Vulcan-Hart 52387, 52386, 52423 User Manual

SERVICE MANUAL FOR

GPC12 & GPC12S, GPC16 & GPC16S

GAS PASTA COOKER

ML NOS. 52386, 52423, 52387 AND 52424

FORM 30911 (12-94)

MODEL GPC12S

SHOWN

VULCAN-HART COMPANY, P.O. BOX 696, LOUISVILLE, KY 40201- 0696, TIL. (502) 778-2791

IMPORTANT FOR YOUR SAFETY

THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO SERVICE AND ADJUST THE EQUIPMENT COVERED BY THIS MANUAL.

POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE SMELL OF GAS IS DETECTED. THIS INFORMATION CAN BE OBTAINED FROM THE LOCAL GAS SUPPLIER.

IMPORTANT

IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN UNITS AT MAIN SHUT OFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION OR MODIFICATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

IN THE EVENT OF A POWER FAILURE, DO NOT ATTEMPT TO OPERATE THIS DEVICE.

TABLE OF CONTENTS

Important Safety Information Page 2 Codes and Standards Information Page 3 Manual Use Information Page 3 Data Plate Information Page 3 Service Warnings Page 3 Tools Required for Servicing Page 3 Section l Service Checks Pages 4-8 Section ll Service Adjustments Pages 9-10 Section lll Removal and Replacement of Controls Pages 11-57 Section lV Wiring Information Page 58

CODES AND STANDARDS

Vulcan-Hart Pasta Cookers are to be installed in accordance with state and local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI-Z223.1 (latest edition), available from the American Gas Association, Inc., 1515 Wilson Boulevard, Arlington, VA. 22209 and with ANSI-NFPA Standard #96 (latest edition),

Removal From Cooking Equipment,

Park, Quincy, MA 02269.

available from the National Fire Protection Association, Batterymarch

HOW TO USE THIS MANUAL

This Manual is dedicated to the servicing of the GPC Series Vulcan Gas Pasta Cooker. The Manual is divided into 4 sections, SERVICE CHECKS, SERVICE ADJUSTMENTS, REMOVAL OF CONTROL PANEL AND REPLACEMENT OF CONTROLS and WIRING INFORMATION. Refer to the Manual Table of Contents when looking for specific performance checks or procedures. For additional Technical assistance contact the Vulcan Hart Service Dept. at the phone number shown on the cover of this manual. Read the following rating plate information and service warnings before preforming any service work.

Vapor

RATING PLATE

The rating plate stating model number, serial number, manufacturing date, gas type, voltage and amperage is located on the inside cooker cabinet door panel.

SERVICE WARNINGS

Hot water and parts can cause burns, use care when servicing this appliance. If cooker is pulled from the installation area for servicing, reinstall the cooker at least 6" away from any combustible construction sides and back and 0" away from noncombustible construction. The high limit is a shut off device which senses the temperature of the appliance to prevent over heating. The high limit operates independently and will automatically cause equipment shut down should the primary control fail. If this situation occurs, DO NOT attempt to bypass the high limit. Low water level will cause the high limit to trip.

TOOLS REQUIRED

The following is a listing of tools required to perform the service checks in this manual

1. Standard set of hand tools.

2. Volt Meter with a sensitivity of at least 20,000 ohms per volts.

3. Temperature tester (thermocouple or digital pyrometer).

4. Gas test kit.

SECTION I SERVICE CHECKS

WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR

MEASUREMENTS WHILE POWER IS APPLIED TO THE APPLIANCE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST.

VENTILATION CHECKS

Insure that adequate ventilation has been provided in accordance to all codes as stated on page 3 of this manual.

CAUTION: The vent of the appliance should be checked every 6 months for restrictions.

GAS SUPPLY CHECKS NOTE: If gas supply piping system is going to be tested at a test pressure of in excess of 1⁄2 psig (3.45 Kpa),

the cooker and its individual shut-off valve must be disconnected from the supply line. If the gas supply pipping system is going to be tested at a test pressure equal to or less than 1⁄2 psig (3.45Kpa), the individual manual shut-off valve must be closed during testing.

The cooker burners operate in conjunction with a combination gas valve pressure regulator. Verify that the valve is set for a rating of 4" Water Column for Natural Gas and 10" Water Column for Propane Gas. If this is proven, verify that the facility pressure is at least 5.5" Water Column for Natural Gas and 12" Water Column for Propane. Also verify that the gas connection pipe line is at least 1⁄2". Verify that the cooker is installed in accordance with all local and state authorities having jurisdiction.

GAS CONNECTION CHECK

1. Insure that facility main gas valve is open.

2. Insure that cooker combination gas valve is open.

3. Using a soap solution check for gas leakage at all gas line connection points.

STORE LINE GAS PRESSURE CHECK

1. Connect manometer to the manual gas shut off valve pressure tap.

2. Be sure gas supply line is open and that shut off valve is open

3. Manometer reading should be at least 5.5 in. water column natural and 12 in. water column for propane gas.

4. If the above is not proven instruct store owner to have pressure problem corrected before performing any other service work to cooker.

COMBINATION VALVE GAS PRESSURE CHECK

1. Check pressure rating of appliance as stated on the cooker door.

2. Turn on all appliance burners.

3. Connect a manometer to the pressure tap of the gas combination valve (gas tap is marked on valve).

4. Open the pressure tap of the manometer.

5. The manometer reading should match the pressure rate inches water column as stated on the appliance rating plate.

6. If pressure rating is off check the incoming store gas pressure line. If store line pressure is good, continue with the following steps.

ON-OFF ROCKER SWITCH (D.P.S.T.)

1. Disconnect power.

2. Follow steps under Removal of Cooker Control Panel.

3. Note and disconnect wiring from switch.

4. With an ohm meter and switch in the "off" position measure for continuity across the (2) switch pins that were connected to power. An ohm reading of infinity should be found.

5. With an ohm meter and switch in the "on" position, measure for continuity across the (2) switch pins that were connected to power. An ohm reading of 0 should be found.

6. If readings measured in either steps 4 or 5 do not agree with what is stated in these steps replace the switch.

SIGNAL LIGHT

1. With power connected follow steps for Removal of Cooker Control Panel except do not disconnect the control panel electric supply wire harness.

2. Turn power switch "on".

3. If light fails to illuminate, with a voltage meter measure for voltage of between 110 and 120 volts across the light connections. If voltage is not found, replace light.

COOKER THERMOSTAT CALIBRATION CHECK

1. Turn cooker on and allow temperature to stabilize by letting the cooker cycle on and off, after reaching the boil temperature, at least three times.

2. Place a pyrometer sensor in the area of the tank probe tubes.

3. After the stabilizing period the water temperature reading of the pyrometer should be 225 degrees F. plus or minus 10 degrees.

4. If readings are not in tolerance see Section II Services Adjustments in this manual.

HI LIMIT CHECK

1. Turn cooker on.

2. Set temperature at boil setting.

3. Place pyrometer in tank near the probe tubes.

4. Observe reading, the hi limit should trip at temperatures of between 235-265 degrees F. If tripping does not occur replace limit.

BURNER PILOT CHECK

1. Follow steps 1-4 under Removal of Burner.

2. Follow steps 1-3 under Removal of Burner Pilot and Orifice.

3. Examine the pilot body and orifice for clogging.

4. If clogged blow through one end of device. If clogging is still evident soak in warm water or use small probe device to clear the obstruction. If clogging still persists install new body or orifice as required.

5. Follow steps 1-2 above to install new parts or reinstall repaired parts.

TRANSFORMER CHECK

1. Follow steps 1-3 under Accessing of Controls Inside the Control Box.

2. Follow Steps 1-4 under Removal of Transformer.

3. With a volt meter and the appliance "on", check the voltage across the load and line terminals. Voltage should match that of the transformer markings. EXAMPLE: Transformer marked - PRI. 120V

SEC. 24VAC

Means that the load input reading should be 120V and the line output reading should be 24V.

4. If the readings do not match replace the transformer.

5. If readings do match but transformer problem is still suspected, check for resistance across the load terminal and the line terminal with an ohm meter. If there is no resistance at either end of the lines replace the transformer.

BASKET LIFT RELAY

1. Follow steps 1-6 under Removal of Basket Lift Back.

2. With power "on" using an ohm meter check for 0 ohms between connections 5 & 3 and also between 6 & 4.

3. With power "off" using an ohm meter check for a coil resistances of above 168 ohms. Also check for continuity of 0 ohms between connections 1 & 5 and 0 & 6.

4. If any of the above checks do not prove out replace the relay.

BASKET LIFT MICRO SWITCH

1. Follow steps 1-6 under Removal of Basket Lift Back.

2. Remove switch wiring. Engage the switch and with an ohm meter check for continuity across the common and normally open circuits. If continuity is not shown replace the switch.

BASKET LIFT MOTOR

1. Follow steps 1-6 under Removal of Basket Lift Back.

2. Follow steps 1-7 under Removal of Basket Lift Motor.

3. With volt meter and power on check for voltage to the motor.

4. Verify that the motor voltage agrees with the voltage as stated on the appliance rating plate.

5. Check the motor wire connections.

6. Disconnect power and disconnect the motor wires at the motor terminals.

7. With ohm meter measure the resistance across the terminals. The resistance should be about 28 ohms.

8. If resistance is not correct replace the motor unit.

BASKET LIFT TIMER

1. Follow steps 1-4 under Removal of Cooker Panel.

2. Check for good wire connection at the terminals.

3. Push power switch "on".

4. With a volt meter check for 24Vac across the input terminals of L1 and L2.

5. With a volt meter check for 24Vac across the load terminals after pushing the timer button and setting the timer. Reading should remain constant at 24vac until the timer runs out.

6. If the above readings are not achieved replace timer.

CHECKING THE SPARK IGNITION CIRCUIT

1 2 3 4 5 6 7 8 9

MV BUR 24V 24V W

MV PV PV GND GNDHOT TH SEN SPK

If erratic ignitor operation is experienced check for the following:

1. If you are experiencing system lock out reset system by turning power switch off, wait several minutes and turn switch on.

2. Check for good metal to metal contact between the pilot bracket and main burner.

3. Check that all lead connections from the ignition module to the ignitor system are solid.

4. Check that GRD (BUR) lead from the module to the pilot burner is solid and that there is not any damage to the wiring. If damage is detected either replace the ignitor assembly or the ignitor wire with no.14-18 gauge, moisture-resistant, thermoplastic insulated wire with a min. 105 degrees C (221 degrees F) rating.

5. Check the ceramic flame rod insulator of the ignitor for cracks or evidence of extreme heat. If one or both of these conditions are found replace the pilot ignitor assembly.

6. Check to insure that ignitor boot is not loose or damaged.

If the above visual checks are positive the following checks should be preformed using a jumper wire and voltage meter.

WARNING: WHEN PERFORMING THE FOLLOWING CHECK DO NOT TOUCH THE STRIPPED END

OF THE JUMPER TO THE SPARK TERMINAL. THE IGNITION CIRCUIT GENERATES OVER 10,000 VOLTS AND ELECTRIC SHOCK CAN RESULT.

NOTE: You will need a short jumper wire made from ignition cable or other heavily insulated wire.

1. Close the manual gas valve

2. Disconnect the ignition cable at the SPARK terminal on the module.

3. Push power switch ON and immediately touch one end of the jumper firmly to the GND terminal on the module. Do not touch the jumper to the SPARK terminal, but, move the free end of the jumper slowly towards the SPARK terminal until a spark is established. Pull the jumper slowly away from the SPARK terminal and note the length of the gap when the sparking stops. See table below for results and action to be taken.

ARC LENGTH ACTION

No arc or arc less than

⁄8". Verify power at module input terminal.

Replace module power is verified.

Arc

⁄8" or longer Voltage output is ok.

If you are getting spark but the spark continues after the pilot is lit check the following.

4. Check for ground wire and ignition cable continuity.

5. Check that flame rod is clean.

6. Check for crack in ceramic insulator.

7. Check that pilot flame covers rod and is steady and blue. Adjust pilot or pilot flame if necessary.

8. If the above are all in good condition replace module.

PILOT CHECK (Pilot will not light)

1. Check that all manual gas valves are open, that supply tubing and pressure are good and pilot orifice is not blocked.

2. Check electrical connections between module and pilot operator on gas combo valve.

3. With volt meter check for 24Vac across PV-MV/PV terminals on module. If voltage is good replace the combo valve. If voltage is bad replace the module.

BURNER CHECK (Main burner will not light)

1. Check for 24Vac across the MV-MV/PV terminals. If voltage is bad replace the module.

2. Check electric connection between the module and gas combo valve. If good replace the combo valve.

3. Follow steps 1-4 under Removal of Burner and check for clogged burner ports. If clogged use a small probing device to open the port.

SECTION II PASTA COOKER SERVICE ADJUSTMENTS

ADJUSTMENT OF GAS REGULATOR

1. Follow steps 1-6 under Combination Gas Valve Regulator Check in Section I of this manual.

2. Remove the regulator adjustment cap from the combination valve. (Fig. 1)

Fig. 1

3. Turn the gas adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure.

4. Adjust pressure so that manometer reading agrees with the rating plate.

THERMOSTAT CALIBRATION

1. Follow steps 1-4 under Thermostat Calibration Check in Section I of this manual.

2. Turn temperature dial to boil setting.

3. Allow cooker to boil and temperature to stabilize for several minutes.

4. Remove temperature dial knob and insert flat head screw driver into the thermostat shaft rotating the thermostat adjustment screw to match pyrometer reading to 225 degrees F. at the dial boil setting. Turn clockwise to increase and counterclockwise to decrease setting. One quarter turn will change the temperature by 18 degrees. (Fig. 2)

Fig. 2

5. Check the temperature cycling again to insure proper calibration.

BASKET LIFT ARM ADJUSTMENT

This procedure is only required if the basket lift arm is not properly raising or lowering the cooker basket into the water at the correct level.

1. Turn cooker off and allow it to cool.

2. Remove the cooker baskets.

3. Pull lift arm from the cooker.

4. Turn by hand the adjustment bolt to the required position. (Fig. 3)

LIFT ARM

ADJUSTMENT BOLT

Fig. 3

SECTION Ill REMOVAL AND REPLACEMENT OF CONTROLS

WARNING: UNPLUG COOKER BEFORE SERVICING. WARNING: SHUT OFF GAS AND WATER LINES BEFORE SERVICING.

CONTROL PANEL COOKER

1. With a 1⁄4" socket, remove (2) screws from the upper right and left hand corners of the control panel. (Fig. 4)

Fig. 4

2. With a 1⁄4" socket, remove (2) #8 hex head screws located on the under flange of the control panel (Fig. 5).

Fig. 5

3. Remove the cooker door panel. (Fig. 6)

4. Fold control panel down. (Fig. 7)

Fig. 6

Figs. 7

5. Disconnect the main and basket lift (if applicable) wire harness and carefully remove the panel from the fryer.

(Figs. 8)

Fig. 8

REMOVAL OF RINSE STATION CONTROL PANEL

1. With a 1⁄4" socket, remove (2) screws from the upper left and right hand corners of the panel. (Fig. 9)

Fig. 9

2. Open the door and with a 1⁄4" socket, remove (2) screws from the right and left corners of the under flange of the panel. (Fig. 10)

Fig. 10

3. Lift door panel off of the rinse station. (Fig. 11)

Fig. 11

4. With a 1⁄8" size allen wrench, loosen the hot and cold water control knob set screws. (Fig. 12)

Fig. 12

5. Pull knobs from the appliance. (Fig 13)

Fig. 13

6. Note that this step is only required if the water valves need to be replaced. If fittings are good go on to step 7. With a flat blade screwdriver and a 5⁄16" deep socket or wrench, remove (4) screws securing the water fittings to the control panel. (Fig. 14)

Fig. 14

7. Disconnect the water hoses and remove panel from the rinse station. (Fig. 15)

Fig. 15

8. Reinstall rinse station panel by reversing steps 1-7.

REMOVAL OF INDICATOR LIGHT

1. Follow steps 1-5 under Control Panel Removal.

2. From the rear of the control panel unscrew the wire cap of light to be replaced.

3. Squeeze the tabs on both sides of the indicator light being replaced and pull the light out through the front of the panel. (Fig. 16)

Fig. 16

4. Reinstall new light by reversing steps 1-3.

REMOVAL OF ROCKER SWITCHES

1. Follow steps 1-5 under Cooker Control Panel Removal.

2. From rear of control panel note and remove wire leads from the rocker switch terminals.

3. Press tabs on both sides of the switch and push the switch through the front of the control panel. (Fig. 17) Retain the switch backup plate for reassembly.

Fig. 17

4. Reinstall new switch by reversing steps 1-3.

REMOVAL OF BASKET LIFT TIMER

1. Remove the timer knob using a 1⁄32" allen wrench. (Fig. 18)

2. Remove the timer mounting hardware. (Fig. 19)

Fig.18

Fig. 19

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