SERVICE MANUAL
SG4 & SG6 SERIES
FULL SIZE GAS
CONVECTION OVENS
MODELS |
|
SG4D |
ML-114875 |
SG4C |
ML-114876 |
SG6D |
ML-114877 |
SG6C |
ML-114878 |
Model SG4D
- 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 |
|
P.O. BOX 696, LOUISVILLE, KY 40201-0696 |
DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC |
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TEL. (502) 778-2791 |
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|
WWW.VULCANHART.COM |
– 1 – |
FORM 35626 Rev. A (02-08) |
© VULCAN-HART, 2008 |
– 2 – |
TABLE OF CONTENTS |
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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 – |
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TABLE OF CONTENTS (Cont.) |
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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
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.
Gas Data
Model |
Input BTU/hr |
Manifold Pressure |
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SG4D, |
Natural |
LP Gas |
Natural |
LP Gas |
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SG4C, |
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SG6D, |
60,000 |
60,000 |
3.5" W.C. |
10" W.C. |
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SG6C |
(0.9 kPa) |
(2.2 kPa) |
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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.
SPECIFICATIONS
Electrical Data
Model |
Volts |
Hertz |
Phase |
Amps |
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SG4D |
120 |
60 |
1 |
7.5 |
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SG4C |
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208 |
60 |
1 |
3.6 |
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SG6D |
|||||
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|
|
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SG6C |
240 |
60 |
1 |
3.75 |
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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
– 5 –
REMOVAL AND REPLACEMENT OF PARTS
COMPONENT LOCATION
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TOP VIEW |
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BLOWER MOTOR |
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OVEN LIGHTS |
COOLING |
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TEMPERATURE PROBE |
FAN |
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GAS BURNERS |
COMPONENT |
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PANEL |
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IGNITER & |
GAS VALVE |
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FLAME SENSE |
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DOOR |
CONTROL |
HIGH LIMIT |
SWITCH |
PANEL |
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PL-56044 |
– 6 –
COVERS AND PANELS
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
MASTER SWITCH
OVEN
COOL
OFF
ON
HEAT
IGNITION
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
PL-56041
2. Reverse the procedure to install.
Control Panel
1.Remove three screws on the right side which secure the control panel. Pull the panel away from the oven.
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CONTROL |
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PANEL |
MASTER SWITC |
H |
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OVEN |
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COOL |
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OFF |
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THERMOSTAT |
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REMOVE |
POWER LEVEL |
SCREWS |
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FAN SPEED |
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LIGHTS |
HI |
ON |
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LOW |
OFF |
SG4D SHOWN
PL-56042-1
2.Disconnect the temperature probe leads from the solid state temperature controller.
3.Unplug the wire harness connector to the control panel components.
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-56043 |
4. Reverse the procedure to install.
– 7 –
CONTROL PANEL COMPONENTS
|
MASTER |
SWITCH |
O |
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VEN |
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COOL |
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ON |
|
OFF |
THERMOSTAT
0 55
50
45
40
35
30
25
POWER |
LEVEL |
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TIMER |
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0 |
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55 |
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50 |
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45 |
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40 |
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35 |
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30 |
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25 |
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FAN |
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SPEED |
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HI |
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LIGHTS |
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ON |
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LOW |
OFF |
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MASTER
SWITCH
ON/HEAT
INDICATOR
LIGHTS
NO IGNITION
LIGHT
TEMPERATURE CONTROLLER (THERMOSTAT)
POWER CONTROL
TIMER
FAN SPEED
SWITCH
LIGHT
SWITCH
POWER
ON |
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ON |
OFF |
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OV |
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C EN |
OFF |
OOL |
LIGHTS
COMPUTER CONTROLLER
NO IGNITION LIGHT
POWER
SWITCH
LIGHT
SWITCH
SG4D/SG6D |
SG4C/SG6C |
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PL-56045-1 |
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PL-56046 |
Procedure
Disconnect the electrical power to the machine and follow lockout / tagout procedures.
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.
– 8 –
COMPONENT PANEL COMPONENTS
PORCELAIN BLOCK ASSEMBLY
PORCELAIN
BLOCK
ASSEMBLY
TRANSFORMER
HEATING
RELAY
IGNITION
MODULE
BOARD
IGNITION
MODULE
HEATING
RELAY
PORCELAIN
BLOCK
ASSEMBLY
PORCELAIN
BLOCK
ASSEMBLY
TRANSFORMER
MOTOR
CONTROL
RELAYS
IGNITION
MODULE
BOARD
IGNITION
MODULE
SG4D/SG6D |
PL-56047 |
SG4C/SG6C |
|
PL-56048
Procedure
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 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.
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.
7. Remove the probe from the bracket(s).
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
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.
3.Remove the bolts securing the gas manifold and place manifold aside.
4. Grasp the burner and lift out.
5.Reverse the procedure to install and check for proper operation.
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.
– 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.
4.Reverse the procedure to install manifold and check for proper operation.
GAS SOLENOID VALVE
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.
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
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.
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.
SPARK IGNITER AND FLAME SENSE
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.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.
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.
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.
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 –