Groen VRC-3E, VRC-6E, VORTEX100 VRC-3E, VORTEX100 VRC-6E Service Manual

SERVICE MANUAL
IMPORTANT INFORMATION, KEEP FOR OPERATOR
This manual provides information for:
Domestic
®
VORTEX100 CONNECTIONLESS
STEAMER
· Self Contained
· Electric Heated
· Capacity: VRC-3E=3 Steamer Pans Per Cavity VRC-6E=6 Steamer Pans Per Cavity
Information contained in this document is known to be current and accurate at the time of printing/creation. Unified Brands recommends referencing our product line websites, unifiedbrands.net, for the most updated product information and specifications.
PART NUMBER 145702, REV. C (01/07)
1055 Mendell Davis Drive
Jackson, MS 39272
888-994-7636, fax 888-864-7636
groen.com
Table of Contents
INTRODUCTION
OPERATION
DIAGNOSTICS / TROUBLESHOOTING
INSTALLATION, CLEANING AND TESTING
Page
1.1 THE GROEN SERVICE CONCEPT .......................................................................................... 5
1.2 THE GROEN CERTIFIED SERVICE.......................................................................................... 5
1.3 WARRANTY AND NON-WARRANTY REPAIRS .....................................................................
..................................................
. 5
1.4 SAFETY ............................................................................................................................... 5-6
1.5 GLOSSARY OF TERMS ......................................................................................................... 6
1.6 TOOLS AND SUPPLIES ......................................................................................................... 6
1.6.1 Reqired Tools .......................................................................................................... 6
1.7.1 Technical Bulletins
.........................................................................................................
7
1.6.2 Recommended Instruments...................................................................................... 6
1.6.3 Helpful Hardware .................................................................................................... 6
1.6.4 Recommended Supplies........................................................................................... 7
1.7 HOW TO USE THIS MANUAL ............................................................................................... 7
2.1 CONTROLS.......................................................................................................................... 9
2.2 OPERATING PROCEDURE .................................................................................................... 10
3.1 INSTALLATION .................................................................................................................... 11-12
3.2 INSTALLATION CHECKLIST .................................................................................................. 13
3.3 CLEANING PROCEDURES .................................................................................................... 13-14
4.1 TROUBLESHOOTING PROCEDURES & QUICK REFERENCE 16-19
.................................................................................................................
4.2 VRC CHECKOUT 20
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Table of Contents
ASSEMBLY / DISASSEMBLY
Page
5.1 AIR TEMPERATURE PROBE.................................................................................................. 21
5.2 CAVITY VENT ASSEMBLY .................................................................................................... 22
5.3 CONTROL PC BOARD .......................................................................................................... 22
5.4 DOOR REMOVAL/INSTALLATION/ALIGNMENT ..................................................................... 22
5.5 DOOR SWITCH .................................................................................................................... 23
5.6 DOOR REVERSING PROCEDURE .......................................................................................... 23
5.7 DOOR GASKET .................................................................................................................... 23-24
5.8 DOOR SPRING..................................................................................................................... 24
5.9 DOOR LOCKING PIN AND LOCK .......................................................................................... 24
5.10 DRAIN VALVE ASSEMBLY.................................................................................................... 24-25
5.11 FAN .................................................................................................................................... 25
5.12 HEATER ELEMENT............................................................................................................... 25-26
5.13 HI-LIMIT THERMOSTAT........................................................................................................ 26
5.14 LEGS................................................................................................................................... 26
5.15 MOTOR, FAN ASSEMBLY..................................................................................................... 27
5.16 MOTOR, STARTING CAPACITOR.......................................................................................... 28
5.17 PANEL BACK....................................................................................................................... 28
5.18 PANEL LEFT SIDE / RIGHT SIDE ............................................................................................ 28
5.19 PANEL, TOP COVER ............................................................................................................ 28
5.20 REMOTE READING THERMOMETER..................................................................................... 29
5.21 WATER LEVEL FLOAT........................................................................................................... 29
5.22 WATER DRAIN KIT INSTALLATION....................................................................................... 30-31
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Table of Contents
PARTS IDENTIFICATION • VRC-3E
PARTS IDENTIFICATION • VRC-6E
SPECIFICATIONS • VRC-3E, VRC-6E
Page
6.1 CAVITY VENT ASSEMBLY .................................................................................................... 32
6.2 CONTROL BOARD AND WIRING HARNESSES ...................................................................... 33
6.3 DOOR ASSEMBLY................................................................................................................ 34
6.4 ELECTRICAL COMPONENTS 208/240/240 VOLTS................................................................. 35
6.5 HEATER ELEMENTS.............................................................................................................. 36
6.6 MOTOR ASSEMBLY.............................................................................................................. 37
6.7 FLOAT ASSEMBLY ............................................................................................................... 38
6.8 INTERIOR & EXTERIOR CABINET.......................................................................................... 39
7.1 CAVITY VENT ASSEMBLY .................................................................................................... 40
7.2 CONTROL BOARD AND WIRING HARNESSES ...................................................................... 41
7.3 DOOR ASSEMBLY................................................................................................................ 42
7.4 ELECTRICAL COMPONENTS 208/240/480 VOLTS................................................................. 43
7.5 HEATER ELEMENTS ............................................................................................................. 44
7.6 MOTOR ASSEMBLY ............................................................................................................. 45
7.7 FLOAT ASSEMBLIES ............................................................................................................ 46
7.8 INTERIOR & EXTERIOR CABINET .......................................................................................... 47
GENERAL SPECIFICATIONS.................................................................................................. 48
ELECTRICAL SPECIFICATIONS.............................................................................................. 48
WIRING DIAGRAM .............................................................................................................. 49
LADDER DIAGRAM .............................................................................................................. 50
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INTRODUCTION
1.1 The Groen Service Concept
Since 1907 Groen has been in the business of designing and manufacturing the finest commercial appliances for the food service industry. Chefs, cooks and kitchen support personnel have come to depend upon the quality of construction and the reliability of operation.
Groen, in turn, depends upon our service centers and their field service personnel to keep the equipment in top operating condi­tion. In order to do this, our designs are made with service and reliability in mind.
Once the Groen equipment is sold, manufactured, delivered and installed, our reputation is clearly in your hands.As part of our team, we value your efforts and input to our product design.
We will do all we can to make your job of keeping the equip­ment in perfect working order as easy as we can. Together, we will keep our customers satisfied.
1.2 Groen Certified Service
The Vortex100 Connectionless Steamer has been carefully designed to provide many years of efficient and reliable service. Part of the quality program is Groen Certified Service. This includes:
• Groen certifies that all equipment delivered to our customers has been inspected and tested for compliance with the specifications.
• Groen certifies that all parts required for service and maintenance will be readily available.
• Groen certifies that this manual will be updated by means of periodic service bulletins to provide the most up-to-date information for field maintenance and service personnel.
1.3 Warranty & Non-Warranty Repair
Groen Warranty provisions are clearly presented in the customer’s Operator Manual.
Certain procedures for the cleaning and/or adjustment of the Vortex Connectionless Steamer are presented in this man­ual for reference, but not warranty related.
This non-warranty symbol is used throughout the manual to tell you which items and activities are NOT covered by the equipment warranty.
1.4 Safety
The Groen Vortex100 Connectionless Steamer has been designed from the start with safety in mind. This includes safety to the operating and maintenance personnel, safety to the facility in which the equipment is installed and safety to the equipment itself.
The steamer has been designed to the highest industry standards and has been certified by the National Sanitation Foundation Testing Laboratory (NSF) and the Underwriters Laboratory (UL) to assure strict compliance.
The steamer contains several devices, which are specifically used to prevent unsafe conditions. If they are disconnected, make sure they are reinstalled properly and tested before the steamer is operated.
The safety precautions in this manual are in accordance with ANSI 535 Standard. Three different signal words alert you to a hazardous situation:
DANGER,WARNING,AND CAUTION
DANGER: The signal word DANGER indicates that a
hazardous situation is about to happen and, if not avoided, will result in death or serious injury.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
• When you open the steamer door, be very careful to avoid escaping steam. Steam can cause burns.
• After removing the fan baffle partition, do not put your hands or other object into the cooking cavity until the fan comes to a complete stop. Rotating fan blades can cause severe injury!
PART NUMBER 145702, REV. C (01/07)
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5
INTRODUCTION
WARNING: The signal word WARNING tells you that a possibly hazardous situation is about to take place which, if not avoided, could cause death or serious injury.
• Always turn off the steamer power before removing and partitions or panels.
• Disconnect the steamer from the power source before performing and internal service work.
CAUTION: The signal word CAUTION warns you of a hazardous situation which, if not avoided, may result in minor or moderate injury.
• Steamer may be hot. Take precautions to prevent any contact with hot surfaces.
• Be sure all interior partitions have been installed before operating the steamer.
• All steamer operators and service personnel should be familiar with correct and safe operating procedures.
• Be sure steamer drain is not blocked as this could result in improper steamer operations.
Two other signal words, not directly related to personal safety, are also used in this manual:
NOTICE and IMPORTANT.
NOTICE is used to alert you to hazards that may result in
component and/or equipment damage.
IMPORTANT is used to highlight an operating or maintenance tip or suggestion.
1.5 Glossary of Terms
The following abbreviations and terms are used in this manual:
BTU British Thermal Unit GPM Gallons Per Minute LED Lighting Emitting Diode MM Millimeter NEC National Electric Code N.P.T. National Pipe Thread NSF National Sanitation Foundation PSI Pounds per Square Inch (Pressure) U.L. Underwriter’s Laboratory, Inc.
1.6 Tools and Supplies
This Section identifies the tools, instruments and supplies which will be required and useful in the inspection, repair and testing of the equipment described in this manual.
Most likely many of these tools and supplies are already in your tool kits and are used in everyday maintenance. Make sure to use only the specified sealants, compounds and dressings.
CAUTION: Care should be taken in using the correct tool as indicated. Using the wrong tool may inflict damage to the part being removed, installed and/or adjusted. Make sure that the calibrations on instruments are periodically checked for accuracy.
1.6.1 Required Tools
• Screw Drivers: Flat Blade No. 1 and No. 2
• Phillips No. 1 and No. 2
• Socket Wrenches: 1/4” through 7/8” (Magnetic)
• Nutdrivers (metric and inches)
• Open Ended Wrenches: 1/4” through 7/8”
• Pipe Wrenches: 6” and 8” size
• Allen Wrenches: 1/16” through 1/4”
• Slip Joint Pliers: ChannelLock or Equivalent
• Wire Crimpers
1.6.2 Recommended Instruments
• Digital Multimeter: Fluke Model 77
1.6.3 Helpful Hardware
• Extension Mirror
• Screw Starter
• Level: 18” Model
• Fuse Puller
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INTRODUCTION
1.6.4 Recommended Supplies
• Pipe Thread Compound: Brand: LACO PipeTite Stik
No. 11176 or equivalent
• Motor Sealant Grease: Bel-Ray
• 2” Aluminum Duct Tape
• Removable Thread Locker:
Locktite Type 242 (Door) Locktite Type 222 (Exterior)
• Clear Silicone Sealant:
Dow ComingType 732
• Silicone Heat Sink Compound:
Non-Fluid Oil Corp., Chemplex 1381
• High Temperature Anti-Seize and Lubricating Compound
Bostix NEVER SEEZ NSBT-16
1.7 How To Use This Manual
Read this manual completely before attempting any disassembly or repairs.
Please note the similarities and differences between the various models described in the manual.
Before making repairs, you should have knowledge of the steamer operation as described in the Operations Section of this manual, and a good understanding of service techniques, as presented by the Groen Service School.
This service manual should be taken with you on all service calls. Use the correct tools in accordance with the procedures shown and use only Groen Certified Replacement Parts when performing steamer repairs.
1.7.1 Technical Bulletins
Technical bulletins are issued by Groen to provide additional and specific technical information to this manual. The technical Bulletin Section of this manual should be used to file all of the Technical Bulletins sent to you from the factory.
When you receive a Technical Bulletin, insert the bulletin in the Technical Bulletin Section of this manual, and write a note in the margin of the page in this manual which is appropriate to the subject covered by the bulletin.
PART NUMBER 145702, REV. C (01/07)
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7
TECHNICAL BULLETINS
1.7.1a
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2.1 Controls
Operator controls are on the front right of the unit.
The VRC-3E and VRC-6E control panels have the following touch pads and indicator lights:
The ON/OFF rocker switch gets the Vortex ready for use,
or shuts it off.
The HOLD indicator light shows that the cavity is at holding
temperature.
The TIMED indicator light stays on when the timer is running.
The low water float probe signals the ADD WATER indicator
light
to illuminate when it’s time to add water.
The open and closed position of the drain valve allows the
unit to be filled with water or drained.
The READY indicator light indicates the unit has
Hour meter records cumulative hours of operation.
Temperature gauge indicates internal temperature of cavity.
achieved the ready temperature.
The push button operations:
1. In the HOLD mode the steam generator stays at a low boil or “holding” temperature. Factory set at 160°F.
2. When the TIMED button is pushed set, the TIMED light will illuminate
and can be set by turning the knob. The unit steams until the timer
counts down to zero and goes into hold. At that time the HOLD light
illuminates and a beeper sounds.
3. When the MANUAL button is pushed, the unit steams continuously. The green MANUAL light will stay illuminated.
OPERATION
TIME display
TIMER knob
MANUAL button and indicator
TIMED button and indicator
HOLD button and indicator
CANCEL button and indicator
FAULT display
ON/OFF rocker switch
Temperature gauge
Hour meter
READY indicator ADD WATER indicator
PART NUMBER 145702, REV. C (01/07)
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2.2 Operating Procedure
2. (When manual filling only) Pour water into the reservoir. When the water level comes up to the high float the reservoir is full and 5 beeps will sound and the ADD WATER light will go off. Close the door. The contactor will turn on when the low float is satisfied and the door is closed.
3. The contactor can be heard cycling to pulse energy into the heating elements.The unit will be ready in about 20 minutes.
4. Load food into pans in uniform layers. Pans should be filled to about the same levels, and should not be mounded.
5. Open the door and slide the pans onto the supports. If you will only be steaming one pan, put it in the middle position. Some foods will cause foam. When cooking foods that foam, such as shrimp, put an empty solid 2” deep pan in the bottom slot of the pan racks.
6. Close the door and take one of the following steps:
• If you want to steam the food for a certain length of time,
push the TIMED button and set the time with timer knob. The timer will automatically run the steamer for the set time and then go into hold. A beeper will sound. Then push CANCEL to stop the beeping.
• If you want to steam continuously, push MANUAL button. The
green light will illuminate. The unit will continue steaming at
a temperature of 203° F or higher.
• If you want to maintain food at holding temperature push
the HOLD button.
WARNING
When you open the door,
stay away from the steam
coming out of the unit.
the steam can cause burns.
6. To remove pans from cavity, open the door. Remove the pans from the steamer, using hot pads or oven mitts to protect your hands from the hot pans.
7. To shut off the unit, push the OFF switch.
8. To drain the remaining water in the water reservoir, move the drain handle to the OPEN position. The drain pan will not hold all of the water in the reservoir. Allow water to cool before draining. Pull drain pan slowly from the unit to avoid spilling.
sloshing.
WARNING
Do not empty until water is cool.
Empty drain pan. Pan will not hold
all water from the reservoir.
Do not over fill drain pan.
OPERATION
1. Push the ON switch and make sure drain handle is in the closed position.
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9KW 10KW 12KW 9KW 10KW 12KW
208 3 15-50P 15-50P 15-50P 15-50R 15-50R 15-50R 240 3 15-30P 15-50P 15-50P 15-30R 15-50R 15-50R 480 3 L16-20P L16-20P CS8165C L16-20R L16-20R CS8169
Hubbel or Hubbel or Equivalent Equivalent
INSTALLING, CLEANING AND TESTING
WARNING
GROUNDING INSTRUCTIONS
This appliance must be connected
to a grounded metallic, permanent
wiring system, or an equipment
grounding conductor must be run
with the circuit conductors and
connected to the equipment
grounding terminal on the station.
3.1 Installation and Start-up
CAUTION
DO NOT INSTALL THE UNIT WITHIN
2 INCHES OF A HEAT SOURCE
(SUCH AS A BRAISING PAN, DEEP FAT
FRYER, CHARBROILER, OR KETTLE).
Electrical Supply Connection – Observe all local, national, or other applicable codes.
Three phrase models of the Vortex100 Connectionless Steamer are supplied with a cord set ready to be connected to a power supply. See the chart below for the correct matching receptacle (not supplied with the unit).
Single phase models are designed to be directly connected (hard wired) to the electrical supply. Allow sufficient loop in the flexible conduit to facilitate inspection, servicing, and cleaning.
Branch Circuit Protection
Field Wiring Table
Use copper wire only – insulation rating 90°C
Voltage Phase Rated Current 60 hz only Demand (amps)
VRC-3E VRC-6E
9KW 6.76KW 12KW 10KW 9KW 208 3 25 19 34 28 25
240 3 22 29 25 22
480 3 11 14.4 13 208 1 44 33 58 49 44 240 1 38 50 43 39
Plug & Receptacle Chart
Three Phase Only
Volts Phase Plug Receptacle
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INSTALLING, CLEANING AND TESTING
Water Connections(s)
No water connection is needed. The water will be poured directly into the water cavity reservoir.
Make sure that the incoming water connection is made with a 3/4” N.H. COLD water supply hose. Rigid pipe is not required. The water pressure should be between 30 and 60 PSIG. Higher pressures will require the use of a pressure regulator. Make sure that all connections are tight with no leaks-no matter how small.
NOTICE: The quality of the water is a factor in the proper performance of the steamer. The water supply should have a minimum value of 30-40 parts per million of total dissolved solid (TDS).
Drain Connection
The Vortex100 Connectionless Steamer should be manually drained to the bottom containment pan supplied by the factory. If the unit is connected to a drain, do not connect more than two units to one drain line or pressure from one unit will effect the second unit.
Steam Vent Assembly Instructions
Remove steam diverter assembly from literature bag which can be found inside unit. Slide loose end as shown over unit steam outlet, tighten worm gear clamp with flat head screw driver. Be sure steam outlet is pointing in the upward position. (Shown below)
Stacking Units Instructions
Remove drain containment pan from the bottom of unit(s). Unscrew to remove adjustable legs from base of Vortex unit(s). Unfasten nuts and bolts on stand platform(s). Place Vortex unit(s) on stand platform.Align the (4) leg holes with the holes in the platform. Secure Vortex units(s) to stand platform(s) using bolts and washers provided with stand, see drawing below.
For double stack units only:
By loosening the left screw and removing the right screw provided, mount steam exhaust bracket assembly to the back panel of the top Vortex100 unit as shown in detail “B” of Figure 1 on the next page. Attach the steam exhaust hose from the bottom Vortex unit’s steam outlet tube to the top Vortex unit’s steam exhaust bracket assembly using hose clamps provided as shown in figure 2 on the next page. (Note: Steam exhaust hose may need to be cut to fit.)
FIGURE 1
FIGURE 2
DETAIL B
SCALE 1 : 1
DOUBLE
STACK
STAND P/N
142363
HOSE
CLAMPS
P/N 073259
HOSE
CLAMPS
P/N 073259
DOUBLE STACK
STEAM
EXHAUST HOSE
DOUBLE STACK
STEAM EXHAUST
BRACKET ASSEMBLY P/N 143243
10-32 SCREW
P/N 004173
• Units with Manual Fill
• Units with Auto-Fill
Drain Line Installation
Units with auto-fill or manual with drain kit
The drain line should not be less than: 1-1/2” - for single units 2” (5E) - for double stacked units There must be a 2” air gap to the (non-pressurized) building drain. Make sure that the drain is sloped AWAY and DOWN from the steamer and that there are no obstruction in the line. Failure to observe these requirements may cause a water trap in the drain line and produce enough back pressure to prevent proper cavity draining-resulting in condensate water leaking from the door. Drain line must not NOT be made of plastic pipe. It must be able to withstand boiling water.
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3.2 Installation Checklist
General
_____ Remove all packaging.
_____ Make sure there is a minimum of 2 inches of
free space around the steamer.
_____ Make sure the steamer is level or pitched
slightly to the rear.
_____ Check that the fan is clean and clear of
foreign material.
Electrical Checks
_____ Make sure the steamer is properly grounded.
_____ Verify that the electrical connections conform
to all local codes and the NEC requirements.
_____ Make sure the power supply branch circuit
conforms to the specifications indicated on the steamer nameplate.
Steamer Door Check
_____ Make sure the door gasket is making good
contact with the cavity frame.
_____ Check that the operators are leaving the door open
when the steamer is shut down overnight or longer.
3.3 Cleaning
To keep your VRC-3E or VRC-6E Connectionless Steamer in proper working condition, use the following procedure to clean the unit.
A. Suggested Tools
• Mild detergent
• Stainless steel exterior cleaner such as Zepper
• Cloth or sponge
• Plastic or wood handle brush with soft bristles
• Spray bottle
• Measuring cup
• Nylon pad
• Towels
• Plastic disposable gloves
B. Procedure
Exterior Cleaning
a. Prepare a warm solution of the mild detergent as
instructed by the supplier. Wet a cloth with this solution and wring it out. Use the moist cloth to clean the outside of the unit. Do not allow freely running liquid to touch the controls, the control panel, any electrical part, or on the side or rear panels.
b. To remove material which may be stuck to the unit use
plastic, wool, a fiber brush, or a plastic or rubber scraper with a detergent solution.
Interior Cleaning
Clean the unit daily or as residue builds upon the bottom of the oven cavity. a. Press OFF to turn the steamer off. Open the door. b. Drain the water from the unit into the drain pan and
allow the unit to cool before cleaning. (Note: If the cavity is full of water, the drain pan will not hold the entire amount and must be emptied more than once.)
c. After the unit has cooled, remove pan and pan racks
from the cavity.
d. Use a mild detergent to wipe down the steamer cavity, the
floats on the inside back panel wall, and the pan racks. The use of Groen descaler/delimer may be required to
remove heavy scale deposits e. Rinse the unit to remove detergent and cleaners. f. Attach pan racks. Unit is ready for use.
INSTALLING, CLEANING AND TESTING
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13
WARNING
Keep water and cleaning solutions
out of controls and electrical
components. Never hose or steam
clean any part of the unit.
Even when the unit has been
shut off, don’t put hands or tools
into the cooking chamber until
the fan has stopped turning.
Don’t operate the unit unless the
removable partition has been put
back in its proper location.
Do not use any acidic cleanser products to clean the unit.
IMPORTANT
Do not use any metal material (such as metal sponges)
or metal implements (such as a spoon, scraper or
wire brush) that might scratch any stainless steel surface.
Scratches make the surface hard to clean and provide
places for bacteria to grow. Do not use steel wool,
which may leave particles imbedded in the surface which
could eventually cause corrosion and pitting.
INSTALLING, CLEANING AND TESTING
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INSTALLING, CLEANING AND TESTING
Notes
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TROUBLESHOOTING
4.1 Vortex100 Troubleshooting Procedure
Each test procedure builds on the prior ones. Always start at the beginning of this procedure, and continue until the results indicate a malfunction. Do not skip steps.
WARNING: Disconnect electrical power before servicing.
Measure input voltage and com­pare to rating plate.
Check input power to determine if it is three phase or single phase
Connect electrical power (circuit breaker or plug)
Input voltage is within 10% of rated voltage
Steamer wiring matches incoming power
Panel lights are off. Red LED on back of control board flashes about once a second.
Wrong model (voltage) installed
Wrong model ordered. Change wiring at terminal block to match incoming power.
No line voltage
Blown 6 amp fuse F1 or F2
480v unit only-torroid circuit breaker
480v unit only-torroid transformer
24 volt control transformer circuit breaker
Control board or relay board
Ribbon connector is not properly seated
Notify customer
When converting from three phase to single phase, do not exceed amperage of breaker or power cord/plug
Standard test
Standard test
Reset breaker
Measure 480vac in and 208+/- 10%vac out
Measure 208 or 240vac in and 24vac +/- 20% out
Substitute to test
Check wiring diagramIncorrect wiring
Push ribbon connector into socket on control board and relay board
SETUP EXPECTED RESULTS PROBABLE DEFECT TEST or COMMENTS
Press on\off switch to ON
Add water to cover high water (upper) float. Close door
Heartbeat LED Flashes
ADD WATER light goes out (manual fill only)
Breaker on 24 Volt transformer
24 volt transformer T1
Low or high water float
Reset breaker
Measure 208 or 240vac in and 24vac +/- 20% out
Run sensor diagnostics
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