SOW_Install_Instr_Attach_1.pdf

Safe-T-element Installation

Instructions

For: GE Cooktop 1+1 Burner Configuration

PTI STEZE (USA)

PTI STEZF (Canada)

Revision B (Feb. 21, 2012)

TABLE OF CONTENTS

1. PREPARATION

1.1 General Safety Instructions

1.2 Before You Start

1.3 Tools & Equipment Needed

1.4 Safe-T-element® Components

1.5 Optional Components

2. INSTALLATION

2.1 Preparing For Installation

2.2 Installing Safe-T-element® Plates

2.3 Mounting the Safe-T-element® Controller

2.4 Wiring Diagram

2.5 Testing

2.6 Applying the Installation Label

3. SAFE-T-ELEMENT® REPLACEMENT PARTS

4. TROUBLESHOOTING

4.1 Common Questions

4.2 Getting Help

Document Number PTI STE88 B Safe-T-element ® Cooktop Installation Instructions

1. PREPARATION

1.1 General Safety Instructions

Safety First!

All wire connection must be made in accordance with local codes and properly insulated. Check with your local utility for electrical codes which apply in your area. Failure to wire your Safe-T-element in accordance with local codes could result in a hazardous condition.

Be sure your Safe-T-element is properly installed and grounded by a qualified service technician. Follow the installation and servicing instruc-tions provided with this product.

Read this manual carefully before installing the Safe-T-element to re-duce the risk of electric shock, fire, burn hazard or other injury.

Do not repair or replace any part of this product unless it is specifically recommended in this manual.

Save these instructions for future reference. If you are installing this unit for someone else, give the Care and Use Manual to that person for future reference.

1.2 Before You Start

WARNING: Shock hazard present due to high voltages.

Ensure that the burners are cool before attempting to install this product.

Cooktop Installation Instructions

1.3 Tools and Equipment Needed

#1 Phillips screwdriver #2 Phillips screwdriver Slot screwdriver Needle nose pliers Wire cutter and stripper 1/4” Nut driver 3/8” Nut driver 5/8” Nut driver 7/8” Punch (Greenlee Part#71BB or similar) 1” Wrench (for punch)

1.4 Safe-T-element® Components

Quantity Description

1 Large Safe-T-element® plate

1 Small Safe-T-element® plate

1 Safe-T-element® Controller

1 Wire Harness

2 Large plate bracket

2 Small plate bracket

14 M3x5mm Bracket Screws (+ 2 extras)

4 M3x6mm Bracket Screws (packaged separately)

2 M3x12mm Thermocouple wire bracket screws

1 90 deg. Conduit connector, 3/8”

1 Steel conduit strap

2 Insulator for flag type electrical connectors

2 Nylon cable tie

1 Thermocouple for large plate

1 Thermocouple for small plate

2 Thermocouple connector bracket

1 Power wire set (1 Red & 1 Black)

2 Wire-nut

5 #8 x 3/4” Wood screws

1 8-32 Nut

1 Care and Use Manual

1 Installation sticker

Optional

Grill thermometer (for testing)

® Cooktop Installation Instructions

Ensure that the Safe-T-element is compatible with the cooktop. Some models may require the replacement of the elements or the use of an adapter kit.

Check the construction of the burners.

The Safe-T-element plates cannot be mounted to element with a ‘delta’ or triangular spider. The ele-ment will need to be replaced with compatible ele-ments with the 3 legged spider.

The Safe-T-element small plates are not compatible with some stoves that have small 6” elements with 5 turns of the element coil. They must be replaced with compatible 4-turn elements. The new elements must have the same or lower power rating.

Element Configuration:

5-Turn 6" Element Replacement 6" 4-Turn 'equivalent' element

1 26

Delta Spider 6" & 8" Ele-ment

Replacement 6" and 8" Y-spider 'equivalent' element

6" element 8" element

2 27

Part/Assembly Adapter Kit Package Qty Pack

ID #

Package Figure

Cooktop Installation Instructions

2. INSTALLATION

2.1 Preparing For Installation

1. Before disconnecting anything test the surface elements to ensure they are functional. To prevent injury do not allow elements to get hot. Turn elements off when slightly warm.

2. Disconnect power to cooktop.

DISCONNECT THE COOKTOP POWER AT THE

DISTRIBUTION PANEL BY REMOVING FUSE

OR SWITCHING OFF THE CIRCUIT BREAKER.

3. Remove brackets securing the cooktop to the counter (not shown). Remove the 4 screws securing the cooktop cover.

(Fig. 1)

4. Inspect all existing wiring for damage or excessive grease buildup. (Fig. 2)

DANGER:

Do not proceed with the installation if there is any damage to wiring or excessive grease buildup.

To avoid risk of personal injury or property damage, have the stove serviced before proceeding with the installation if either of these conditions is found.

IMPORTANT!

This document describes a typical installation.

There may be slight variations from model to model which must be accommodated. Please contact Pioneering Technology for assistance.

Fig. 1

Fig. 2

2.2 Installing Safe-T-element

Plates

1. IMPORTANT!

Verify that the power supply to the cooktop is disconnected and the burner elements are cool.

2. Remove burner element from its socket. (Fig.3)

3. Remove its center cover piece. If its welded to the spider, snip it with aviation snips. (Fig.4)

4. Put the thermocouple wire through the gap in the element as shown, carefully, holding it by the wire only. (Fig.5)

CAUTION!

HOLD & BEND THE THERMOCOUPLE WIRE ONLY. DO

NOT HOLD OR BEND THE WIRE AT THE CONNECTION

TO THE THERMOCOUPLE BRACKET AS IT MAY

BREAK THE THERMOCOUPLE JUNCTION ON THE

BRACKET. (Fig.6)

5. Put the other end through the next gap as shown carefully, holding it by the wire only. (Fig.6)

Fig. 6

Fig. 5

Fig. 4

Fig. 3

Cooktop Installation Instructions

6. Hold the thermocouple wire bracket in place.(Fig.7) Where possi-ble, the bracket must be mounted behind the existing element grounding bracket. Where this is not possible, the temperature sensor bracket may be mounted in front of the element grounding bracket provided the following requirements are met:

The thermocouple bracket can be mounted in a position where it can hook onto the element grounding bracket to pre-vent movement; and, A minimum spacing of ½ inch is left between the thermocou-ple bracket and the exposed terminals of the element.

NOTE: The kit includes 2 different sized thermocouple brackets.

Ensure you mount the correct one for the element.

7. Secure the temperature sensor bracket to the element using the

M3x12mm screws. (Fig.8)

8. Place the Safe-T-element® plate top-side down. Place burner element top-side down on the Safe-T-element® plate. The electrical connections for the element must be placed opposite the notch in the plate. (Fig.9)

9. Loosely secure the Safe-T-element® plate to the burner element using thermocouple assembly bracket and 2 M3x5mm screws using the #1 Phillips screw driver. (Fig.10)

10. Use 2 additional brackets to secure the plate to the element.

Tighten the 6 screws until the bracket is snug against the plate.

Be careful not to over tighten the screws. If the M3x5mm screws do not screw into the plate use the longer M3x6mm screws. If using an electric screwdriver ensure that the torque setting is set between 2 & 3.

11. Repeat the above steps for the other 3 burner elements.

12. Use 2 additional brackets to secure the plate to the element.

Tighten the 6 screws until the bracket is snug against the plate.

Be careful not to over tighten the screws. (Fig.11)

13. Repeat the above steps for the other 3 burner elements.

Fig. 11

Fig. 10

Fig. 9

Fig. 8

Fig. 7

® Cooktop Installation Instructions

2.3 Installing Safe-T-element

Wire Harness :

1. Disconnect existing wires between conduit and cooktop. Move cooktop aside for easy access to base. Refer to Fig.12.

2. Remove existing conduit and set aside.

3. Enlarge conduit opening using punch as shown. Use flange on cooktop heat shield to help align the tool.

4. Attach 45° connector of new conduit to cooktop base. Press through hole until it snaps in place.

5. Push other end of conduit through existing hole until conduit lays flat.

Fig. 14

Fig. 13

Fig. 12

Fig. 15

Fig. 16

6. Secure conduit to burner box using strap provided.

7. Connect the red and black wires to the same terminals as the original wires. Refer to wiring diagram on page 14.

8. Disconnect one of the yellow wires and install a plastic insulator

9. Connect the Safe-T-element® yellow wire with the blue insulator to the cooktop yellow wire. Connect the other yellow wire to the control dial.

10. Repeat for Safe-T-element® brown wire with cooktop orange wire.

Fig. 17

Fig. 18

Fig. 19

Fig. 20

Fig. 21

11. Connect securely ground wire to cooktop using original screw which held the conduit connector.

12. Attach other end of Safe-T-element conduit to controller. Press through hole until it snaps in place.

13. Connect yellow and brown wires to Control Board relays with yellow and brown labels.

14. Cut the red and black wires in the original conduit leaving about 6 inches protruding from conduit. Strip 1/2” of insulation from ends of wires.

15. Install 90 degree conduit connector to end of conduit from the electrical box. Attach to the Controller. Connect both ground wires using stud on Controller box.

Fig. 22

Fig. 23

Fig. 24

Fig. 25

Fig. 26

16. Connect red wires from both conduits and 6” red power wire us-ing supplied wire nut. Repeat for black wires.

17. Connect red and black power wires to the Control Board if not already done.

18. Tuck the wires neatly into the space next to the Control Board and install the top using 4 self-tapping screws.

19. Mount the Controller to the cabinet wall next to the existing elec-trical box.

WARNING: Controller must be mounted in vertical orienta-tion with conduits toward the bottom as shown in Fig. 30.

20. Secure conduit to cabinet wall using strap removed step 2. Use cable ties provided to neatly secure the conduits to each other.

Fig. 30

Fig. 29

Fig. 28

Fig. 27

Fig. 31

21. Run the 2 thermocouple wires through the space between the control dials to avoid pinching them during reassembly. (Fig.16)

22. Leave several inches of slack near the burner element to allow easy access for cleaning.

23. Reinstall top being careful not to pinch any wires.

24. Installation is complete. It is recommended that elements be tested prior to attempting to cook on the cooktop.

Fig. 35

Fig. 33

Fig. 32

Fig. 34

2.4 Wiring Diagram

LINE (208-240VAC)

CONTROL DIALCONTROL DIAL

NOTES:

1. SOME EXISTING WIRING OMITTED FOR

CLARITY

TITLE

Safe-T-element Cooktop Wiring Diagram

COOKTOP

H1

H2

L1

L2

H1

H2

L1

L2

LARGE ELEMENT

SMALL ELEMENT

PILOT LIGHT

L1 L2 G

CONTROLLER

® Cooktop Installation Instructions

2.5 Testing

1. Place your hand on the front-right plate and turn on the ele-ment. Ensure that the light for that element lights up.

2. Feel for heat from the plate. Be extremely careful during this test as the element may heat up very quick-

ly. Move your hand away at the first sign of heat.

3. Turn off the element. Repeat for other elements. Do not turn on all the elements at the same time to test. By doing so it is not possible to check if the wiring is correct.

4. Installation is complete.

Optional

A grill thermometer can be used to measure the tempera-ture of the plates to ensure proper operation.

2.6 Applying the Installation Label

1. Hand write the installation date, the Manufacturer’s Rep. & the installer’s name on the installation label.

2. Apply the installation label (Fig 36a) ON THE Safe-T-element® Controller (Fig 36b). This label must be applied for Pioneering Technology to honor the one-year warranty from the installation date of the product.

Safe -T-element

MODEL # PTI STE

Serial no: 12345 Installation Date: Aug 25, 2010

Manufacturer’s Rep: ABC Service Company Inc.

Fig. 36a

Fig. 36b

Cooktop Installation Instructions

Part/Assembly Replacement Parts Qty Pack

ID #

Package Figure

Controller Controller 1 21

Small Plate, Mounting and Thermocouple wires

Small plate 1

Small mounting bracket 2

Small mounting bracket with short-end of thermocouple wire

Mounting bracket screws (M3x5mm)

Large Plate, Mounting Brackets and Thermocouple wires

Large Plate

Large mounting bracket

Large mounting bracket with short-end of thermocouple wire

Mounting bracket screws (M3x5mm)

Large Plate Thermocouple wire with Mounting Bracket

Large mounting bracket with short-end of thermocouple wire

Thermocouple wire connector bracket

Small Plate Thermocouple wire with Mounting Bracket

Small mounting bracket with short-end of thermocouple wire

Thermocouple wire connector bracket

(M3x5mm)

Wire Harness Relay wire set 1 22

3.0 Safe-T-element

Replacement Parts (order by Pack ID #’s)

® Cooktop Installation Instructions

Part/Assembly Replacement Parts/

Adapter Kit Package Qty

Pack

ID #

Package

Figure

Power Wires Power wire set 1 23

Screw set Self-tapping screws, wood screws 1 24

7/8” Punch Greenlee Part#71BB 1 25

Cast-iron plate Cleaner

Range Solid Element Cleaner -

Restores and protects solid cook-ing elements. Helps maintain the original matte black appearance.

When used regularly, protects the surface from rusting and spotting.

1 16 http://www.repairclinic.com/SSPartDetail.aspx?s=t-12830-%3d%3di12830&PartID=12830

Cooktop Installation Instructions

4. TROUBLESHOOTING

4.1 Common Questions

4.2 Getting Help

If you require assistance with the installation of Safe-T-element please call

Pioneering Technology Corp. at toll free: 1-800-433-6026 or 905-712-2061 x 228 between the hours of 9:00am and 5:00pm EST or email: service@pioneeringtech.com.

PROBLEM POSSIBLE CAUSE/SOLUTION

Cooktop does not operate Incorrect wiring. If this is the first time operating the cooktop after installation check all connec-tions.

Fuse has blown or circuit breaker has tripped.

Check cooktop fuses and breaker at panel.

WARNING: Do not reset breaker/replace fuse until cause is identified and corrected. Failure to do so may result in injury or damage.

One element does not operate

Thermocouple wire connection broken.

Ensure thermocouple wire connected.

Check thermocouple wire for damage.

One or more of the elements get too hot (up to 450°C/ 842ºF)

It is normal to have hot spots on the plate if the Safe-T-element is operated without a pot or pan.

The Safe-T-element is designed to keep the average temperature of the plate at approximately 350°C (662ºF). If the element is operated without a pot or pan then there may be some hot spots due to irregular heating by the ele-ment below. This is normal provided that the high-est temperature does not exceed 450°C (842ºF).

Thermocouple wire has a short circuit. Check wire for damage. Replace if necessary.

One or more of the elements get too hot (greater than 450°C / 842ºF) Safe-T-element is not connected properly.

Check wiring and ensure thermocouple and relay wires are connected correctly.

Controller defective. Replace controller and test again.