Braun Carestyle 3 SteamGenerator/Iron Repair
Completely unexpected a friend delivered today a Braun Carestyle 3 steamgenerator/Iron at my door for repair. It wasn’t his but of an acquaintance and these devices are not exactly known for their service-friendly designs because disassembling is a lot of work and needs to be done with care. Mostly because of all internal wiring and water tube connections which make it hard to simply remove the electronics . Which was no different with this Braun Carestyle Iron also because the front buttons made it difficult to remove the board from the case and its holder.
I first removed the 3 Torx screws on the top thinking they were holding the holder in which the board with the electronics was mounted. But apparently they weren’t holding anything. Maybe added by the owner? I then removed 4 longer cross head screws at the bottom side.
The 4 shorter screws on previous photo are the screws that we have to remove to extract the controller board from the white plastic holder. But first we have to pull out the 4 long transparent rod-shaped light ‘sticks’ from the front side of the case out of the board holder.
And we also have to press the Standby button inside and remove the eco button from their front holes before we finally can lift the entire plastic white printholder up out of the case.
The 4 mentioned long transparent sticks are light extenders for the smd leds on the controller board. On above photo we see this printholder after it is removed from the inside case. To be able to do this we also have to carefully press the 2 small flexible flaps on top of the holder on the front side out of their square shaped white plastic holders before we can lift the entire holder up. When we re-assemble the holder back in the case later on we simply shift the 2 white top flaps back into the square white plastic holders on the inside of the case front first from below in up going direction. And this will correctly connect the printholder with the buttons back to the case front inside again.
Next photos clearly show that all connected wires and water tubes make it harder to examine the device. Why taking photos is never a bad thing to do! Which reduces making any stupid mistakes. First photo shows the printholder with the electronics board and the connections after the bottom is removed. Next photo shows all wire connections that are visible if we look at the bottom of the printholder (the side that normally is mounted under the inside top of the case). Those wires show the On/off switch. The left brown wire to the standby switch is connected to the mains EU power plug. And the right side of this On/off switch has a double wire plug attached. And after the 4 short cross head screws are removed, we can remove the board from its plastic holder for further inspection. Of course after all attached wires to this board are removed.
On previous photos is visible how the printholder was removed. Next photo shows the 24V [IRON] relay that on a small ‘floating’ pcb with also a second 24V relay [BOILER] on the component side is mounted.
The darker brown wire on the right goes as double wire to the On/off switch and also to connection LINE on the left board side (the second connection left next to the first yellow wire [BOILER]). The lighter brown wire on this relay board goes to the Iron cable. And the brown wire that is connected entirely on the right of the board [F5] probably goes to a thermic fuse on the Boiler Heater element. And the yellow wire from that thermic fuse with marking 32-5 goes to the previous mentioned BOILER connection. I will include a clear wiring schematic later on.
After inspection of the board both zeners and 1 larger resistor were found defect. The resistor with code red-purple-black-gold was clearly open (27 Ohm circa 2 of 3W?). And the 24V zener type 1N5359B (D2 on pcb) was a special 5W diode now entirely shorted with a resistance of just about 0.16 Ohm. And also the 5V1 zener type BZX85C 5V1 was now shorted (just about 19 Ohm). Other components are likely not killed because after both zeners shorted, also series resistor 27 Ohm acted as fuse by blowing open.
Luckily the board is clearly marked on all wire connections with text of their functions. Which does simplify the repair. Next photos show more of all inside parts of this Braun Carestyle 3.
Previous photos showed the 3 defect components plus the board after the defect components R1, D2 and D3 were removed and will be replaced as soon as those parts are received. Above shown schematic explains how the power supply of this transformerless Braun steamgenerator works. Mark the special 1uF X2 275VAC capacitor C1. And also C2 is a special safety X2 275VAC capacitor! Below another clear view on all wire connections of this board. Next followed by a wiring diagram of this device to clear up all internal connections.
SMD transistors Q6 and Q4 had code 13 11 (11 was placed horizontally). The other components were hard to identify. Also because the entire board likely was varnished with plastic spray or some other moisture protecting layer. From the examined circuit it however looks like Q5 and Q7 are npn transistors.
Now all I can do is wait on the already ordered parts from Aliexpress. As most of the examining work is already done. And reassembling everything back will be a piece of cake since it is all heavily documented now.
Because of the rather ridiculous shipping cost for these very small and very light weighing parcels het is useless to order just a single component. And I noticed that where it previously said free shipping it turned out being rather expensive. With shipping cost being higher than the item prices ordered!
* 5 x 27R 5W voor EUR 4,61 + EUR 2,00 (where it said attractive shipping costs)
* 100pcs 1W Zener diode DO-41 5V1 voor € 1,23 + 0,86 shipping Product properties: 1N4733A 5V1. (Getting the original BZX85C 5V1 1300mW zenerdiode was apparently not possible).
* 10pcs/lot 1N5359B IN5359B 24V 5W Zener diode voltage regulator tube line new original at € 1,28 X1 + 0,86 shipping.
* 75Pcs 3W Carbon Film Resistors 27 ohm ~ 750 ohm 5% Assorted Kit Resistance 15 Values*5pcs
for € 3,23 X1 + 2,12 shipping. Product properties: 27R to 750R
Because I am not certain what wattage the 27 Ohm resistor was I ordered both the 3W and 5W resistors. In case they are too big I have to order 1 or 2 Watt resistors.
Bill of total costs: 6,61 + 2,09 + 2,14 + 5,35 = 16,19 Euro.
The cost of the needed components will be about 1.6283 Euro. The repair won’t exactly be profitable since I ordered at least tenfold the amount of this repair on components. And of course time and other cost are neither calculated here yet. But because of the high shipping cost I still rather buy more parts for future repairs.
I’m confident that this Braun Carestyle 3 Steamgenerator/Iron will work in a week or 3-4 for a long time. Because both zeners short circuited there was no overvoltage on the 5V and the 24V power lines of the controller board. And the over-current interrupted the current through the 27 ohm series resistor until the entire device was deactivated completely. Without blowing up other components on the controller board. Also because none of the capacitors were defect. They all checked out fine! I found the controller board sold on eBay for $29 US dollar but after this repair there is no need to buy a new board.
Although Braun could have used better safer 1N4007 diodes (1000V MAX and 700V RMS) for D1,D4 and D5 they all still were just 1N4004 (400V MAX and 280V RMS) diodes. Which was no problem here so they were cost effective. The resistance measured on the Iron heater was about 75,9 Ohm. The resistance of the Boiler heater was about 34,3 Ohm. Be aware!: These water pumps can’t be measured with a digital meter because it simply shows a very high resistance. I therefore tested the water pump with a in series placed light bulb for safety straight on the 230VAC and it worked splendidly! The resistance of the EV unit (also called Elettrovalvola bobina ferro caldaia CareStyle 3 5 7 IS30 IS50 IS70 IS71) measured about 2,26 KOhm.
For the Iron and the EV this would represent about 23 Watt for the EV, and about 669 Watt for the Iron out the formula (230V^2)/R. And out the Boiler resistance of 34,3 Ohm follows a Power dissipation of about 1542 Watt. Which in total matches the given 2200-2400 Watt on the label.
The EV [board connection F7] is controlled by triac T2. And the Water pump is controlled by Triac T1 [Board connection F6]. Board connection F5 is the Therm connection. Of course also both Triacs tested fine with my Peak Atlas DCA75 semiconductor tester!
And to make sure the AMP connectors are placed firmly back on the board I also squeeze the amp connectors a bit with a pair of pliers so that they don’t show to much freedom. Because when they were pulled off from the board connections they lost a bit of their grip.
Enfin, I am quite sure this will be a helpful service manual for fixing any electronic defect in the Braun Carestyle 3 steamgenerator/Iron !
Albert van Bemmelen, Weert, The Netherlands.
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Note: You can read his previous repair article in the below link: