AccuTemp E6 SERVICE MANUAL

Page 1
EVOLUTION
ELECTRIC
SERVICE MANUAL
ACCUTEMP PRODUCTS INC
8415 N. CLINTON PARK DR ● FORT WAYNE, IN 46825 ● 800 480-0415 ● www.accutemp.net
SP8027-1203 Email: service@accutemp.net
Page 2
IMPORTANT FOR YOUR SAFETY
The Safety Instructions listed on this page below, should be posted
in a prominent location as a reminder of safe practices; as well as,
recommended actions to follow in the event of an equipment
or facility’s utility issue.
In the event of a Power Failure, DO NOT attempt to operate this appliance.
DO NOT store or use Gasoline, or any other Flammable Vapor and/or Liquids in the vicinity of this
or any other appliance.
IMPROPER installation, adjustment, alteration, service, or maintenance can cause personal injury
or death; and/or property damage. Read the installation, operation, and service/maintenance
instructions thoroughly; before installing or servicing this equipment.
Only QUALIFIED service technicians/electricians should perform the equipment installation, to
ensure that all electrical and safety requirements are met; and that all wiring is performed in
accordance with all national, state, and local electrical codes.
SP8027-1203 i
Page 3
WARNING SYMBOL DEFINITIONS
SYMBOL DEFINITIONS
Symbols are used to attract your attention to possible dangers. They are only effective if
the operator uses proper accident prevention measures. Some of the symbols are boxed
text; while others maybe just picture icons. Please give this information the respect they
deserve for safe operation.
Warning Text Boxes
Below are denitions of the warning text boxes.
DANGER
Indicates an imminently hazardous situation;
which, if unchanged, will result in death or
serious injury.
Indicates a potentially hazardous situation;
which, if unchanged, will result in death or
serious injury.
Symbol Icons
Below are denitions of the symbol icons used
in this manual.
ALERT
Noties the reader of an important
message or warning; usually a
safety related message.
INFORMATION
Noties the reader of an important
information that may or may not
be safety related.
CAUTION -
CAUTION
Indicates a potentially hazardous situation; which, if unchanged, will result in minor or
moderate injury.
HOT SURFACE
DANGEROUS
VOLTAGE
NOTE
Advises the reader of information or
instructions, vital to the operation or
maintenance of the equipment.
SP8027-1203 ii
EARTH GROUND
Page 4
SAFETY PRECAUTIONS
DANGER
ELECTRICAL SHOCK HAZARD WHILE WORKING ON
ENERGIZED EQUIPMENT.
Unplug equipment prior to removing any components effected by electricity.
BURN HAZARD WHILE WORKING ON STEAM PRODUCING
EQUIPMENT.
When accessing the cooking chamber, be sure to always stand back while slowing
opening the door to allow the chamber to vent off the steam. Never reach into the cooking
chamber before it has completely vented off the steam.
Never reach into the cooking chamber or handle hot items without wearing the proper
heat protective gloves. Steam coming out of the holes on the right side of the cooking chamber
is invisible and can cause severe burns.
Water inside the steam chamber, creating steam, has a temperature of 212°F and will
cause burns if touched or spilled on the skin.
PERSONNEL INJURY HAZARD WHILE PICKING UP OR
MOVING HEAVY EQUIPMENT.
Always use 2 people and proper lifting techniques when picking-up, moving, or
ipping-over heavy equipment.
SLIP & FALL HAZARD WHILE WORKING ON WATER
HOLDING EQUIPMENT.
Keep the oor in front of the equipment clean and dry. If spills occur, clean them up
immediately to avoid potential injuries.
SP8027-1203 iii
Page 5
WARNING & CAUTION NOTES
ONLY QUALIFIED SERVICE TECHNICIANS
SHOULD PERFORM MAINTENANCE ON
THIS EQUIPMENT.
CAUTION
DO NOT use abrasive materials, such as wire brushes or metal scouring pads to clean the Water Sensors.
DO NOT use Aluminum Oxide Sandpaper to clean the Water Sensors. It leaves a residue that will not allow Water Sensors to work properly.
DO NOT manually ll water above the Water Level Mark on the left side of steam chamber above the High Limit Level Sensor.
SP8027-1203 iv
Page 6
TABLE OF CONTENTS
SAFETY
Important For Your Safety.......................................................................................................................................i
Warning Symbol Denitions..................................................................................................................................ii
Safety Precautions................................................................................................................................................iii
Warning & Caution Notes.....................................................................................................................................iv
T.O.C. & MANUAL HISTORY
Table of Contents...............................................................................................................................................v-vi
Revision Sheet........................................................................................................................................................1
NOTES
Troubleshooting Notes...........................................................................................................................................2
OPERATIONAL & COMPONENT INFORMATION
Purpose Reference of Main Component Chart...................................................................................................3-5
Additional Component Part Numbers....................................................................................................................5
Sequence of Operation........................................................................................................................................6-7
Modifying Control/Keypad Program Settings.......................................................................................................8
TROUBLESHOOTING
Troubleshooting Flow-Diagram.............................................................................................................................9
Flow-Diagram Reference Troubleshooting Chart..........................................................................................10-12
COMPONENT REMOVAL & INSTALLATION
Location of Electrical Components Picture Overview.........................................................................................13
Electrical Components Removal & Installation.............................................................................................14-19
Cord & Plug Assembly................................................................................................................
Fuses............................................................................................................................................
Contactor.....................................................................................................................................
Transformer.................................................................................................................................
Water Sensor Control Board.......................................................................................................
Control Relay #1.........................................................................................................................
Water Sensors..............................................................................................................................
Control/Keypad Board................................................................................................................
Door Switch................................................................................................................................
Chamber Pressure Switch...........................................................................................................
Solid State Relay.........................................................................................................................
Temperature (RTD) Probe...........................................................................................................
Overtemp Switch (ThermalLimit SW3)............................[2 PERSONS REQUIRED].............
14 14 14 15 15 15
16 16 17
18 18
19 19
SP8027-1203 v
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TABLE OF CONTENTS
COMPONENT REMOVAL & INSTALLATION (CON’T)
Location of Cast Heater Picture Overview..........................................................................................................20
Cast Heater Replacement Kit...............................................................................................................................21
Cast Heater Removal & Installation.............................................. [2 PERSONS REQUIRED]....................22-24
Cast Heater Installation Notes & Cautions..........................................................................................................24
Miscellaneous Components Removal & Installation.....................................................................................25-26
Auto-Fill Valve............................................................................................................................
High Water (Overll) Reed Switch.......................................[2 PERSONS REQUIRED]..........
Float Ball (Magnetic)...................................................................................................................
Drain Ball-Valve...........................................................................................................................
Drip Pan.......................................................................................................................................
Door Components Removal & Installation....................................................................................................27-29
Door Assembly.............................................................................................................................
Inner Door Panel..........................................................................................................................
Door Handle Latch Assembly......................................................................................................
Door Hinge...................................................................................................................................
Door Gasket..................................................................................................................................
25 25 26 26 26
27 27 28 28 29
SCHEMATIC & CHARTS
Electrical Schematic AT1T-3595 Rev G (208-240V/ 1Φ)...................................................................................30
Electrical Schematic AT1T-3595 Rev G (208-240V/ 3Φ)...................................................................................31
Electrical Schematic AT1T-3595 Rev G (208-240V/ 3Φ/ 17KW)......................................................................32
Electrical Schematic AT1T-3595 Rev G (440-480V/ 3Φ)...................................................................................33
SP8027-1203 vi
Page 8
REVISION SHEET
Current Revision: 1203 Prior Revision: N/A Date: 3/31/12 Date: N/A
Change: Initial Release.
SP8027-1203 Pg 1
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TROUBLESHOOTING NOTES
TROUBLESHOOTING NOTES
If the steamer is not reaching temperature:
Ensure that the steamer is not in the HOLD Mode verses the COOK Mode. The default mode for the steamer, when the PWR button is turned ON, is COOK. So, if the operator presses the Timer Button then the Cook/Hold button; the operator has just placed the steamer in the HOLD Mode and the steamer will not reach 212°F (COOK Mode). Ensure that the steam vent (located on the back of the steamer) is not blocked or clogged. If the customer has added an extended exhaust pipe, this could increase the chances of vent blockage, if the exhaust pipe is not installed properly. The exhaust pipe should be made of copper, galvanized or stainless steel. The exhaust pipe should have a diameter of 3/4”; and be sloped 1/4” for every 12” of length
(recommend a height no greater than 24”). Also, the addition of extra ttings that can alter the gravitational ow of the steam condensation, can cause blockage. If
vent blockage does occur, it will cause the chamber pressure switch to stay open; which prevents the heater from turning back on; and the temperature will continue to drop. Blocked vent can additionally cause steam to blow out of the door.
Auto-Fill Steamer: If the steamer is overlling with water and
causing the steamer to shut-off:
Ensure the steamer is level, front to back and side to side. An un-level steamer can cause the water in the steam chamber to collect in the front of the steamer, causing the Over-Fill Float Ball to raise and trip the Reed Switch prematurely (every time the steamer is turned ON). Once the Reed Switch trips, it will cause an Over-Fill Light and Buzzer; while turning off the steamer and preventing its usage. Ensure that both of the Water Sensors are clean. Build-up of scale or crud will prevent the Water Sensors from providing the appropriate control signals to the
Auto-Fill Valve, causing it to overll with water.
Ensure that the water pressure being supplied to the Auto-Fill Valve should not be greater than 60 psi. If water pressure is to high, then a larger volume of water will
be added to the steam chamber during the auto-ll cycle; causing the steamer to overll with water.
SP8027-1203 Pg 2
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PURPOSE REFERENCE OF MAIN COMPONENTS
Component Part # Purpose
Contactor
(3 Pole)
Transformer AT0E-2662-5 Steps-down the Supply Line Voltage to 24 -28VAC.
Overtemp Switch
(Thermal Limit
SW3)
Control / Keypad
Board
Water Sensor
Control Board
AT0E-1587-4
12KW & Lower
AT1E-2653-3
14KW & Up
AT1E-2653-4
AT0E-3625-1
AT0E-3230-2
Provides line voltage to the Solid State Relay(s), when the contactor’s • coil is closed by the control signal sent from the Water Control Board. Provides line voltage to the Transformer.
Normally closed switch that provides a safety feature to the machine • in case the Cast Heater overheats. If the Cast Heater overheats, the switch will open and turn the steamer off; while lighting the red LED Overtemp Light on the Control Panel. The steamer will not turn on until the temperature has dropped enough to allow the Overtemp Switch to close again.
Human interface for steamer operations through push-buttons, • operations, & display readouts. Provides power to the Solid State Relay(s) (24VDC).• Receives input from the Temperature (RTD) Sensor and displays the • water temperature on the LED readout. Maintains the preset HOLD temperature.
Receives inputs from Water Sensor Probes and implements • corresponding actions for those inputs based on the water level in the steam chamber. Controls the Auto-Fill Valve ( if installed) and receives inputs that provides actions for the desired water level needs.
Teon exterior with a stainless steel center that uses the minerals
Water Sensor
Probe
Low Water Level
Probe
High Limit
Water Level
Probe
SP8027-1203 Pg 3
AT1E-2652-1
in the water to complete the electrical circuit to the Water Control Board.
MUST BE CLEAN TO WORK PROPERLY.
Once the Low Water Sensor is satised, it will allow the Solid State • Relay(s) to activate. If the water level is below the sensor, the Water Board will activate • the Auto-Fill Valve (if installed) lling the unit the water until the High Limit Water Sensor is satised.
On initial chamber water ll, once the water level reaches and • satises the Operational Water Sensor, the Water Board will keep the Auto-Fill Valve open for 30 additional seconds.. After initial chamber water ll, when the water level drops below the • sensor’s operational level; the Water Board will open the Auto-Fill Valve for 30 seconds to raise the water level back above the High Limit Water Sensor. This process will repeat as long as the water level stays above the • Low Water Sensor.
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PURPOSE REFERENCE OF MAIN COMPONENTS
Component Part # Purpose
Auto-Fill Valve
(OPTIONAL)
Water Over-Fill
Sensor Switch
(OPTIONAL)
Control Relay #1
(AC)
Door Switch AT0A-3660-1
Chamber
Pressure Switch
AT1A-3841-1
Reed Switch:
AT0A-3519-2
Float Ball:
AT0P-3233-1
AT0E-2825-5
S#: 34769 & Up
AT0E-3617-2
S#: 34768 & Lower
AT1A-3847
Solenoid Valve that allows water to ow into the steam chamber; that • is controlled automatically by the Water Board based on inputs from the Water Sensor Probes.
Magnetic Reed Switch is used in conjunction with a Float Ball. If the • water rises too high, the switch opens and turns off the steamer. When the switch opens, the High Water Overll LED will light. The • user will have to drain the water out and turn the steamer back ON; otherwise, the steamer will remain shutdown.
Controls AC Volt input & output signals which provide actions from • the Water Sensor Board and Auto-Fill Valve (if installed).
Magnetic Switch used to ensure that the door is closed and latched • prior to generating steam Solid State Relay(s) will not activate if this switch is not closed (Door Open).
Normally closed switch that allows pressure to build-up inside the • steam chamber. Opens when the steam chamber pressure reaches 1/2 PSI.• Solid State Relay(S) will not activate if this switch is not closed (Switch Open).
Solid State Relay AT0E-2059-3
6 KW:
AT1A-3530-1
8 KW:
AT1A-3530-2
10 KW:
Cast Heater
Replacement Kit
AT1A-3530-3
12 KW:
AT1A-3530-4
14 KW:
AT1A-3530-6
17 KW:
AT1A-3530-7
Provides line voltage to the Cast Heater elements, once the Controller • /Keypad Board sends the 24V control signal to the relay(s). The relay(s) are only activated if the Door Switch & Chamber • Pressure Switch are closed. The number of Solid State Relays used, depends on the phase and • wattage needs of the unit.
Transfers the heat, generated from the internal elements; to boil the • water to create steam. Cast Heater can be wired to single or 3 phase; and have a parallel, • delta, or wye conguration. Cast Heater must be replaced with the same wattage heater as • specied in the model number.
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PURPOSE REFERENCE OF MAIN COMPONENTS
Component Part # Purpose
Temperature
(RTD)
Sensor
Door Assembly AT1A-3600-1
Drain Valve AT1P-2239-1
AT0E-3626-1
ADDITIONAL COMPONENT PART NUMBERS
Component Part # Component Part #
Pilot Lamp, 24V Red AT0E-1800-2 Door Hinge (Pair) AT1H-2058-3
Fuse, 1.25A 250V AT0E-2731-2 Door Latch Assy, Ceramic Magnet AT1H-3609-1
Provides temperature input to Control/Keypad Board, which displays • the temperature in the steam chamber based on resistance changes from the Temperature (RTD) Sensor. Used to maintain the preset HOLD mode temperature.
Keeps the steam trapped inside the steam chamber to allow pressure • to build and cycle the Chamber Pressure Switch.
Manually Open/Close valve used to drain water from the steam • chamber.
Gasket, Door AT1G-2633-1 Door Latch Mounting Plate AT1M-3046-1
Inner Door Assembly AT1A-3647-1
SP8027-1203 Pg 5
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SEQUENCE OF OPERATION
INDICATORS AND WATER CONTROL BOARD OPERATION (Manual & Auto-Fill):
PWR Button Pushed & Water Level Is Below the Low Water Level Sensor - AUTO-FILL
The Low Water Light Indicator will be lit. PRE is displayed on the Control/Keypad Board. The Water Sensor Board sends a signal to the Water Sensor Board’s K1 Relay to open the • Auto-Fill Valve and start lling the steam chamber with water.
(The red LED light on the Water Sensor Board will be ashing continuously.)
PWR Button Pushed & Water Level Is Below the Low Water Level Sensor - MANUAL FILL
The Low Water Light Indicator will be ON and Alarm will sound.PRE is displayed on the Control/Keypad Board.
(The red LED light on the Water Sensor Board will be ashing continuously.)
PWR Button Pushed & Low Water Level Sensor Is Satised - MANUAL & AUTO-FILL
The Low Water Light Indicator and Alarm ( only manual ll units use an alarm for low water condition), will be OFF. This is minimum water level needed for the Contactor to close and turn the Cast Heater ON.
(The red LED light on the Water Sensor Board will have about a 1 second ash delay.)
Water Level Is At the High Limit Water Level Sensor - AUTO-FILL
When the water level in the chamber touches the High Water Limit Probe, the Water Sensor • Board will continue to activate the Auto-Fill Valve for an additional 30 seconds; and then turns the valve off. (This will occur every time the water level falls below the High Limit
Probe.) (The red LED light on the Water Sensor Board will have about a 2 second ash delay.)
Water Level Is Filled Too High in the Steam Chamber - AUTO-FILL
The Float Ball rises on the Over-Fill Reed Switch sensor peg until the magnetic eld from • the Float Ball is above the Reed Switch, causing the Reed Switch to open. This causes the Control Relay #1 AC coil’s voltage to drop, dis-engaging the relay from the steamer’s normal operation; illuminating the High Water (Over-Fill) Indicator Lamp and sounding the buzzer. The loss of Control Relay #1 will remove the power signal to the Contactor’s control coil, • which opens the contacts and prevents Line Voltage to the Solid State Relay(s). This stops the Cast Heater from generating heat.
(To restart the steamer, open the Drain Valve to drain the water, until the High Water (Over-• Fill) Indicator Light goes out. Press the PWR button ON to restart the start-up procedure.)
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SEQUENCE OF OPERATION
CAST HEATER GENERATING HEAT OPERATION (Manual & Auto-Fill):
Power Cord Plugged-In & PWR Button Not Pushed
Line Voltage comes into the 3 Pole Contactor’s L1 - L3 terminals. (Refer to the unit’s
specic wiring schematics to determine the wire color to “L” Terminal location.)
Line Voltage is then taken off of L1 & L2 of the Contactor and applied to the Transformer, • which steps-down the Line Voltage to 24VAC. From the two, 1.25Amp, fuses; power goes through the Overtemp Switch, then goes to • the Water Sensor Board, to Control Relay #1 (CR#1) coil, to the High Water Overll Reed Switch (Auto-Fill Only), to the Control/Keypad Board, and to Pin 6 of CR#1. Power also ows through CR#1, Control/Keypad Board, Water Sensor Board and Contactor (once the water level condition is met).
(The red LED light on the Water Sensor Board will be ashing continuously.)
PWR Button Pushed & Low Water Level Sensor Is Satised
(The red LED light on the Water Sensor Board will have about a 1 second ash rate.)
The Water Sensor Control Board’s K2 Relay will close, sending power to the Contactor’s • coil; closing the contacts and allowing Line Voltage to be sent to the normally open Solid State Relay(s). The Control/Keypad Board will send a 24VAC signal to the Solid State Relay(s); closing the • Relay(s) (as long as the Door Switch and the Chamber Pressure Switch are closed). The Solid State Relay(s) then pass Line Voltage to the Cast Heater’s Elements generating • heat evenly over the bottom of the steam chamber; creating steam for cooking.
Temperature Sensor (RTD) and Control/Keypad Board
As the water temperature rises, the RTD will provide a signal, based on the resistance of the • sensor, to the Control/Keypad Board to provide a digital temperature display. Control Panel will show PRE (Preheat) on initial start-up until the steam chamber reaches 195°F, then COO (Cook) will be displayed between 195°F and 212°F. The operating default mode on initial PWR ON is COOK mode; which automatically causes • the steamer to go to the normal operating boiling point, which is 212°F at sea level. In COOK mode, the 24VAC output from the Control/Keypad Board is continuously on, so • that the unit’s temperature is controlled by the Chamber Pressure Switch, which opens at 1/2 inches of water column or higher. In HOLD mode (HLD), the steamer’s regulated temperature will change to the HOLD temperature’s preset value. The Control/Keypad Board will regulate temperature via the RTD input, based on the current HOLD mode preset value. (This value can be changed
using the program function on the Control/Keyboard Control.)
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MODIFYING CONTROL / KEYPAD PROGRAM SETTINGS
Hrs/Min/Sec
LED Lights
UP Arrow
DOWN Arrow
S1 - Increase Program Item (Will cycle the Hrs/Min/Sec LED light) S4 - Decrease Program Item (Will cycle the Hrs/Min/Sec LED light) S3 - Increase Program Value (Will change the Digital Readout display) S6 - Decrease Program Value (Will change the Digital Readout display)
S2 - Exit & Save
ENTERING PROGRAM MODE: Simultaneously, depress and hold S4 & S6 for minimum of 8 seconds or
until the Hrs LED blinks and the display shows a Hold Temp number (default is 180°F). Now the Controller can operate under the Program Function Parameters.
S1
S4
POWER
S5
S2
TIMER
S3
S6
COOK/HOLD
TEMP Display
Program Mode Function Parameter Table
Hrs LED Min LED Sec LED PARAMETER MIN MAX ELECTRIC
Blink OFF OFF HOLD Temp Value = Degree F MIN Temp MAX Temp 180
ON OFF OFF Default Timer Value = Hours 0 8 0
OFF ON OFF Default Timer Value = Minutes 0 59 30
OFF OFF ON TEMP Probe Offset = Degree F 0 50 0
ON ON ON TEMP Probe Offset = Neg/Pos Diff NEG = 1 POS = 0 0
Blink Blink Blink Hysteresis
ON Blink Blink TEMP Regulating Mode
Blink ON Blink Proportioning BAND TIME 4 10 10
Blink Blink ON Proportioning BAND WIDTH 4 10 10
TO RESET CONTROLLER TO FACTORY DEFAULT VALUES,
PRESS AND HOLD S4, THEN PRESS S5.
SP8027-1203 Pg 8
2 10
On/Off = 0 PID = 1
2
1
Page 16
START
TROUBLESHOOTING FLOW-DIAGRAM
POWER
ON
NO
Steamer
Plugged-In
YES
Breaker
ON
YES
Check
Internal
Power
Voltages
SEE C
Component
Voltages
Correct
YES
Call
AccuTemp
Service
NO
NO
NO
YES
SEE
SEE
SEE
A
B
D
Ball
WARNING
LIGHTS
YES
Control Panel
Error Code
NO
Low Water
Light
NO
Over Temp
Light
NO
High Water
(Over-Fill)
Light
YES
Float Ball
Installed
NO
Float Ball
Present
YES
YES
YES
YES
YES
NO
SEE
SEE
SEE
SEE
Ball
E
F
G
H
SEE
STEAMER
HEATING
YES
Temp
Low
NO
Steam Out
The Door
NO
Food Over
Cooked
NO
Food
Under
Cooked
YES
Different
Problem
With
Steamer
Operations
NO
YES
YES
YES
YES
NO
SEE
I
SEE
J
SEE
K
SEE
L
SEE
M
DONE WITH
CHART
YES
Call
AccuTemp
Service
Call
AccuTemp
Service
NO
Call
AccuTemp
Service
(800) 480-0415 or service@accutemp.net
SP8027-1203 Pg 9
Page 17
REF
FLOW-DIAGRAM REFERENCE TROUBLESHOOTING CHART
LETTER
POSSIBLE CAUSE EVALUATION
A
B
C
D
E
Power Cord Disconnected
Breaker Is Tripped
Transformer
Fuses Check for blown fuses.
Over-Temp Switch
Control panel not responding.
Bad Component or Faulty Wiring
Error Code: -1F or -99F for Temperature (RTD) Probe.
Conrm proper voltage is present at receptacle. Plug-in Power Cord.
Unplug steamer and check line voltage at plug-in receptacle. Reset Breaker.
Check for proper incoming line voltage to the primary side and 24VAC on the secondary side.
Check between the violet wire, terminal J3 on the Water Contrl Board, and the brown wire after the fuse.
Check for 24VAC incoming power at pins J2-1 & J2-2. Check for output at pins J7-3 & J7-4 (On/Off) = 24VAC
Check the wiring to the component; including wire-to­connectors, GND’s, and damage. If a component output is bad, then it may need replaced.
Check for 1000 ohms (at room temp) on Control/Kepad Board on J3 - Pins 1 & 2. EC: -1F = Open Temp (RTD) sensor EC: -99F = Shorted Temp (RTD) sensor
G
H
Ensure water level is above Low Water Sensor Probe
F
Low Water Sensor Not Satised
Steamer Has Over-Heated
Too Much Water In Steam Chamber
Operational Water Level Sensor Faulty
Float Ball & Reed Sensor Faulty
inside the steam chamber. Ensure that the Low Water Sensor is cleaned and that the Water Board is working properly.
Check that the water level inside steam chamber is not empty; and rell if needed.
If an Auto-Fill unit, then ensure that water supply is not shut-off, or Auto-Fill Valve is faulty.
Ensure Water Sensors are clean.
DO NOT OPEN DOOR!
Open Drain Valve until the High Water Light goes off. If light DOES NOT go out and no water in steamer, then possibly a sensor fault.
Ensure the top Water Sensor is clean. Check that Water Board is working properly.
Ensure Float Ball is not stuck on the Sensor Post. Ensure Sensor Post & inside of the Float ball are clean. Check continuity of the Reed Switch (Float over sensor creates continuity; the Float off the sensor is open.)
SP8027-1203 Pg 10
Page 18
FLOW-DIAGRAM REFERENCE TROUBLESHOOTING CHART
REF
LETTER
I
POSSIBLE CAUSE EVALUATION
Control/Keypad Panel Check for 24-30VAC output (J7 Pins 1 & 2).
Ensure Door is shut and handle is latched. Check the Door Switch for continuity with Door
Door Switch Not Engaging
Chamber Pressure Switch
Steam Vent Blocked
closed. Check the butt splices and wire connection terminals for good crimps.
Switch is normally closed. Check the Chamber Pressure Switch for continuity. Ensure Chamber Pressure Switch is not stuck open.
Steam should be coming out of vent at back of steamer. Check for blockage in the vent, which can cause the Chamber Pressure Switch to open. Ensure that there is at least a minimum of 1/4” slope for every foot added, of extended exhaust piping. Ensure that any extended exhaust piping is made of galvanized or stainless steel, or copper; and a minimum of 3/4” in diameter. If blockage is present, try to pour some hot water down the vent piping to unclog the blockage (may have to blow out the blockage if water doesn’t help).
Check for 24-30 VAC on pins A1 & A2 of each Solid State Relay. (Green LED should be lit.)
Solid State Relay(s)
Cast Heater
Contactor
Steam Temperature Is Not At Desired Cook Temperature
J
Steam Vent Blocked
Ensure that Relay Contacts are closing when receiving the 24-30 VAC from the Control/Keypad Board. Check that proper line voltage is being passed through the Solid State Relay to the Heating Elements.
Check that the correct Amps (based on KiloWatts of unit) are being drawn from each Element. Ensure that all the required voltages (based on required phase needs of the unit) are present to each Element.
Check that the Contactor is not open, preventing the line voltage to the Solid State Relay(s).
Check that the Door is closed and no steam is escaping from it. Verify that Low Water indicator light is not lit. Check that steamer is in the COOK mode and NOT in the HOLD mode.
See Ref Letter I.
SP8027-1203 Pg 11
Page 19
FLOW-DIAGRAM REFERENCE TROUBLESHOOTING CHART
REF
LETTER
K
L
M
POSSIBLE CAUSE EVALUATION
Door Assembly
Pressure Switch
Steam Vent Blocked
Food Cook Time Too Long
Food Cook Time Not Long Enough
Check to see if the Door is seating completely around the face of the Steamer. Check that the Door Gasket does not have any cuts, nicks, debris, or discolorations (white or grey).
Check that the Chamber Pressure Switch opens and closes checking the Ohms reading while blowing into its input hose. (Disconnect the hose from the chamber inlet hole.)
See Ref Letter I.
Ensure that the proper Cook Time is being used.
Refer to the Owners Manual for cooking tips if no mechanical reason is found for this symptom.
See Ref Letter K.
Ensure that the steamer is in the COOK mode and not the HOLD mode. (HOLD has a preset temp value that is below that of 212°F.) Check that proper pan placement is being utilized for best cooking conditions. (See Owners Manual) Ensure that the Drain Ball-Valve is shut tightly or possible loss of heating efciency.
Refer to the Owners Manual for cooking tips if no mechanical reason is found for this symptom.
NOTE
If your symptoms are not listed in the Flow Chart and/or the REF Chart, then
additional troubleshooting may be required.
If you need additional ideas for troubleshooting or want to conrm your symptoms
with one of our Service Techs, please contact us by phone or e-mail listed below
with the unit’s S/N or Model information.
AccuTemp Service Dept. Phone (800) 480-0415
AccuTemp Service Dept. Email service@accutemp.net
SP8027-1203 Pg 12
Page 20
LOCATION OF ELECTRICAL COMPONENTS
Solid State
Relays
&
Heat
Sinks
Power Cord Contactor
Chamber Pressure Switch
Heater/PWR
Terminal Strip
Control/
Keypad
Board
Water Sensors
Transformer Fuses Water Sensor
Control Board
SP8027-1203 Pg 13
Control
Relay #1
Page 21
ELECTRICAL COMPONENTS REMOVAL & INSTALLATION
CORD & PLUG ASSEMBLY
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the Power Cord Leads (Black, 3. White, Red, and/or Green) from L1-3 of the Contactor (note the wire color to its location terminal). On the inside of the unit, remove the retaining 4. nut on the threads of the Power Cord Cable Fitting & pullout the Power Cord.
Re-install in reverse order.5.
FUSES
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Pry the Fuses out of the Fuse Block with a 3. at-head screwdriver or fuse puller.
Re-install in reverse order.4.
CONTACTOR
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the wires (note the wire color to its 3. location terminal). Remove the 2 mounting nuts and then remove 4. the Contactor.
Re-install in reverse order.5.
SP8027-1203 Pg 14
Page 22
ELECTRICAL COMPONENTS REMOVAL & INSTALLATION
TRANSFORMER
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the wires (note the wire color to its 3. location terminal). Remove the 2 mounting nuts and then remove 4. the Transformer.
Re-install in reverse order.5.
WATER SENSOR CONTROL BOARD
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the wires (note the wire color to its 3. location terminal). Carefully4. , push in the locking leg on the 4 plastic posts while pulling the Water Board up off the posts (note the board’s orientation). Remove the Water Board.5.
Re-install in reverse order.6.
CONTROL RELAY #1
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the wires (note the wire color to its 3. location terminal). Remove the 2 mounting screws and then 4. remove Control Relay #1.
Re-install in reverse order.5.
SP8027-1203 Pg 15
Page 23
ELECTRICAL COMPONENTS REMOVAL & INSTALLATION
WATER SENSORS
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Open the door and 3. ensure that all the water is drained from the steam chamber. Disconnect the wire from the backside of the 4. Water Sensor (access via left-side panel). Remove the retaining nut that mounts the Water 5. Sensor to the Steam Chamber. Push the Water Sensor through the hole in the 6. steam chamber from the backside.
Re-install in reverse order. 7. Torque Sensor Nuts to between 12-15 In-Lbs.
CONTROL / KEYPAD BOARD
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the wires (note the wire color to its 3. location terminal). Remove the 7 mounting nuts and then remove 4. the Control Panel CCA. (5. If accessing the Program Mode is needed, go to page 8 for more details.)
Re-install in reverse order.6.
SP8027-1203 Pg 16
Page 24
ELECTRICAL COMPONENTS REMOVAL & INSTALLATION
DOOR SWITCH
Door Latch on the Left-Hand Side
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the probe wires: Control/Keypad 3. Panel J7 Pin 1 & the White/Brown wire from the Chamber Pressure Switch (the wires to the location pins are enter-changeable). Push back the insulation, so you can access the 4. other mounting nut to be removed. Remove the 2 mounting nuts and then remove 5. the Door Switch. Fg 1
Re-install in reverse order.6.
Fg 2
Fg 1
Door Latch on the Right-Hand Side
Unplug the Unit.1. Remove the Left-Side, Right-Side, and Top 2. Panel by removing the Sheet Metal Screws holding it in place. Disconnect the probe wires: Control/Keypad 3. Panel J7 Pin 1 & the White/Brown wire from the Chamber Pressure Switch; and pull the wires up, over the top of the steamer (the wires to the location pins are enter-changeable). Remove the insulation on the right side, to 4. access the Door Switch to be removed. Fg 2 Remove the 2 mounting nuts and then remove 5. the Door Switch. Fg 3
Re-install in reverse order.6.
Fg 3
SP8027-1203 Pg 17
Page 25
ELECTRICAL COMPONENTS REMOVAL & INSTALLATION
CHAMBER PRESSURE SWITCH
Unplug the Unit & remove the Left-Side Panel 1. by removing the Sheet Metal Screws holding it in place. Disconnect the Wiring Terminals from the 2. Chamber Pressure Switch (note the wire color to its location terminal). Remove the hose clamp and disconnect the 3. hose from the Chamber Pressure Switch. Remove the 2 mounting nuts holding the 4. Chamber Pressure Switch to chamber cavity. Remove the Chamber Pressure Switch5.
Re-install in reverse order.6.
SOLID STATE RELAY (SSR)
Unplug the Unit.1. Remove the Left-Side Panel by removing the 2. Sheet Metal Screws holding it in place. Disconnect the wires for the desired SSR 3. being replaced (note the wire color to its location terminal). Remove the thread-cover nuts on the back of 4. the steamer, while removing the 2 mounting bolts holding the SSR Assy to the inside-back of the component chamber; and then remove the desired Solid State Relay.
Re-install in reverse order.5.
SP8027-1203 Pg 18
Page 26
ELECTRICAL COMPONENTS REMOVAL & INSTALLATION
TEMPERATURE (RTD) SENSOR
Unplug the Unit.1. Remove the Left-Side, Right-Side, and Top 2. Panel by removing the Sheet Metal Screws holding it in place. Disconnect the probe wires from the Control/3. Keypad Panel and pull them from the left, over the top, to the steamer’s right-side (the wires to the location pins are enter-changeable). Remove the mounting nut and then remove the 4. Temperature (RTD) Sensor.
Re-install in reverse order. 5. Ensure Thermal Paste is applied to the Temperature (RTD) Sensor.
OVERTEMP SWITCH (THERM LIMIT SW3)
Unplug the unit.1. Using an additional person2. , turn the unit upside-down and remove its legs. (Unbolt unit
from stand and then turn unit upside-down if
applicable.) Remove Left-Side Panel & Bottom CoverPanel 3. by removing the Sheet Metal Screws holding it in place. (Remove Drain Pan Rails if
applicable.)
Remove the Insulation as needed to provide 4. access to remove the Overtemp Switch from the bottom of the Cast Heater. (Note the
insulation location for proper tting when re-installed.)
Disconnect the wires to the Overtemp Switch 5. (note the wire color to the location pin). Unscrew the Overtemp Switch, and remove it 6. from the bottom of the Cast Heater.
Re-install in reverse order. 7. Ensure Thermal Paste is applied to the Overtemp Switch and its threading.
SP8027-1203 Pg 19
Page 27
LOCATION OF CAST HEATER
Cast Heater
SP8027-1203 Pg 20
Page 28
CAST HEATER REMOVAL & INSTALLATION
NOTE
The 1/4-20# Nut Special Locking Nut, Can Only Be Used Once.
Ensure That A New Cast Heater Replacement Kit Is Ordered and Received; Prior to
Removing or Installing the Cast Heater.
Part #: AT1A-3530-X
*
Order the Cast Heater Replacement Kit for the Correct Heater Wattage Required.
Thermal
Paste
Overtemp
Switch
* (See Page 4)
Cast Heater
Installation
1/4-20#
Locking
Nuts
Paint
Brush
SP8027-1203 Pg 21
Instructions
Page 29
CAST HEATER REMOVAL & INSTALLATION
AN ADDITIONAL PERSON IS REQUIRED, WHEN CONDUCTING MAINTENANCE INVOLVING TURNING THE UNIT OVER. IF HEATER WIRES HAVE NON-BRAIDED INSULATION, THE HEATER IS NOT A CAST HEATER. CONTACT ACCUTEMP SERVICE AT 800-480-0415. USE THE INCLUDED CAST HEATER REPLACEMENT KIT INSTRUCTION BOOKLET IN CONJUNCTION WITH THE REMOVAL & INSTALLATION PROCEDURES IN THIS MANUAL.
CAST HEATER
Unplug the unit and drain all the water out 1. of the steamer. Remove Left-Side by removing the Sheet 2. Metal Screws holding it in place. Disconnect the 6, braided-insulation, 3. Heater Wires from their Terminal Board Connections. (Note the heater wires’ numbers to their location terminals.) Using an additional person4. , turn the unit upside-down and remove its legs. (Unbolt
unit from stand and then turn unit upside-
down if applicable.) Remove the Bottom Cover by removing 5. the Sheet Metal Screws holding it in place. (Remove Drain Pan Rails if applicable.) Remove insulation as needed to access the 6. Cast Heater. (Note the insulation’s location to ensure proper tting when re-installed.) Disconnect the wires to the Overtemp 7. Switch (note the wire color to its location pin). Unscrew the Overtemp Switch, and remove 8. it from the bottom of the Cast Heater. F-A Remove any insulation and thread lock 9. material from the heater studs using a scouring pad.
REMEMBER:
F-A
F-F
F-E
F-B
F-D
F-C
SP8027-1203 Pg 22
Page 30
CAST HEATER REMOVAL & INSTALLATION
18
22
24
6
14
16711
2
10
12
3
1951713
21
15
23
8
20
19
NOTE
If Heater Studs are Discovered Broken While Removing the Cast Heater
OR
If a Heater Stud Breaks-Off While Removing or Installing the Cast Heater
Call AccuTemp Service Dept (800) 480-0415.
CAST HEATER (CON’T)
10. Using Fig G, loosen all 24 nuts by starting with Nut #24 and working down to #1.
11. Remove all 24; Locking Nuts (F-C), Lock Washers (F-D) & Flat Washers (F-E) from the Cast Heater. (Discard the used Locking Nuts; keep and clean the Lock & Flat Washers.)
12. Remove both Heater Mounting Brackets from the top of the heater by letting them hang, by the wires, over the electrical compartment. F-B
13. Remove the Cast Heater. F-F (Might have to lift heater by its heater wires, or use a at-head screwdriver to pry up the Cast Heater from the Thermal Compound.)
14. Re-install in reverse order. SEE NEXT PAGE FOR INSTALLATION NOTES.
Heater
Wires
Should
Be On
Terminal
Block Side
4
Steamer
Fig G
Only using a brass or stainless-steel brush; scrape, remove, and
clean-off any remaining Thread Sealant and Thermal Compound
residue from the bottom of the steamer, even around the studs.
Front
Side
Of
The
SP8027-1203 Pg 23
Page 31
CAST HEATER INSTALLATION NOTES & CAUTIONS
1348765
12
10
11915
1316141922
241820
232117
NOTE
CAST HEATER’S SHINY SIDE FACES THE BOTTOM OF THE STEAMER!
Using a Paint Brush, Apply Thermal Paste to the Shiny Side of the Cast Heater.
Bellevelle Washers should look like mini-volcanos when placed on heater stud.
The HEX Locking Nut Needs to be Torqued Between 23 - 27 IN-LBS.
Tighten Starting with Nut #1 and Follow the Numbered Layout Pattern to Nut #24.
Tighten Twice in This Pattern.
2
Notch
Cut-Out
Goes
Towards
the
Front
Side
of
the
Steamer
CAUTION
DO NOT OVER TORQUE THE LOCKING NUTS.
Over Torquing The Zinc Nuts Can Cause the Studs to Break-Off. This Will Cause
Heating Issues; and the Steamer Will Not Operate Correctly or Safely.
SP8027-1203 Pg 24
Page 32
MISCELLANEOUS COMPONENTS REMOVAL & INSTALLATION
AUTO-FILL VALVE
Unplug the Unit & drain any remaining water from the 1. steam chamber. Close the supply water valve and disconnect the Supply 2. Water Hose coming into the steamer. Remove the Left-Side Panel by removing the Sheet 3. Metal Screws holding it in place. Disconnect the wires from the Auto-Fill Valve (4. note the wire color to its location pin). Disconnect the Auto-Fill Valve Hose Fitting. 5. F-H On the back of the steamer, remove the 4 mounting 6. screws securing the Auto-Fill Valve bracket on the inside of the steamer. Remove the Auto-Fill Valve.7.
Re-install in reverse order. 8. Ensure Sealant is re-applied to all pipe threading.
F-H
OVER-FILL REED SWITCH
Unplug Unit & close the supply water valve.1. Disconnect the garden hose from the back of the 2. steamer & drain any remaining water from the steam chamber. Remove the Left-Side Panel by removing the Sheet 3. Metal Screws holding it in place. Disconnect the REED Switch wires (4. note the wire color to its location pin). Turn the unit upside-down and remove its legs. 5. (Unbolt from stand and then turn unit upside-down if applicable.) Remove Bottom Cover by removing the Sheet Metal 6. Screws holding it in place. (Remove Drain Pan Rails if applicable.) Remove the front, insulation pieces that are laying 7. on-top of the Over-Fill Reed Switch. (Wire is ran in-between the insulation pieces.) Remove the retaining nut and lock washer holding the 8. Reed Switch inside the Sensor Post. Remove the High Water Reed Switch. 9. F-I
Re-install in reverse order.10.
F-I
SP8027-1203 Pg 25
Page 33
MISCELLANEOUS COMPONENTS REMOVAL & INSTALLATION
FLOAT BALL (MAGNETIC)
Open the steamer Door and remove the left-1. side pan rail. Lift and remove the steam collection cover 2. plate. Remove the Float Ball off of the High Water 3. Reed Switch Sensor Post.
Re-install in reverse order. 4. Ensure Sensor Post & Float Ball hole are clean before re-installing.
DRAIN VALVE
Unplug the Unit & drain any remaining water 1. from the steam chamber. Turn the unit upside-down and remove its 2. legs. (Unbolt from stand and then turn unit upside-down if applicable.) Remove Bottom Cover by removing the Sheet 3. Metal Screws holding it in place. (Remove Drain Pan Rails if applicable.) Remove the Drain Handle Cover Plate, and the 4. insulation surrounding the Drain Valve. Remove the Drain Pipe from the Drain Valve.5. Remove the Drain Valve.6.
Re-install in reverse order. 7. Ensure Sealant is re-applied to all pipe threading.
Drain Cover
Plate
DRIP PAN
Split Drip Pan
Unplug the Unit.1. Remove the 4 Sheet Metal Screws at the 2. bottom of the Front Panel. Slide the Drip Pan(s) out from between the 3. Front Panel and the Bottom Panel. (Ensure the
split Drip Pans are sloped towards the center of the steamer.)
Re-install in reverse order.4.
SP8027-1203 Pg 26
Solid Drip Pan
Page 34
DOOR COMPONENTS REMOVAL & INSTALLATION
DOOR ASSEMBLY
Unplug the unit and shut the Door.1. Remove the Hinge Covers. 2. Fig J Remove the 3 hinge screws going into the face 3. of the steamer of the Bottom Hinge. Fig K While supporting the Door on the hinge-side, 4. remove the 3 hinge screws into the face of the steamer of the Top Hinge. Pull the door handle and remove the Door.5.
Re-install in reverse order. 6. Ensure Anti-sieze is re-applied to all hinge screws.
If the Door Handle Latch Is Moved to the Opposite
Side, Ensure That the Door Switch Is Moved to the
Corresponding Door Handle Latch Side .
Fig J
Fig K
Face Screws
STEAMER WILL NOT OPERATE IF NOT DONE.
INNER-DOOR PANEL
Unplug the unit and shut the Door.1. Remove the Hinge Covers. 2. Fig J Remove the very bottom screw on the door 3. hinge-side of the Bottom Hinge. Remove the very top screw on the door 4. hinge-side of the Top Hinge. Pull the door handle and open the door5. Lift and pull out the Inner Door Panel.6.
Re-install in reverse order. 7. Ensure Anti-sieze is re-applied to all hinge screws.
Ensure That the Inner Door is Reinstalled with its
Middle Brace Bar Behind the Door Latch Tab. Fig L
Also, Ensure That the Screw Retainer Openings are
Lined-Up with the Door’s Hinge Side. Fig M
Inner Door
Fig L
Fig M
SP8027-1203 Pg 27
Page 35
DOOR COMPONENTS REMOVAL & INSTALLATION
DOOR HANDLE LATCH ASSEMBLY
Unplug the unit & shut the Door.1. Remove the Hinge Covers. 2. Fig J Remove the very bottom screw on the door 3. hinge-side of the Bottom Hinge & remove the very top screw on the door-side hinge of the Top Hinge. Pull the door handle and open the door4. Lift and pull out the Inner Door Panel.5. Remove the 3 mounting nuts and screws, 6. holding the Door Handle Latch to the side of the door, and the Inner Door Holding Tab. Remove the Door Handle Latch Assembly.7.
Re-install in reverse order. 8. Ensure Anti-sieze is re-applied to all hinge screws.
DOOR HINGE
Unplug the unit & shut the Door.1. Remove the Hinge Covers. 2. Fig J Remove the 3 hinge screws going into the face 3. of the steamer of the Bottom Hinge. While supporting the Door on the hinge-side, 4. remove the 3 hinge screws into the face of the steamer of the Top Hinge. Pull the door handle and remove the Door.5. Remove the very bottom screw on the door 6. hinge-side of the Bottom Hinge & remove the very top screw on the door-side hinge of the Top Hinge. Lift and pull out the Inner Door Panel.7. Remove the remaining door-side screws for 8. the hinge or hinges to be replaced. (Note the
orientation of the Hinge Spacer Bars as they relate to the Hinge orientation.)
Remove the Door Hinge or Hinges.9.
Re-install in reverse order. 10. Ensure Anti-sieze is re-applied to all hinge screws.
Ensure That the Inner Door is Reinstalled
with its Middle Brace Bar Behind the
Door Latch Tab. Fig L
Also, Ensure That the Screw Retainer
Openings are Lined-Up with the Door’s
Hinge Side. Fig M
SP8027-1203 Pg 28
Page 36
DOOR COMPONENTS REMOVAL & INSTALLATION
DOOR GASKET
Unplug the unit & shut the Door.1. Remove the Hinge Covers. 2. Fig J Remove the very bottom screw on the door 3. hinge-side of the Bottom Hinge & remove the very top screw on the door-side hinge of the Top Hinge. Pull the door handle and open the door4. Lift and pull out the Inner Door Panel.5. Remove the 6, Gasket retaining brackets by 6. removing the 12 nyloc mounting nuts holding them in place. Remove the Door Gasket.7.
Re-install in reverse order. 8. Ensure Anti-sieze is re-applied to all hinge screws.
INSTALLATION NOTE:
Make sure the new Door Gasket is untangled. Starting at one corner, stretch the Gasket to the opposite corner. Repeat this sequence until all 4 corners are seated. Push the Gasket down all the way around
to ensure the Gasket seats rmly on the
inner door.
Ensure That the Inner Door is Reinstalled with its
Middle Brace Bar Behind the Door Latch Tab. Fig L
Also, Ensure That the Screw Retainer Openings are
Lined-Up with the Door’s Hinge Side. Fig M
Gasket Retaining
Brackets
Gasket
Gasket Retaining
Bracket
SP8027-1203 Pg 29
Page 37
ELECTRIC EVOLUTION WIRING SCHEMATIC (208-240V/ 1Φ)
SP8027-1203 Pg 30
Page 38
ELECTRIC EVOLUTION WIRING SCHEMATIC (208-240V/ 3Φ)
SP8027-1203 Pg 31
Page 39
ELECTRIC EVOLUTION WIRING SCHEMATIC (208V/ 3Φ/ 17KW)
SP8027-1203 Pg 32
Page 40
ELECTRIC EVOLUTION WIRING SCHEMATIC (440-480V/ 3Φ)
SP8027-1203 Pg 33
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