Southbend GCX-2S User manual

southbend

A MIDDLEBY COMPANY

ELECTRONICS SERVICE & TROUBLESHOOTING MANUAL

FOR

MODEL ECX-2S AND GCX-2S

DUAL COMPARTMENT PRESSURELESS STEAM COOKERS

southbend

A MIDDLEBY COMPANY

1100

Old Honeycutt Road

Fuquay-Varina, NC 27526

(919) 552-9161

FAX (919) 552-9798

(800) 348-2558

INDEX

SECTION 2

UNITS PRODUCED PRIOR TO JANUARY 1987

PAGE 19

-

INTRODUCTION

WARNING-CAUTION

WIRING SCHEMATICS AND DIAGRAMS

TEST EQUIPMENT

PAGE 20 - START UP NON POWERED TEST PROCEDURES

PAGE 20 - DOOR SWITCH NON POWERED TESTING

PAGE 20 - PRESSURE SWITCH NON POWERED TESTING

PAGE 21 - TRANSFORMER NON POWERED TESTING

PAGE 21 - STEAM SOLENOID NDN POWERED TESTING

PAGE 21 22 - KEYBOARD INSPECTION

PAGE 23 - TESTING. INITIAL DISPLAY VIEW "00"

TRANSFORMER VOLTAGES

PAGE 23 - TESTING, KEYBOARD

PAGE 24 - TESTING, PRESSURE SWITCH

READY LAMPS

PAGE 25 - TESTING, DOOR SWITCH

COOKING MODE

STEAM SOLENOID

PAGE 26 - TESTING. COOK LAMP

COOKING MODE

STEAM SOLENOID

PAGE 27 - TESTING. TIMEKEEPING

PAGE 28 - CONTROL BOARD WIRING DIAGRAM

PAGE 29 - KEYBOARD ENCODER DISPLAY DIAGRAM

PAGE 30 - FRONT PANEL KEYBOARD DIAGRAM

PAGE 31 - DOOR SWITCH DIAGRAM

PAGE 32 - TROUBLESHOOTING SUMMARY CHART

INDEX

PAGE

1 .

—

INTRODUCTION

WARNING - CAUTION

WIRING SCHEMATICS AND DIAGRAMS

TEST EQUIPMENT

S E C T I O N 1

UNITS PRODUCED FROM JANUARY 1387 AND ON

PAGE 2 - START UP NON POWERED TEST PROCEDURES

PAGE 2 - DOOR SWITCH NON POWERED TESTING

PAGE 2,3 - PRESSURE SWITCH NON POWERED TESTING

PAGE 3 - TRANSFORMER NON POWERED TESTING

PAGE 4 - STEAM SOLENOID NON POWERED TESTING

PAGE 4 - KEYBOARD INSPECTION

PAGE 5

TESTING. INITIAL DISPLAY VIEW "00"

TRANSFORMER VOLTAGES

PAGE 5

TESTING. KEYBOARD

BUZZER

PAGE 7 — TESTING, PRESSURE SWITCH

READY LAMP

PAGE 8 — TESTING, DOOR SWITCH

COOKING MODE

STEAM SOLENOID

PAGE 9 — TESTING. COOK LAMP

PROGRAMMING JUMPERS

PAGE 10 - TESTING. CLOCK

PAGE 11 - CONTROL BOARD WIRING DIAGRAM

PAGE 12 - TYPICAL SYSTEM WIRING DIAGRAM

PAGE 13 — KEYBOARD ENCODER DISPLAY DIAGRAM

PAGE 11 - FRONT PANEL KEYBOARD DIAGRAM

PAGE 15 — DOOR SWITCH DIAGRAM

PAGE 16 - TROUBLESHOOTING SUMMARY CHART

PAGE 17 - ECN1 (ENGINEERING CHANGE NOTE)

INCORRECT DIGIT ENTRY MODIFICATION

S E C T I O N 1

UNITS PRODUCED AFTER JANUARY 1987

PAGE 1 OF 32

INTRODUCTION

THIS MANUAL HAS BEEN PRODUCED IN TWO SECTIONS

Section 1 - Refers to current model steamers that have been produced AFTER January 1987.

Refers to older model steamers that were produced PRIOR to January 1987 Section 2 -

Identification of the difference in the models is accomplished by noting that the control board,

Part No. 8-5003 has a different mode of miring connectors. Prior to Janaury 1987, the upper

board wiring was accomplished with a (4) four position terminal block, and the side board

wiring was accomplished with a 7 pin push on connector.

PLEASE REFER TO THE APPROPRIATE SECTION DEPENDANT ON THE

MODE OF WIRING TO THE PART NO. 8-5003 CONTROL BOARD.

This manual has been prepared to aid the service technician to troubleshoot and repair the MODEL ECX or GCX -2

dual steam cooking appliance. We suggest that this entire manual be read thoroughly and that all instructions be

followed carefully. This manual should be retained for future reference. Only a qualified technician with some basic

knowledge of electrical and electronic skills should be allowed to work on this equipment.

WARNING - CAUTION

YOU WILL BE WORKING ON LIVE EQUIPMENT. DANGEROUS VOLTAGES ARE PRESENT IN THIS

EQUIPMENT WHEN IN THE ON MODE, TESTING ROUTINES SHOULD BE PERFORMED BY A QUALIFIED

ELECTRONICS TECHNICIAN OR ELECTRICIAN ONLY.

WIRING SCHEMATICS AND DIAGRAMS

Please refer to all attached diagrams and schematic for all tests and verifications to be performed.

TEST EQUIPMENT

The Following test equipment mill be required.

1. ANALOG multimeter (impedance of 1000 OHMS/V or greater)

OR

DIGITAL multimeter (impedance of 1 MEG OHMS/V or greater)

2. Alligator quick Jumper leads. (if required)

PAGE 2 OF 32

SECTION 1

START UP

A. With the appliance in an off (shutdown) condition. it is recommended that the following non live

test routines be performed prior to applying power to the appliance.

1. Verify that all printed circuit boards are properly secured with lockwashers to the mounting

locations.

2. Verify that the interconnect connectors between the control board (P/N 8-5003) connector and

the keyboard /display (P/N 8-5002) are all properly mated.

3. Verify that all internal wiring is in good condition and properly connected as per the appropriate

miring diagram for the appliance, and that all terminals are properly secured to the wiring.

Door Switch P/N 8-5061

Pressure Switch P/N 3-PA36

Transformer P/N 4-T199

Peripheral devices -

Steam Solenoid P/N 3-S230

B.

May be tested in a non live condition as per the following routines.

1. Door Switch - Connect multimeter, OHMS setting To Terminals # 5 and 6, Upper and

Lower

Open and close the appropriate door

a. Meter should show a short when door closed

b. Meter should sham an open when door open

If meter not corresponding to a and b above

Verify and realign magnet if necessary,

or

Verify terminals are properly connected

c.

or

d. Inspect glass door switch and replace if necessary.

2. Pressure Switch

- Connect multimeter, OHMS setting To Terminals # 7 and 8, Upper

Control Board

Operate the pressure switch manually

a. Meter should show a short when pressure ok

b. Meter should show an open when pressure low

c. If meter not corresponding to a and b above

Verify that the yellow mire is connected to (c) COMMON of the pressure

switch.

PAGE 3 of 32

SECTION 1

START UP - CONTINUED

Pressure Switch Verify that the blue mire is connected to (NO) NORMALLY OPEN of the pressure

switch.

Verify terminals are properly connected both at the pressure switch and the

printed circuit board locations.

d. Verify the operation of the pressure switch on the lower control board as per

above.

2.

Cont'd

e. Replace pressure switch if necessary.

Connect multimeter, OHMS setting (lo scale) To Terminals 10 & 12, Upper

Control Board

Verify that the quick disconnect terminals are secure to the wires.

Meter should read between 2 and 3 OHMS a.

Change meter lead that is connected to Terminal 10 to Terminal 14

b. Meter should read between 2 and 3 OHMS

A meter reading of less than 1 Ohm on the secondary side of the transformer

constitues a short circuit of the transformer .

or

An open circuit indicates that the transformer is faulty

3. Transformer

(secondary)

c.

Replace the transformer if this meter reading is obtained.

IT IS IMPERATIVE THAT THE TRANSFORMER SIDE CONNECTED TO

TERMINALS 10 & 12 BE IN PROPER OPERATION, IF NOT

THE TIMING CLOCK WILL NOT FUNCTION

Repeat the above procedure on the lower control board. d.

Connect multimeter, Ohms setting To input (black leads) of the transformer

Meter should read between SO and 60 OHMS

A reading of less than SO OHMS indicates that the transformer may be snorted.

or

An open circuit indicates that the transformer is faulty.

Transformer

(primary )

a.

Replace the transformer if necessary.

PAGE 4 OF 32

SECTION 1

START UP - CONTINUED

Connect multimeter, OHMS setting To Terminals 1 & 2, upper control

board.

Verify that the quick disconnect terminals are securely fastened to the

mires.

Meter should read 10S OHMS approximately

A reading less than 50 OHMS indicates a faulty solenoid coil. or

An open circuit indicates a faulty solenoid coil.

a.

Replace steam solenoid if necessary.

Repeat above procedure for lower control.

4. STEAM

SOLENOID

b.

Replace steam solenoid if necessary.

5. KEYBOARD

INSPECTION

a.

PART NO. 8

-

5005

prior to powering up the appliance, the front face keyboard should be

inspected for an physical damages. The face covering should be a

smooth faced surface with absolutely no tears or punctures.

Replace if necessary.

** "NOTE" **

PINOUTS ARE

IDENTICAL TO

PART NO.

8-5001

It would be advisable to test the integrity of the keyboard prior to

reinstalling the 8-S002 display board, see drawing # P/N 8-5004 FRONT

PANEL KEYBOARD REAR VIEW Diagram for proper key/pin outputs.

Test using multimeter on OHMS scale for contuity when depressing the

appropriate keyboard function. A resistance of less than -100 ohms is

normal, over is not acceptable.

b.

Replace if necessary.

If required to replace the keyboard panel, or when replacing the internal

electronic printed circuit board, Part no. 8-5002. ensure that all pins on

the keyboard mate into the lower socket on the display board.

c.

Failure to locate all pins into the sockets will disallow keyboard switch

functions from operating correctly.

Also ensure that when remating the connector on the 8-5003 control

board, that all pins on the 8-5002 board mate properly into the connector.

d.

Failure to locate all pins into the sockets will cause the cooker electronics

to not function properly.

PAGE 5 OF 32

SECTION 1

WARNING - CAUTION

BEFORE TURNING THE APPLIANCE ON:

1. VERIFY THAT ALL WIRING IS CONNECTED AND SECURED PROPERLY.

2. VERIFY THAT THE MULTIMETER HAS BEEN DISCONNECTED.

3. VERIFY THAT THE CONTROL BOARDS AND DISPLAY BOARDS ARE. SECURED AND

INTERCONNECTED PROPERLY.

1. VERIFY THAT THE WATER AND GAS OR ELECTRIC SUPPLY IS ON. AT THE MAIN SWITCH OR INLET

LOCATIONS.

YOU WILL BE WORKING ON LIVE EQUIPMENT, DANGEROUS VOLTAGES ARE

PRESENT IN THIS EQUIPMENT. TESTS SHOULD BE PERFORMED

CAUTIOUSLY BY A QUALIFIED ELECTRONICS TECHNICIAN OR

A QUALIFIED ELECTRICIAN ONLY

TESTING

1. Turn on the appliance and allow the equipment to perform the normal start up sequence. (approx 18-20

minutes)

2. Note that upon initial power on:

a. Both digital "COOK TIME-MINUTES" windows will display "00" .

b. The "READY" green light, and the "COOK" red light should be off.

Should "00" not be visible in the front panel windows. connect multimeter, AC 200 Volt setting or

higher. to Terminals 3 & 4 on either the upper or lower control board.

Observe that approximately 120 Volts AC should be present. View this voltage at both Control boards.

If this voltage is not obtained, check the integrity of the system internal fuse and/or the transformer.

c.

Replace the defective component as required.

Should this reading be obtained, now connect the multimeter, IS Volts AC setting to Terminals # 10 and

12, on either the upper or lower control board.

Observe that approximately 12 Volts AC should be present. Change meter lead that is connected to

Terminal # 10 to Terminal # 14, Observe the same reading of approximately 12 Volts AC. View These

voltages at both Control Boards.

d.

If this voltage is not obtained, check the internal fuse, and or transformer and wiring. Replace the

defective component as required.

PAGE 6 OF 32

SECTION 1

TESTING - Continued

3. Touch number 8 twice on both keyboard panels, observe ail segments of "88" in both display

windows light up. AS well, touch all other numbers and observe that they function.

4. On both keyboard sections, touch "CANCEL" and the display windows will show "00", if numbers

other than "00 are displayed.

5. Do not at this time depress the "START" button as the unit is not at a ready state.

Units produced after January 1987, all keyboard entries sound the control board buzzer to signify

keyboard contact and interboard connector integrity between the keyboard, display board and

control board.

6.

Should the integrity of the keyboard be correct and the mating connectors are connected properly

and not damaged, it may be necessary to change the Display board only, Part No. 8-5002, if the

corresponding digits do not enter according to keyboard entry.

6A. PLEASE See Addendum ECN at the end of this manual for incorrect digit entry. (# 8 = 0, or #1 = 6)

It should be noted that the buzzer built on to the control board P/N 8-5003 is extremely loud. These

units are shipped with a protective label "REMOVE AFTER WASHING".

This label is provided by the buzzer manufacturer to protect the internal sounding (electronic)

element in the process of assembly with other electronic components during the manufacturing

process.

It is not advisable to leave this label fully intact to lower the volume of the buzzer as this may

damage the sounding element when the buzzer is activated.

7.

There are three openings under this protective label for the sound to escape the resonant

chamber.

IT IS HIGHLY RECOMENDED TO PREVENT DAMAGE TO THE SOUNDING ELEMENT TO OPEN A

MINIMUM OF A LEAST CD ONE OF THESE OPENINGS TO PREVENT IRREPAIRABLE DAMAGE TO

THE BUZZER.

8. After the initial start up time of approximately 18 to 20 minutes, observe that the steam pressure

guage indicates steam pressure in a range of 9 to 12 PSI. When steam pressure is at this level,

note that both green "READY" lights mill be LIT indicating that the Steam-Ex is now ready for the

cooking cycle.

PAGE 7 OF 32

SECTION 1

TESTING - Continued

a. Should both green "READY" lights be off. it may be necessary to readjust the pressure switch setting.

or

IF both READY lights do not Light up when adequate steam pressure is indicated on the pressure

gauge,

Verify that all wiring involved in the pressure switch miring path is correct and secure to both the upper

and lower control boards as per the P/N 8-5003 TYPICAL SYSTEM WIRING DIAGRAM supplied in

this manual.

and/or

Verify that the pressure switch is properly wired as per the P/N 8-5003 TYPICAL SYSTEM WIRING

DIAGRAM, and functions correctly as directed to test in a non powered condition an page #2 and 3

Section B2.

b.

Replace the pressure switch or wiring as necessary .

If only one READY lamp is lit, On the non lit control board, Connect multimeter, DC 15 Volts or higher

setting, RED (+) to Terminal #8, BLACK (-) to Terminal #7

c.

Observe that if adequate pressure is available and the pressure switch is operating correctly, a meter

reading of approximately 0 Volts DC should be obtained.

If a meter reading of 12 Volts DC is observed when pressure is adequate, recheck the pressure switch

connections and the wiring. Should the pressure switch be correctly mired and miring in proper order,

replace. the Control board P/N 8-5003.

If a meter reading of 0 VDC is obtained at Terminal #7, Remove the RED (+) multimeter lead from

Terminal #7 and manually touch and hold to PIN #1 (THE UPPERMOST PIN) of the INTERCONNECT

SOCKET TO KEYBOARD/DISPLAY Connector.

Observe that a reading of approximately 0 Volts DC is obtained,

1. If 0 VOLTS is obtained - replace the Display board P/N 8-5002

8.

d.

2. If approximately 12 Volts DC is obtained - replace the Control board P/N 8-

5003

WARNING - CAUTION

WHEN DEEMED NECESSARY TO REPLACE COMPONENTS DURING LIVE

POWERED TESTING PROCEDURES. SHUTDOWN THE APPLIANCE

ELECTRICALLY BOTH LOCALLY AT THE APPLIANCE AND THE MAIN

SERVICE BREAKER OR FUSE PANEL

BEFORE ATTEMPTING TO REPLACE COMPONENTS OF THE APPLIANCE

PAGE 8 OF 32

SECTION 1

TESTING - Continued

Test the integrity of each DOOR SWITCH in this manner:

a. Connect multimeter, DC 15 Volts or higher, RED (+) to Terminal # 5. BLACK (-) to Terminal

#6

With the appropriate door closed, b.

Observe a reading of approximately 0 Volts DC

Open the Door, c.

Observe a reading of approximately 12 Volts DC

If the above readings are not satisfied, remove and inspect the door switch and perform a

nan papered continuity test as outlined on Page 2 Section 1.

d.

Should the Door Switches function correctly, Verify that the wiring and terminals are in good

order.

e. Replace or reinstall the door switch and realign door magnet if required.

9.

f. If meter readings are still not obtained, replace the Control Board P/N 8-5003.

Test each Steam Solenoid Valve output in this manner:

a: Connect multimeter, AC setting. 200 Volts or higher, To Terminals #1 and #2, leave the

connections made.

In a NON-COOKING mode, a reading of less than 10 VAC should be obtained and the

solenoid should be de-energized.

If this reading is higher than 15 VAC,

Check the continuity of the Solenoid coil in a nan powered state as outlined on Page 4

Section 4.

b.

If the Solenoid Coil proves to be correct, and the above reading is not correct, replace the

Control board P/N 8-5003

Program a COOKING time via the keyboard, Ensure that the FRONT DOOR is closed,

Ensure that steam is adequate via the READY light, Depress the START button on the

keypad,

Note that the cooker should now go into a cooking mode,

10.

c.

The RED "COOK" lamp should be lit and the solenoid will have energized, and the buzzer

mill have sounded

PAGE 9 OF 32

SECTION 1

TESTING - Continued

IF the "COOK" lamp has lit up, and the solenoid is energized,

A meter reading of approximately ISO VAC should he obtained

10. d.

If this reading is not obtained, and the solenoid is not energized, replace

the control Board P/N 8-5003.

If the Solenoid is energized but the "COOK" lamp is not lit,

Disconnect the multimeter from Terminals 1 & 2

Reconnect multimeter, DC setting, IS Volts or higher, BLACK (-) to Terminal

#6, Touch and hold the RED (+) lead to PIN S (the second damn From the tap)

on the INTERCONNECT SOCKET TO KEYBOARD/DISPLAY CONNECTOR.

IF a meter reading of 0 VDC is obtained, 1.

Replace the Display Board P/N 8-S002.

IF a meter reading of approximately 12VDC is obtained, and the unit is

in the cooking mode,

e.

2.

Replace the Control Board P/N 8-S003.

W A R N I N G - CAUTION

THE COOKING COMPARTMENTS CONTAIN LIVE STEAM WHEN IN THE

COOKING MODE. TO AVOID SCALDING AND/OR BURNS, STAND CLEAR

WHEN OPENING EACH COMPARTMENT DOOR

In a NON-COOKING mode, should the Steam Solenoid valve be energized,

The READY lamp lit, The COOK lamp off

11.

Replace the Control Board P/N 8-S003

12. The Timing Clock Function is Programmed an the Control Board P/N 8-S003,

a. 60 HZ Operation - Cut Jumpers # 2, 3, 4 and 5 ONLY

b. SO HZ Operation - Cut Jumper # 1 ONLY

DO NOT CUT ALL JUMPERS, AS THIS WILL DISALLOW THE

TIMEKEEPING TO PERFORM PRECISELY

PAGE 10 OF 32

SECTION 1

TESTING - Continued

In the event that when in a cooking mode the display windows do not count

downwards,

12. c.

It should be verified that the 12 VAC power is available at Terminals #

10 and 12

BEFORE

Replacement of the Control Board P/N B-S003 should be the first choice,

Then and/or the Display Board P/N B-5002

When Verified that the appliance is operating correctly, shutdown the

unit,

15.

Verify that ail Electronic Printed Circuit Boards are secured with

lockwashers under the hold down screws.

Verify that all other hardware and components are correctly fastened. 14.

Reinstall all panels and covers securely.

FOR CONVENIENCE WE HAVE ADDED A

TROUBLESHOOTING - SYMPTOM - CORRECTION CHARTS

ON THE FOLLOWING PAGES

SEE ATTACHED DIAGRAMS AND SCHEMATICS TO AID IN

TROUBLESHOOTING AND REPAIR

SEE ADDENUM ECN1 AT THE END OF THIS MANUAL SECTION

FOR INCORRECT DIGIT ENTRY (#B - 0, #4 = 6. ETC.)

SEE SECTION 2 FOR GUIDE TO SERVICING

MANUFACTURED PRIOR TO JANUARY 1987

PAGE 11 OF 32

PAGE 12 OF 32

PAGE 13 OF 32

PAGE 14 OF 32

PAGE 15 OF 32

PAGE 16 OF 32

REFER TO TROUBLE/SERVICE MANUAL FOR COMPLETE TEST PROCEDURES BEFORE REPLACING COMPONENTS

TROUBLE / FAULT POSSIBLE CAUSE CHECK AND REPLACE

NO DISPLAYS ON POWER UP - "00 LIT UP" FUSE. TRANSFORMER. WIRING. CONTROL AC FUSE. TRANSFORMER. WIRING. CONTROL

STEAM SOLENOID NOT ENERGIZING STEAM SOLENOID, WIRING, CONTROL STEAM SOLENOID. WIRING. CONTROL BOARD

STEAM SOLENOID ALWAYS ENERGIZED CONTROL BOARD. CROSSED WIRING CONTROL BOARD. WIRING

NO READY LAMP BURNT LAMP. NO PRESSURE. BAD BOARD PRESSURE, WIRING. CONTROL OR DISPLAY

NO COOKING LAMP BURNT LAMP, DOOR SWITCH. BAD BOARD DOOR SW. PRESSURE. CONTROL OR DISPLAY

STEAM DOES NOT STOP WHEN DOOR OPENED DOOR SWITCH. WIRING. CONTROL BOARD DOOR SWITCH. WIRING. CONTROL BOARD

CLOCK DOES NOT COUNT DOWN 12VAC AT T10 1& 12. CONTROL. DISPLAY TRANSFORMER. WIRING. CONTROL. DISPLAY

CLOCK NOT ACCURATE TIMEKEEPING PROGRAMMING JUMPERS. CONTROL PROGRAMMING JUMPERS. CONTROL BOARD

KEYBOARD DOES NOT ENTER DIGITS KEYBOARD. INTERCONNECTIONS. DISPLAY KEYBORRD. INTERCONNECTIONS. DISPLAY

KEYBOARD DOES NOT START COOKING CYCLE KEYBOARD. INTERCONNECTIONS. CONTROL KEYBOARD. INTERCONNECTIONS. CONTROL

KEYBOARD DOES NOT CANCEL DIGITS KEYBOARD. INTERCONNECTIONS. CONTROL KEYBOARD. INTERCONNECTIONS. CONTROL

KEYBOARD DOES NOT STOP COOKING CYCLE KEYBOARD. INTERCONNECTIONS, CONTROL KEYBOARD. INTERCONNECTIONS. CONTROL

NO BUZZER SOUND WHEN DIGITS ENTERED INTERCONNECTIONS. BUZZER INTERCONNECTIONS. CONTROL BOARD

NO BUZZER AT END OF COOKING CYCLE CONTROL BOARD. BUZZER CONTROL BOARD. DISPLAY BOARD

BUZZER DOES NOT STOP WHEN DOOR OPENED DOOR SWITCH. WIRING. CONTROL BOARD DOOR SWITCH. WIRING. CONTROL BOARD

READY LAMP NOT ON WHEN PRESSURE OK PRESSURE SWITCH. WIRING. BOARDS PRESSURE SWITCH. WIRING. BOARDS

COOKING LAMP NOT ON WHEN COOKING INTERCONNECTIONS, CONTROL, DISPLAY INTERCONNECTIONS. CONTROL. DISPLAY

EX-2 TROUBLESHOOTING MANUAL CHART

OWN BY: RGS MAY 1988 REV. 0

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Southbend GCX-2S User manual

Southbend GCX-2S User manual

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