Vulcan-Hart VL3GAS, VL3GMS, VL3GPS, VL2GMS, VL2GAS User Manual

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SERVICE MANUAL

VL BOILER BASE SERIES

CONVECTION STEAMERS

 

(GAS, ELECTRIC, DIRECT AND REGENERATED)

 

VL2GPS

ML-52391

VL2DPS

ML-52749

 

VL2GMS

ML-52388

VL2DMS

ML-52750

 

VL2GAS

ML-52390

VL2DAS

ML-52751

 

VL2GSS

ML-52389

VL2DSS

ML-52752

 

VL3GPS

ML-52395

VL3DPS

ML-52753

 

VL3GMS

ML-52392

VL3DMS

ML-52754

 

VL3GAS

ML-52394

VL3DAS

ML-52755

 

VL3GSS

ML-52393

VL3DSS

ML-52756

 

VL2EPS

ML-52741

VL2RPS

ML-52757

 

VL2EMS

ML-52742

VL2RMS

ML-52758

 

VL2EAS

ML-52743

VL2RAS

ML-52759

 

VL2ESS

ML-52744

VL2RSS

ML-52760

VL2GPS SHOWN

VL3EPS

ML-52745

VL3RPS

ML-52761

VL3EMS

ML-52746

VL3RMS

ML-52762

 

 

VL3EAS

ML-52747

VL3RAS

ML-52763

 

VL3ESS

ML-52748

VL3RSS

ML-52764

- NOTICE -

This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. If you have attended a Vulcan Service School for this product, you may be qualified to perform all the procedures described in this manual.

This manual is not intended to be all encompassing. If you have not attended a Vulcan Service School for this product, you should read, in its entirety, the repair procedure you wish to perform to determine if you have the necessary tools, instruments and skills required to perform the procedure. Procedures for which you do not have the necessary tools, instruments and skills should be performed by a trained Vulcan Service Technician.

Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.

A product of VULCAN-HART

LOUISVILLE, KY 40201-0696

Form 24650 (May 1999)

 

VL SERIES STEAMERS

TABLE OF CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Compartment Pan Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Steam Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gas Steamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electric Steamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Steamer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gas Powered Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrically Powered Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Regenerated Steam Powered Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Direct Steam Powered Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Boiler Blowdown and Steamer Shut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cooking Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cabinet Base Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cooking Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

REMOVAL AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Water Level Controls - Low Level Cut off and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Water Level Gauge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Cycling and High Limit Pressure Switches

 

(Gas and Electric Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

High Limit Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Boiler Fill and Cold Water Condenser Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Pilot and Thermocouple Assembly (Gas Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Gas Combination Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Compartment Gasket and Door Screw Nut, Door and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Heater Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Regenerated Steam Models (Steam Coil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

SERVICE PROCEDURES AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Clean-out (All Boiler Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Deliming Only (Models with Deliming Port Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Descaler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Water Level Control(s) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Cycling and High Limit Pressure Switches

 

(Gas and Electric Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Fill and Cold Water Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Compartment Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

High Limit Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Boiler Not Filling with Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Boiler Blowdown Drain Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Boiler Slow to Pressurize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

Inlet Water Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Pilot and Thermocouple Assembly (Gas Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Gas Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Air Shutter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Automatic Ignition Systems (Gas Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Gas Manifold Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

Page 2 of 88

VL SERIES STEAMERS

Direct Steam Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Regenerated Steam (Older Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Heater Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Thermal Switch - Prevent and Automatic Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Water Level Gauge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Steam Gate Valve(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

Water Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

Solid State - Low Level Cut-off & Differential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

Electro Mechanical - Low Level Cut-off & Differential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

Gas Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

Electric Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

Schematics, Gas Steamers, Boiler Controls

 

VL2G AND VL3G - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

Manual Ignition, Standard Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

Electronic Ignition, Standard Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

Manual Ignition, Csd-1 Code Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

Electronic Ignition, Csd-1 Code Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

Wiring Diagrams, Gas Steamers, Boiler Controls

 

VL2G AND VL3G - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

Manual Ignition, Standard Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

Electronic Ignition, Standard Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

Manual Ignition, Csd-1 Code Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

Electronic Ignition, Csd-1 Code Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

Schematics, Electric Steamers, Boiler Controls

 

VL2E AND VL3E - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

Auto Blowdown, Standard Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

Auto Blowdown, Cal-code Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

Wiring Diagrams, Electric Steamers, Boiler Controls

 

VL2E AND VL3E - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

Auto Blowdown, Standard Controls (Contactor - 1 Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

Auto Blowdown, Standard Controls (Contactors - 2 Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

Manual Blowdown, Cal-code Controls (Contactors - 1 Std. 1 Aux.) . . . . . . . . . . . . . . . . . . . . . .

68

Auto Blowdown, Cal-code Controls ( Contactors - 1 Std. 1 Aux.) . . . . . . . . . . . . . . . . . . . . . . . .

70

Auto Blowdown, Cal-code Controls (Contactors - 2 Std. 2 Aux.) . . . . . . . . . . . . . . . . . . . . . . . .

72

Manual Blowdown, Cal-code Controls (Contactors - 2 Std. 2 Aux.) . . . . . . . . . . . . . . . . . . . . . .

74

Wiring Diagrams, Electric Heater Circuits

 

VL2E AND VL3E - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

Schematic and Wiring Diagrams, Direct Steamers, Cabinet Base

 

VL2D AND VL3D - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77

Wiring Diagrams, Regenerated Steamers, Boiler Controls

 

VL2R AND VL3R - Prevent, Automatic, Standard and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

Schematic and Wiring Diagrams - Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

© VULCAN 1999

 

Page 3 of 88

VL SERIES STEAMERS - GENERAL

GENERAL

INTRODUCTION

Steam Cooking

Large capacity pressure steamers offer an efficient way to produce a wide variety of foods in small portions or larger batches. Steamers can be used to cook fresh foods, blanch foods for complete cooking later or will steam defrost and cook frozen foods. Cooking with steam assures the food will retain its maximum color, flavor and nutritional value with the least expenditure of energy and labor.

Compartment Pan Capacity

PANS PER

SIZE

DEPTH

COMPARTMENT

(INCHES)

 

 

 

 

4

12" x 20"

6.0

 

 

 

6

12" x 20"

4.0

 

 

 

8

12" x 20"

2.5

 

 

 

6

*18" x 20"

1.0

 

 

 

* Remove center support for 18x20 inch pans

Model Designations

V L X X XX

Cooking Control Types:

PS - Prevent Steam

AS - Automatic Steam

SS - Standard Steam

MS - Manual Steam

Heating System:

G - Gas

E - Electric

D - Direct

R - Regenerated

Number of Compartments

Large Capacity Pressure

Steamer

Vulcan

Boiler Code Descriptions

Vulcan-Hart incorporates redundant controls in compliance with California Code (Cal-Code) and CSD-1 as an option on steam equipment when required by state and/or local building code requirements. Descriptions of the codes are listed below.

Cal-Code Construction - Redundant controls in the electrical safety circuits that, if tripped, must manually be reset after the condition causing the trip subsides. These controls consist of one dual function water level cycling and low level cut off control and one single function low water level cutoff control (Aux - LLCO) and a high pressure relief switch in conjunction with a mechanical pressure relief valve.

CSD-1 Construction - Redundant controls in the electrical safety circuits that, if tripped, must manually be reset after the condition causing the trip subsides. These controls consist of one dual function water level cycling and low level cut off control and one single function low water level cutoff control (LLCO) and a high pressure relief switch in conjunction with a mechanical pressure relief valve. Additionally, both circuits have individual indicator lights that will illuminate for a visual verification of the shutdown mode.

Cal-Code and CSD-1 construction both require operator intervention in the event of a shutdown. CSD-1 is more informative by using indicator lights to show which safety system was shutdown.

WATER CONDITIONING

Furnishing the boiler with soft water to reduce scale formation is important. Scale formation will reduce steam output, cause premature component failure, and shorten equipment life. Most water supplies contain scale producing minerals such as Calcium and Magnesium. As steam is generated, the minerals remain and dissolve into the water. As the concentration of these minerals increases past a certain point, they precipitate from the water and coat the inside of the boiler, heating elements, thermostat bulbs and water level probes. Because of the high temperature of these surfaces, the precipitated minerals bake onto them and become very difficult to remove.

Page 4 of 88

VL SERIES STEAMERS - GENERAL

This causes several problems:

1.Reduce the heat transfer efficiency of the heating system.

2.Cause premature failure of Electric heaters.

3.Water level probes will give false readings.

4.Thermostat bulbs will sense temperature incorrectly.

These problems are common to any manufacturer's steamer regardless of design, but they can all be prevented by furnishing the boiler with soft water. Vulcan recommends the water contain less than 60ppm of “total dissolved solids” (TDS) and have a PH factor between 7 to 8. These water properties can be achieved by using a properly maintained water softener.

Other chemical properties in water supplies can also affect good steam generation and vary from within each state and locality.

The water level probes in the boiler use ions in the water to detect the water level. Do not use fully demineralized or de-ionized water since it is "non conductive" and the water level can not be detected.

NOTE: The use of strainers, or filters will not remove minerals from the water.

Vulcan recommends that a local water treatment specialist be consulted before the installation of any steam generating equipment.

Steamers that operate over a long period of time without the benefit of a water softener, which have developed a heavy scale build up, should be cleaned before using a water softener.

TOOLS

Standard

Standard set of hand tools.

Volt-Ohm-Meter (VOM) with AC current tester.

(Any quality VOM with a sensitivity of at least 20,000 ohms per volt can be used)

Gas leak checking equipment.

Gas pressure manometer

Temperature meter and thermocouple.

Special

CLR Treatment Kit - Used to remove Calcium/Lime/Rust from a boiler (Contact Vulcan Authorized Service Centers ).

Adaptor to test thermocouple closed circuit voltages (DC) on gas models with manual ignition (purchase locally).

NOTE: Adaptors vary between manufacturers. An example of one adaptor type is pictured below.

SPECIFICATIONS

Water Supply

Supply pressure should be

20-80 psig

In line strainer for supply line

(Not Supplied)

Supply connection

cold

Total dissolved solids (TDS)*

less than 60 ppm

Total alkalinity

less than 20 ppm

Silica

less than 13 ppm

Chloride

less than 30 ppm

PH factor

7 to 8

(*17.1 ppm = 1 grain of hardness)

Steam Supply

Dry steam must be provided to the steamer for suitable use. If the steam is heavy with condensate, a Ball Float Trap must be used in the line and plumbed in before the pressure reducing valve. To ensure rapid heat up of heavy cold loads, the steam supply line must be sized to maintain pressure as outlined below.

 

DIRECT STEAM

REGENERATED

 

STEAMERS

STEAMERS -

 

(POTABLE)

OLDER MODELS

 

 

(*NON-POTABLE)

 

 

 

 

 

 

Supply

15 psi (min.)

15 psi (min.)

Pressure Input

 

 

 

 

 

Flow Rate

50 lb. per hour per

125 lb. per hour

 

compartment

 

 

 

 

Pressure

10 psi (furnished)

set accordingly for good

Reducing Valve

 

steam generation (10-

Output

 

12psi)

 

 

 

*Potable steam is not required for regenerated models but could be used.

Page 5 of 88

VL SERIES STEAMERS - GENERAL

Gas Steamers

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MANIFOLD

 

LINE PRESSURE

 

 

 

 

 

 

INPUT

 

(INCHES W.C.)

 

 

 

AMPS

 

 

PRESSURE

 

 

 

 

 

 

(BTU/HR)

 

 

 

 

(MAX)

 

 

(INCHES W.C.)

 

 

 

 

 

LOAD

 

 

NATURAL

 

PROPANE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(WATTS)

 

 

 

 

 

 

 

 

 

 

 

MAX

 

 

 

 

 

 

 

 

 

 

 

 

 

MODEL

NAT.

PROP.

NAT.

PROP.

RECOMMEND

MIN

RECOMMEND

MIN

 

120V

 

 

 

 

 

 

60HZ

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL2GPS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL2GMS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL2GAS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL2GSS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL3GPS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL3GMS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL3GAS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VL3GSS

200,000

200,000

4.0

10.0

7.0

5.0

11.0

11.0

14.0

360

3.0

 

 

 

 

240,000

240,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Electric Steamers

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AMPERAGE

 

 

 

 

 

 

 

 

 

 

 

 

1 PHASE

3 PHASE

3 PHASE - 4 WIRE

 

 

 

 

 

 

 

 

 

 

MODEL

TOTAL

208V

240V

208V

240V

480V

220/380V & 240/415V

 

KW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24*

116

100

67

58

29

34

 

 

 

 

 

 

 

 

 

 

VL2EPS

36

 

 

100

87

44

50

 

 

 

 

 

 

 

 

42

 

 

117

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

48

 

 

 

116

58

67

 

 

 

 

 

 

 

 

 

 

 

24*

116

100

67

58

29

34

 

 

 

 

 

 

 

 

 

 

VL2EMS

36

 

 

100

87

44

50

 

 

42

 

 

117

 

 

 

 

 

 

 

 

 

 

 

 

 

 

48

 

 

 

116

58

67

 

 

 

 

 

 

 

 

 

 

 

24*

116

100

67

58

29

34

 

 

 

 

 

 

 

 

 

 

VL2ESS

36

 

 

100

87

44

50

 

 

 

 

 

 

 

 

 

42

 

 

117

 

 

 

 

 

 

 

 

 

 

 

 

48

 

 

 

116

58

67

 

 

24*

116

100

67

58

29

34

 

 

 

 

 

 

 

 

 

 

VL2EAS

36

 

 

100

87

44

50

 

 

 

 

 

 

 

 

 

42

 

 

117

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

48

 

 

 

116

58

67

 

*std

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 6 of 88

VL SERIES STEAMERS - GENERAL

STEAMER OPERATION

Ensure that all utility connections to the steamer have been made and are turned on.

On models that are CSD-1 equipped, amber colored lights for hi pressure and low water level will illuminate and stay on until the boiler is full and the manual reset switch pressed.

Gas Powered Steam Boiler

5.Open the cabinet door and turn main power switch ON. The red light will illuminate, water will begin filling the boiler and the blowdown solenoid valve will close. The boiler should fill, in four to eleven minutes. Observe water level gauge glass to verify that water is in boiler and that the level in the gauge glass is about half full. Both valves on gauge glass assembly must be open to fill the gauge. Older models equipped with a manual “ball” type blowdown valve must be closed for the boiler to fill. The cycling pressure switch will maintain the proper steam pressure in the boiler by cycling the heating system on and off to generate steam pressure.

A.On Models with Manual Ignition - The knob on the gas combination control valve has three positions (On-Pilot-Off) for control of main burners and pilot. Turn knob on gas combination valve to PILOT then depress and light pilot burner with a lit taper. Maintain knob in depressed position for about 30 seconds and release. Observe that pilot burner flame stays on. If the flame should go out, wait 5 minutes before relighting.

Turn knob on gas combination control valve to ON. If the water level in the boiler has reached the minimum level, burners will ignite and begin to heat the water in the boiler. After approximately 15 minutes, steam should be present for cooking product. Observe that the boiler pressure gauge indicates steam pressure of 9-11 psi for models with a pressure regulating valve or 4-6 psi for models without the valve.

B.On Models with Automatic Ignition - The knob on the gas combination control valve has two positions (On-Off) for control of main burners and pilot. For the automatic ignition system to work, the knob must be set in the ON position or gas for the pilot and main burners will not flow.

Also, the ignition control module ON/OFF/RESET switch must be in the ON position to operate. This switch is located on the upper left side of the electrical control box for the ignition control module. A red light will illuminate when the switch is in the ON position. DO NOT ATTEMPT TO MANUALLY LIGHT THE PILOT IN AN AUTOMATIC TYPE IGNITION SYSTEM.

After the main power switch is turned ON and the ignition control modules RESET switch is in the ON position, sparking will begin three seconds later to light the standing pilot. If the pilot lights, a signal is sent back through the ignition cable indicating the presence of pilot flame and sparking stops. If the water level in the boiler has reached the minimum level, the burners will ignite and begin to heat the water in the boiler. After approximately 15 minutes, steam should be present for cooking product. Observe that the boiler pressure gauge indicates a steam pressure of 9-11 psi for models with a pressure regulating valve or 4-6 psi for models without the valve. If a pilot flame is not established immediately, sparking will continue for 90 seconds. After that duration, the ignition control module will lock out and needs to be reset to start the pilot and burner lighting cycle again.

Electrically Powered Steam Boiler

Open the cabinet door and turn main power switch ON. The red light will illuminate, water will begin filling the boiler and the blowdown solenoid valve will close. The boiler should fill, in approximately 11 minutes. Observe water level gauge glass to verify that water is in boiler and that the level in the gauge glass is about half full. Both valves on gauge glass assembly must be open to fill the gauge. Older models equipped with a manual “ball” type blowdown valve must be closed for the boiler to fill. If the water level in the boiler has reached the minimum level, the heater contactors will close, the heaters will energize and begin to heat the water in the boiler. After approximately 15 minutes, steam should be present for cooking product. Observe that the boiler pressure gauge indicates steam pressure of 9-11 psi for models with a pressure regulating valve or 4-6 psi for models without the valve.

Regenerated Steam Powered Boiler

Open the cabinet door and turn main power switch ON. The pilot light will illuminate, water will begin filling the boiler and the blowdown solenoid valve will close. Models equipped with a manual “ball type” blowdown valve need to be closed for the boiler to fill. The boiler should fill, in approximately 15 minutes.

Page 7 of 88

VL SERIES STEAMERS - GENERAL

Observe water level gauge glass to verify that water is in boiler and that the level in the gauge glass is about half full.

Both valves on the gauge glass assembly must be open to fill the gauge. When the water reaches the minimum level, the steam solenoid valve will open, allowing steam to enter the steam coil in the heat exchanger tank and begin heating the water. After approximately 20 minutes, a sufficient amount of pressurized steam should be present for cooking product.

Direct Steam Powered Cooker

1.Open the cabinet door and turn main power switch ON.

A.The red light on the switch will illuminate.

B.If steam pressure is above the minimum setting on the cooking compartment pressure switch then the switch will close, ready light will come ON and power to the other controls will be supplied.

C.Observe that the steam pressure gauge in the cabinet base, indicates 10-12 psi.

2.Steamer is ready to cook product.

Boiler Blowdown and Steamer Shut off

Turn the steamer off at least once daily and blow down the boiler to remove sediments, scalants and lime build-up in the boiler. Always blowdown the boiler when it is under maximum pressure and no steam is being used.

3.Automatic blowdown.

A.Newer Models - Open the cabinet door and turn main power switch OFF. The switches’ red light will go out, the blowdown/drain solenoid valve will be deenergized and the boiler will begin to drain. The cold water condenser solenoid will continue to operate, as needed, to condense steam and to cool the water going into the drain.

B.Older Models - Turn power switch OFF and depress blowdown timer button. Blowdown timer will operate for 4 minutes. At the end of blowdown, turn fill switch ON and allow boiler to fill.

4.Manual blowdown.

A.All Models - Turn power switch OFF. Open blowdown valve located on the bottom front of the cabinet base. After the boiler has completely drained, close blowdown valve and turn fill switch to ON and allow boiler to fill.

Cooking Compartment Controls

Close the compartment door and turn the screw handle clockwise until the gasket touches the compartment surface then ½ turn further to adequately seal the compartment. If steam leaks occur after compartment heat up and pressurization, turn handle clockwise again to increase the sealing force until the leak stops.

Proceed to the cooking compartment control instructions that apply to the steamer in use.

1.Manual

A.Set the manual timer to the desired cooking time. If preheating is desired, allow five to ten minutes (recommended) of additional time at the beginning of the cook cycle. The length of time will vary with the type, size, temperature and condition (frozen or thawed) of the product and must be determined from experience. Pull the steam control arm handle forward and lock it by pulling the handle down. This closes the steam exhaust gate valve and opens the steam inlet gate valve, allowing steam to enter the compartment. During preheat, cooler air and condensate are exhausted from the compartment through the steam trap (condenser) until the temperature reaches 180°F, closing the internal bellows. Throughout the cooking cycle, the compartment pressure should be 6 psi if equipped with a compartment pressure regulating valve. On models without the compartment pressure regulating valve, the compartment pressure cycles with the boiler pressure between 4 and 6 psi.

B.When the timer bell rings to signal the end of a cook cycle, turn it OFF. Lift the steam control arm handle to unlatch team control arm. An internal spring will automatically pull the arm to the rear. This closes the steam inlet gate valve and opens the steam exhaust gate valve, allowing steam and pressure to exit the compartment.

C.Wait approximately 30 seconds for the steam to exhaust from the compartment and to depressurize. Turn the screw handle on the compartment door counterclockwise until the gasket no longer seals against the compartment surface. After the remaining steam escapes, move the latch paddle to the left and open the door.

Page 8 of 88

VL SERIES STEAMERS - GENERAL

2. Standard

3. Automatic

A.Set the timer to the desired cooking time. The timer must be set past five minutes to change the state of the timer control micro switch contacts. If preheating is desired, allow five to ten minutes (recommended) of additional time at the beginning of the cook cycle. The length of time will vary with the type, size, temperature and condition (frozen or thawed) of the product and must be determined from experience.

B.Pull the steam control arm handle forward and lock it by pulling the handle down. This closes the steam exhaust gate valve and opens the steam inlet gate valve, allowing steam to enter the compartment.

C.Press the compartment power switch to energize the timer and red light. The balance of the cooking sequence is automatic. During preheat, cooler air and condensate are exhausted from the compartment through the steam trap (condenser) until the temperature reaches 180°F, closin g the internal bellows. Throughout the cooking cycle, the compartment pressure should be 6 psi if equipped with a compartment pressure regulating valve. On models without the compartment pressure regulating valve, the compartment pressure cycles with the boiler pressure between 4 and 6 psi.

D.Approximately one minute before timer reaches zero the steam control solenoid is energized to unlatch the steam control arm. An internal spring will automatically pull the arm to the rear. This closes the steam inlet gate valve and opens the steam exhaust gate valve, allowing steam and pressure to exit the compartment. When the timer reaches "0" the red light shuts off and a buzzer sounds indicating the end of the cook cycle. Turn the compartment power switch OFF to silence the buzzer and remove power from the compartment controls.

E.Turn the screw handle on the compartment door counterclockwise until the gasket no longer seals against the compartment surface. After the remaining steam escapes, move the latch paddle to the left and open the door.

A.Set the timer to the desired cooking time. The timer must be set past five minutes to change the state of the timer control micro switch contacts.

B.Pull the steam control arm handle forward and lock it by pulling the handle down. This closes the steam exhaust gate valve and opens the steam inlet gate valve, allowing steam to enter the compartment.

C.Press the compartment power switch to supply power to the compartment controls. The automatic compartment controls, feature load compensated cooking time by utilizing a thermal switch. With this feature, when the compartment temperature reaches 180°F (the temperature at which preheating or defrosting is complete) the red light will then come on and the timer will start. For a small food load, the delay time before the timer starts might be a minute or less. For a large food load, the delay time could be four to five minutes. During preheat, cooler air and condensate are exhausted from the compartment through the steam trap (condenser) until the temperature reaches 180°F, closin g the internal bellows. Throughout the cooking cycle, the compartment pressure should be 6 psi if equipped with a compartment pressure regulating valve. On models without the compartment pressure regulating valve, the compartment pressure cycles with the boiler pressure between 4 to 6 psi.

D.Approximately one minute before timer reaches zero the steam control solenoid is energized to unlatch the steam control arm. An internal spring will automatically pull the arm to the rear. This closes the steam inlet gate valve and opens the steam exhaust gate valve, allowing steam and pressure to exit the compartment. When the timer reaches "0" the red light shuts off and a buzzer sounds indicating the end of the cook cycle. Turn the compartment power switch OFF to silence the buzzer and remove power from the compartment controls.

E.Turn the screw handle on the compartment door counterclockwise until the gasket no longer seals against the compartment surface. After the remaining steam escapes, move the latch paddle to the left and open the door.

Page 9 of 88

VL SERIES STEAMERS - GENERAL

4.Prevent

A.Set the timer to the desired cooking time. The timer must be set past five minutes to change the state of the timer control micro switch contacts.

B.Pull the steam control arm handle forward and lock it by pulling the handle down. This opens the steam inlet gate valve, allowing steam to enter the compartment.

C.Press the compartment power switch to supply power to the compartment controls. The prevent compartment controls feature load compensated cook times by utilizing a thermal switch. With this feature, when the compartment temperature reaches 180°F (the temperature at which preheating or defrosting is complete) the red light will come on and the timer will start. For a small food load, the delay time before the timer starts might be a minute or less. For a large food load, the delay time could be four and five minutes. During preheat, the steam exhaust solenoid valve (N.O.) is open to allow the full free venting of cooler air and condensate from the compartment. When the temperature reaches 180°F, the exhaust solenoid valve is energized and closes. The compartment should then pressurize to 6 psi.

D.Approximately one minute before timer reaches zero the steam control solenoid is energized to unlatch the steam control arm. An internal spring will automatically pull the arm to the rear. This closes the steam inlet gate valve and opens the steam exhaust gate valve, allowing steam and pressure to exit the compartment. When the timer reaches "0" the red light shuts off and a buzzer sounds indicating the end of the cook cycle. Turn the compartment power switch OFF to silence the buzzer and remove power from the compartment controls.

E.Turn the screw handle on the compartment door counterclockwise until the gasket no longer seals against the compartment surface. After the remaining steam escapes, move the latch paddle to the left and open the door.

Page 10 of 88

VL SERIES STEAMERS - GENERAL

COMPONENT FUNCTION

CABINET BASE BOILER CONTROLS

Water Level

 

Gauge Assembly . . . . . . . . . . . . . . .

Permits a visual confirmation the water level is being maintained in

 

boiler during operation. The correct water level is a point one-half of the

 

height of the glass. The manual valves at the top and bottom of this

 

assembly must be fully open and only closed if the glass tube is

 

damaged.

Water Level Control and

 

Level Sensing Probes . . . . . . . . . . .

These controls allow water to enter the boiler to fill and maintain the

 

proper water level. They will also shut off the heat source to the boiler if

 

the water level drops too low. The water level control works by using

 

three different probe lengths to monitor the water level. The probes

 

consist of a high level (HL), low level (LL) and low water cut-off (LLCO).

Boiler Fill Solenoid Valve . . . . . . . .

Admits water to the boiler when demanded by the water level control to

 

maintain the correct water level in the boiler.

Cold Water Condenser

 

Solenoid Valve . . . . . . . . . . . . . . . . .

Allows cold water flow into the boiler blowdown drain box to condense

 

steam and cool the hot water before its discharge into the drain.

Cycling Pressure Switch . . . . . . . . .

Controls boiler pressure between prescribed limits by turning the heat

 

source on and off.

High Limit Pressure Switch . . . . . .

A switch of identical design to the cycling pressure switch but used as a

 

high limit. The pressure settings are at higher and lower limits than the

 

cycling pressure switch in order to turn off the heat source before the

 

boiler pressure reaches its limit and automatically resets after the

 

pressure drops below the lower limit set point.

Blowdown/Drain

 

Solenoid Valve . . . . . . . . . . . . . . . . .

This valve is plumbed into the drain line of the boiler. Newer steamer

 

models will automatically blowdown when power is turned off by using a

 

normally open solenoid valve. Older models can have a solenoid valve

 

that is activated by depressing a separate blowdown timer button or

 

have a manual “ball” type valve.

Inlet Water Strainer . . . . . . . . . . . . .

A strainer is used in the water inlet line to prevent foreign matter from

 

becoming lodged in the fill or cold water condenser solenoid valves and

 

to keep unwanted particles out of the system. A "Y" strainer should be

 

inserted upstream of the fill solenoid valve. On models using a direct

 

steam supply, a strainer is also used in the pressure regulating valve.

Power Switch . . . . . . . . . . . . . . . . . .

When turned ON, power is supplied to the controls and the steam

 

generating process is started in the boiler. The power switch is located

 

on the front of the boiler control box.

Water Inlet Valve . . . . . . . . . . . . . . .

The water inlet valve is used to stop water flow to the steamer when the

 

steamer is being serviced. Newer models will have a small Petcock type

 

valve while older models will be a “ball” type valve. This valve should

 

remain open during normal operation.

High Limit Thermostat . . . . . . . . . .

A protective device that shuts off the heat source if the boiler

 

temperature exceeds a specified limit. All standard models are equipped

 

with a surface high limit.

Descaler . . . . . . . . . . . . . . . . . . . . . .

Hangs submerged in water inside the boiler and is used to help control

 

boiler surface scaling. Two descalers are used in each boiler.

Page 11 of 88

 

VL SERIES STEAMERS - GENERAL

Handhole Cover Assembly . . . . . .

. When unbolted and removed, allows internal examination and cleaning

 

of boiler shell and its components if required.

Boiler Pressure Gauge . . . . . . . . . .

Indicates the amount of steam pressure in the boiler.

Check Valve . . . . . . . . . . . . . . . . . . .

On models with the delime piping assembly option, prevents the ejection

 

of hot water and steam out of the delime funnel if the manual delime fill

 

valve were to be opened.

Delime Port Assembly . . . . . . . . . . .

On models with the delime piping assembly option, allows the boiler and

 

other internal components to be delimed, easily removing calcium, lime

 

and rust build up.

Gas Pilot . . . . . . . . . . . . . . . . . . . . .

Should always remain lit to light the main burners upon a call for heat

 

unless the steamer will not be in use for an extended period. If the pilot

 

flame goes out, wait 5 minutes before relighting.

Gas Burners . . . . . . . . . . . . . . . . . . .

Heats the water in the boiler to generate steam.

Gas Combination Control Valve . . .

A gas solenoid valve that opens to allow gas flow when a call for heat is

 

made. Also regulates the manifold gas pressure and supplies the gas

 

pilot.

Transformer . . . . . . . . . . . . . . . . . . .

Provides 24VAC power to ignition control module. (gas models with

 

electronic ignition)

Ignition Control Module . . . . . . . . .

Ignition Control Module

Reset (ON/OFF) Switch . . . . . . . . . .

Heater Contactor

(Electric Boilers) . . . . . . . . . . . . . . .

Heating Elements

(Electric Boilers) . . . . . . . . . . . . . . .

Steam Header Assembly . . . . . . . . .

Controls and monitors gas heating. Energizes pilot valve coil to supply gas to pilot, generates spark to ignite gas at the pilot, monitors the presence of flame and energizes main valve coil upon a call for heat to supply gas to the main burners. The pilot and main solenoids are part of the gas combination control valve. (gas models with electronic ignition)

Controls power to the ignition control module and allows a reset of the module if the gas ignition exceeds trial time. (gas models with electronic ignition)

When coil is energized, supplies power to the electric heating elements.

Heats the water in the boiler to generate steam.

Main steam supply line from the boiler to the steam header inlet in the cooking control compartment.

Pressure Relief Valve . . . . . . . . . . . A mechanical device that opens to relieve steam pressure in the boiler if the pressure exceeds 15 psi.

Compartment Pressure

Regulating Valve . . . . . . . . . . . . . . . Reduces steam pressure form the boiler or building steam (direct and regenerated models) to supply the compartments a steam pressure of 6 psi. Standard on PS, option on MS, SS and AS compartment controls.

Page 12 of 88

VL SERIES STEAMERS - GENERAL

COOKING COMPARTMENT CONTROLS

The top half of the steamer consists of two to three separate cooking compartments depending on the model. Each compartment functions independently with its own set of controls. Power is supplied to the controls through the compartment power switch and the cooking timer control micro switch contacts. Prevent and Automatic models have a load compensating thermal switch that prevents the controls from receiving power until the compartment reaches 180°F to close the switch.

Compartment Power Switch . . . . . .

Supplies power to the cooking compartment controls.

Cooking Light (Red) . . . . . . . . . . . .

When lit, indicates steamer is in a cooking cycle. (All models except

 

manual)

Cooking Timer . . . . . . . . . . . . . . . . .

Use to set desired cooking cycle time between 0-60 minutes. Energizes

 

the buzzer when time expires (All models except manual). On Prevent

 

models, also de-energizes the steam exhaust solenoid valve one minute

 

before the end of a cook cycle to allow compartment venting.

Buzzer . . . . . . . . . . . . . . . . . . . . . . .

Signals end of a cook cycle, must be turned off manually. (All models

 

except manual)

Steam Exhaust Solenoid Valve . . .

A normally open valve that allows full compartment venting of air and

 

condensate up to 180°F during compartment heat up and “limited free

 

venting” after energized by the closing of the thermal switch. The valve

 

remains closed to allow compartment pressurization to 6 psi until one

 

minute before the end of a cook cycle at which point the timer control

 

micro switch contacts (SW2) change state and de-energize the valve to

 

vent the compartment of pressure and steam. (prevent models)

Steam Header Inlet (manifold) . . . .

Main steam supply line from the boiler for each cooking compartment.

 

Supplies steam to the manual steam gate valves.

Compartment Pressure Gauge . . . .

Indicates the amount of steam pressure in cooking compartments.

Steam Control Arm Solenoid . . . . .

When energized, engages the lift arm (plunger) to raise the steam

 

control arm off of the catch, allowing it to return to its rear position. This

 

closes the steam inlet gate valve and opens the steam exhaust gate

 

valve. (prevent, automatic and standard models)

Thermal Switch

 

(Load Compensator) . . . . . . . . . . . .

Controls power to the preheat cycle components. Turns the cooking light

 

on, energizes the steam exhaust solenoid valve and energizes the

 

cooking timer motor to start timing, after the compartment reaches

 

180 F. (prevent and automatic models)

Steam Gate Valves . . . . . . . . . . . . .

Manual valves actuated by the steam control arm. Allows steam to flow

 

into the cooking compartment through the inlet steam gate valve when

 

the arm is in a forward position and exhaust the steam through the

 

exhaust steam gate valve when the arm is at the rear. Prevent models

 

use a steam exhaust solenoid valve to exhaust the steam and a single

 

steam gate valve as the steam inlet. The automatic, standard and

 

manual models use one steam gate valve to exhaust the steam and

 

one additional steam gate valve as the steam inlet.

Steam Trap (Condenser) . . . . . . . . .

Exhausts air and condensate from compartment during preheat until the

 

compartment temperature reaches approximately 180 F. The bellows

 

then close, stopping the exhaust. (all models except prevent)

Page 13 of 88

Vulcan-Hart VL3GAS, VL3GMS, VL3GPS, VL2GMS, VL2GAS User Manual

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

COMPONENT LOCATIONS

Page 14 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

Page 15 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

COOKING COMPARTMENT CONTROLS - COMPONENT CONFIGURATIONS

1.

Prevent

thermal switch, inlet steam gate valve, steam exhaust solenoid

 

(shown above)

valve, steam control arm solenoid, timer, buzzer and power switch

 

 

with light. Does not use a steam trap.

 

 

 

2.

Automatic

same as prevent except does not include steam exhaust solenoid

 

 

valve but does include an exhaust steam gate valve and two steam

 

 

traps.

 

 

 

3.

Standard

same as automatic except does not include thermal switch.

 

 

 

4.

Manual

manual and exhaust steam gate valves and a manual timer.

 

 

Includes two steam traps.

 

 

 

Page 16 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

WATER LEVEL CONTROLS - LOW LEVEL CUT OFF AND DIFFERENTIAL

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Solid State

1.Open the cabinet base doors.

2.Remove the two screws at the top of the boiler control box and allow cover to drop down.

3.Water level control is mounted on the back side of cover.

4.Disconnect lead wires from the board and remove the water level control.

5.Reverse procedure to install and check for proper operation.

Electro Mechanical

1.Open the cabinet base doors.

2.Remove the two screws from the left and right side of the water level control box and lift cover off.

3.Disconnect lead wires from the control being replaced and remove.

4.Reverse procedure to install and check for proper operation.

WATER LEVEL GAUGE

ASSEMBLY

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Open the cabinet base doors and remove the right side panel.

2.Close the valve at the top and at the bottom of the gauge assembly.

3.Unscrew the packing nuts at the top and bottom of the glass tube.

4.Slide the glass tube upwards until the bottom of the tube is clear of the fitting and lift it out.

5.When reinstalling the tube use new sealing washers. Do not over tighten the packing nuts; it could break the gauge glass.

6.Open the top and bottom valves and check for proper operation.

CYCLING AND HIGH LIMIT

PRESSURE SWITCHES

(GAS AND ELECTRIC MODELS)

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Open the cabinet base doors and remove the left side panel.

2.Remove the two screws at the top of the boiler control box and allow cover to drop down.

3.The pressure switches are located at the rear of the box. The pressure switch on the right is the cycling or primary control; the one on the left is the high limit control. They are identical switches, differing only in their settings.

4.Remove the cover from the pressure switch being replaced and disconnect the lead wires.

5.Disconnect the pressure fittings at the bottom of the switch.

6.Remove the mounting screws on the back side of the control box and lift out the pressure switch.

7.Preset the new pressure switch to the approximate cut-out (off) and cut-in (on) set points before installing. See the boiler pressure chart under “CYCLING AND HIGH LIMIT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

8.Reverse procedure to install.

9.Adjust the pressure switch(s) final set points as outlined under “CYCLING AND HIGH LIMIT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” in “SERVICE PROCEDURES AND ADJUSTMENTS” and check for proper operation.

Page 17 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

BOILER ASSEMBLY

 

HIGH LIMIT THERMOSTAT

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT.

WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH A SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

1.Blow down the boiler and allow to cool, if necessary.

2.Ensure that all utilities to the steamer are off and disconnected. Drain any excess water from the boiler.

3.Disconnect the steam supply line, power leads and drain lines from the cooking compartment top to the boiler base.

4.Disconnect all plumbing connections and power leads from the components inside the control boxes that would obstruct the removal of the boiler through the front of the base, then remove those control boxes.

5.Disconnect the remaining plumbing and electrical connections from the boiler to the controls.

6.Remove the screws holding the flue and flue collector to the base.

7.Remove the anchor screws holding the boiler to the frame. Slide the boiler forward. The burner box, anchored only by the boiler, must be prevented from sliding forward with the boiler.

8.Reverse procedure to install a new boiler and check for leaks and proper operation.

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Open the cabinet base doors.

2.Electric models only - for gas models proceed to step 3.

A.Newer Models - are not equipped with a hi limit thermostat but rely on the Hi limit pressure switch instead.

B.Older Models - the high limit thermostat is located behind the contactor box cover. On electric boilers with two heating elements, the thermostat is connected to one of the heating element lugs. On electric boilers with four heating elements, the thermostat is located on an aluminum plate between the center pair of elements at the top of the elements. Remove the thermostat lead wires and mounting nuts, replace thermostat and check for proper operation.

3.Gas Models only.

A.Remove the thermostat cover which is located on the front of the boiler. Disconnect the thermostat lead wires and remove the nuts securing the high limit thermostat to the boiler surface.

4.Reverse procedure to install and check for proper operation.

Page 18 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

BOILER FILL AND COLD WATER CONDENSER SOLENOID VALVES

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Turn off the water supply to the steamer.

2.Open the cabinet base doors and remove the two screws at the top of the boiler control box and allow cover to drop down. Both solenoid valves are located side by side near the front of the boiler control box with the boiler fill on the right and the cold water condenser to the left.

3.Disconnect the power lead wires from the solenoid valve being serviced.

4.Disconnect the water lines for the valve being serviced and remove the valve.

5.Reverse procedure to install.

PILOT AND THERMOCOUPLE ASSEMBLY (GAS MODELS)

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT.

WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH A SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

1.Open the cabinet doors to access the pilot and thermocouple assembly. The assembly is located to the right of the center burner and half way back from the front.

2.Disconnect thermocouple and pilot gas supply tubing from the combination control valve.

3.Remove the two screws holding the pilot to its bracket.

4.Replace the thermocouple or pilot assembly and check for proper operation.

GAS COMBINATION CONTROL

VALVE

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING: SHUT OFF THE GAS SUPPLY BEFORE SERVICING THE UNIT.

WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH A SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

NOTE: Gas combination control valves are not serviceable and should not be disassembled. Once the problem has been isolated to this control, replace it. Do not attempt to repair the assembly.

1.Open the cabinet base doors and remove the two screws at the top of the boiler control box and allow cover to drop down.

2.Disconnect electrical supply wires and conduit running to the combination control valve.

3.Disconnect the thermocouple lead (if applicable), pilot gas supply tube from control and pipe connections on each side of the control.

4.Reverse procedure to install.

5.Set manifold pressure as outlined under “GAS MANIFOLD PRESSURE ADJUSTMENT” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

6.Check for proper operation.

Page 19 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

COMPARTMENT GASKET AND DOOR SCREW NUT, DOOR AND BUSHINGS

Gasket

1.Open the compartment door to be replaced.

2.Remove screws securing the gasket retaining plate to the gasket.

3.Lift the gasket off the inner door plate.

4.Position the new gasket on the inner door plate and reverse procedure to install.

NOTE: Damage to the gasket sealing surface, such as nicks or cuts, will cause steam leakage.

Door Screw Nut

1.Open compartment door to be serviced.

2.Turn screw handle fully clockwise to extend inner door plate assembly.

3.Lift the inner door plate assembly up, until the mounting pins are out of the holes in the pressure bar and set the assembly aside.

4.Turn screw handle fully counterclockwise and remove from door.

5.Remove screws mounting the pressure bar to the backside of the compartment door.

NOTE: A compression spring is mounted behind each screw. Set aside for reuse.

6.Remove screws mounting the door screw nut (bronze) to the backside of the compartment door.

7.Reverse procedure to install and check for proper operation.

Door and Bushing

1.Open the compartment door to be replaced.

2.Remove the right side pan support inside the compartment.

3.Remove the four bolts inside the compartment that secure the block hinges to the exterior side of the compartment.

CAUTION: Door is extremely heavy and will drop when bolts are removed.

4.At this time, the bushings can be replaced if necessary, by removing the bushings from the pin on each block hinge.

5.Reverse procedure to install and check for proper operation.

Page 20 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

HEATER CONTACTORS

 

REGENERATED STEAM MODELS

 

 

(STEAM COIL)

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Open the cabinet base doors, remove the two screws from the contactor box cover and lift cover off.

2.Disconnect the electrical lead wires to the coil and the power supply wires from the contactor being replaced.

3.Remove the screws form the base of the contactor and lift out.

4.Reverse procedure to install and check for proper operation.

HEATING ELEMENTS

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Open the cabinet base doors, remove the two screws from the contactor box cover and lift cover off.

2.Disconnect the electrical lead wires to the element being replaced.

3.Remove the bolts securing the heating element flange to the boiler and lift the element out.

4.Clean the mating surface of the boiler and install a new flange gasket and heating element.

5.Check for leaks and proper operation.

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING: SHUT OFF THE STEAM SUPPLY BEFORE SERVICING THE UNIT.

1.Disconnect pipe unions in the steam supply line to the coils and in the condensate discharge line from the coils.

2.Remove header that supplies steam to the coils by disconnecting union at each coil.

3.Remove coil condensate collection header.

4.Remove bolts securing the coil being replaced and pull coil forward.

5.Clean the mating surfaces of the steam coil flange and the boiler.

6.Reverse procedure to install a new steam coil and gasket.

7.Check steamer for proper operation.

Page 21 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

SERVICE PROCEDURES AND ADJUSTMENTS

WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRES ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST.

BOILER

Inspection

It is recommended the boiler be inspected for excessive scale and lime build up on a quarterly basis. In hard water areas or for steamers heavily used, a more frequent interval should be used. This inspection consists of an internal examination and cleaning of the boiler, an examination of the two hanging descalers, and for lime build up on the water level probes. Also, a check of all boiler controls, including the pressure switches.

Periodic service must be performed as outlined in these procedures. See “WATER CONDITIONING” under “GENERAL”.

WARNING: READ AND FOLLOW THE INSTRUCTIONS ON THE CLR BOTTLE. USE PLASTIC OR RUBBER GLOVES TO AVOID SKIN CONTACT. IF CLR LIQUID COMES IN CONTACT WITH THE SKIN, RINSE WITH CLEAN WATER.

Clean-Out (All Boiler Models)

1.Turn steamer OFF and drain boiler.

2.Remove hand hole plate and gasket (top front) from the boiler by removing the nut and clamp, then tapping the cover lightly to free it while holding the cover stud. This prevents the cover from dropping into boiler.

3.Remove old descaler retaining springs if present.

4.With a wire brush, or equivalent, dislodge and remove all loose scale from boiler shell. The loose material must be either scooped from the boiler or flushed through the drain.

5.Check probe canister and float valve assembly (regenerated models) for a scale build up and clean as necessary.

6.Check drain hole for obstructions.

7.Inspect the condition of the descalers as outlined in this section and replace if necessary.

8.Mix the deliming solution according to the instructions for the chemical being used.

NOTE: Boiler water capacities vary between seven to nine gallons for both gas and electric models depending on the boiler size and BTU/KW rating.

NOTE: If deliming solution accidently comes in contact with steamer components, lightly rinse off with clean water.

A.Models with Blowdown Timer - Pour deliming solution into boiler shell. Proceed to step 9.

B.Models without Blowdown Timer - Turn off the incoming water supply. Turn the power switch ON to close the drain valve. Pour deliming solution into boiler shell. Proceed to step 9.

C.Models with Deliming Port Assembly - Before pouring deliming solution into boiler, clean the seating surfaces for the hand hole gasket and then install a new gasket. Position the hand hole plate and tighten down. Turn off the incoming water supply. Turn the power switch ON to close the drain valve. Open the deliming assembly valve and pour the deliming solution into the port. Close the deliming assembly valve and proceed to step 10.

9.Clean the seating surfaces for the hand hole gasket and then Install a new gasket. Position and tighten the hand hole plate.

Page 22 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

10.Cooking compartment timers are to be in the OFF position. Turn the boiler switch ON and open water valve if necessary.

11.Boiler is to operate under pressure for 90 minutes or per the instructions for the chemical in use.

12.Drain boiler by normal methods.

13.Refill boiler and allow to heat until fully pressurized.

14.Repeat step 13 three times.

15.The steamer is now ready for normal operation.

Deliming Only (Models with Deliming Port Assembly)

Boiler deliming should be performed on a weekly, bi-weekly or monthly basis, depending on the quality of the local water supply. See “WATER CONDITIONING” under “GENERAL”.

On steamers using a water purification system, follow the instructions for that system to delime the boiler. Only use the type of chemical recommended or described in the instructions for deliming with this type of system.

1.Turn steamer OFF and drain boiler.

2.Mix the deliming solution according to the instructions for the chemical being used.

NOTE: Boiler water capacities vary between seven to nine gallons for both gas and electric models depending on the boiler size and BTU/KW rating.

NOTE: If deliming solution accidently comes in contact with steamer components, lightly rinse off with clean water.

A.Models with Blowdown Timer - Open the deliming assembly valve and pour the deliming solution into the port. Close the deliming assembly valve and proceed to step 3.

B.Models without Blowdown Timer - Turn off the incoming water supply. Turn the power switch ON to close the drain valve. Open the deliming assembly valve and pour the deliming solution into the port. Close the deliming assembly valve and proceed to step 3.

3.Top compartments are to be in the OFF position. Turn the boiler switch ON and open water valve if necessary.

4.Boiler is to operate under pressure for 90 minutes or per the instructions for the chemical in use.

5.Drain boiler by normal methods.

6.Refill boiler and allow to heat until fully pressurized.

7.Repeat step 6 three times.

8.Steamer is now ready for normal operation.

Descaler

The descaler is accessible through the hand hole opening. It is a coiled wire wound around a solid cylindrical core, and hangs by an open loop from the shell's horizontal stay rod, about 4 inches from the front of the shell. If the wire is eaten through, or if the core of the descaler is eaten away to half its original size, a new descaler should be installed.

To install a new descaler, stretch its wire coil so the descaler hangs with its core completely below the minimum water level in the boiler, but hanging free. The descaler must not contact the bottom of the boiler shell, electric heating elements or regenerating steam coils.

Page 23 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

WATER LEVEL CONTROL(S)

TEST

Loose electrical connections may prevent the heat from coming on or may cause the boiler to overfill. An accumulation of lime scale on or near the water level sensing probes may cause them to retain water (moist) on the probe surface and give a false reading. Also, a cracked or damaged insulator may give a false reading. These conditions may prevent the boiler from filling or cause dry firing. Dry firing will result in damage to the heating elements on electric models or to the boiler on gas or electric models.

WARNING: THE FOLLOWING STEPS REQUIRE POWER TO BE APPLIED TO THE UNIT DURING THE TEST. USE EXTREME CAUTION AT ALL TIMES.

Solid State - Low level Cut-Off & Differential Control

1.Turn the power switch ON.

2.Ensure that water is filling the boiler.

A.Confirm that water supply valve(s) are turned on.

B.Observe boiler water level in the water level gauge. If empty, boiler should fill in approximately 11 minutes.

3.Check the voltage across terminals L1 & L2 on the board. Meter should read 120VAC.

A.If voltage is correct then the high level (HL) relay should energize, closing HL-3 contacts and the HL LED should light up. The boiler fill solenoid should then energize and start filling the boiler. Verify boiler fill solenoid valve is receiving 120VAC and water is flowing through it.

B.If boiler fill solenoid is receiving power but no water is flowing, inspect fill solenoid for malfunction or valve for clogged ports. If solenoid is bad or ports can not be cleaned, then replace boiler fill solenoid and check for proper operation.

C.If boiler fill solenoid is not receiving power and the electrical connections have been checked, then the HL relay is not being energized or the HL-3 contacts are not closing. Replace water level control board and check for proper operation.

4.If boiler is filling properly, when the water level reaches the low level cut-off (LLCO) probe, LLCO relay should energize closing LLCO-2 contacts, heat source should come on (standard models only) and LLCO LED will light.

5.Once the water level reaches the high level (HL) probe, the inverse latching relay of the board (solid state) should energize and lock through the low level probe (LL) and ILR-1 contacts. With ILR-2 contacts open, the HL relay is de-energized and HL LED goes out. With the HL-3 contacts open, the boiler fill solenoid should de-energize and stop the boiler fill.

6.If water is in the boiler but is not being detected by the water level probes, the probes may need cleaned and/or boiler delimed. See “Water Level Probes” as outlined below for inspecting and cleaning of probes and “BOILER” for a procedure on boiler inspection, clean-out and deliming.

7.Turn the power switch OFF and disconnect the lead wire from each probe. Check the probes as outlined below.

A.With an ohmmeter, check between the probe terminal and boiler shell. An open circuit should be present when the boiler is empty. If resistance is present, remove and inspect the probes as outlined below under “Water Level Probes”. When the boiler is full of water, a resistance reading should be measurable between the probes and boiler.

NOTE: The actual resistance reading will depend on water quality and probe condition.

8.After performing steps 1-5A and verifying the water level control boards operation, if the control is not functioning as described, then replace it and check for proper operation.

Electro Mechanical - Low level Cut-Off & Differential Control

WARNING: THE FOLLOWING STEPS REQUIRE POWER TO BE APPLIED TO THE UNIT DURING THE TEST. USE EXTREME CAUTION AT ALL TIMES.

1.Ensure that water is filling the boiler.

A.Confirm that water supply valve(s) are turned on.

B.Observe boiler water level in the water level gauge.

C.Verify boiler fill solenoid valve is receiving 120VAC and water is flowing through it.

2.Check for correct voltage being applied to the low level and differential water level controls.

A.Turn the water supply valve off then turn the power switch ON. Check the input voltage across terminals 1 & 2. Meter should read 120VAC. If voltage is correct proceed to step 2B. If voltage is incorrect, find the source of the problem and repeat this step.

Page 24 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

B.With the boiler empty, check the voltage across terminals 9 & 10. Meter should read 300 to 350VAC. If voltage is correct proceed to step 3. If voltage reading is approximately 30VAC then the internal contactor is energized but the probes are scaled over and moist and/or have a damaged insulator giving a false reading. See “Water Level Probes“ listed below for inspecting and cleaning and “BOILER” for procedures on boiler inspection, clean-out and deliming. If you do not read any voltage, then contactor coil on the water level control is bad and the control should be replaced. Check for proper operation after replacement.

3.If water is in the boiler but is not being detected by the water level probes, the probes may need cleaned and/or boiler delimed. See “Water Level Probes“ listed below for inspecting and cleaning and “BOILER” for procedures on boiler inspection, clean-out and deliming.

4.Turn the power switch OFF and disconnect the lead wire from each probe. Note the location of the probes and the number of the wire connected to it.

A.Check the resistance between the probe terminal and boiler shell. An open circuit should be present when the boiler is empty. If resistance is present, remove and inspect the probes as outlined below under “Water Level Probes”. A resistance reading should only be measurable between the probes and boiler shell (ground) when the boiler is full of water.

NOTE: The actual resistance reading will depend on water quality and probe condition.

5.If after performing steps 1-4 and the control is not functioning properly, verify the water level controls operation as outlined in “WATER LEVEL CONTROLS” under “ELECTRICAL OPERATION”.

6.After checking the above items, if the low level cut off or differential water level control does not appear to be functioning as described, then replace the control and check for proper operation.

Water Level Probes

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1.Remove the cover over the water level probes and disconnect the lead wire from each probe. Note the location of each probe and the number of the wire connected to it. Remove each water level probe for examination.

2.If lime scale build up is evident on the probe, thoroughly clean it removing all deposits from the probe and insulator. Do not use any thing abrasive on the insulator; use a soft cloth.

3.Inspect the probes for a cracked or damaged insulator. If a probe appears to be damaged, replace it with a new one and proceed to step 5. If a probe does not appear to be damaged then proceed to step 4.

4.Check through the probe socket opening in the top of the canister assembly for the presence of water. Water must drain from the probe canister and if in doubt, pour water into the canister and observe that it drains quickly. If water fails to drain from the canister, remove the cover or canister assembly and clean.

5.Reverse procedure to install and check for proper operation.

CYCLING AND HIGH LIMIT

PRESSURE SWITCHES

(GAS AND ELECTRIC MODELS)

WARNING: THE FOLLOWING STEPS REQUIRE POWER TO BE APPLIED TO THE UNIT DURING THE TEST. USE EXTREME CAUTION AT ALL TIMES.

Remove the boiler control box cover as outlined under “CYCLING AND HIGH LIMIT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” to access the two controls. The pressure switch on the right is the cycling or primary control; the one on the left is the high limit control. They are identical switches, differing only in their settings.

Turn the power ON and let the boiler come up to pressure. Close and seal one of the compartment doors, set a time past 5 minutes on the cooking timer, pull the steam control arm handle forward and turn the compartment power switch ON to exhaust pressure from the boiler. Observe boiler pressure gauge readings for several cycles and compare them with the pressure settings in the chart.

If the readings differ, adjust the pressure settings as described below.

Page 25 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

Two slotted and square headed adjustment screws extend through the top of the switch case. A pressure scale and indicating pointers are visible through the sight glass window to indicate the approximate pressure setting. The adjustment screw directly above the right side pointer changes the cut-out (off) set point and the adjustment screw directly above the left side pointer changes cut-in (on) set point. Adjust the screw to obtain the proper cut-out (off) setting first, then adjust the other screw to obtain the proper cut-in (on) setting. Turn the screw clockwise to increase the pressure setting and counterclockwise to decrease the pressure setting. The pressure settings for each switch are listed below.

BOILER PRESSURE SETTINGS (PSI)

CONTROL

VL

CYCLING

HIGH

 

 

LIMIT

TYPE

MODELS

 

 

 

 

ON

OFF

ON

OFF

 

 

 

 

 

 

 

 

 

PS

 

 

 

 

With

 

 

 

 

 

AS

 

 

 

 

Compartment

 

 

 

 

 

9

11

6

15

Pressure

SS

 

 

 

 

Regulating Valve

 

 

 

 

 

 

 

 

 

 

MS

 

 

 

 

 

 

 

 

 

 

With-Out

AS

 

 

 

 

 

 

 

 

 

Compartment

SS

4

6

2

15

Pressure

 

 

 

 

 

Regulating Valve

MS

 

 

 

 

 

 

 

 

 

FILL AND COLD WATER

SOLENOID VALVES

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Check to assure the solenoid valve is receiving power. If the solenoid valve is receiving power but the valve is not opening, the coil may be malfunctioning. Replace the solenoid valve and check for proper operation. If the solenoid valve is receiving power and the valve appears to be opening but little or no water is flowing through it, then the valve ports may be clogged with debris or a valve component malfunctioning. To check solenoid valve further, follow the procedure outlined below.

Disassembly

NOTE: It is recommended that the valve be removed for cleaning as outlined in this procedure. This will prevent damage to the lines and fittings when the stem is removed from the body.

1.Remove the coil assembly from the valve stem by lifting up on the retaining cap at the top of the solenoid valve and sliding the metal cover plate off.

2.Clamp the body of the valve in a vise.

3.Mark a scribe line on the stem nut to the valve body for proper retightening.

4.Remove the stem locking nut to remove the stem from the valve body.

5.All parts are now accessible for inspection and cleaning.

NOTE: If internal solenoid parts appear to be damaged or worn, then replace the solenoid valve. Do not reuse damaged or worn parts. No internal solenoid parts are available as a service replacement.

A.Check rubber seal on bottom of plunger.

B.Check plunger spring.

C.Check O-ring in valve body.

D.Check ports in valve body.

6.Reverse procedure to install.

COMPARTMENT PRESSURE

ADJUSTMENT

Remove the left side panel from the boiler base to access the compartment pressure regulating valve. If the steamer is equipped with the compartment pressure regulating valve and the steamer is operating, set the pressure regulating valve to read 6 psi on the compartment gauge. Turn the hex head screw at the top clockwise to increase the pressure and counterclockwise to decrease. If the steamer is not equipped with the compartment pressure regulating valve, then the compartment will cycle at the same pressures of the boiler. A mechanical pressure relief valve serves as a safety backup control and is pre-set for a maximum of 8 psi.

Page 26 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

HIGH LIMIT THERMOSTAT

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Remove thermostat (bi-metallic disk type) as outlined under “HIGH LIMIT THERMOSTAT” in “REMOVAL AND REPLACEMENT OF PARTS”. Inspect the temperature sensing side of thermostat for corrosion or rust. Clean mounting and thermostat surfaces before remounting or replacing. A good metal-to-metal contact is essential for proper functioning of the thermostat. This service must be performed at least once a year. If thermostat mating surface can not be throughly cleaned or is severely pitted and rusted, then replace and check for proper operation.

BOILER NOT FILLING WITH

WATER

Ensure that water to the steamer is turned on, then turn power switch ON. After approximately 10 minutes, if no water is observed in the water level gauge sight glass, then check for a problem with the boiler fill solenoid valve, water level control(s) or the water level probes. See “WATER LEVEL CONTROL TEST”. Also, ”water hammering” in the supply line, in conjunction with a check valve can cause a high water pressure pocket in the water line to the fill solenoid valve. The fill solenoid valve will not be able to overcome this pressure and operate to supply the boiler with water. Shut off the water supply and relieve the pressure in the line. Turn the water supply back on and check for proper operation.

NOTE: To eliminate this problem, the customer must install a “water hammer suppression device” in the supply line to the boiler.

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Scalants may be covering the water level control probe giving a false indication of a sufficient water level in the boiler. Remove and thoroughly clean the water level probes to remove scalants and lime build up. Also, Check through the probe socket opening in the top of the canister assembly for the presence of water.

Water must drain from the probe canister and if in doubt, pour water into the canister and observe that it drains quickly.

If water fails to drain from the canister, remove the cover or canister assembly and clean. These conditions indicate extremely poor water quality being supplied to the boiler and/or boiler clean out and deliming has not been performed.

The water condition must be cleared up immediately with a proper water conditioner to avoid further problems with the steamer. Re-install the water level probes and canister assembly (if applicable). Perform a boiler inspection, clean-out and deliming procedure as outlined under “BOILER”. Check for proper operation.

Water may be draining through an open boiler blowdown solenoid valve as quickly as it’s fed to the boiler. Loose wiring, a burned out coil or particles of scale trapped in the valve seat may prevent the valve from closing.

Newer steamer models use a plunger type rod that raises and lowers to permit steam/water flow out of boiler. If debris has accumulated around the water orifice, the plunger may not seat properly to close off the opening. If this symptom is suspect, remove the solenoid as outlined in “FILL AND COLD WATER SOLENOID VALVES”. Remove any debris found on sealing surfaces, reassemble and install. If the solenoid valve still does not function properly, replace it with a new valve and check for proper operation.

Older steamer models have a movable blade and when closed, the blade reacts as a guillotine that should be free to move fully down into the valve pocket (projection at bottom of valve) so that the pierced hole in the blade aligns perfectly with the body opening. If debris has accumulated in the bottom of the valve pocket, then the blade will not move into the pocket completely. If this symptom is suspect, remove the solenoid as outlined in “FILL AND COLD WATER SOLENOID VALVES”.

NOTE: On this valve body, remove the two assembly bolts holding the brass body together and remove the loose internal parts. Remove any debris found on sealing surfaces, reassemble and install. If the solenoid valve still does not function properly, replace it with a new valve and check for proper operation.

BOILER BLOWDOWN DRAIN

SOLENOID VALVE

The water contained in the boiler, being under pressure, should be blown through this valve and be noticeably visible exhausting out the steamer drain. Daily boiler blowdown is essential to proper operation and component life by removing sediment and scalants that may be lodged in the chamber of the boiler.

Page 27 of 88

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