Vulcan-Hart SG4D User Manual
Model SG4D
SERVICE MANUAL
SG4 & SG6 SERIES
FULL SIZE GAS
CONVECTION OVENS
MODELS
SG4D ML-114875
SG4C ML-114876
SG6D ML-114877
SG6C ML-114878
- 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-Hart, 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
– 1 –
P.O. BOX 696, LOUISVILLE, KY 40201-0696
TEL. (502) 778-2791
FORM 35626 Rev. A (02-08)
© VULCAN-HART, 2008
– 2 –
TABLE OF CONTENTS
GENERAL .............................................................................................................................................................. 5
Introduction ............................................................................................................................................... 5
Installation ................................................................................................................................................ 5
Operation ................................................................................................................................................... 5
Cleaning .................................................................................................................................................... 5
Lubrication................................................................................................................................................. 5
Specifications ........................................................................................................................................... 5
Electrical Data .................................................................................................................................... 5
Gas Data............................................................................................................................................. 5
Tools ......................................................................................................................................................... 5
Standard ............................................................................................................................................. 5
Special ................................................................................................................................................ 5
REMOVAL AND REPLACEMENT OF PARTS ..................................................................................................... 6
Component Location ................................................................................................................................. 6
Covers and Panels ................................................................................................................................... 7
Top Front Cover.................................................................................................................................. 7
Bottom Front Cover ............................................................................................................................ 7
Control Panel ...................................................................................................................................... 7
Right Side Panel ................................................................................................................................. 7
Control Panel Components ....................................................................................................................... 8
Procedure ........................................................................................................................................... 8
Component Panel Components ................................................................................................................ 9
Procedure ........................................................................................................................................... 9
Temperature Probe .................................................................................................................................. 10
Gas Burners .............................................................................................................................................11
Gas Orifice ...............................................................................................................................................12
Gas Solenoid Valve .................................................................................................................................12
Ignition Control Module ............................................................................................................................ 13
Spark Igniter and Flame Sense ...............................................................................................................13
Blower and Motor ..................................................................................................................................... 14
Oven Doors and Bearings .......................................................................................................................15
Roller Latch Assembly.............................................................................................................................16
Door Catch Assembly ..............................................................................................................................16
Door Window ............................................................................................................................................ 16
Door Switch ..............................................................................................................................................17
High Limit Thermostat .............................................................................................................................18
Interior Lights ...........................................................................................................................................18
Lamp Assembly.................................................................................................................................18
Cooling Fan ..............................................................................................................................................19
Fan Installation Tips ..........................................................................................................................19
SERVICE PROCEDURES AND ADJUSTMENTS ............................................................................................... 20
Solid State Temperature Controller Test (SG4D/SG6D) ........................................................................20
Test Steps .........................................................................................................................................20
Solid State Temperature Controller Calibration (SG4D/SG6D)..............................................................21
Calibration Steps ...............................................................................................................................21
Calibration Tips ................................................................................................................................. 21
Temperature Probe Test (SG4D/SG6D) .................................................................................................22
Test Steps .........................................................................................................................................22
– 3 –
TABLE OF CONTENTS (Cont.)
Computer Controller (SG4C/SG6C) ......................................................................................................... 23
Operation ...........................................................................................................................................23
Setup Mode ....................................................................................................................................... 23
Probe Test .........................................................................................................................................23
Solid State Relay Test ......................................................................................................................24
Computer Controller Calibration (SG4C/SG6C) .......................................................................................24
Calibration Steps ............................................................................................................................... 24
Gas Pressure Adjustment ....................................................................................................................... 25
Verification of Spark at Igniter ................................................................................................................ 26
Door Switch Adjustment .......................................................................................................................... 26
Flame Current Measurements .................................................................................................................27
Blower Adjustment ...................................................................................................................................27
Door Adjustment ...................................................................................................................................... 28
Door Strike Adjustment............................................................................................................................ 28
Door Catch Roller Adjustment ................................................................................................................. 29
ELECTRICAL OPERATION .................................................................................................................................30
Component Description ...........................................................................................................................30
Plug, Socket and Components (SG4D/SG6D) ........................................................................................31
Plug, Socket and Components (SG4C/SG6C) ........................................................................................32
Sequence of Operations ..........................................................................................................................33
SG4D/SG6D with Solid State Temperature Controller ..................................................................... 33
Cook Cycle ........................................................................................................................................ 33
Timer Cycle .......................................................................................................................................34
Cool Down Cycle (Solid State Temperature Controller) ...................................................................34
SG4C/SG6C with Computer Controller ............................................................................................. 35
Normal Cook Cycle ..................................................................................................................... 35
Temperature and Time Cycle (Normal Cooking)............................................................................... 37
Function Switch (SG4C/SG6C) .........................................................................................................37
Roast and Hold Cycle........................................................................................................................ 37
Wiring Diagrams .......................................................................................................................................38
Schematics .............................................................................................................................................. 40
TROUBLESHOOTING ..........................................................................................................................................42
Error Codes ..............................................................................................................................................44
– 4 –
GENERAL
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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 a two-speed 1/2 HP electric
motor, porcelain interior and two 30,000 BTU/hr burners as standard equipment. A power level control permits
variable burner input from 15,0000 BTU/hr to 60,000 BTU/hr.
Models SG4D and SG6D are equipped with solid state-controls and a 60-minute timer (a 5-hour timer is optional).
Models SG4C and SG6C have a computer control with built-in Roast & Hold.
Models SG6D and SG6C have a 4" deeper cavity than models SG4D and SG4C.
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.
OPERATION
Detailed operation instructions are included with each
oven.
CLEANING
Detailed cleaning procedures are included in the
Installation & Operation Manual for the appropriate
model.
LUBRICATION
Motor bearings are sealed and prelubricated.
Gas Data
TOOLS
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).
• Gear puller to remove blower.
Special
• Temperature tester (thermocouple type).
• Manometer
SPECIFICATIONS
Electrical Data
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D4GS
C4GS
D6GS
C6GS
0210615.7
8020616.3
04206157.3
– 5 –
REMOVAL AND REPLACEMENT OF PARTS
COMPONENT LOCATION
TOP VIEW
BLOWER MOTOR
OVEN LIGHTS
TEMPERATURE PROBE
GAS BURNERS
IGNITER &
FLAME SENSE
HIGH LIMIT
DOOR
SWITCH
COOLING
FAN
COMPONENT
PANEL
GAS VALVE
CONTROL
PANEL
PL-56044
– 6 –
COVERS AND PANELS
RIGHT SIDE
REMOVE
SCREWS
REMOVE
SCREWS
CONTROL
PA NE L
ON
HI
OFF
LOW
LIGHTS
FAN SPEED
SG4D SHOWN
TH
ERMO
ST
AT
POWER
LEVE
L
OFF
OV
E
N
COOL
MA
STER
SWITC H
PL-56042-1
BOTTOM FRONT COVER
REMOVE SCREWS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Top Front Cover
1. The top front cover is secured with four
screws, two on each side of cover. Remove
these screws, then remove the cover from
the oven.
REMOVE SCREWS
TOP FRONT COVER
OVEN
COOL
AST
M
HEAT
IGNITION
Control Panel
1. Remove three screws on the right side which
secure the control panel. Pull the panel away
from the oven.
CH
IT
SW
ER
F
F
O
ON
2. Disconnect the temperature probe leads from
the solid state temperature controller.
3. Unplug the wire harness connector to the
control panel components.
PL-56040
2. Reverse the procedure to install.
Bottom Front Cover
1. The bottom front cover is secured with six
screws, two on each side of cover and two on
the top. Remove these screws then remove
the cover from the oven.
REMOVE SCREWS
BOTTOM FRONT COVER
2. Reverse the procedure to install.
4. Reverse the procedure to install.
Right Side Panel
1. Remove the screws that secure the right side
of the control panel.
2. Remove the remaining screws securing the
right side panel.
3. Pull the right-side panel out at the bottom
then down to remove.
RIGHT SIDE
REMOVE
SCREWS
PL-56041
PL-56043
4. Reverse the procedure to install.
– 7 –
CONTROL PANEL COMPONENTS
O
COOL
FAN
VE
N
SPEED
MASTER SWITCH
OFF
THERMOSTAT
0
25
POWER LEVEL
TIMER
0
25
HI
LOW
MASTER
SWITCH
ON
ON/HEAT
INDICATOR
LIGHTS
NO IGNITION
LIGHT
COMPUTER
CONTROLLER
55
50
45
40
35
30
TEMPERATURE
CONTROLLER
(THERMOSTAT)
POWER CONTROL
NO IGNITION
55
50
45
40
35
30
LIGHTS
ON
OFF
TIMER
FAN SPEED
SWITCH
LIGHT
SWITCH
P
O
WER
ON
LIG
HT
S
ON
O
FF
O
V
EN
C
OOL
O
FF
LIGHT
POWER
SWITCH
LIGHT
SWITCH
SG4D/SG6D
Procedure
1. Remove the control panel as outlined under Covers and Panels.
2. Remove the component being replaced.
3. Reverse the procedure to install the new component, then check oven for proper operation.
procedures.
SG4C/SG6C
PL-56045-1
Disconnect the electrical power to the machine and follow lockout / tagout
– 8 –
PL-56046
COMPONENT PANEL COMPONENTS
PORCELAIN
BLOCK
ASSEMBLY
TRANSFORMER
HEATING
RELAY
IGNITION
MODULE
BOARD
PORCELAIN
BLOCK
ASSEMBLY
TRANSFORMER
MOTOR
CONTROL
RELAYS
IGNITION
MODULE
BOARD
PORCELAIN
BLOCK
ASSEMBLY
Procedure
SG4D/SG6D
procedures.
IGNITION
MODULE
PL-56047
HEATING
RELAY
PORCELAIN
BLOCK
ASSEMBLY
SG4C/SG6C
IGNITION
MODULE
PL-56048
Disconnect the electrical power to the machine and follow lockout / tagout
1. Remove the right side panel as outlined under Covers and Panels.
2. Disconnect the wire leads to the component being replaced.
3. Remove the component.
4. Reverse the procedure to install the new component and check oven for proper operation.
– 9 –
TEMPERATURE PROBE
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove the right-side panel as outlined under
Covers and Panels.
2. Disconnect probe leads from the solid state
temperature controller on the SG4D/SG6D or
the computer controller on the SG4C/SG6C.
3. Remove the racks and right rack support.
7. Remove the probe from the bracket(s).
4. Remove the upper and lower door seals.
5. Loosen the three screws securing the right
side air scoop to the rear heat exchanger.
Rotate the air scoop off of the heat exchanger
tube into the oven cavity.
6. Remove the screws that secure the perforated
side panel and lift out.
SG4C/SG6C Temperature Probe Shown
8. Push the probe through the oven wall and into
the control panel area.
9. Reverse the procedure to install the new
probe.
10. Calibration:
A. SG4D/SG6D: Adjust the temperature
controller as outlined under Solid State
Control Calibration.
B. SG4C/SG6C: Adjust the computer
controller as outlined under Computer
Controller and/or Computer Controller
Calibration in Service Procedures and
Adjustments.
– 10 –
GAS BURNERS
5. Reverse the procedure to install and check
for proper operation.
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing
the oven.
1. Remove the lower front cover as outlined
under Covers and Panels.
2. There are two burners located on the bottom
left and right side of the oven. Disconnect the
ignition cable and the flame sense lead from
each burner.
A. Ensure the spacers are in place on the
ignition wires. The spacers are intended
to keep the ignition wires from laying flat
on the oven chassis.
B. Ensure that the bracket on the back of
the burner is inserted into the slot at the
rear of the burner chamber.
Note: Check the flame current by following the Flame
Current Measurement procedures under the
Procedures and Adjustments Section of this manual.
3. Remove the bolts securing the gas manifold
and place manifold aside.
4. Grasp the burner and lift out.
– 11 –
GAS ORIFICE
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing
the oven.
1. Remove the lower front cover as outlined
under Covers and Panels.
2. Remove the bolts securing the gas manifold
and place manifold aside.
3. There are two gas orifices on the manifold.
Remove each orifice and replace with the
correct orifice for the given altitude as needed.
3. Disconnect compression fittings from the
valve.
4. Loosen the bolts securing the valve and
bracket assembly, then remove the screws
securing the valve to the bracket.
4. Reverse the procedure to install manifold and
check for proper operation.
GAS SOLENOID VALVE
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing
the oven.
1. Remove the control panel and the right side
panel as outlined under Covers and Panels.
2. Disconnect the lead wires.
5. Reverse the procedure to install the
replacement gas valve.
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.
– 12 –
IGNITION CONTROL MODULE
SPARK IGNITER AND FLAME SENSE
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove the right side cover as outlined
under Covers and Panels.
2. Loosen the screws securing the mounting
bracket to the component panel and remove
the bracket.
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing
the oven.
1. Remove the two gas burners as outlined
under Gas Burners.
2. Remove the screws securing the igniter and
flame sense to each burner. Remove the
assembly.
3. Disconnect the lead wires and igniter cables
from the ignition module board.
4. Remove the ignition module board from the
mounting bracket.
5. Reverse the procedure to install the
replacement ignition module board.
6. Check for proper operation.
3. The spark gap is 1/8" from the inside of the
spark rod to the inside to the ground rod. The
ground rod (the end of the spark) is 1/8" above
the burner. If the gap is not correct or poor
sparking is occurring, then adjust accordingly.
4. Reverse the procedure to install the assembly
and check for proper operation.
– 13 –
BLOWER AND MOTOR
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove racks.
2. Remove the screws securing the snorkel and
remove the snorkel.
5. Remove the screws that secure the motor
mounting plate to the rear wall.
6. Place a piece of cardboard on the bottom of
the oven cavity to protect its surface from
any damage during motor assembly removal.
3. Remove screws securing baffle panel and
remove the panel.
4. If replacing:
A. Blower Only - Loosen set screws on
blower hub and using a bearing puller,
remove blower from motor shaft.
1) Reverse procedure to install and
adjust blower position as outlined
under the Blower Adjustment in
Service Procedures and Adjustments
section.
B. Motor - Perform step 4A and continue
procedure.
7. Pull the motor assembly into the oven cavity
and place it on the cardboard.
8. Remove the junction box cover from the
motor, disconnect lead wires and remove the
conduit.
9. Remove motor mounting bolts and flat
washers, then lift the motor from the mounting
plate.
10. Position the replacement motor on the motor
mounting plate and install mounting bolts and
washers. Hand tighten mounting bolts only.
11. Reconnect to lead wires at the motor, and
replace conduit and junction box cover.
– 14 –
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