or HSI ignite inspection. Step Check if the gas supply valve is open completely. Check if the Cooktop is igniting. Check that the gas pressure is normal, at 7 (NG), (LP) Step Check that the HSI is igniting. -> If not igniting, check that HSI is connected properly, replace the HSI, then check for proper operation. If still no flame after HSI successfully ignites, check the Safety valve for any problems. (If there is a lot of moisture around the Safety valve, it will not operate properly. Also check the current) Check that GBR is set up appropriately with NG / LP setting. Check for Regulator damage. Check the Main gas line connection and each Gas line, Manifold, for signs of gas leakage. Check for any issues with Temp. Sensor and PCB. Check for any issues with the orifice. Refer to Oven, Igniter defect, Heating defect (Tip / Tip )

35 - 5/6 - Tip 7-4. E-0A (Overheating Defect) Inspection Gas supply or HSI ignite inspection. Step Check that the gas pressure is normal, at 7 (NG), (LP) Step Check that GBR is set up appropriately with NG / LP setting. Check for Regulator damage. Check the Temp. Sensor resistance and wiring. (normal R : ~080Ω at room temp.) 4 Check the PCB wiring and if there s any Relay terminal or pattern damage.. CN60, T60, T60, T604, T605 connection check

36 - 6/6 - Tip 7-5. E-0E Error Inspection Door Lock Motor & Door Lock Switch connection inspection. Step Check if Door Lock Motor is connected properly. Check if PCB is connected properly. (CN 50) Step Check if input voltage to Door lock motor is 0V. Measure the Door lock motor coil s resistance value. (normal R : 750~850Ω) Check the Door Latch assembly for any issues.