AccuTemp S32083D100 Service Manual

SERVICE MANUAL

SERIAL NUMBERS 25384 AND UP

ACCUTEMP PRODUCTS, INC.

8415 NORTH CLINTON PARK - FORT WAYNE, IN 46825 - 800.480.0415 - www.accutemp.net

MP5006-1001 Rev A

TABLE OF CONTENTS

CONNECTIONLESS MODELS

Introduction____________________________________________________ 4 Sequence of Operation___________________________________________ 4 Trouble Shooting Guide__________________________________________ 5-7 Removal and Installation – 6 Pan Models

Removal from Stand________________________________________ 8 Removal of Legs___________________________________________ 8 Gast Vacuum Pump________________________________________ 8 Thermostat________________________________________________ 9 Temperature Probe_________________________________________ 9 Timer_____________________________________________________ 9 Vacuum and Temperature Gauges_____________________________ 10 Contactor__________________________________________________ 10 Vacuum Hoses and Tees_____________________________________ 10 Solid State Relays___________________________________________ 11 Lamps_____________________________________________________11 Fuses_____________________________________________________ 11 Water Sensor Control Board__________________________________ 12 Water Sensors______________________________________________ 12 Control Relays______________________________________________12 Fast Cook / Thermostat Toggle Switch__________________________ 12 On/Off Switches_____________________________________________13 Cord and Plug Assy._________________________________________ 13 Drain Valve_________________________________________________13 Gutters____________________________________________________ 13 Pressure Switch____________________________________________ 14 Dual Pressure Switch________________________________________ 14 Firebar Heater Replacement___________________________________14-15 Cast Heater________________________________________________ 15 Door Removal______________________________________________ 16 Inner Door Removal_________________________________________ 16 Floating Inner Door Removal__________________________________ 16 Gasket Replacement_________________________________________16 Inner Door Valve Cup Replacement_____________________________16 Door Latch Replacement______________________________________17

Removal and Installation – 3 Pan Model

Light Board_________________________________________________17

MP5006-1001 Rev A

AUTOFILL MODELS

Introduction & Sequence of Events– 3 & 6 Pan Models________________ 18 Trouble Shooting Guide___________________________________________ 19 Removal and Installation

Water Fill / Sensor Control Board______________________________ 20 Water Fill Valve_____________________________________________ 20

Overfill Sensor Switch_______________________________________ 21 Schematics – 6 Pan Models________________________________________ 22-28 Schematics – 3 Pan Models________________________________________ 29-35 Parts___________________________________________________________ 36 - 39

MP5006-1001 Rev A

INTRODUCTION-CONNECTIONLESS 3 & 6 PAN MODELS

The AccuTemp Steam ‘N’ Hold steamer takes time-proven method of cooking with steam and adds the advantage of control. This is accomplished by reducing the internal atmospheric pressure of the Steam ‘N’ Hold cooking chamber, thereby lowering the temperature at which water begins to boil. This allows the operator to control the temperature of the steam for cooking. Controlling the steam temperature gives the operator the ability to cook the food to the desired temperature without over-cooking, resulting in a more tender, juicier, nutritious product with less shrinkage than was previously possible. Once the cooking time expires, the steamer automatically enters the “Hold” mode. In this mode, the thermostat regulates the internal temperature, but vacuum is released, returning the cooking chamber to normal atmospheric pressure. At this time, steam is no longer generated and the cooking chamber is held at the desired temperature at a relative humidity of 100%. This eliminates food from drying out by suppressing the evaporation of the products’ natural moisture. As a result, most food products can be held in a ready to serve state for several hours after cooking, with no appreciable loss in taste, appearance or consistency.

SEQUENCE OF OPERATION

MAIN ON / OFF SWITCHES

Power is supplied through the power cord to the main contactor. Power comes off the back side of the contactor to the water board. While power is supplied to the water board, current is conducted thru the water sensors in the cooking chamber which must sense that water is in the unit to allow it to come on. The over-temp and water board are in series. Both must be satisfied before the unit can turn on. When the ON button is pressed it completes the circuit. The main contactor will pull in and will send power to the solid state heater relays at the same time latching the CR1 and CR2 control relays. Power is also sent to the timer and thermostat. The timer has 3 settings: HOLD, TIME and CONTINUOUS. When the timer is engaged power will be sent to the control relay on the top of the pump and the pump will start.

MP5006-1001 Rev A

TROUBLE SHOOTING GUIDE

STEAMER TROUBLE SHOOTING GUIDE

SYMPTOM

POSSIBLE CAUSE

EVALUATION

Unit will not power up

No water in the steamer

Fill with up to 3 gallons of water. Make sure the water level is above the sensors.

Water Sensors

Scrub and clean with a scotch brite pad. Incoming power supply

Check breakers, reset if required. Check the power plug to be sure it is firmly in the receptacle. Measure incoming power, call the Power Co., if necessary.

Steamer fuses

Check and or replace Fuse holder

Check and or replace On switch and contacts

Check for continuity Control Relays

Check continuity of the coil. Check for power to relay coil. Visually check for contact pull in and contact condition. Check for voltage across relay terminals.

Water Board

Check to see if the LED on the water board is on when the unit is powered up. Clean the sensors and re-inspect. Check for incoming power and check to make sure the ground is correct. If the LED light does not come on, replace the board. Boards with a 10 second delay is just the opposite Hi Limit

NOTE

: Serial No. 3865 to 19117 have a

resetable Hi-Limit.

Unplug

the unit and locate the access panel on the rear of the unit. Push the button in until it clicks. If this fails to start the unit after plugging back in, check the control relay and/or the off contact. These units also have a auto- reset hi-limit (purple and brown wires). If this is open while the unit goes to low water it needs to be replaced.

Unit is cooking slow

Low vacuum pressure, Vacuum pump.

Remove the top left pan rail in the steaming chamber. There will be 1 or two holes. If there are two holes, the one towards the front is for the pressure switch and does not need to be plugged. There may be a third hole located on the lower left side of the chamber and this must be plugged in addition to the top hole. From a cold start, plug all the holes with your fingers, turn the unit on and observe the reading on the vacuum gauge. The correct reading should be between 20 to 25 inches of pressure. 0 to 5 inches of pressure denotes a faulty pump. Check all the hoses and connections for any leaks. If the pump does not run at all, give the fan blade a push start through the grill. If the pump starts, it has a bad run capacitor. Replace as needed.

MP5006-1001 Rev A

Unit is cooking slow (cont)

Pressure switch

In the FAST cook mode, the pressure switch will close once the steam chamber reaches the thermostat setting. As the temperature rises, the vacuum pressure falls. Once the unit reaches 210 to 212 degrees, the pressure will be at zero. Cycle times when the unit is calling for heat should be around 8 to 10 seconds on and 60 to 90 seconds off. Replace the pressure switch if the cycle times are off or if you can suck air through the switch.

Unit is cooking slow (cont)

Door Gasket

Check for cuts or cracks. Replace as needed

Door Alignment

With the unit on and the pump running, perform the Dollar Bill test on the door. Close the door on a Dollar Bill. (all four sides of the door) There should be resistance when pulling the bill out. If the bills comes out easily, remove the hinge covers. Loosen all of the screws, turn the thermostat to150 degrees, enable the timer, shut the door and turn the unit on so it creates a vacuum and draws the door in and then retighten the screws. Door Sealing

If the door alignment process does not fix the problem, remove the inner door and place it on a flat surface and check for any warpage. Also check that the suctions cups are sealing. If they have turned gray or white then replace. Use one of the pan rails as a straight edge. Straighten and re-bend the inner door until it is flat and re-install using the door alignment procedure. Quick Release Door

On the inner door, check that the four suction cups are sealing and that the spring is functioning properly. Replace as needed.

Unit is over-temping

Solid State Relay

Check the cycle times as stated above. Check the voltage between T1 and L1. If the LED light is on, there should be 0 voltage. If the unit does not cycle, and the LED stays on, replace the relay.

Over-temp

Ohm out the Hi-limit to see if it is good. Clean the sensors and check the water board. If the low water light comes on while the unit is heating up, refer to the Hi-limit procedure.

Thermocouple (type J)

Check that the thermocouple is wired correctly to the thermostat. White is positive (Terminal 6) and Red is negative (terminal

7). Reversing the terminals will result in a run-away condition. See attached chart for DC-milli volt readings.

MP5006-1001 Rev A

Unit is over-temping (cont)

Thermostat

When a unit is at an altitude of 2,500ft+ water boils at this altitude at about 207 degree's. In thermostat mode unit starts blowing steam out the door just after heat light goes out. (It will do this because of extra heat in the element when it shuts off at about 205 degree's, drift point is at least 2 degree's). If you have the tech set thermostat at 190 degree's and put in fast cook it will run at the point customer wants to cook at

Thermostat

Check resistance between terminals 4 & 5. AC thermostats should read line voltage and DC thermostats should be between 3 to 34 DC volts. Thermocouple (type J)

See above

Unit is not coming up to proper temperature

Heating elements

Check for resistance between the two outside double white wires on the terminal block. On 17kW units check to terminals 1 & 6, 2 & 5, and 3 & 4 on the terminal block. See attached chart for resistance readings.

TYPE J THERMOCOUPLE READINGS - THERMOELECTRIC VOLTAGE IN DC MILLIVOLTS

F°0123456789

1.076

1.105

1.134

1.162

1.191

1.22

1.249

1.277

1.306

1.335

1.364 80

1.364

1.392

1.421

1.45

1.479

1.508

1.537

1.566

1.594

1.623

1.652 90

1.652

1.681

1.71

1.739

1.768

1.797

1.826

1.855

1.884

1.913

1.942

100

1.942

1.972

2.001

2.03

2.059

2.088

2.117

2.146

2.175

2.205

2.234

110

2.234

2.263

2.292

2.322

2.351

2.38

2.409

2.439

2.468

2.497

2.527

120

2.527

2.556

2.585

2.615

2.644

2.673

2.703

2.732

2.762

2.791

2.821

130

2.821

2.85

2.88

2.909

2.938

2.968

2.997

3.027

3.057

3.086

3.116

140

3.116

3.145

3.175

3.204

3.234

3.264

3.293

3.323

3.353

3.382

3.412

150

3.412

3.442

3.471

3.501

3.531

3.56

3.59

3.62

3.65

3.679

3.709

160

3.709

3.739

3.769

3.798

3.828

3.858

3.888

3.918

3.948

3.977

4.007

170

4.007

4.037

4.067

4.097

4.127

4.157

4.187

4.217

4.246

4.276

4.306

180

4.306

4.336

4.366

4.396

4.426

4.456

4.486

4.516

4.546

4.576

4.606

190

4.606

4.636

4.666

4.696

4.726

4.757

4.787

4.817

4.847

4.877

4.907

200

4.907

4.937

4.967

4.997

5.028

5.058

5.088

5.118

5.148

5.178

5.209

210

5.209

5.239

5.269

5.299

5.329

5.36

5.39

5.42

5.45

5.48

5.511

MP5006-1001 Rev A

REMOVAL AND INSTALLATION 6 PAN MODEL

REMOVAL FROM STAND

Using a 7/16” wrench, remove the 4 ¼’-20 x ½” bolts and lock washers located on the mounting brackets going into the bottom of the unit. When reinstalling, make sure the “L” brackets that hold the drip pan are facing inward.

REMOVAL OF LEGS

Units with legs use the same “L” brackets used on the stand but are held on by 8 ¼”-20 X ½” bolts and lock washers. Use a 7/16” wrench to remove these to access the bottom panel.

GAST VACUUM PUMP

1. Unplug the unit.

2. Remove the sheet metal screws on the left side panel of the unit.

3. Disconnect the wires to the relay and mark the locations.

4. Remove the hoses from the pump head.

5. Remove the two 3/8” nuts holding the muffler on and pull out of the way.

6. Remove the bolts on the pump bracket and pull the whole assembly out.

7. Remove the 4 Phillips screws washers and spacers on the bracket.

8. Remove the brass fittings on the head of the pump.

9. Reassemble in reverse order.

MP5006-1001 Rev A

THERMOSTAT

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit.

3. Remove the knob and the seal nut with a ½” nut driver on the front of the unit.

4. Disconnect the wires and mark the pin locations.

5. Reassemble in reverse order.

Note: AC thermostats have 6 pins and DC thermostats have 7 pins.

TEMPERATURE PROBE

1. Unplug the unit.

2. Remove the sheet metal screws on the left side panel of the unit.

3. Remove the white wire from terminal # 6 and the red wire from terminal # 7.

4. Follow the red and white wire down to the bottom of the unit.

5. Peel the insulation aside and remove the retaining nut with a 3/8” nut driver.

6. Reassemble in reverse order.

TIMER

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit.

3. Remove the knob and retaining nut with a ½” nut driver on the front of the unit.

4. Disconnect the wires and mark the pin locations.

5. Reassemble in reverse order.

Note: Don’t remove jumper wires.

AC Thermostat

DC Thermostat

MP5006-1001 Rev A

VACUUM AND TEMPERATURE GAUGES

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit.

3. On the vacuum gauge, remove the hose form the inlet connection.

4. Remove the two 10/24 nuts.

5. On the temperature gauge, remove the retaining nut on the inlet connection.

6. Follow the capillary leads down to where the probe is mounted to the unit.

7. Remove the two 3/8” nuts.

8. Reassemble in reverse order.

CONTACTOR

1. Unplug the unit.

2. Remove the sheet metal screws on the left side panel of the unit.

3. Remove the red, black and white leads on both sides of the contactor.

4. Remove coil wires.

5. Remove the 6/32” nyloc nuts that secure the contactor.

6. Reassemble in reverse order.

VACUUM HOSES AND TEES

1. Unplug the unit.

2. Remove the sheet metal screws on the left side panel of the unit.

3. Check all hoses and Tees for cracks or leakage.

4. Remove clamps and replace.

MP5006-1001 Rev A

SOLID STATE RELAYS

1. Unplug the unit.

2. Remove the sheet metal screws on the left side panel of the unit.

3. Remove the wires attached to the relay and mark their locations.

4. Remove the two mounting screws.

5. Reassemble in reverse order.

Note. Relays not mounted on a heat sink should use a heat pad or thermal paste.

LAMPS

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit.

3. Remove the two wires on the lamp terminals.

4. With a pair of pliers, depress the locking ears on the switch and push the lamp thru the front.

5. Push new lamp in the mounting hole. Make sure locking ears engage.

6. Reattach the wires.

FUSES

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit.

3. Pry the fuses out of the fuse block with a pocket screw driver.

MP5006-1001 Rev A

WATER SENSOR CONTROL BOARD

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit

3. Disconnect the wires and mark the pin locations.

4. Remove the nylon mounting pins.

5. Reassemble in reverse order.

WATER SENSORS

1. Unplug the unit.

2. Remove the sheet metal screws on the left side panel of the unit.

3. Open the door and drain all the water from the chamber.

4. Remove the 8/32” hex nut from the back side of the sensor with an 11/32” wrench and remove the sensor lead.

5. Use a ¾” wrench to remove the nut on the sensor.

6. Push the sensor thru the hole from the backside.

7. Reassemble in reverse order.

Note: Do not exceed 15 inch pounds when tightening the sensor mounting nut.

CONTROL RELAYS

1. Unplug the unit

2. Remove the sheet metal screws on the left side panel of the unit.

3. Disconnect the wires and mark the pin connections.

4. Remove the 6/32” nyloc nuts.

5. Reassemble in reverse order.

+ 27 hidden pages