Induction - Main Principles: Technical Manual

Merloni Electroménager S.A.
"

Technical Manual
INDUCTION - MAIN PRINCIPLES
Language Edition Page

GB 02-08-02/01 1-29
Merloni Electroménager S.A. "

Summary
1 INDUCTION MODULE 3
2 «STANDARD» INDUCTION GENERATOR (POWER CARD) 4
3 «FISH KETTLE» GENERATOR (POWER CARD) 4
4 INDUCTORS 5
5 KEYBOARD 7
6 FILTER 8
7 FOAM GASKET 8
8 FAN 9
9 ELECTRICAL BLOCK DIAGRAM 9
10 ACCESS TO THE DIAGNOSTIC DISPLAY 10
11 READING THE ERROR CODE TABLE 10
12 ERROR CODE TABLE 11
13 TIG664 DIAGNOSTIC FLOW CHART 12
14 TIXXX AND KTI XXXX DIAGNOSTIC FLOW CHART 13
15 WARNING: ELECTRIC SHOCKS 14
16 PRACTICAL ACTION CASES: FLOW CHARTS 14
17 GENERATOR BREAKDOWN CONFIRMATION 17
18 INDUCTOR STATUS CHECK 18
19 COOKEYE 19
20 COOKEYE DIAGNOSTIC FLOW CHART 21
21 INFRARED REMOTE CONTROL - TIG664 ONLY 22
22 GENERATOR KIT 26
23 INFORMATION SHEETS 27
24 SOME FIGURES 28
25 TERMINOLOGY 28
Technical Manual Language Edition Page

INDUCTION - MAIN PRINCIPLES GB 02-08-02/01 2-29

1 INDUCTION MODULE
Fig. 1 View from inductor side
Cooking
zone or
inductor
Fig. 2 View from generator side
Flat cable
(to keyboard)
Filter
Generator
Generator
Identification Flat cable

label (to keyboard)
Filter
Fan
Each module consists of 2 (TI322) to 4 (TI644) induction cooking zones.

The cooking zones are managed in pairs by a generator, except «3 ring» tables,
on which one of the generators only manages a single cooking zone.


2 «STANDARD» INDUCTION GENERATOR (POWER CARD)
Fig. 3
Dissipator Foam Gasket Power
Transistors (IGBT)
Supply
lugs Current
transformers
Control Stage
Fuse
Fixing screw
Fan
(single)
Connector
Connector
to keyboard
Identification
label Inductor
screw terminals
Connectors
Sensors
Inductors
In the view above, the IGBT’s, inductor screw terminals, the Inductor Sensor
connector and the current transformer the furthest left from the generator, are
concerned with the least powerful generator cooking zone («Petit Split»
cooking zone). The same items furthest to the right concern the most
powerful cooking zone («Quad» cooking zone, «Grand Split» or «Fish Kettle»
see photo below).
IGBT Q3 and Q4, screw terminals CNX5 and CNX7, Inductor Sensor
connector JP2, current transformer T3 T4 = Most powerful cooking zone.
IGBT Q1 and Q2, screw terminals CNX1 and CNX3, Inductor Sensor
connector JP1, current transformer T1 T2 = Least powerful cooking zone.
3 «FISH KETTLE» GENERATOR (POWER CARD)
Fig. 4
Fish kettle zone

extension relay
2 Additional
terminals
for the fish kettle
cooking zone


4 INDUCTORS
They consist of a printed card on which are glued respectively ferrites, a

dielectric insulator, the coils and another dielectric insulator.
Fig. 5
The QUAD (3000W) inductor The QUAD coils
Serial
number
The PETIT SPLIT (1200W) inductor The PETIT SPLIT coils
The GRAND SPLIT (1800W) inductor The GRAND SPLIT coils
Temperature sensor Connector and connection lugs


Soldered onto the printed card are the temperature sensor, the sensor
connector and the inductor lugs.
The connection of the sensors and the inductor lugs on the generator is
intuitive.
The inductor is not «polarised» and because of this the wires coming to the
lugs from the generator can be inverted, but greater importance will be given
to the «fluidity» of the cabling and the length of the wires.
The wires and the sensor connector are black (Quad) or red (Split) on the
inductor and on the generator; however, greater importance is given to
respecting these colours exclusively on the generator (the particular case of
the fish kettle cooking zone) or the Sensor connector is red on the inductor,
and the wire and the connector of the generator are black.
ATTENTION: The fish kettle cooking zone is the combination of the two
Petit Split inductors. In this case, the connection of one inductor in
relation to the other is essential and must be respected.
Fig. 6
The 2 ends of the

Closest to the complete cooking
extension relay, zone are shared
CNX4 is (the card track makes
connected to the the 2 lugs common)
extension zone of
the fish kettle
cooking zone
Temperature sensor
wires
«Initial» area of the

fish kettle cooking
zone CAR. This zone's
«Extension» zone of sensor connected to
the fish kettle the generator
cooking zone
The «initial» zone is identifiable by the presence of the sensor connection to

the generator, a connection not present on the «extension» zone of the fish
kettle cooking zone.


5 KEYBOARD
Fig. 7 TI644 keyboard
Optocouplers
Supply Generator Connector Communicating Generator Connector

Signals «exchanged» Signals «exchanged»
+12V, +5V, RST, TxD, RxD, GND TxD et RxD
The keyboard is connected by means of 2 6-point connectors to two
generators, whose functions are identical but whose effect on the keyboard is
different.
The first connector links the keyboard to the generator called the «Supply
Generator» (by extension, the connector is called the «Supply Connector»). The
generator supplies the keyboard with its 12V and 5V supply via this
connector. In addition, it supplies the order of synchronisation of the
exchanges of data between keyboard and generators. Finally, two
communication lines through which the data passes are also used on this
connection.
The second connector links the keyboard to the generator called the
«Communicating Generator» (by extension this connector is called the
«Communicating Connector») because the only signals exchanged are those
for communication between generator and keyboard. This connector can be
identified by the close presence to it of two integrated circuits called
«Optocouplers».


Fig. 8 TIG644 keyboard connections

Connector to
Communicating
Generator
Optocoupler pins
Connector to Supply
Generator
6 FILTER
Enables interference to be attenuated bi-directionally (at input and at output).

The Deltatronic filter has a fusible track that can be damaged in the case of a
generator breakdown (power stage breakdown).
Fig. 9
Deltatronic filter Schaffner filter
Attention: The Schaffner filter can be connected to all the generators of

all the modules of the range. On the other hand, the Deltatronic filter
can only be connected to the supply generator of the TIG664.
7 FOAM GASKET
Fig. 10


This allows good pressure on the module and consequently on the inductors
under the ceramic glass. It is used on the following two table generators: TI864,
TI754, TI644, CII596, TI643, KTI7424, KTI6114, KTI6014, KTI6004, KTI6003.
The replaced generator has no gasket, and this must be added at the
time of replacement.
8 FAN
Fig. 11
It allows the ventilation, and consequently the cooling of the heat dissipator
and the electronic power components. 4 ventilation speeds are managed by
the generator supplying it: 40%, 60%, 80% and 100%. The speed depends on
the power demanded and the temperature of the dissipator.
9 ELECTRICAL BLOCK DIAGRAM
Fig. 12
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10 ACCESS TO THE DIAGNOSTIC DISPLAY
So as not to make the TIG664 unusable because of a fault in one of its

components, this exercises independent management of the safety
aspects of each cooking zone and of the keyboard. The table carries out
a continuous diagnostic routine. If a fault is identified, the cooking
zone(s) concerned are locked. The flashing display then becomes:
11 READING THE ERROR CODE TABLE
For this reason, when operating normally, no error code is displayed, except
the general error code .
In addition to the self-test when the table is switched on, access to the
diagnostic display can be obtained by pressing the Stop/Start button until the
code appears. Maintain the pressure and then press for 3 seconds on
the Lock key; 2 beeps will sound. Then release the keys and the diagnostic
cycle starts in accordance with the following sequence:
1. Display and turning on of the residual pilot lamp of the rear left
cooking zone for (2’’).
2. Display and turning on of the residual pilot lamp of the rear right
3. Display and turning on of the residual pilot lamp of the rear left
4. Display of the keyboard version and turning on of the residual pilot lamp of
the front left cooking zone for (2’’).
5. End if no fault identified, otherwise display (in the form “88”

showing the error number) of the error code or codes (2’’ each).


12 ERROR CODE TABLE

PROBABLE CAUSES
CONNECT. GENE. COMM. KEYBOARD

CONNECT. GENE. SUPP. KEYBOARD
CONNECTION INDUC. RER
CONNECTION INDUC. FRR

CONNECTION INDUC. REL
CONNECTION INDUC. FRL

CODE DESIGNATION
GENE. COMM
GENE. SUPP.
INDUC. RER
INDUC. FRR
INDUC. REL
INDUC. FRL
KEYBOARD
E.00 ON/OFF key out of action ✔
E.12 Key(s) out of action ✔

FRL cooking zone temperature sensor ✔ (3) ✔ (2) ✔ (1)
E.20 in CC C+F C+F C/F
FRL cooking zone temperature sensor ✔ (3) ✔ (2) ✔ (1)
E.21 in CO C+F C+F C/F
REL cooking zone temperature sensor ✔ (3) ✔ (2) ✔ (1)
REL cooking zone temperature sensor ✔ (3) ✔ (2) ✔ (1)
E.23 in CO C+F C+F C/F
FRR cooking zone temperature sensor ✔ (3) ✔ (2) ✔ (1)
✔ (3) ✔ (2) ✔ (1)
E.25 FRR cooking zone temperature in CO
C+F C+F C/F
RER element temperature sensor in ✔ (3) ✔ (2) ✔ (1)
E.26 CC C+F C+F C/F
✔ (3) ✔ (2) ✔ (1)
E.27 RER cooking zone temperature in CO
C+F C+F C/F
E.30 Keyboard temperature sensor in CC ✔
E.31 Keyboard temperature sensor in CO ✔

Dissip. temperature sensor Gene.
E.32 Supp. CC
✔
E.33 Supp. CO
✔
Dissip. temperature sensor Gene. (1), (2), (3): Order of incrimination
E.34 Comm. CC
✔
of the component
E.35 Comm. CO
✔ C+F: If the fault occurs when hot AND when cold
E.40 Keyboard display error ✔ C/F: If the fault occurs when hot OR when cold
Synchro. signal absent ✔ (2) ✔ (3) ✔ (1)
E.54 Communication C+F C+F C/F
12V DC voltage absent ✔ (2) ✔ (3) ✔ (1)
E.55 Keyboard on Standby ap. Diag C+F C+F C/F
E.60 EEPROM (statistical memory) fault ✔
No communication with supplying ✔ (2) ✔ (3) ✔ (1)
E.70 gene. C+F C+F C/F
No communication with ✔ (2) ✔ (3) ✔ (1)
E.71 communicating gene. C+F C+F C/F
Communication delay with ✔ (2) ✔ (3) ✔ (1)
E.72 supplying gene. C+F C+F C/F
Communication delay with ✔ (2) ✔ (3) ✔ (1)
E.73 communicating gene. C+F C+F C/F
Communication interference (Chk) ✔ (2) ✔ (3) ✔ (1)
E.74 Supp. Gene. Keyboard C+F C+F C/F
E.75 Comm. Gene. Keyboard C+F C+F C/F
E.76 Supp. Gene. Keyboard C+F C+F C/F
E.77 Comm. Gene. Keyboard12 C+F C+F C/F

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15 WARNING: ELECTRIC SHOCKS
The electronic generator supply is connected directly to the mains supply.

Consequently, it is essential never to handle (connection, disconnection,
fingers on components) the live cooking zones of the appliance.
However, a screw-driver can be used to press the keys.
16 PRACTICAL ACTION CASES: FLOW CHARTS
Some practical breakdown cases and appropriate actions are listed below in
the form of a flow chart.
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Fig. 16
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17 GENERATOR BREAKDOWN CONFIRMATION
An initial static check (de-energized) can be carried out. Using a multimeter,

check the resistance present between the IGBT end pins; it should not be less
than 10kW.
Fig. 18
Static IGBT check Static Transil check
Fusible generator track Fusible filter track
If this is not so, the IGBT is broken. It is probable that the Transil diode is also
damaged. Test it to check; a zero resistance implies a breakage. In this case,
the fusible generator track (power stage) is also damaged. The generator must
obviously be replaced.
However, if the static test does not confirm the malfunction of this generator
zone (power stage), it is necessary to check the control stage starting with the
efficiency of the «glass» fuse located by the generator supply lugs.
Fig. 19
If the fuse is operational, a voltage reading with the generator live must be
taken. This measurement consists in ensuring the actual presence of mains
voltage in the generator at the power and control stages.


If the 230V are present, another reading is carried out at the connector where
the flat cable to the keyboard is connected. If one of the voltages is absent,
the generator has a malfunction.
Fig. 20
Measurement 230VAC power stage Measurement 230VAC control stage
Voltage measurement 12VCC Voltage measurement 5VCC
On the other hand, if all the voltages are correct, the malfunction stems from
the generator communication stage, and investigation is more complex.
18 INDUCTOR STATUS CHECK
In the case of generator replacement, it is necessary to check the condition of

the 2 inductors managed by it. To do this, they must be unclipped and a
visual check made to see that the printed circuit board (PCB) is not burned,
and that the solder points are «clean and smooth». Attention: when refitting the
inductors, ensure that the insulator between them and the aluminium sheet is
in place.


Fig. 21
Burned PCB. Faulty inductor Faulty soldering
19 COOKEYE
CookEye is an electronic component that carries out a temperature

measurement by means of its «optics» which converts heat energy into
electrical energy.
Fig. 22
CookEye optics Red Type B White Type A
CookEye transmits the energy measured at the table by means of an infrared

LED (using the remote controller principle). Two CookEyes are supplied with
the table, and these two components are differentiated by their colour. In fact,
they both transmit on the same frequency, but each one has an identification
code that it transmits to the table. Consequently, the use of two CookEyes of
the same type on the same table will cause malfunctions.
Fig. 23
CookEye red LED
Infrared operating warning
transmission light
LED (LED IR)
CookEye operating
push-button


Press once on the red button to start CookEye (red LED flashes every 3
seconds). One 3-second pressure on the button turns CookEye off.
CookEye is powered by a non-replaceable battery. Operating parameters
(calibration) for each component are stored in a volatile memory, and the
absence of power causes loss of data and the requirement to recalibrate
CookEye.
CookEye is sealed against splashing but not against immersion.
The infrared receiver for the table (TIG664) is located above the timer
selection keys.
Fig. 24
CookEye orientation. Rapid check Keyboard receiver position
Reflection of th
infrared
beam
CookEye
infrared transm
Infrared table
receiver
Below is a flow chart allowing the identification of the cause of a CookEye

malfunction, or the malfunction of the TIG664 «automatic» functions.

20
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21 INFRARED REMOTE CONTROL - TIG664 ONLY
The remote control for the TSG534 table is only compatible with the TIG664.
Its use is an auxiliary aid to diagnostics.
The following keys are available:
Fig. 26
0 to 9: Numeric keypad.
A to F: Hexadecimal keypad.
OK: To validate a command.
ON: To take control.
OFF: To cancel control.
DIA.: To start a diagnostic.
CODE: To enter the user code.
NEW: To start the subcontractor production test.
FONC.: To access special functions.
+.: To move around the menus.
-.: To move around the menus.
ON command
You can take over control at any time. To take control of the table, press the
ON key. The table emits 3 beeps. When under control, only the OFF, DIA,
NEW and CODE keys are operational.
OFF command
Relinquishing control can be done at any time. To relinquish control, press the
OFF key. The table emits 3 beeps. When not under control, only the ON key
is operational.
DIA command
To start a diagnostic cycle, just press the DIA key. When the diagnostic
command is active only the ON and OFF keys are operational. (Must be under
control).


NEW command
Just press the NEW key to start a keyboard production test cycle (used by the
manufacturer of the table's electronic module). Exiting this mode can only be
done by disconnecting the keyboard.
CODE command
The CODE command allows the input of the user code for access to the
special functions. To execute the CODE command, take over control and then
press the CODE key. The table emits 1 beep. When the CODE command is
active, only the OFF and DIA buttons and the numeric keypad are
operational.
Then enter the code 0123, for level I access, or code 2707 for level II
access.
FONC command
The FONC command gives access to a pull-down menu of special functions.
To execute this command, the table must be under control.
Moving around the menu is done by using the + and - buttons, and the
desired function is validated (1 beep) or invalidated (2 beeps) by pressing the
OK button.
ATTENTION: Always invalidate a function (the function number must
be displayed in the format F.xx ) before relinquishing control.
F.00 - Diagnostic function – Access level I.
Validated by pressing the OK button, this function puts the table in display
diagnostics mode. Once finished, the F.00 function code reappears. The
diagnostic sequence and the error codes are defined above.
F.01 – Not Applicable
F.02 – Deletion of statistics memory – Access level II.
Validated by pressing the OK button, 5 beeps are emitted, and the Statistics
memory is deleted. Follow this sequence with a cold reset (function F.05), and
do not switch the table on or off before this operation.
F.03 - Direct reading of the operational context – Access level I.
Validated by pressing the OK button, this function puts the table into a
permanent display (Timer display) of the appliance operational context, or
more precisely, of the RAM registers.
The movement of this function in the list of registers (FB80h from function
validation to FF7Fh maximum) can be carried out using the + and - buttons.
However, it is possible to enter the hexadecimal address of the required
register on the numeric keypad.
Pressing the NEW button allows the contents of the register to be modified by
entering the new value with up to four decimal places on the numeric keypad.
Attention: in certain cases, this operation can prove dangerous to the integrity
of the system, and should remain the expert tool that it was designed to be.


All the operational context of the TIG664 is accessible, but the most
exploitable zone in terms of service is that of the statistics shown below.
Addr. Designation Addr. Designation Addr. Designation Addr. Designation
FC74 Keyboard Soft Version FC94 Operating time FCB4 E.72 delay number FCD4 No. of data transmitted
FC75 FC95 FRR cooking zone (hours) FCB5 Supplying Gene. Response FCD5 CookEye A (Multiple)
FC76 Number of short mains FC96 Operating time FCB6 E.73 delay number FCD6 No. of data outside
Communicating gene.
FC77 interrupts FC97 FRL cooking zone (hours) FCB7 FCD7 CookEye A tolerance
response
FC78 Number of long mains FC98 FCB8 Number of E.74 faults FCD8 Number of overflow 1’
FC79 interrupts FC99 FCB9 Supp. Gene. Checksum FCD9 CookEye A
Number of cooking zone
FC7A Interference reset number FC9A FCBA Number of E.75 faults CFDA Energy deviation number
shutdowns
FC7B FC9B By hourly safety FCBB Comm. Gene. Checksum FCDB CookEye A
FC7C Number of very long mains FC9C Ambient temperature FCBC Number of E.76 faults FCDC Operating time
FC7D interrupts FC9D Maximum Keyboard FCBD NACK Supplying Gene. FCDD CookEye B (minutes)
Software malfunction
FC7E FC9E FCBE Number of E.77 faults FCDE Number of data transmitted
number
FC7F (WatchDog) FC9F FCBF NACK Communicating Gene. FCDF CookEye B (Units)
Minimum ambient Maximum ambient
FC80 Supply gene. reset attempt FCA0 FCC0 FCE0 Number of data transmitted
temperature temperature
FC81 number Supply FCA1 of Keyboard FCC1 REL inductor FCE1 CookEye B (Multiple)
FC82 Switch-on time FCA2 FCC2 Maximum temperature FCE2 Number of data outside
FC83 of appliance (seconds) FCA3 FCC3 RER inductor FCE3 CookEye B tolerance
Number of thermal
FC84 Switch-on time FCA4 FCC4 Maximum Temperature FCE4 Number of overflow 1’
limitations
FC85 of the appliance (hours) FCA5 per keyboard FCC5 FRR inductor FCE5 CookEye B
FC86 Operating time FCA6 FCC6 Maximum temperature FCE6 Energy deviation number
REL cooking zone
FC87 FCA7 FCC7 FRL inductor FCE7 CookEye B
(seconds)
FC88 Operating time FCA8 Number of times FCC8 Minimum temperature FCE8 Error discrimination number
RER cooking zone
FC89 FCA9 keyboard overheats FCC9 REL inductor FCE9 Or CookEye A and B collision
(seconds)
FC8A Operating time FCAA FCCA Minimum temperature FCEA Maximum temperature
FRR cooking zone
FC8B FCAB FCCB RER inductor FCEB Supp. Gene. Dissipator
(seconds)
FC8C Operating time FCAC Fault number on the FCCC Minimum temperature FCEC Maximum temperature
FRL cooking zone
FC8D FCAD keyboard keys FCCD FRR inductor FCED Comm. Gene. Dissipator
(seconds)
FC8E FCAE Number of rapid transitory FCCE Minimum temperature FCEE Minimum temperature
FC8F FCAF disturbances FCCF FRL inductor FCEF Supp. Gene. Dissipator
FC90 Operating time FCB0 E.70 absence number FCD0 Operating time FCF0 Minimum temperature
FC91 REL cooking zone (hours) FCB1 Supp. gene. responses FCD1 CookEye A (minutes) FCF1 Comm. Gene. Dissipator
FC92 Operating time FCB2 E.71 absence number FCD2 Number of data transmitted FCF2 Impulse counter
FC93 RER cooking zone (hours) FCB3 Comm. gene. responses FCD3 CookEye A (Units) FCF3 of the infrared receiver.
Exploitation of statistics:
The values viewed are decimals.
For each item of data supplied, its value is calculated as follows:
Contents (even address) x 256 + Contents (odd address)
Example: keyboard software version
FC74 = 0 and FC75 = 121 so 0x256 + 121 = 121
Example: Switch on time (hours)
FC84 = 50 and FC85 = 120 so 50x256 + 120 = 12920 hours, i.e. 538 days,
i.e. about 1.5 years.
F.04 – Test CookEye Production – Access level I.
Validated by pressing on the OK key (1 beep), this function puts the table in
CookEye test mode for use by the manufacturer of this component. The type
of component (A or B) appears on the Timer display as soon as it is identified
by the table. The data received by the table will only be displayed (same
display) when they are stable.


F.05 – Cold reset – Access level II.

Validated by pressing on the OK key, this function forces a cold table Reset
without recording statistics. The table starts up again with a diagnostic cycle.
F.07 – Test CookEye Utilisation Test– Access level I.
Validated by pressing on the OK key (1 beep), this function puts the table into
CookEye test mode for use by the manufacturer of this component. The
energy value received by the table is shown on the Timer display and 1 beep
is sounded. The component type is identifiable by the points separating the
left-hand digit from the other digits: 1 point CookEye Type A, 2 points
CookEye Type B.
F.08 – Keyboard thermal safety inhibition – Access level I.
No relevance for the TIG664.
F.09 - Keyboard key test – Access level I.
Validated by pressing on the OK key, this function puts the table into
keyboard test mode (1 beep), or cancels this mode (2 beeps). In this
operating mode all the bar graphs automatically display the level stemming
from the activated key. The acceptable level for a key that is pressed is
configured by the display on the Timer from the name of the key (On, Loc for
lock, Fxh for a + key, Fxb for a - key, FxP for a Booster key, Fxt for a Timer
key and x representing the number of the cooking zone).
F.10 - Display Test – Access level I.
Validated by pressing on the OK key, this function puts the table into display
test mode (1 beep), or cancels this mode (2 beeps). This mode consists of a
sequence of blinking (5 seconds) and steady illumination (5 seconds) of all
the luminous points of the display.
F.13 – Endurance function – Access level I.
Validated by pressing on the OK key, this function puts the table into the
endurance mode in accordance with the following procedure. Once in this
mode (display «c. 0»), it is necessary to enter for each cycle (c. 0, c. 1 and c. 2),
with the remote control, 2 times 2 hexadecimal numbers, the first 2 being the
level at which each cooking zone regulates (00h to 0Eh) and the following
two being the time of operation (or shutting down) of the cooking zone (00h
to FFh minutes max.).
However, no adjustment is necessary if, after the appearance of c. 0, one of
the + or - keys is pressed. In fact, the + key generates a cycle of 15 minutes in
position 14, 90 minutes in position 8 and 120 minutes turned off. The – key
itself generates a cycle of 15 minutes in position 8, 120 minutes in position 5
and 120 minutes turned off.


Once these parameters are completed, the table goes to endurance mode
(display «End»), and quitting this mode is done by pressing again on the OK key.
22 GENERATOR KIT
This is available in the form of a rigid package with an interior of conducting

cellular foam. In fact, a very sensitive component, the current transformer
must be protected from possible shocks. Two transformers are located on
each generator (1 per inductor).
Any generator with one of the two transformers damaged must not be
installed, since there is a risk that the IGBT's of the corresponding
cooking zone will be broken.
Fig. 27
Operational transformer Non-operational transformer
In addition, it is essential that the cabling specification of a fish kettle cooking

zone be available when the operation takes place.
Finally, it is important that each replaced component should be retained with
the information sheet below, one copy of which must be sent to Thionville by
mail.
Fig. 28
Generator identifiers Inductor serial number: 38011066

203683AX-13/02


23 INFORMATION SHEETS
APPLIANCE
Model Serial number Installation date
ENVIRONMENT
What is there above it?
What is there to the left? APPLIANCE What is there to the right?
What is there below it?
ACTION
Action date Town Country
CTRM / STAM
DESCRIPTION OF THE BREAKDOWN

………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
WHEN DID THE BREAKDOWN OCCUR ?
Installation Switch-on Cooking zone switch-on While operating
WITH WHICH UTENSIL ?

Type Make/range Diameter
Example:
Model FRYING PAN Make / range TEFAL INTEGRAL Diameter 220
COMPONENT(S) REPLACED
Supply Generator Filter Communicating Generator Filter
Inductor(s) Petit Split Grand Split Quad Initial* Extension*
*In the case of the fish kettle cooking zone
Fan Keyboard Flat supply cable Flat communicating cable
Serial number (inductor or generator): …..........……………………………………………………………..................................................................

(see preceding page for the localisation of the codes)
1 COPY WITH REPLACED COMPONENT(S)


24 SOME FIGURES
Consumption on stand-by: 10 Watts max.
«Mains interrupt» backup time: 30 seconds min.
CookEye service life: 5 years min. (30 minutes operation per day)
25 TERMINOLOGY
ACQUISITION
The moment when the generator identifies the utensil placed on an inductor
as being ferromagnetic and applies the required power to it. The setting
becomes fixed.
SUPPLYING
Applied to the generator which as well as communicating with the keyboard
also supplies its power. Generally, this generator is the one furthest from the
keyboard.
Applied to the keyboard connector through which it is connected to the
Supplying generator.
RELEASE
The moment when the generator no longer detects the utensil. No further
power is applied to the utensil and the setting blinks.
COMMUNICATING
Applied to the generator that only exchanges communication signals with the
keyboard. Generally, this generator is the one closest to the keyboard.
Applied to the keyboard connector that connects it to the Communicating
generator. The connector is always located close to 2 optocouplers (8-pin
integrated circuits).
FLAT CABLE
Flat cable fitted with a connector at each end allowing linkage between
generator and keyboard or keyboard and residual pilot lamp card.


Merloni Elettrodomestici S.p.A.

viale Aristide Merloni, 47 - 60044 Fabriano - Italy
tel. 0732/6611 - telex 560196 - fax 0732/662954
www.Merloni.com
Language Edition Page

GB 02-08-02/01 29-29

Induction - Main Principles: Technical Manual

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Induction - Main Principles: Technical Manual

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Merloni Electroménager S.A.

INDUCTION - MAIN PRINCIPLES

Language Edition Page

2 «STANDARD» INDUCTION GENERATOR (POWER CARD) 4

3 «FISH KETTLE» GENERATOR (POWER CARD) 4

9 ELECTRICAL BLOCK DIAGRAM 9

10 ACCESS TO THE DIAGNOSTIC DISPLAY 10

11 READING THE ERROR CODE TABLE 10

12 ERROR CODE TABLE 11

13 TIG664 DIAGNOSTIC FLOW CHART 12

14 TIXXX AND KTI XXXX DIAGNOSTIC FLOW CHART 13

15 WARNING: ELECTRIC SHOCKS 14

16 PRACTICAL ACTION CASES: FLOW CHARTS 14

17 GENERATOR BREAKDOWN CONFIRMATION 17

18 INDUCTOR STATUS CHECK 18

20 COOKEYE DIAGNOSTIC FLOW CHART 21

21 INFRARED REMOTE CONTROL - TIG664 ONLY 22

Technical Manual Language Edition Page

Fig. 1 View from inductor side

Fig. 2 View from generator side

Identification Flat cable

Each module consists of 2 (TI322) to 4 (TI644) induction cooking zones.

Technical Manual Language Edition Page

2 «STANDARD» INDUCTION GENERATOR (POWER CARD)

3 «FISH KETTLE» GENERATOR (POWER CARD)

Fish kettle zone

Technical Manual Language Edition Page

They consist of a printed card on which are glued respectively ferrites, a

The QUAD (3000W) inductor The QUAD coils

The PETIT SPLIT (1200W) inductor The PETIT SPLIT coils

The GRAND SPLIT (1800W) inductor The GRAND SPLIT coils

Temperature sensor Connector and connection lugs

Technical Manual Language Edition Page

The 2 ends of the

«Initial» area of the

The «initial» zone is identifiable by the presence of the sensor connection to

Technical Manual Language Edition Page

Fig. 7 TI644 keyboard

Supply Generator Connector Communicating Generator Connector

Technical Manual Language Edition Page

Fig. 8 TIG644 keyboard connections

Enables interference to be attenuated bi-directionally (at input and at output).

Deltatronic filter Schaffner filter

Attention: The Schaffner filter can be connected to all the generators of

Technical Manual Language Edition Page

9 ELECTRICAL BLOCK DIAGRAM

&2 0 0 8 1 ,&$ 7,2 1 &2 0 0 8 1 ,&$ 7,2 1

,1 '8 &72 5 ,1 '8 &72 5

0 $ ,1 6 ),/7 (5 )$1 0 $ ,1 6 ),/7 (5

Technical Manual Language Edition Page

10 ACCESS TO THE DIAGNOSTIC DISPLAY

So as not to make the TIG664 unusable because of a fault in one of its

11 READING THE ERROR CODE TABLE

5. End if no fault identified, otherwise display (in the form “88”

Technical Manual Language Edition Page

12 ERROR CODE TABLE

CONNECT. GENE. COMM. KEYBOARD

CONNECTION INDUC. RER

CONNECTION INDUC. FRR

CONNECTION INDUC. FRL

E.00 ON/OFF key out of action ✔

E.12 Key(s) out of action ✔

E.31 Keyboard temperature sensor in CO ✔

7 XUQ RII IRU

7 XUQ RII IRU

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