Vulcan-Hart ML-135225-00G72 User Manual

SERVICE MANUAL
900RE SERIES HEAVY DUTY GAS GRIDDLES
MODELS
924RE ML-135221-00G24 936RE ML-135222-00G36 948RE ML-135223-00G48 960RE ML-135224-00G60 972RE ML-135225-00G72
- NOTICE -
This manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. If you have attended a Vulcan Service School for this product, you may be qualified to perform all the procedures described in this manual.
This manual is not intended to be all encompassing. If you have not attended a Vulcan Service School for this product, you should read, in it's entirety, the repair procedure you wish to perform to determine if you have the necessary tools, instruments and skills required to perform the procedure. Procedures for which you do not have the necessary tools, instruments and skills should be performed by a trained Vulcan Service Technician.
Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.
For additional information on Vulcan-Hart or to locate an authorized parts
and service provider in your area, visit our website at www.vulcanhart.com
VULCAN-HART DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC
WWW.VULCANHART.COM
P.O. BOX 696, LOUISVILLE, KY 40201-0696
TEL. (502) 778-2791
F35628 (10-04)
TABLE OF CONTENTS
GENERAL ........................................................................................................................................3
Introduction ................................................................................................................................3
Installation ..................................................................................................................................3
Operation....................................................................................................................................3
Cleaning .....................................................................................................................................3
Lubrication..................................................................................................................................3
Specifications............................................................................................................................. 3
Tools ...........................................................................................................................................3
REMOVAL AND REPLACEMENT OF PARTS ..............................................................................4
Component Location ................................................................................................................. 4
Control Panel ............................................................................................................................. 5
Covers and Panels .................................................................................................................... 5
Bullnose Weld Assembly ..........................................................................................................5
Heat Shield.................................................................................................................................5
Back Panel .................................................................................................................................5
Power On/Off Switch .................................................................................................................6
Indicator Light ............................................................................................................................ 6
Thermostat .................................................................................................................................6
Flame Switch..............................................................................................................................7
Ignitor Module ............................................................................................................................ 7
Gas Burner .................................................................................................................................8
Pilot Solenoid .............................................................................................................................8
Pilot .............................................................................................................................................9
Dual Solenoid.............................................................................................................................9
SERVICE PROCEDURES AND ADJUSTMENTS...................................................................... 10
Thermostat Calibration ........................................................................................................... 10
Main Burner Adjustment ........................................................................................................ 10
Gas Pressure Measurement .................................................................................................. 11
Extended Shutdown ............................................................................................................... 11
ELECTRICAL OPERATION ......................................................................................................... 12
Component Description.......................................................................................................... 12
Sequence of Operation .......................................................................................................... 12
SCHEMATIC DIAGRAMS ............................................................................................................ 13
TROUBLESHOOTING GUIDE..................................................................................................... 18
F35628 (10-04)
© VULCAN-HART, 2004
— 2 —
GENERAL
INTRODUCTION
Procedures in this manual will apply to all models unless specified. Pictures and illustrations can be of any model unless the picture or illustration needs to be model specific. All models are equipped with 30,000 BTU/HR burners as standard equipment. One burner is used for every 12 inches of griddle surface.
All models use an automatic spark igniter to light the burners.
INSTALLATION
Generally, installations are made by the dealer or contracted by the dealer or owner. Detailed installation instructions are included in the Installation & Operation Manual which is sent with each unit.
SPECIFICATIONS
Electrical Data
Model Volts Hertz Phase Amps 924RE 120 60 1 0.5
936RE 120 60 1 0.5 948RE 120 60 1 0.5 960RE 120 60 1 0.5 972RE 120 60 1 0.5
Gas Data
Model Input BTU/HR Manifold Pressure
Natural LP Gas Natural LP Gas 924RE 60,000 60,000 5.0” W.C. 10” W.C. 936RE 90,000 90,000 (1.1 kPa) (2.2 kPa) 948RE 120,000 120,000 960RE 150,000 150,000
972RE 180,000 180,000
TOOLS
OPERATION
Detailed operation instruction are included in the Installation and Operation Manual which is sent with each unit.
CLEANING
Detailed cleaning procedures are included in the Installation and Operation Manual which is sent with each unit.
LUBRICATION
No lubrication is required on this equipment.
Standard
· Hand tools (standard set)
· VOM with AC current tester (any
quality VOM with a sensitivity of at least 20,000 ohms per volt can be used)
· Temperature tester (thermocouple type)
· Manometer
— 3 —
F35628 (10-04)
Back Panel
Griddle
REMOVAL AND REPLACEMENT OF PARTS
COMPONENT LOCATION
Bullnose
Deflector Plate
Heat Shield
Control Plate
Control Panel
Grease Drawer
Flame Switch
Dual Solenoid
Ignitor Module
Panel Connector
Ignitor Module
Flame
Switch Dual Solenoid
Pilot Solenoid
F35628 (10-04)
Figure A
— 4 —
CONTROL PANEL
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
1. Remove the two screws securing the control panel. One screw is located at each end of the control panel.
2. Pull the control panel forward and disconnect the electrical connector near the right end.
Panel Connector
Griddle
Bullnose
Figure C
3. Reverse the procedure to install.
Heat Shield
1. Remove control panel.
2. The heat shield clamps on the front of the griddle and can be removed by grasping the top of the shield and pulling forward.
Remove Screw
Control Panel
Figure B
3. Reverse the procedure to install.
COVERS AND PANELS
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
Bullnose Weld Assembly
1. Remove control panel.
2. The bullnose weld assembly is secured with two screws, one on each side of the bottom of the assembly. Remove these screws, then remove the bullnose weld assembly from the griddle.
Back Panel
Griddle
Deflector Plate
Heat Shield
Figure D
3. Reverse the procedure to install.
Back Panel
1. Remove all screws from rear of griddle securing the back panel.
2. Remove the back panel. (See Figure D)
3. Reverse procedures to install.
— 5 —
F35628 (10-04)
POWER ON/OFF SWITCH
INDICATOR LIGHT
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
1. Remove the control panel.
2. Label and disconnect the wires to the power ON/OFF switch.
3. Squeeze the switch retainer and slide the switch out through the front of the control panel.
ON/OFF Switch
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
1. Remove the control panel.
2. Label and disconnect the wires to the Red indicator light.
3. Squeeze the light retainers and slide the indicator light out through the front of the control panel.
4. Reverse procedures to install and check for proper operation.
THERMOSTAT
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
Figure E
4. Reverse procedures to install and check for proper operation.
1. Remove the control panel.
2. Remove the knob.
3. Remove the two screws and two washers securing the thermostat and thermostat dial to the control panel, then remove the thermostat and thermostat dial.
4. When installing a new thermostat reverse the procedure and be sure to position the thermostat dial with OFF at the top.
5. Check calibration. Refer to the Service Procedures and Adjustments section of this manual.
F35628 (10-04)
— 6 —
FLAME SWITCH
IGNITOR MODULE
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
1. Remove the control panel.
2. Label and disconnect the wires to the flame switch.
3. Remove the two screws securing flame switch to control plate.
4. Remove sensor from the pilot assembly. Sensor can be accessed from the front of unit or from underneath the unit via the pilot assembly access cut out opening. The sensor is a snap in fit device.
5. When installing a new flame switch, reverse the procedure. Be sure to carefully route and attach the sensor to the pilot assembly and check for proper operation.
Remove Probe From Pilot Assembly
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
1. Remove the control panel.
2. Label and disconnect the black, green, and white wires from the ignitor module.
3. Disconnect the ignitor cable from the bottom of the ignitor module.
4. Remove the two screws securing ignitor module to module bracket.
5. Remove ignitor module from module bracket.
6. When installing a new ignitor module reverse the procedure and check for proper operation.
Disconnect Wires
Ignitor Module
Flame Switch Sensor
Remove Screws
Module Bracket
Figure F
Ignitor Electrode
Flame Switch
Disconnect Wires
— 7 —
Module Bracket
Remove Screw
Figure G
Disconnect Wire
F35628 (10-04)
GAS BURNER
PILOT SOLENOID
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
1. Remove the back panel.
2. Cut shipping tie from burner.
3. To remove the burner, reach through the back of the unit and lift the burner up over the guide screw then pull the burner out through the back of the unit.
4. Replace the burner by inserting the burner through the rear of the unit, engaging the burner venturi onto the burner valve orifice at the front of unit. From the front of the unit, remove the control panel to check that the venturi is properly fitted over the orifice.
5. Reassemble the control and back panels then check for proper operation.
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
WARNING: SHUT OFF THE GAS BEFORE
SERVICING THE GRIDDLE.
1. Remove the control panel.
2. Label and disconnect the two wires connected to the solenoid.
3. Disconnect the input compression fitting and the two output compression fittings.
4. Remove the two screws attaching solenoid to single solenoid bracket and remove solenoid.
Input Compression Fitting
Guide Screw
Burner
Figure H
Orifice
Output
Remove Screws
Compression Fittings
Figure I
5. Reverse procedure to install the replacement gas solenoid.
WARNING: ALL GAS JOINTS DISTURBED
DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.
6. Verify gas pressure as outlined under the GAS PRESSURE ADJUSTMENT in Service Procedures and Adjustments. Check for proper operation.
F35628 (10-04)
— 8 —
PILOT
DUAL SOLENOID
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
WARNING: SHUT OFF THE GAS BEFORE
SERVICING THE GRIDDLE.
1. Remove control panel and heat shield for visual access of the pilot.
2. Reaching underneath the front of the griddle remove the pilot tube fitting and disengage the pilot tube from the pilot.
3. Reaching up through the square pilot access cut out, remove the screw retaining the pilot bracket to the unit and slip the entire pilot assembly out from under the front section of the unit.
4. Remove the pilot from the bracket.
5. Reverse procedures to install new pilot.
WARNING: DISCONNECT THE ELECTRICAL
POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
WARNING: SHUT OFF THE GAS BEFORE
SERVICING THE GRIDDLE.
1. Remove the control panel.
2. Label and disconnect the two wires connected to each solenoid.
3. Disconnect the input compression fitting and the two output compression fittings.
4. Remove the screw securing solenoids to solenoid bracket and remove solenoid.
Disconnect Wires
WARNING: ALL GAS JOINTS DISTURBED
DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.
6. Verify gas pressure as outlined under the GAS PRESSURE ADJUSTMENT in the Service Procedures and Adjustments section of this manual. Check for proper operation.
Pilot Bracket
Pilot Assembly
Remove Screw
Figure J
Disconnect
Screw
Fittings
Figure K
5. Reverse procedure to install the replacement dual solenoid.
WARNING: ALL GAS JOINTS DISTURBED
DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.
6. Verify gas pressure as outlined under the GAS PRESSURE ADJUSTMENT in Service Procedures and Adjustments. Check for proper operation.
— 9 —
F35628 (10-04)
SERVICE PROCEDURES AND ADJUSTMENTS
WARNING: CERTAIN PROCEDURES IN
THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST.
THERMOSTAT CALIBRATION
1. Set the thermocouple in the center of the burner section to be calibrated.
2. Set the ON/OFF switch to the ON position. Adjust the thermostat knob of the burner to be calibrated to 350 degrees.
3. Allow the burners to cycle on and off at least twice. Observe the griddle heat light and thermocouple readings. The thermocouple reading should be 350 degrees plus or minus 15 degrees the instant the heating light comes on.
If the unit is not within these calibration specifications follow the steps below.
4. Gently, remove the thermostat knob from the unit without rotating the thermostat shaft.
5. Loosen (2) screws securing the temperature dial plate to the unit. Gently, replace the thermostat knob onto the unit without moving the thermostat shaft.
6. Hold the thermostat knob in place and rotate the dial plate so that the 350 degree position aligns with the knob temperature indicator mark.
7. While holding the dial plate in position, gently remove the knob without moving the shaft . Tighten down the (2) dial plate securing screws.
8. Replace the thermostat knob and verify that thermocouple reading, knob indicator and dial setting all agree.
9. Turn the knob and ON/OFF switch to the OFF position.
10. Remove the thermocouple.
Thermostat Dial
Loosen Screws
Knob
Figure L
MAIN BURNER ADJUSTMENT
For efficient burner operation, it is important that a proper balance of gas volume and primary air supply is maintained, to give complete combustion. Insufficient air supply results in a yellow streaming flame. Primary air supply is controlled by the air shutter on the front of the burner venturi. Loosen the screws on the venturi and adjust the air shutter to just eliminate yellow tips on burner flames. Lock the air shutter in place by tightening the screws. Repeat this procedure with all burners.
1. All units are equipped with fixed orifices for use with natural or propane gas and no adjustment is necessary.
F35628 (10-04)
— 10 —
2. Units for operation of natural or propane gas are also equipped with a factory preset pressure regulator with an outlet pressure of 5” W.C. (Water Column) for natural gas supply and 10” W.C. for propane gas supply, and should not require further adjustment.
3. The burners and pilot flames may be observed through round holes in the front panel.
GAS PRESSURE MEASUREMENT
1. Set the power ON/OFF switch to the OFF position.
2. Turn the gas supply off at manual shutoff valve.
3. Remove the screws securing the control panel and move the panel forward sufficiently to access the plug on the manifold pressure port.
4. Remove the plug from the manifold pressure port.
5. Install hose barb adapter and attach manometer tube.
WARNING: THE FOLLOWING STEPS
REQUIRE POWER TO BE APPLIED TO THE UNIT DURING TEST. USE EXTREME CAUTION AT ALL TIMES.
6. Turn the power switch to the ON position.
7. Turn only one burner on to the maximum temperature.
8. Check gas pressure.
9. Turn all burners on to the maximum temperature.
10. Check gas pressure.
11. Turn all other equipment on same supply line on.
12. Check gas presssure.
NOTE: Pressure drop should not be greater
than ±½” W.C. If gas pressure requires adjustment, the adjustment screw is located under a cap on the regulator.
PRESSURE READINGS (IN W.C.)
Gas Type
Natural Propane Manifold 5 10 Recommended 7-9 (Line) 11-12 (Line) Minimum 6 (Line) 11 (Line) Maximum 14 (Line) 14 (Line)
Manifold Pressure Port
Figure M
Plug
— 11 —
13. Turn off all burners.
14. Turn ON/OFF switch to OFF position.
15. Disconnect manometer and reinstall plug.
F35628 (10-04)
ELECTRICAL OPERATION
COMPONENT DESCRIPTION
Power Switch ON/OFF – Switch turns power
ON or OFF.
Ignition Control Module – Provides ignition spark. Turned on when ON/OFF switch is set to the ON position and turned off when flame switch closes.
Burner On Lights – Illuminates to indicate burner is turned on.
Thermostats – Turns burner on and sets operating temperature.
Flame Switch – When the flame switch is heated by the pilot the switch contacts close and turn on the single and/or dual burner solenoids.
Gas Valve (Single Solenoid) – Contains one valve. The valve controls a single burner. The solenoid is turned on when the ON/OFF switch is in the ON position and the corresponding thermostat is rotated out of the OFF position. When the solenoid is turned on (operated) gas flows to the burners.
Gas Valve (Dual Solenoid) – Contains two valves. Each valve controls a separate burner. Solenoids are turned on when the ON/OFF switch is in the ON position and the corresponding thermostat is rotated out of the OFF position.
Pilot Gas Valve (Single Solenoid) – Contains one valve. The valve controls the gas to the pilot. The solenoid is turned on when the ON/OFF switch is in the ON position and turned off when the flame switch closes.
SEQUENCE OF OPERATION
Operation of all size griddles is the same. The following discussion is for the 48” griddle. This griddle has four thermostats, two flame switches, two dual solenoids and one pilot solenoid.
The neutral wire from the power source is directly connected to the following terminals:
A terminal on each thermostat
The N terminal on each ignition module
One terminal on the pilot solenoid
When the power ON/OFF switch is set to the ON position, voltage is applied to the following terminals:
Terminal L1 on each ignition module
turning the module on
One side of each flame switch
The remaining terminal on the pilot
solenoid energizing the solenoid
The ignition module which is now connected across the power lines turns on and provides the voltage for the ignition spark. The pilot valve solenoid is energized allowing gas to flow to the pilot where it is ignited by the spark. The pilot flame heats up the flame switch. When the flame switch is sufficiently hot, the switch closes. The voltage through the flame switch is applied to one side of each burner solenoid and one side of the burner ON light.
When the pilot flame is sensed, the ignition module will shut off automatically.
F35628 (10-04)
When a thermostat is rotated out of the OFF position the neutral return wire is connected to the other side of the burner light causing the light to be illuminated. At the same time the neutral is connected to the other side of the burner solenoid causing the solenoid to operate and allowing gas to flow to the burner.
— 12 —
SCHEMATIC DIAGRAMS
Schematic Drawing for 24” Griddle
— 13 —
EMPLOYER DES FILS D’ALIMENTATION ADEQUATS 200°C OR EQUIVALENT
1. USE SUPPLY WIRES SUITABLE FOR 200°C OR EQUIVALENT
2. HARNESS PART NO. 723526-1
B NOTE:
F35628 (10-04)
SCHEMATIC DIAGRAMS
F35628 (10-04)
Schematic Drawing for 36” Griddle
— 14 —
EMPLOYER DES FILS D’ALIMENTATION ADEQUATS 200°C OR EQUIVALENT
1. USE SUPPLY WIRES SUITABLE FOR 200°C OR EQUIVALENT
2. HARNESS PART NO. 723527-1
B NOTE:
SCHEMATIC DIAGRAMS
Schematic Drawing for 48” Griddle
— 15 —
EMPLOYER DES FILS D’ALIMENTATION ADEQUATS 200°C OR EQUIVALENT
1. USE SUPPLY WIRES SUITABLE FOR 200°C OR EQUIVALENT
2. HARNESS PART NO. 723528-1
B NOTE:
F35628 (10-04)
SCHEMATIC DIAGRAMS
F35628 (10-04)
Schematic Drawing for 60” Griddle
— 16 —
EMPLOYER DES FILS D’ALIMENTATION ADEQUATS 200°C OR EQUIVALENT
1. USE SUPPLY WIRES SUITABLE FOR 200°C OR EQUIVALENT
2. HARNESS PART NO. 723529-1
B NOTE:
SCHEMATIC DIAGRAMS
Schematic Drawing for 72” Griddle
— 17 —
EMPLOYER DES FILS D’ALIMENTATION ADEQUATS 200°C OR EQUIVALENT
1. USE SUPPLY WIRES SUITABLE FOR 200°C OR EQUIVALENT
2. HARNESS PART NO. 723530-1
B NOTE:
F35628 (10-04)
TROUBLESHOOTING GUIDE
SYMPTOM
Indicator light fails to light when power ON/OFF switch is set to ON position
Indicator light fails to go out when power ON/OFF switch is set to the OFF position
Griddle does not heat when thermostat is turned on
CAUSE
Not plugged in
Faulty ON/OFF switch
Store circuit breaker tripped
Faulty lamp
Faulty power ON/OFF switch
Not plugged in
Faulty ON/OFF switch
Store circuit breaker tripped
Faulty thermostat
Problem with pilot valve
REMEDY
Plug griddle into correct voltage outlet
Replace ON/OFF switch
Reset circuit breaker
Replace lamp
Replace switch
Plug griddle into correct voltage outlet
Replace ON/OFF switch
Reset circuit breaker
Replace thermostat
Check operation of pilot valve
Igniter stays on too long after pilot flame is established
Igniter fails to light
Problem with igniter
Problem with flame switch
Loose wire connection
Flame switch has not had enough time to heat up
Flame switch bulb not hot enough
Problem with igniter
Unit not plugged in
Store circuit breaker tripped
Check operation of igniter
Check operation of flame switch
Check for bad connection and correct
Allow more time for flame switch to heat up
Check alignment of pilot and flame switch
Check for obstruction or wrong size orifice
Check for proper gas pressure
Replace igniter
Plug griddle into correct voltage outlet
Reset circuit breaker
F35628 (10-04)
Problem with power ON/OFF switch
Loose wire connection
— 18 —
Replace ON/OFF switch
Check and repair wire connection
TROUBLESHOOTING GUIDE
SYMPTOM
Pilot does not light after igniter has been on several minutes
Pilot fails to remain lit after igniter goes out (Pilot may cycle on and off normally several times after cold start-up before the pilot heats up.)
CAUSE
Problem with pilot valve
Gas supply not purged of air
No gas supply
Loose wire connection
Obstructed or wrong size pilot orifice
Problem with alignment of pilot and igniter
Loose wire connection
Air blowing pilot out
Obstructed or wrong size pilot orifice
Problem with alignment of pilot and flame switch
REMEDY
Check operation of pilot valve
Purge gas lines
Check that gas supply is on
Check and repair wire connection
Check for obstruction or wrong size orifice
Realign pilot and igniter
Check and repair wire connection
Correct air flow
Check for obstruction or wrong size orifice
Realign pilot and igniter
Burner does not come on (burner light does not come on)
Heat does not turn off, burner light is off, temperature is above thermostat setting
Heat does not turn off, burner light is on, temperature is above thermostat setting
Temperature varies
Problem with flame switch
Thermostat setting too low
Problem with thermostat sensor
Problem with temperature controller
Problem with thermostat gas valve
Loose wire connection
Problem with thermostat gas valve
Problem with temperature controller
Low gas pressure
Check operation of flame switch
Adjust thermostat to a high temperature setting
Replace sensor
Check or replace controller
Check thermostat gas valve
Check and repair wire connection
Check or replace thermostat gas valve
Check or replace temperature controller
Check and adjust proper gas pressure
Faulty thermostat sensor
— 19 —
Replace faulty thermostat and sensor
F35628 (10-04)
FORM 35628 (10-04)
PRINTED IN U.S.A.
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