Vulcan-Hart VL2ESS, VL2EPS, VL2GSS, VL2GAS, VL3EAS Service Manual

...

SERVICE MANUAL

VL BOILER BASE SERIES

CONVECTION STEAMERS

(GAS, ELECTRIC, DIRE CT AND REGENERATED)

VL2GPS ML-52391 VL2DPS ML-52749 VL2GMS ML-52388 VL2DMS ML-52750 VL2GAS ML-52390 VL2DAS ML-52751 VL2GSS ML-52389 VL2DSS ML-52752 VL3GPS ML-52395 VL3DPS ML-52753 VL3GMS ML-52392 VL3DMS ML-52754 VL3GAS ML-52394 VL3DAS ML-52755 VL3GSS ML-52393 VL3DSS ML-52756 VL2EPS ML-52741 VL2RPS ML-52757

VL2GPS SHOWN

This Manual is prepared for th e use of trained Vulcan Service Technicians and should not be used by those not properly qu alifi ed. If yo u have attend ed a Vulcan Service School for this product, you may be qualified to perform all the procedures described in this man ual.

This manual is not intended to be all encompassing. If you have not attended a Vulcan Service School for this produc t, y ou should read, in its entirety, th e repair procedure you wish to perform to determine if you have the necessary tools, instruments a nd s k ills required to perfo rm t he procedure. Procedures for which you do not have th e n ecessary tools, instruments and skills should be performed b y a t rained Vul can Service Technician.

VL2EMS ML-52742 VL2RMS ML-52758 VL2EAS ML-52743 VL2RAS ML-52759 VL2ESS ML-52744 VL2RSS ML-52760 VL3EPS ML-52745 VL3RPS ML-52761 VL3EMS ML-52746 VL3RMS ML-52762 VL3EAS ML-52747 VL3RAS ML-52763 VL3ESS ML-52748 VL3RSS ML-52764

- NOTICE -

Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.

A product of VULCAN-HART LOUISVILLE , KY 40201-0696 Form 24650 (M ay 1999)

VL SERIES STEAMERS

TABLE OF CONTENTS

GENERAL............................................................................. 4

Introduction ........................................................................ 4

Compartment Pan Capacity ........................................................ 4

Model Desi Water Conditi onin

Tools ............................................................................. 5

Specifications ...................................................................... 5

Water Supply ................................................................... 5

Steam Supply ................................................................... 5

Gas Steamers .................................................................. 6

Electric Steamers................................................................ 6

Steamer Operation .................................................................. 7

Gas Powered Steam Boiler ........................................................ 7

Electrically Powered Steam Boiler ................................................... 7

enerated Steam Powered Boiler .................................................. 7

Direct Steam Powered Cooker ...................................................... 8

Boiler B lowdown and Steamer Shut off ................................................ 8

Cookin

Component Func tion ................................................................ 11

Cabinet Base Boiler Controls ...................................................... 11

Cookin

nations .............................................................. 4

.................................................................. 4

Compartment Control s ..................................................... 8

Compartment Control s .................................................... 13

REMOVAL AND REPLACEMENT OF PARTS ................................................ 14

Component Locat ions ............................................................... 14

Water Level Controls - Low Level Cut off and Differ ential .................................... 17

Water Level Gau Cyclin

Boiler Assembly.................................................................... 18

Boiler Fill and Cold W ater Condenser Solenoid Valves ...................................... 19

Pilot and Thermocoupl e A ssembly (Gas Models) ........................................... 19

Gas Combinat ion Control Valve ........................................................ 19

Compartm ent Gasket and Door Screw Nut, Door and Bushin

Heater Contactor s .................................................................. 21

Heatin Re

SERVICE PROCEDURES AND ADJUSTMENTS .............................................. 22

Boiler............................................................................ 22

Water Level Control(s) T est ........................................................... 24

Cyclin

Fill and Cold Wat er S olenoid Valves .................................................... 26

Compartment Pressure Adjustment ..................................................... 26

Hi Boiler Not Fillin

Boiler B lowdown Drain Solenoid Valve .................................................. 27

Boiler Slow to Pressurize............................................................. 28

Inlet Water Strainer ................................................................. 29

Pilot and Thermocoupl e A ssembly (Gas Models) ........................................... 29

Gas Burners....................................................................... 31

Automatic I

Gas Manifold Pressure Adjustment ..................................................... 33

and High Limit Pressure Switches

(Gas and Electr ic Models) ........................................................ 17

h Limit Thermostat ............................................................... 18

Elements .................................................................. 21

enerated Steam Models (Steam Coil) ................................................ 21

Inspection..................................................................... 22

Clean-out (All Boiler Models) ...................................................... 22

Delimin

Descaler...................................................................... 23

and High Limit Pressure Switches

(Gas and Electr ic Models) ........................................................ 25

h Limit Thermostat ............................................................... 27

Air Shutter Adjustment ........................................................... 31

Inspection..................................................................... 31

e Assembly ......................................................... 17

s ............................... 20

Only (Models with Deliming Port Assembly).................................... 23

with Water ........................................................... 27

nition S y stems (Gas Models) ................................................ 31

Page 2 of 88

VL SERIES STEAMERS

Direct Steam Models ................................................................ 34

enerated Steam (Older Models) ..................................................... 34

Heater Contactor s .................................................................. 34

Heatin

Elements .................................................................. 34

Thermal Switch - Prevent and Aut omatic M odels ........................................... 36

Water Level Gau

e Assembly ......................................................... 36

Steam Gate Valve(s) ................................................................ 37

ELECTRICAL OPERATION .............................................................. 38

Water Level Controls ................................................................ 38

Solid State - Low Level Cut-off & Differential Contr ol .................................... 38

Electro M ec hanical - Low Level Cut-off & Differential Control .............................. 40

Sequence of O per ation .............................................................. 42

Gas Models ................................................................... 42

Electric Models ................................................................. 45

Schematics, Gas Steam er s, B oiler Controls

VL2G AND VL3G - P r event, A utomati c , Standard and Manual ............................. 49

Manual I Electronic I Manual I Electronic I

Wi ri n

Diagrams, Gas Steamers, Boiler Controls

nition, Standard Controls .............................................. 49

nition, Standard Controls ............................................ 50

nition, Csd-1 Code Controls ............................................ 51

nition, Csd-1 Code Controls .......................................... 52

VL2G AND VL3G - P r event, A utomati c , Standard and Manual ............................. 54

Manual I Electronic I Manual I Electronic I

nition, Standard Controls .............................................. 54

nition, Standard Controls ............................................ 56

nition, Csd-1 Code Controls ............................................ 58

nition, Csd-1 Code Controls .......................................... 60

Schematics, Elect r ic Steam er s, B oiler Controls

VL2E AND VL3E - Prevent, A utomati c , Standard and Manual ............................. 62

Auto Blowdown, Standard Cont r ols .............................................. 62

Auto Blowdown, Cal-code Controls .............................................. 63

Wi ri n

Diagrams, El ec tric Steamers, Boiler Controls

VL2E AND VL3E - Prevent, A utomati c , Standard and Manual ............................. 64

Auto Blowdown, Standard Cont r ols (Contactor - 1 Std.) .............................. 64

Auto Blowdown, Standard Cont r ols (Contactors - 2 Std.) .............................. 66

Manual Blowdown, Cal-c ode Controls (Contactor s - 1 Std. 1 Aux. ) ...................... 68

Auto Blowdown, Cal-code Controls ( Contactor s - 1 Std. 1 Aux. ) ........................ 70

Auto Blowdown, Cal-code Controls (Contactor s - 2 Std. 2 Aux. ) ........................ 72

Manual Blowdown, Cal-c ode Controls (Contactor s - 2 Std. 2 Aux. ) ...................... 74

Wi ri n

Diagrams, El ec tric Heater Circuits

VL2E AND VL3E - Prevent, A utomati c , Standard and Manual ............................. 76

Schematic and Wirin

Diagrams, Dir ec t Steamers, Cabinet Base

VL2D AND VL3D - Prevent, Automati c , Standard and Manual ............................. 77

Wi ri n

Diagrams, Regenerated Steamers, Boiler Controls

VL2R AND VL3R - Prevent, Automati c , Standard and Manual ............................. 78

Schematic and Wirin

Diagrams - Compar tment Contr ols .................................... 80

Prevent ...................................................................... 80

Automatic..................................................................... 81

Standard ..................................................................... 82

Manual ....................................................................... 83

TROUBLESHOOTING .................................................................. 84

Page 3 of 88

VL SERIES STEAMERS - GENERAL

GENERAL

INTRODUCTION

Steam Cooking

e capacity pr essure steam er s offer an efficient

Lar way to produce a wide v ar iety of foods in smal l portions or lar cook fresh foods, blanch foods for com plete cookin later or will steam defrost and cook froz en foods. Cookin maximum c olor, f lavor and nutriti onal value with the least expenditure of ener

Compartment P an Capacity

PANS PER

COMPARTMENT

* Remove center support for 18x20 i nc h pans

er batches. Steamers can be used to

with steam assures the food will retain its

y and labor.

SIZE

4 12" x 20" 6.0 6 12" x 20" 4.0 8 12" x 20" 2.5 6 *18" x 20" 1.0

DEPTH

(INCHES)

Boiler Code Descriptions

Vulcan-Hart incorporates redundant controls in compliance with Californi a Code ( Cal-Code) and CSD-1 as an option on steam equipment when required by state and/or local buildin requirem ents. Descriptions of the codes are li sted below.

Cal-Code Construction electrical safet y c ircuits that, if tripped, must manually be reset aft er the conditi on c ausi n subsides. These controls consist of one dual function water level cyclin control and one sin off control (A ux - LLCO) and a hi switch in conjunc tion with a m ec hanical pressure relief valve.

CSD-1 Constructi on electrical safet y c ircuits that, if tripped, must manually be reset aft er the conditi on c ausi n subsides. These controls consist of one dual function water level cyclin control and one sin off control (LLCO) and a hi in conjunction with a m ec hanical pressure relief valve. A dditional ly, both circuits have individual indicator li verifi c ation of the shutdown mode.

hts that will illuminate for a visual

- Redundant controls in the

and low level cut off

le function low water level cut-

- Redundant controls in the

and low level cut off

le function low water level cut-

h pressure relief switch

code

the trip

h pressure relief

the trip

Model Designations

L X X XX

Cooking Control Ty pes: PS - Prevent Steam AS - Automatic Steam SS - Standard Steam MS - Manual Steam

Heatin G - Gas E - Electric D - Direct R - Re

Number of Compartments Lar

Steamer Vulcan

System:

enerated

e Capacity Pr essure

Cal-Code and CSD-1 construc tion both requi r e operator int er vention in the event of a shutdown. CSD-1 is more informative by usin to show which safety system was shutdown.

indicator lights

WATER CONDITIONING

Furnishing the boiler with soft water to reduc e scale formation is important. Scale formation will reduce steam output, cause premature component f ailure, and shorten equipment life. Most water supplies contain scale pr oduc in and Ma minerals remain and dissolve i nto the water. As the concentration of these m inerals increases past a certain point, they prec ipitate from the water and coat the insi de of the boiler, heati n thermostat bulbs and water lev el probes. Because of the hi precipitated mi ner als bake onto them and bec ome very difficult t o rem ove.

nesium. As steam is generated, the

h temperat ur e of these surfaces, the

minerals such as Calcium

element s,

Page 4 of 88

VL SERIES STEAMERS - GENERAL

This causes several pr oblems:

1. Reduce the heat transfer effici enc y of the heatin

syste m.

2. Cause premature failure of Electric heaters.

3. Water level probes will

ive false readings.

4. Thermostat bulbs will sense temperature incorrectly.

These problems are common to any manufacturer's steamer re prevented by furnishin

ardless of design, but they can all be

the boiler with soft water. Vulcan recommends the water contain less than 60ppm of “ total dissolved solids” (TDS) and hav e a PH fact or between 7 to 8. These water properties can be achieved by usin

a properly maintained

water softener. Other chemical proper ties in water supplies can also

affect

ood steam generation and vary from within

each state and locality. The water level probes in t he boiler use ions in t he

water to detect the water level. Do not use

fully demineralized or de-ionized water since i t is "non conductive" and the water level can not be detected.

NOTE: The use of strainers, or filters will not remove mi ner als from the water.

Vulcan recommends that a local water treat ment specialist be consulted before t he installat ion of any steam

Steamers that operate over a lon

enerating equipment .

period of time without the benefit of a water softener, whic h have developed a heavy scale build up, shoul d be cleaned bef or e usi n

a water softener.

TOOLS

Standard

NOTE: A daptors vary between manufact ur er s. A n

example of one adaptor type is pictur ed below.

SPECIFICATIONS

Water Supply

Supply pressure should be 20-80 psi In line str ainer for suppl y line (Not Supplied) Supply connect ion cold Total dissolved solids (TDS)* less than 60 ppm Total alkalinity less than 20 ppm Silica less than 13 ppm Chloride less than 30 ppm PH factor 7 to 8

(*17.1 ppm = 1

Steam Supply

Dry steam must be provided to the steam er for suitable use. If the steam is heavy wit h c ondensate, a Ball F loat Trap must be used in the li ne and plumbed in before the pr essure reducin ensure rapid heat up of heavy c old loads, the steam supply line must be sized to maintain pr essure as outlined below.

rain of har dness)

valv e. To



Standard set of hand tools.



Volt-Ohm-Meter (VOM) with AC current tester. (Any quali ty VOM with a sensitivity of at least

20,000 ohms per volt can be used)



Gas leak checkin



Gas pressure manometer



Temperat ur e meter and thermocouple.

equipment .

Special



CLR Treatm ent Kit - Used to remov e Calcium/Lime/Rust from a boiler ( Contact Vulcan Author ized Service Centers ).



Adaptor to test thermocoupl e c losed circuit

es (DC) on gas models with m anual

volta

nition ( pur c hase l oc ally).

Page 5 of 88

DIRECT STEAM

STEAMERS (POTABLE)

Supply

Pressure Input

Flow Rate 50 lb. per hour per

Pressure

Reducing Valve

Output

*Potable stea m is no t required for regene rated models but could be used.

15 psi (min.) 15 psi (min.)

compartment

10 psi (furnished) set accordingly for good

REGENERATED

STEAMERS OLDER MODELS (*NON-POTABLE)

125 lb. per hour

steam generation (1012psi)

Gas Steamers

VL SERIES STEAMERS - GENERAL

INPUT

(BTU/HR)

MODEL NAT. PROP. NAT. PROP. RECOMMEND MIN RECOMMEND MIN

VL2GPS

VL2GMS

VL2GAS

VL2GSS

VL3GPS

VL3GMS

VL3GAS

VL3GSS

200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000 200,000 200,000 240,000 240,000

MANIFOLD

PRESSURE

(INCHES W.C.)

4.0 10.0 7.0 5.0 11.0 11.0 14.0 360 3.0

NATURAL PROPANE

LINE PRESSURE

(INCHES W.C.)

MAX

LOAD (WATTS)

AMPS (MAX)

120V 60HZ

Electric Steamers

MODEL

VL2EPS

VL2EMS

VL2ESS

VL2EAS

*std

TOTAL

24* 116 100 67 58 29 34 36 100 87 44 50 42 117 48 116 58 67 24* 116 100 67 58 29 34 36 100 87 44 50 42 117 48 116 58 67 24* 116 100 67 58 29 34 36 100 87 44 50 42 117 48 116 58 67 24* 116 100 67 58 29 34 36 100 87 44 50 42 117 48 116 58 67

AMPERAGE

1 PHASE 3 PHASE 3 PHASE - 4 WIRE

208V 240V 208V 240V 480V 220/380V & 240/415V

Page 6 of 88

VL SERIES STEAMERS - GENERAL

gauge g

gaug

gauge g

gaug

STEAMER OPERATION

Ensure that all utility connections to the steamer have been made and are turned on.

On model s that are CSD-1 equipped, amber colored

hts for hi pr essure and low water level will

li illuminate and stay on until the boiler is full and the manual reset switc h pr essed.

Gas Powered S t eam Boiler

5. Open the cabinet door and turn main power switch ON. The red li will be solenoid valve will close. The boiler should fill, in four to eleven minut es. Observe water l evel

that the l evel in the full. Both valves on be open to fill the equipped with a m anual “ball” type blowdown valve must be closed for the boiler to fill. The cyclin steam pressure in the boiler by cyclin heatin pressure.

in filling the boiler and the blowdown

lass to verify that water is in boiler and

pressure switch will m aintain the proper

system on and off to generate steam

On Models with Manual Ignition

knob on the has three positions (On- P ilot-O ff) for control of mai n bur ner s and pi lot. Turn knob on then depress and li lit taper. Maint ain knob in depressed position for about 30 seconds and release. Observe that pilot burner flame stays on. If the flame should before reli

Turn knob on valv e to ON. If the water level in the boiler has reached the mi nimum level, burners will i the boiler . After appr oxim ately 15 minutes, steam should be present for cookin product. Observe that the boiler pressure

psi for models with a pressure re valve or 4- 6 psi for models without the valve.

On Models with Automatic Ignition

The knob on the valve has two positions (On-Of f) f or control of mai n bur ner s and pi lot. For the automatic i knob must be set in the ON position or for the pilot and main burners will not flow.

as combination valve to PILOT

nite and begin to heat t he water in

e indicat es steam pressure of 9-11

ht will illuminate, water

lass is about half lass a ssembly must

e. Older models

the

- The

as combination control valve

ht pilot burner with a

o out, wait 5 minutes

hting.

as combination control

ulatin

as combination control

nition system to work, the

Also, the i ON/OFF/RESET swit ch must be in the ON position to oper ate. This switch i s l oc ated on the upper left side of the electrical control box for t he i A red li is in the ON position. DO NOT ATTEMPT TO MANUALLY LIGHT THE PILOT IN AN AUTOMATIC TYPE IGNITION SYSTEM.

After the main power switch i s tur ned ON and the i switch is in the O N posi tion, sparkin

in three seconds later to light the

be standin sent back throu indicat in sparkin boiler has reached t he minimum l evel, the burners will i water in the boiler. After approximately 15 minut es, steam should be present f or cookin pressure pressure of 9-11 psi for models with a pressure re models without the valve. If a pilot flame is not establi shed i mmedi ately, sparki n will continue f or 90 seconds. After that duration, the i lock out and needs to be reset to start the pilot and bur ner li

Electrically Powered St eam Boiler

Open the cabinet door and turn main power switch ON. The red li

the boiler and the blowdown solenoid valve

fillin will close. The boiler should fill, in approximately 11 minut es. Observe water l evel that water is in boiler and that the level in the

lass is about half full. Both valves on gauge glass assembly must be open to fill the models equipped with a manual “ball” type blowdown valve must be closed for the boiler to fill. If t he water level in the boi ler has reached the minimum level, the heater c ontactors will close, the heaters will ener the boiler . After appr oxim ately 15 minutes, steam should be present for c ook in the boiler pr essure of 9-11 psi for models with a pressure re valve or 4- 6 psi for models without the valve.

Regenerated St eam P owered Boiler

Open the cabinet door and turn main power switch ON. The pilot li

the boiler and the blowdown solenoid valve

fillin will close. Models equipped with a manual “ball type” blowdown valve need to be closed for the boiler to fill. The boiler should fill, in approximately 15 minut es.

nition c ontrol module

nition c ontrol module.

ht will illuminate when the switch

nition cont rol modules RESET

will

pilot. If the pilot lights, a signal is

h the ignition c able

the presence of pilot flame and

stops. If the water level in the

nite and begin to heat t he

product. Observe that the boiler

e indicat es a steam

ulating valve or 4- 6 psi for

nition c ontrol module will

hting cycle again.

ht will illuminate, water will begin

lass to verif y

e. Older

ize and begin to heat t he water in

product. Observe that

e indicat es steam pressure

ulatin

ht will illuminate, water will begin

Page 7 of 88

VL SERIES STEAMERS - GENERAL

gauge g

gaug

Observe water level is in boiler and that the level in the

lass to verify that water

lass is

about half full. Both valves on the

open to fill the

e. When the water reaches the

lass a ssembly must be

minimum level, the steam sol enoid valve will open, allowin exchan

steam to enter the steam coil in the heat

er tank and begin heating the water. After approximately 20 minutes, a suffic ient amount of pressurized steam should be present for cooki n product.

Direct Steam Powered Cooker

1. Open the cabinet door and turn main power

switch ON. A. The red li

ht on the switch will illuminate.

B. If steam pr essure is above the m inimum

settin

on the cooking compartment pressure switch then the switch will close, ready li

ht will come ON and power to the

other controls will be supplied.

C. Observ e that the steam pr essure

e in

the cabinet base, indicates 10-12 psi.

2. Steamer is ready to cook product .

Boiler Blowdown and Steamer Shut off

Turn the steam er off at least once daily and blow down the boiler to r emov e sedi ments, scalants and lime build-up in the boiler . Always blowdown the boiler when it is under maximum pr essure and no steam is bein

used.

3. Automatic blowdown. A. Newer Models

- Open the cabi net door and turn main power switch OFF. The switches’ red li

ht will go out, the

blowdown/drain solenoid valve will be de-

ized and the boi ler will begin to

ener drain. The c old water condenser solenoid will continue to operat e, as needed, to condense steam and to cool the water

oing into the drain.

B. Older Models

- Turn power switch OFF and depress blowdown timer button. Blowdown timer will operate for 4 minutes. At the end of blowdown, turn fill switch ON and allow boil er to fill.

4. Manual blowdown. A. A ll Models

- Turn power switch OFF. Open blowdown valve located on the bottom front of the cabi net base. After the boiler has completely drained, c lose blowdown valve and t ur n fill switch to ON and allow boiler to fill.

Cooking Compartment Controls

Close the compar tment door and t ur n the screw handle clock wise

until the gasket touches the compartment surfac e then ½ turn f ur ther to adequately seal t he c ompartm ent. If steam leaks occur after compart ment heat up and pressurization, turn handle clockwise

again to inc r ease the seal in

force unt il the l eak stops. Proceed to the cook in

compartment control

instructions that apply to the steamer in use.

1. Manual

A. S et the manual timer to the desired

cookin

tim e. If preheating is desired, allow five to ten mi nutes (recomm ended) of additional time at t he be cook cycle. The len

th of time will v ary

inning of the

with the type, si z e, temperat ur e and conditi on ( frozen or thawed) of the product and must be determined f r om experience. Pull t he steam control ar m handle forward and lock it by pullin This closes the steam exhaust and opens the steam inlet allowin Durin

steam to enter the compartment.

preheat, cool er air and condensate

the handle down.

ate v alve

ate v alve,

are exhausted from the compartm ent

h the steam tr ap ( c ondenser) until

throu the temper ature reaches 180°F, closin the internal bellows. Throughout the cookin

cycle, the compartment pressure should be 6 psi if equipped with a compartment pressure re

ulating valve. On model s without the compartment pressure re

ulating valv e, the compartment pressure cycles with the boiler pressure between 4 and 6 psi.

B. When the timer bell rin

s to signal the end of a cook cycle, turn it OFF. Lift the steam control arm handle to unlatch team c ontrol arm. An internal sprin

will automatically pull the ar m to the rear. This closes the steam inlet steam exhaust

ate v alve and opens the

ate v alve, allowing steam

and pressure to exit the compartment.

C. W ait approximately 30 seconds for the

steam to exhaust from the compartment and to depressurize. Tur n the screw handle on the compartment door countercloc k wise

er seals against the compartment

lon surface. After the remainin

until the gasket no

steam escapes, move the latch paddle to the left and open the door.

Page 8 of 88

VL SERIES STEAMERS - GENERAL

2. Standard A. S et the timer to the desired c ook in

The timer must be set past five minutes to

e the state of the tim er c ontrol micro

chan switch contacts. I f preheati n

is desired, allow five to ten mi nutes (recomm ended) of additional time at t he be cook cycle. The len

th of time will v ary

inning of the

with the type, si z e, temperat ur e and conditi on ( frozen or thawed) of the product and must be determined f r om experience.

B. P ull the steam control arm handle forward

and lock it by pullin

the handle down. This closes the steam exhaust and opens the steam inlet allowin

steam to enter the compartment.

ate v alve,

C. Press the compart ment power switch to

ize the timer and red light. The

ener balance of the cookin automatic. Durin

sequence is

preheat, cool er air and condensate are exhausted from the compartment throu

h the steam tr ap (condenser) until the temper ature reaches 180°F, closin Throu

hout the cooki ng cycle, the

the internal bellows.

compartment pressure should be 6 psi if equipped with a compartment pr essure

ulating valve. On models without the

re compartment pressure re

ulating valve, the compartment pressure cycles with the boiler pressure between 4 and 6 psi.

D. Approximatel y one minute before timer

reaches zero the steam c ontrol solenoid is

ized to unl atch the steam control

ener arm. An internal sprin

will automatically pull the ar m to the rear. This closes the steam inlet steam exhaust

ate v alve and opens the

ate v alve, allowing steam and pressure to exit the compartment. When the tim er r eac hes "0" the red li shuts off and a buz z er sounds indicatin the end of the cook cycle. Turn the compartment power swi tch OFF to silence the buzzer and remove power from the compartment controls.

E. Turn the screw handle on the

compartment door counter c lockwise

asket no longer seals against the

the compartment surfac e. After the remainin steam escapes, move the l atch paddle to the left and open the door.

time.

ate v alve

until

3. Automatic A. S et the timer to the desired c ook in

The timer must be set past five minutes to

e the state of the tim er c ontrol

chan micro switch contacts.

B. P ull the steam control arm handle forward

and lock it by pullin

the handle down. This closes the steam exhaust and opens the steam inlet allowin

steam to enter the compartment.

ate v alve,

C. Press the compart ment power switch to

supply power to the com par tment cont r ols. The automatic com par tment cont r ols, feature load compensated cookin utilizin

a thermal switch. With this feature, when the compartment temperat ur e r eac hes 180°F (the temperat ur e at which preheatin defrosti n

is compl ete) the red light will then come on and t he timer will start. For a small food load, the delay ti me before the timer starts mi For a lar

e food load, the delay time coul d

ht be a mi nute or less.

be four to five minutes. Durin cooler air and c ondensate ar e exhausted from the compartment thr ou

h the steam trap (condenser) until the temperature reaches 180°F, closin bellows. Throu

hout the cooki ng cycle, the

the internal

compartment pressure should be 6 psi if equipped with a compartment pr essure

ulating valve. On models without the

re compartment pressure re

ulating valve, the compartment pressure cycles with the boiler pressure between 4 to 6 psi.

D. Approximatel y one minute before timer

reaches zero the steam c ontrol solenoid is

ized to unl atch the steam control

ener arm. An internal sprin

will automatically pull the ar m to the rear. This closes the steam inlet steam exhaust

ate v alve and opens the

E. Turn the screw handle on the

compartment door counter c lockwise

asket no longer seals against the

the compartment surfac e. After the remainin steam escapes, move the l atch paddle to the left and open the door.

time.

ate v alve

time by

preheat,

until

Page 9 of 88

VL SERIES STEAMERS - GENERAL

4. Prevent A. S et the timer to the desired c ook in

The timer must be set past five minutes to

e the state of the tim er c ontrol

chan micro switch contacts.

B. P ull the steam control arm handle forward

and lock it by pullin This opens the steam inlet allowin

steam to enter the compartment.

the handle down.

ate v alve,

C. Press the compart ment power switch to

supply power to the com par tment cont r ols. The prevent compartment cont r ols feature load compensated c ook times by utilizin a thermal switch. With this feature, when the compartment temperature reaches 180°F (the t emperature at whic h preheatin red li

or defrosting is complete) the

ht will come on and the t imer wil l start. For a small food load, the delay time before the timer star ts mi or less. For a lar

e food load, the delay

ht be a mi nute

tim e c ould be four and five mi nutes. Durin

preheat, the steam exhaust solenoid valve (N.O.) is open to allow the full free venti n

of cool er air and condensate from the compar tment. When the temper ature reaches 180°F, t he exhaust solenoid valve is ener closes. The com par tment should t hen pressurize to 6 psi.

time.

ized and

D. Approximatel y one minute before timer

reaches zero the steam c ontrol solenoid is

ized to unl atch the steam control

ener arm. An internal sprin

will automatically pull the ar m to the rear. This closes the steam inlet steam exhaust

ate v alve and opens the

E. Turn the screw handle on the

compartment door counter c lockwise

asket no longer seals against the

the

until

compartment surfac e. After the remainin steam escapes, move the l atch paddle to the left and open the door.

Page 10 of 88

COMPONE NT FUNCTION

CABINET BASE BOILER CONTROLS

Water Level

Gauge Assembly ...............

Water Level Cont rol and

Level Sensing Probes ...........

VL SERIES STEAMERS - GENERAL

Permi ts a visual c onfirmation the water level is bein boiler durin

ht of t he glass. The manual valves at t he top and bottom of this

hei assembly must be full y open and only closed if the dama

These controls allow water to enter the boiler to fill and maintain the proper water level. T hey will also shut off the heat source to the boiler if the water level drops too l ow. T he water level control works by usin three different pr obe lengths to moni tor the water level. The probes consist of a hi

operation. The correct water l evel is a point one-half of the

ed.

h level (HL), low level (LL) and low water cut-off (LLCO ) .

maint ained in

lass tube is

Boiler Fill Solenoid Valve ........

Cold Water Condenser

Solenoid Valve .................

Cycling Pressure Switch .........

High Limit Pressure Switch ......

Blowdown/Drain

Solenoid Valve .................

Inlet Water Strainer .............

Admits water to the boiler when dem anded by the water level control to maintain the correct water level in the boiler.

Allows cold water flow into the boiler blowdown drain box to condense steam and cool the hot water before its dischar

Controls boiler pressure between prescribed limits by tur nin source on and off.

A switch of identical desi

h limit. T he pr essure settings are at higher and lower limits than t he

hi cyclin boiler pressure reaches its limit and autom atically resets after the pressure drops below the lower limit set point.

This valve is plumbed into the drai n line of the boiler. Newer steamer models will automatically blowdown when power is turned off by usi n normally open solenoid valve. Older models can have a solenoid valve that is activated by depressin have a manual “ball” type valve.

A strainer i s used in t he water inlet l ine to prevent for ei becomin to keep unwanted partic les out of the system. A "Y" str ainer should be inserted upstream of the fill solenoid valve. On models usin steam supply, a str ainer is also used in the pressure re

pressure switch in order to tur n off the heat source before the

lodged in the fill or cold water condenser solenoid valves and

n to the cycling pressure switch but used as a

a separate blowdown timer button or

e into the drain.

the heat

n matter from

a direct

ulating valve.

Power Switch..................

Water Inlet Valve ...............

High Limit Thermostat ..........

Descaler ......................

When turned ON, power is supplied to the control s and the steam

enerating process is started in the boiler. The power switch is located

on the front of the boiler control box. The water inlet valve is used to stop water flow to the steamer when the

steamer is bei n valve while older models will be a “ball” type valve. This valve should remain open dur in

A protective device that shuts off the heat source if the boiler temperat ur e exceeds a specified limit. A ll standard m odels are equipped with a surface hi

s submerged in water inside t he boiler and is used to hel p c ontrol

Han boiler surface scalin

Page 11 of 88

servi c ed. Newer models will have a small Petcock type

normal oper ation.

h limit.

. Two descalers are used in each boiler.

VL SERIES STEAMERS - GENERAL

Handhole Cover Assembly ....... When unbolted and removed, allows internal examination and cleanin

of boiler shell and i ts components if required.

Boiler Pressu re Gauge .......... Indicates the amount of steam pressure in the boiler.

Check Valve ................... On models with the delime pipin

of hot water and steam out of the delime funnel if the manual delime fill valve were to be opened.

Delime Port Assembl y ........... O n models with the delime pipin

other inter nal components to be delimed, easily removin and rust build up.

Gas Pilot ..................... Shoul d always remain lit to li

ht the main burners upon a call for heat

unless the steamer will not be in use for an extended period. If the pilot flame

oes out, wait 5 minutes before relighting.

Gas Burners................... Heats the water in the boiler to

Gas Combination Control Valve . . . A

as solenoid v alve that opens to allow gas flow when a call for heat is

made. Also re

ulates the m anifol d gas pressure and supplies the gas

pilot.

Transformer ................... Provides 24VAC power to i

electronic i

nition)

Ignition Control Module ......... Controls and monit or s

nition c ontrol module. (gas models with

as heating. Energizes pilot valve coil to supply

as to pilot, generates spark to ignite gas at the pilot, moni tors the presence of flame and ener supply the

as to the mai n bur ner s. The pilot and main solenoi ds are part of

as combination control valve. (gas models with elec tronic ignition)

izes mai n valve coi l upon a call for heat to

Ignition Control Module

Reset (ON/OFF) Switch .......... Controls power to the i

module if the

nition)

as ignition exceeds trial tim e. (gas models with elec tronic

nition c ontrol module and allows a reset of the

assembly opti on, prevents the ejecti on

assembly opti on, allows the boil er and

calcium, lime

enerate steam.

Heater Contacto r

(Electric Bo ilers) ............... When coil is ener

ized, supplies power to the electric heating element s.

Heating Elements

(Electric Bo ilers) ............... Heats the water in the boil er to

enerate steam.

Steam Header Assembly ......... Main steam supply line fr om the boiler to the steam header inlet i n the

cookin

control compartm ent.

Pressure Relief V alve ........... A m ec hanical device that opens to relieve steam pr essure in the boiler if

the pressure exceeds 15 psi.

Compartment P ressure

Regulating Valve ............... Reduces steam pressure form t he boiler or bui ldin

enerated models) to supply the compartment s a steam pressure of 6

steam (dir ec t and

psi. Standard on PS , option on MS, S S and A S c ompartm ent controls.

Page 12 of 88

VL SERIES STEAMERS - GENERAL

COOKING COMPARTMENT CONTROLS

The top half of t he steamer consists of two to three separate cooking compartments depending on the model . Each compartment functions independently with i ts own set of controls. Power i s supplied to the controls throu the compartment power switch and the cook in models have a load compensatin

thermal switch that prevents the contr ols from r ec eiving power until the

compartment reaches 180°F to close the switch.

tim er c ontrol micro switch contacts. Prev ent and Automat ic

Compartment Power Switch......

Cooking Light (Red) ............

Cooking Timer .................

Buzzer .......................

Steam Exhaust S olenoid Valve . . .

Steam Header Inlet (manifold) ....

Compartment P ressure Gauge ....

Steam Contro l Arm Solenoid .....

Supplies power to the cook in When lit, indicates steam er is in a cookin

compartment controls.

cycle. (All models except

manual) Use to set desired cookin

cycle time between 0-60 minutes. Energizes the buzzer when time expir es (All models except manual). On P r event models, also de-ener before the end of a cook cycle to allow compartment venti n

nals end of a cook cycle, must be turned of f manual ly. (All models

izes the steam exhaust solenoid valve one minute

except manual) A normal ly open v alve that allows full com par tment ventin

condensate up to 180°F durin vent in

” after energized by the closing of the t her mal switch. The valve

compartment heat up and “limited free

of air and

remains closed to allow compar tment pressurization to 6 psi until one minute before the end of a cook cycle at which point t he timer control micro switch contacts (SW2) chan

e state and de-energize the valve to

vent the compartment of pr essure and steam . (prev ent models) Main steam suppl y line f r om the boiler for each c ook in

Supplies steam to the manual steam

ate v alves. Indicates the amount of steam pressure in cookin When ener

control arm off of t he c atch, all owin closes the steam i nlet

ized, engages the lift arm ( plunger) to raise the steam

it to return to its rear position. This

ate v alve and opens the steam exhaust gate

compartment.

compartments.

valve. ( pr event, automati c and standar d models)

Thermal S witch

(Load Compensator) ............

Steam Gate Valves .............

Steam Trap ( Condenser) .........

Controls power to the preheat cycle components. Turns the cookin on, ener cookin

izes the steam exhaust solenoid valve and energizes the

timer motor to start timing, aft er the compartment reaches

light

180(F. (prevent and automatic models) Manual valves actuated by the steam control ar m. Allows steam to flow

into the cook in the arm is in a forward position and exhaust the steam throu exhaust steam use a steam exhaust solenoid valve t o exhaust the steam and a si n steam

ate v alve as the steam inlet. The automatic, standar d and manual models use one steam one additional steam

Exhausts air and condensate from c ompartm ent durin

compartment through the inlet steam gate v alve when

h the

ate v alve when the arm is at the rear . Prev ent models

ate v alve to exhaust the steam and

ate v alve as the steam inlet.

preheat until the compartment temperature reaches approx imately 180(F. The bel lows then close, stoppi n

the exhaust. ( all models except prevent)

Page 13 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

COMPONENT LOCATIONS

Page 14 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

Page 15 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

COOKING COMPARTMENT CONTROLS - COMPONENT CONFIGURATIONS

1. Prevent (shown above)

thermal switch, inlet steam valve, steam control ar m solenoid, timer, buzzer and power switch with li

ht. Does not use a steam tr ap.

2. Autom atic same as prevent except does not valve but does

include an exhaust steam gate v alve and two steam

ate v alve, steam exhaust sol enoid

include steam exhaust solenoi d

traps.

3. Standard same as automatic except does not include thermal switch.

4. Manual manual and exhaust steam

ate v alves and a manual timer.

Includes two steam t r aps.

Page 16 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

gaug

gauge g

WATER LEVEL CONTROLS -

LOW LEVEL CUT OFF AND

DIFFERENTIAL

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Solid State

1. Open the cabinet base doors.

2. Remove the two screws at the top of the boiler

3. Water level control is mounted on the back

4. Disconnect lead wir es from the boar d and

5. Reverse procedur e to install and c hec k for

Electro Mech anical

DISCONNECT THE ELECTRICAL

control box and allow cover to drop down.

side of cover.

remove the water level control.

proper operation.

4. Slide t he the tube is cl ear of the fittin

5. When r einstallin washers. Do not over tighten the packi ng nuts; it coul d br eak the

6. Open the top and bottom valves and check for proper operation.

lass tube upwards until the bot tom of

and lift it out.

the tube use new sealin

lass.

CYCLING AND HIGH LIMIT

PRESSURE SWITCHES

(GAS AND ELECTRIC MODELS)

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Open the cabinet base doors and remov e the left side panel.

2. Remove the two screws at the top of the boiler control box and allow cover to drop down.

DISCONNECT THE ELECTRICAL

1. Open the cabinet base doors.

2. Remove the two screws from t he left and r i side of the water level control box and lift cover off.

3. Disconnect lead wir es from the c ontrol bein replaced and remove.

4. Reverse procedur e to install and c hec k for proper operation.

WATER LEVEL GAUGE

ASSEMBLY

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Open the cabinet base doors and remov e the

2. Close the valve at the top and at the bottom of

3. Unscrew the packin

DISCONNECT THE ELECTRICAL

ht side panel.

the

of the

e assembly.

nuts at the top and bottom

lass tube.

3. The pressure switches are located at the rear of the box. The pressure switch on the ri cyclin the hi switches, dif ferin

4. Remove the cover from the pressure switch bein

5. Disconnect the pressure fittin of the switch.

6. Remove the mount in of the control box and lif t out the pressure switch.

7. Preset the new pressure switch to the approximate cut-out (off) and cut-i n ( on) set points before installin chart under “CYCLI NG AND HIGH LIMIT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

8. Reverse procedur e to install .

9. Adjust the pressure switch(s) final set poi nts as outlined under “ CY CLING AND HIGH LI M IT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” in “SERVICE PROCEDURES AND ADJUSTMENTS” and check for pr oper oper ation.

or prim ar y c ontrol; the one on the left is

h limit contr ol. They are identical

only in t heir settings.

replaced and disconnect the lead wires.

s at the bottom

screws on the back side

. See the boiler pressure

ht is the

Page 17 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

BOILER ASSEMBLY

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING:

SERVICING THE UNIT.

WARNING:

DURING SERVI CING MUST BE CHE CK E D FOR LEAKS. CHECK WITH A SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

1. Blow down the boiler and allow to cool, if

2. Ensure that all utilities to the steamer are off

3. Disconnect the steam supply li ne, power leads

4. Disconnect all plumbin

5. Disconnect the remainin

6. Remove the screws holdin

7. Remove the anchor screws holdin

DISCONNECT THE ELECTRICAL

SHUT OFF THE GAS BEFORE

ALL GAS JOINTS DISTURBED

necessary.

and disconnected. Drain any excess water fr om the boiler .

and drain lines from the cookin top to the boi ler base.

connections and power leads from the components inside the control boxes that would obstruct the removal of the boiler throu remove those control boxes.

electrical connections from the boiler t o the controls.

collector to the base.

the frame. Slide the boil er forward. The burner box, anchored only by the boiler, must be prevented from slidin

h the front of the base, t hen

forward with the boiler.

compartment

plumbing and

the flue and flue

the boiler to

HIGH LIMIT THERMOSTAT

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Open the cabinet base doors.

2. Electric model s onl y - for to step 3.

A. Newer Models

B. Older Models

3. Gas Models only. A. Remov e the thermostat c over which is

4. Reverse procedur e to install and c hec k for proper operation.

DISCONNECT THE ELECTRICAL

as models proceed

- are not equipped wit h a hi limit thermostat but rely on the Hi l imit pressure switch instead.

- the high limit thermostat is located behi nd the contactor box cov er . On electr ic boiler s with two heatin element s, the thermostat is connected to one of the heat in electric boilers with four heati n the therm ostat is located on an aluminum plate between the cent er pair of elements at the top of the elements. Remove the thermostat lead wires and mounti n replace thermostat and check for proper operation.

located on the front of the boil er . Disconnect the t her mostat lead wires and remove the nuts securin thermostat to the boiler surface.

element lugs. On

element s,

nuts,

the high limit

8. Reverse procedur e to install a new boiler and check for leaks and proper operation.

Page 18 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

BOILER FILL AND COLD WATER

CONDENSER SOLENOID VALVES

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Turn off the water supply t o the steamer.

2. Open the cabinet base doors and remov e the

3. Disconnect the power lead wir es from the

4. Disconnect the water lines for t he valve bein

5. Reverse procedur e to install .

DISCONNECT THE ELECTRICAL

two screws at the top of the boiler control box and allow cover to drop down. Both solenoid valves are l oc ated side by side near the front of the boiler control box with the boiler fill on the

ht and the cold water c ondenser t o the left.

solenoid valve bein

servi c ed and r emov e the valve.

servi c ed.

PILOT AND THERMOCOUPLE

ASSEMBLY ( GAS MODELS)

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING:

SERVICING THE UNIT.

WARNING:

DURING SERVI CING MUST BE CHE CK E D FOR LEAKS. CHECK WITH A SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

DISCONNECT THE ELECTRICAL

SHUT OFF THE GAS BEFORE

ALL GAS JOINTS DISTURBED

GAS COMBINATION CONTROL

VALVE

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING:

BEFORE SERVICING THE UNIT.

WARNING:

DURING SERVI CING MUST BE CHE CK E D FOR LEAKS. CHECK WITH A SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

NOTE:

servi c eable and should not be disassembled. Once the problem has been isolated to this control, replace it. Do not attempt to repair the assembly.

1. Open the cabinet base doors and remov e the two screws at the top of the boiler control box and allow cover to drop down.

2. Disconnect elec trical suppl y wir es and conduit runnin

3. Disconnect the t her mocouple l ead ( if applicable), pil ot and pipe connections on each side of the control.

4. Reverse procedur e to install .

5. Set manifold pr essure as outlined under “GAS MANIFOLD PRESSURE ADJUSTMENT” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

6. Check for pr oper oper ation.

DISCONNECT THE ELECTRICAL

SHUT OFF THE GAS SUPPLY

ALL GAS JOINTS DISTURBED

Gas combination control valves are not

to the com bination cont r ol valve.

as supply tube from control

1. Open the cabinet doors to access the pilot and thermocouple assembly. T he assembly is located to the ri half way back from the front.

2. Disconnect thermocouple and pi lot

from the combination contr ol valve.

tubin

3. Remove the two screws holdin bracket.

4. Replace the ther mocouple or pilot assembly and check for pr oper oper ation.

ht of t he c enter burner and

as supply

the pilot to its

Page 19 of 88

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

COMPARTMENT GASKET AND

DOOR SCREW NUT, DOOR AND

BUSHINGS

Gasket

1. Open the com par tment door t o be r eplaced.

2. Remove screws securin plate to t he gasket.

3. Lift the

4. Position t he new and rever se procedur e to install .

asket off the inner door plate.

the gasket retainin

asket on the inner door plate

4. Turn screw handle fully counter c lockwise remove from door.

5. Remove screws mountin the backside of the compartment door.

NOTE:

each screw. Set aside f or r euse.

6. Remove screws mountin

7. Reverse procedur e to install and c hec k for

Door and Bushing

1. Open the com par tment door t o be r eplaced.

2. Remove the ri

3. Remove the four bolts inside the compartm ent

CAUTION: Door is extremel y heavy and will drop when bolts are removed.

A compression sprin

(bronze) to the bac k si de of the compartment door.

proper operation.

ht side pan support inside the

compartment.

that secure the bl oc k hin of the compartm ent.

the pressure bar to

is mounted behind

the door screw nut

es to the exter ior side

and

NOTE:

as nicks or cuts, will cause steam leaka

Door Screw Nu t

1. Open compartment door t o be serviced.

2. Turn screw handle fully cl oc k wise

3. Lift the inner door plate assembly up, until the

Dama

inner door plate assembly.

mounti n pressure bar and set the assembly aside.

e to the gasket sealing surface, such

to extend

pins are out of the holes in the

4. At this time, t he bushi n necessary, by removin pin on each block hin

5. Reverse procedur e to install and c hec k for proper operation.

Page 20 of 88

s can be replaced if

the bushings from the

VL SERIES STEAMERS - REMOVAL AND REPLACEMENT OF PARTS

ge g

HEATER CONTACTORS

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Open the cabinet base doors, remove the two

2. Disconnect the electrical lead wires to the coil

3. Remove the screws form the base of the

4. Reverse procedur e to install and c hec k for

DISCONNECT THE ELECTRICAL

screws from the contactor box c over and l ift cover off.

and the power supply wires from the contact or bein

replaced.

contactor and lift out.

proper operation.

HEATING ELEMENTS

REGENERATED STEAM MODELS

(STEAM COIL)

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING:

BEFORE SERVICING THE UNIT.

1. Disconnect pipe unions in the steam suppl y line to the coils and in the condensate dischar line from the c oils.

2. Remove header that supplies steam to the coils by disconnecti n

3. Remove coil c ondensate c ollection header.

4. Remove bolts securin and pull coil for ward.

5. Clean the m atin flan

DISCONNECT THE ELECTRICAL

SHUT OFF THE STEAM SUPPLY

union at each coil.

the coil being replaced

surfaces of the steam coil

e and the boiler .

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Open the cabinet base doors, remove the two

2. Disconnect the electrical lead wires to the

3. Remove the bolts securi n

4. Clean the m atin

5. Check for leaks and proper operation.

DISCONNECT THE ELECTRICAL

screws from the contactor box c over and l ift cover off.

element bein

e to the boiler and lift the el ement out.

flan

install a new flan element .

replaced.

the heating element

surface of the boiler and

asket and heatin

6. Reverse procedur e to install a new steam c oil

asket.

and

7. Check steamer for proper operation.

Page 21 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

ging

SERVICE PROCEDURES AND ADJUSTMENTS

WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRES ELECTRICAL TEST OR

MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POI NTS ARE NOT EASI LY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST.

BOILER

Inspection

It is recommended the boiler be inspected for excessive scale and li me build up on a quar terly basis. In hard water areas or f or steamers heavily used, a more frequent inter val shoul d be used. This inspection consi sts of an internal examination and cleanin han water level probes. Also, a c hec k of all boiler controls, includin

Periodic service must be perfor med as outlined in these procedures. See “WATER CO NDITIONING” under “GENERAL”.

WARNING: READ AND FO LLOW THE INSTRUCTIONS ON THE CLR BOTTLE. USE PLASTIC OR RUBBER GLOVES TO AVOID SKIN CONTACT. I F CLR LIQUID COMES IN CO NTACT WITH THE SKIN, RINSE WITH CLEAN WATER.

Clean-Out (All Boiler Models)

1. Turn steamer OFF and drain boiler.

2. Remove hand hole plat e and

of the boiler, an examinat ion of the two

descalers, and for lime build up on the

the pressure switches.

asket (top f r ont) from the boiler by r emov in then tappin holdin from droppin

the cover lightly to free it while

the cover stud. This prevents the cover

into boiler.

the nut and clamp,

NOTE: B oiler water capacities vary between seven to nine dependin

NOTE: If delimin contact with steamer components, li with clean water.

allons f or both gas and electric models

on the boiler si z e and B TU/KW rating.

solution accidently comes in

htly rinse off

A. M odels with Blowdown Timer

delimin to step 9.

B. M odels without Blowdown Timer

the incomin switch ON to cl ose the dr ain valve. Pour delimin to step 9.

C. Models with Delimin

Before pourin boiler, c lean the seatin hand hole

asket. Position the hand hole plate and ti supply. Turn t he power switch O N to close the drain valve. Open t he delimin assembly valve and pour the delimin solution i nto the port. Close the delimin assembly valve and proceed to step 10.

solution into boiler shell. Proceed

water supply. Turn t he power

solution into boiler shell. Proceed

Port Assembly -

deliming solution into

asket and then instal l a new

hten down. Turn of f the inc oming water

- Pour

surfaces for the

- Turn off

3. Remove old descaler retainin present.

4. With a wire brush, or equi valent, dislod remove all loose scale from boiler shel l. The loose material must be either scooped fr om the

h the drain.

boiler or flushed throu

5. Check probe canister and float valve assembly

enerated models) for a scale build up and

(re clean as necessary.

6. Check drain hol e for obstructions.

7. Inspect the condi tion of the descalers as outlined in this section and r eplace if necessary.

8. Mix the delimin instructions for the chemical bein

solution according to the

springs if

used.

e and

Page 22 of 88

9. Clean the seatin asket and then Install a new gasket. Position

hten the hand hole plate.

and ti

surfaces for the hand hole

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

ging

10. Cooking compartment ti mers are to be in t he OFF position. Turn the boiler switch ON and open water valve if necessary.

11. Boiler is to operate under pressure for 90 minut es or per the instructions for the chemical in use.

12. Drain boiler by normal methods.

13. Refill boiler and allow to heat until fully pressurized.

14. Repeat step 13 three times.

15. The steamer is now ready for norm al operation.

Deliming Only (Models with Deliming Port Assembly)

Boiler delimin bi-weekly or monthly basis, dependin

should be performed on a weekly,

on the quality of the local water supply. S ee “ WAT E R CONDITIONING” under “GENERAL”.

On steamers usin

a water purif ication system, follow the instructions for that system to deli me the boiler. Only use the type of chemical recommended or described in t he instructions for delimin

with this

type of system.

1. Turn steamer OFF and drain boiler.

2. Mix the delimin

instructions for the chemical bein

solution according to the

used.

NOTE: B oiler water capacities vary between seven to nine dependin

NOTE: If delimin contact with steamer components, li

allons f or both gas and electric models

on the boiler si z e and B TU/KW rating.

solution accidently comes in

htly rinse off

with clean water.

A. Models with Blowdown Timer - Open

the delimin delimin delimin

assembly valve and pour the solution i nto the port. Close the assembly valve and proceed to

step 3.

B. Models without Blowdown Timer - Turn

off the incomin

water supply. Turn t he power switch ON to close the drain valve. Open the delimin pour the deli min Close the deli min

assembly valve and

solution i nto the port.

assembly valve and

proceed to step 3.

3. Top compartments are to be in the OFF position. Turn the boil er switc h ON and open water valve if necessary.

4. Boiler is to operate under pressure for 90 minut es or per the instructions for the chemical in use.

5. Drain boiler by normal methods.

6. Refill boiler and allow to heat unti l ful ly pressurized.

7. Repeat step 6 three times.

8. Steamer is now ready for norm al operation.

Descaler

The descaler is accessible throu openin cylindr ical core, and han

. It i s a coiled wire wound around a solid

s by an open loop from the

h the hand hole

shell's horizontal stay rod, about 4 inches from the front of the shell . If t he wir e is eaten throu

h, or if

the core of the descaler is eaten away to hal f its

inal size, a new descaler should be installed.

ori

To install a new descaler, stretch its wire coil so the descaler han minimum water level in the boi ler, but han The descaler m ust not contact the bottom of the boiler shell, elect r ic heatin re

Page 23 of 88

s with its core completely below the

free.

element s or

enerating steam coils.

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gaug

WATER LEVEL CONTROL(S)

TEST

Loose electric al connections may prev ent the heat from comin An accumulation of lime scale on or near the water level sensin water (moist) on the probe surface and readin

ive a false reading. These conditions may prevent the boiler from fillin will result in damage to the heati ng element s on electric models or t o the boiler on models.

WARNING:

POW E R TO BE APPLIED TO THE UNIT DURING THE TEST. USE EXTREME CAUTION AT ALL TIMES.

Solid State - Low level Cut-Of f & Differential Control

1. Turn the power switch ON.

2. Ensure that water is fillin

A. Confirm that water supply valve(s) are

B. Observe boiler water level in the water

3. Check the volta

the board. Meter shoul d r ead 120V A C. A. If volta

B. If boiler fill solenoid is receivin

C. If boiler fill solenoid is not

4. If boiler is fillin

reaches the low level cut- off ( LLCO) probe, LLCO relay should ener contacts, heat source shoul d c ome on (standard model s onl y ) and LLCO LED will li

on or may cause the boiler to overfill.

probes may cause them to retain

ive a false

. Also, a crac k ed or damaged insulator may

or cause dry firing. Dry firin

as or electri c

THE FOLLOWI NG ST EPS REQUIRE

the boiler .

turned on.

level approximately 11 minutes.

(HL) relay should ener contacts and the HL LED should li The boiler fill solenoid should then ener boiler fill solenoid valve is receivin 120VAC and water is flowing through it.

no water is fl owin malfunction or valve for clo solenoid is bad or port s can not be cleaned, then r eplace boiler fill solenoid and check for pr oper oper ation.

and the electr ical connect ions have been checked, then t he HL r elay is not bein energized or the HL-3 c ontacts are not closin and check for pr oper oper ation.

ht.

e. If empty, boiler should f ill in

e across terminals L1 & L2 on

e is correct t hen the high level

ize, closing HL-3

ht up.

ize and start filling the boiler. Verify

power but

, inspect fill solenoid for

ed ports. If

receiving power

. Replace water l evel c ontrol board

properly, when the water level

ize closi ng LLCO-2

5. Once the water level r eac hes the hi (HL) probe, the inverse l atchin board (solid state) shoul d ener throu

h the low level probe (LL) and ILR-1 contacts. Wit h ILR-2 contacts open, t he HL relay is de-ener With the HL-3 cont ac ts open, the boiler fil l solenoid should de-ener fill.

6. If water is in the boil er but is not bein by the water level probes, t he pr obes may need cleaned and/or boiler delimed. See “Water Level Probes” as outlined below for inspectin and cleaning of probes and “BOILER” for a procedure on boil er inspection, clean-out and delimin

7. Turn the power switch OFF and disconnect the lead wire f r om each probe. Check the probes as outlined bel ow.

A. Wi th an ohmmeter, check between the

NOTE:

water quality and pr obe c ondition.

8. After performin water level control boards operation, if the control is not functionin replace it and check for pr oper oper ation.

Electro Mechanical - Low level Cut-Off & Differenti al Control

WARNING:

POW E R TO BE APPLIED TO THE UNIT DURING THE TEST. USE EXTREME CAUTION AT ALL TIMES.

1. Ensure that water is fillin A. Confirm that water supply valve(s) are

B. Observe boiler water level in the water

C. Verify boiler fill solenoid valve is receivin

2. Check for correct volta low level and different ial water level controls.

A. Turn the water supply valve off then turn

probe terminal and boiler shell. An open circui t should be present when the boiler is empty. If resistance is present, remove and inspect the probes as outlined below under “Water Level Probes”. When the boiler is full of water, a resistance r eadin should be measurable bet ween the probes and boiler.

The actual r esi stanc e r eadin

THE FOLLOWI NG ST EPS REQUIRE

turned on.

level

120VAC and water is flowing through it.

the power switch ON. Check t he input volta should read 120VAC. If volta proceed to step 2B. I f volta find the source of the problem and repeat this step.

ized and HL LED goes out.

ize and stop the boi ler

steps 1-5A and verifying the

as described, then

the boiler .

e being applied to the

e across terminals 1 & 2. Meter

h level relay of the ize and lock

detected

will depend on

e is correct

e is incorrect,

Page 24 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gaug

B. Wi th the boiler empty, chec k the voltage

across terminals 9 & 10. Meter should read 300 to 350VAC. I f volta proceed to step 3. If volta approximately 30V A C then the internal contactor is ener scaled ov er and moist and/or have a dama See “Water Level Probes“ listed below for inspectin procedures on boiler inspection, clean-out and delimin volta level control is bad and the control should be replaced. Check for proper operat ion after r eplacement.

3. If water is in the boil er but is not bein by the water level probes, t he pr obes may need cleaned and/or boiler delimed. See “Water Level Probes“ listed below for inspectin cleanin boiler inspection, clean-out and deli min

4. Turn the power switch OFF and disconnect the lead wire f r om each probe. Note the locati on of the probes and the number of the wire connected to i t.

A. Chec k the resistance between the probe

terminal and boil er shel l. An open should be present when the boiler is empty. If resistance is present, remove and inspect the probes as outlined below under “Water Level Probes”. A resi stanc e readin between the probes and boiler shell (

NOTE: The actual resistanc e r eadin water quality and pr obe c ondition.

5. If after performi n not functionin controls operation as outlined in “W A TER LEVEL CONTROLS” under “ELECTRICAL OPERATION”.

6. After checkin cut off or differential water l evel c ontrol does not appear to be functioni n replace the control and check for proper operation.

Water Level Prob es WARNING: DISCONNECT THE ELECTRICAL

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

ed insulator giving a false reading.

and cleaning and “BOILER” for

e, then contactor coil on the water

and “BOILER” for procedures on

should only be m easurable

round) when the boiler is full of water.

properly, veri fy the water l evel

the abov e items, if the low level

ized but the pr obes are

. If y ou do not read any

steps 1-4 and the control is

as described, then

e is correct

e reading is

detected

and .

circuit

will depend on

2. If lime scal e build up is evident on t he pr obe, thorou the probe and insulat or . Do not abrasiv e on the insulator; use a sof t cloth.

3. Inspect the probes f or a c r ac k ed or dama insulator. If a probe appears to be dama replace it with a new one and proceed to step

5. If a pr obe does not appear to be dama then proceed to step 4.

4. Check throu top of t he c anister assembly for the presence of water. Water must drain from the probe canister and if in doubt, pour water into the canister and observe that it drains quickly. If water fails to drain from the canister, rem ove the cover or canister assembly and clean.

5. Reverse procedur e to install and c hec k for proper operation.

hly clean it removing all deposit s from

use any thin

ed,

h the probe socket opening in the

CYCLING AND HIGH LIMIT

PRESSURE SWITCHES

(GAS AND ELECTRIC MODELS)

WARNING: THE FOLLOW I NG ST EPS REQUIRE

POW E R TO BE APPLIED TO THE UNIT DURING THE TEST. USE EXTREME CAUTION AT ALL TIMES.

Remove the boil er c ontrol box c over as outl ined under “CYCLING AND HIGH LI MI T PRESSURE SWIT CHES (GAS AND ELECTRIC MODELS)” to access the two controls. The pr essure switch on the

ht is the cycling or prim ar y c ontrol; the one on the

ri left is the hi switches, dif ferin

Turn the power ON and let the boiler c ome up to pressure. Close and seal one of t he c ompartm ent doors, set a time past 5 minut es on the c ook in tim er , pull the steam control ar m handle forward and turn the compartment power switch O N to exhaust pressure from the boiler. Observe boi ler pressure

e readings for several cycles and compare

them with the pressure settin If t he r eadin

described below.

h limit contr ol. They are identical

only in t heir settings.

s in the chart.

s differ, adjust t he pr essure settings as

1. Remove the cover ov er the water level probes and disconnect the lead wire from each probe. Note the location of eac h pr obe and the number of the wire connected t o it. Rem ove each water level probe for exam ination.

Page 25 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gaug

Two slotted and square headed adjustment screws extend thr ou pressure scale and indicat in

h the sight glass window to indicate t he

throu approximate pressure settin directly above the ri

h the top of the switch case. A

pointers are visibl e . The adjustment screw

ht side pointer c hanges the cut-out (off) set point and the adjustment screw directly above the left

side pointer changes cut-in (on) set point. A djust the screw to obtain t he pr oper cut-out (off) settin to obtain t he pr oper c ut-in (on) settin screw clockwise countercloc k wise The pressure settin

fir st, then adjust the ot her screw

. Turn the

to increase the pressure setting and

to decrease the pressure setting.

s for each switch are listed

below.

BOILER PRESSURE SETTINGS (PSI)

CONTROL

TYPE

With

Compartment

Pressure

Regulating Valve

MODELS

PS AS SS MS

CYCLING HIGH

LIMIT

ON OFF ON OFF

911615

1. Remove the coil assembly f r om the valve stem by liftin the solenoid valve and slidin

up on the retaining cap at the top of

the metal cover

plate off.

2. Clamp t he body of the valve in a vise.

3. Mark a scribe l ine on the stem nut to the v alve body for proper r eti

4. Remove the stem lockin

htening.

nut to remove the

stem f r om the valve body.

5. All parts are now accessible for i nspect ion and cleanin

NOTE:

dama Do not reuse dama

If internal solenoid parts appear to be

ed or worn, then replace the solenoid valve.

ed or worn parts. No internal solenoid parts are avail able as a servic e replacem ent.

A. Chec k r ubber seal on bottom of plun B. Chec k plun C. Check O-rin

er spring.

in valve body.

er.

D. Check ports in valve body.

With-Out

Compartment

Pressure

Regulating Valve

46215SS

FILL AND COLD WATER

SOLENOID VALVES

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Check to assure the solenoid valve is receivin power. If t he sol enoid valve is receiving power but the v alve is not openin malfunctionin check for pr oper oper ation. If the solenoid valve is receivin openin then the valve ports may be clo valve component malfunct ionin valve further, foll ow the proc edur e outlined bel ow.

Disassembly NOTE:

removed for c leanin This will prevent dama when the stem is rem oved from the body.

DISCONNECT THE ELECTRICAL

, the coil may be

. Replace the sol enoid valve and

power and the valve appears to be

but little or no water i s flowing through it,

ed with debris or a

. To check solenoid

It is recommended that the valve be

as outlined i n this procedure.

e to the lines and fittings

6. Reverse procedur e to install .

COMPARTMENT PRESSURE

ADJUSTMENT

Remove the left side panel from t he boiler base to access the compartment pressure re If t he steamer is equipped wit h the compartment pressure re operatin

ulating valve and t he steamer is

, set the pressure regulating valve t o r ead 6 psi on the compar tment screw at the top clock wise to increase the pressure and countercloc k wise to dec r ease. If the steamer is not equipped with t he c ompartm ent pressure

ulating valve, then the compartment will cycle at

re the same pressures of the boiler. A mechanical pressure relief valve serves as a safety backup control and is pre-set for a maximum of 8 psi.

ulating valve.

e. Turn the hex head

Page 26 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

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HIGH LIMIT THERMOSTAT

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Remove thermostat (bi-metallic disk type) as outlined under “ HIGH LIMIT THERMOSTAT” in “REMOVAL AND REPLACEMENT OF PARTS”. Inspect the temperature sensin for corr osi on or r ust. Clean mount in surfaces befor e r emountin metal - to-metal contact i s essential for proper functionin performed at least once a year . If t her mostat matin surface can not be throughly cleaned or is severely pitted and rusted, then replace and chec k for proper operation.

DISCONNECT THE ELECTRICAL

side of ther mostat

and thermostat

or replaci ng. A good

of the t her mostat. This servic e must be

BOILER NOT FILLING WITH

WATER

Ensure that water to the steamer is turned on, then turn power switch ON. After approximat ely 10 minut es, if no water i s observed in the water level

e sight glass, then check for a problem with the boiler fill solenoid valve, water level control(s) or the water level probes. See “WATER LEVEL CONTROL TE S T”. Also, ”water hammerin supply line, in conjunction with a check valve can cause a high water pressure pocket in the water line to the fill solenoid valve. The f ill solenoid valve will not be able to overcome this pressure and operate to supply the boi ler with water. Shut off the water supply and reli eve the pressure in the line. Turn the water supply back on and check for proper operation.

NOTE

: To eliminat e this problem , the customer must install a “water hammer suppression device” in the supply line to the boiler.

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Scalants may be coverin probe level in the boiler. Remove and thorou water level probes to rem ove scalant s and l ime build up. A lso, Check throu openin presence of water.

Water must drai n from the probe canister and i f in doubt, pour water into the canister and observe that it drai ns qui c k ly.

DISCONNECT THE ELECTRICAL

the water level contr ol

iving a false i ndication of a sufficient water

h the probe socket

in the top of the canister assembly for the

” in the

hly clean the

If water fails to dr ain from the canister, remove the cover or c anister assembly and clean. These conditi ons i ndicate extremely poor water quality bein

supplied to the boiler and/or boiler cl ean out

and delimin The water condition must be cl ear ed up imm ediately

with a proper water conditioner to avoid further problems with the steamer. Re-install t he water level probes and canister assembly ( if appl icable). Perform a boiler inspection, clean-out and delimin procedure as outli ned under “ B OILER”. Check for proper operation.

Water may be drainin blowdown solenoid valve as qui c k ly as it’s fed to the boiler. Loose wirin scale trapped in the valve seat may prevent the valve from closin

Newer steamer models use a plun raises and lowers to permi t steam/water flow out of boiler. If debri s has accumulated around the water orif ice, the pl un off the openin the solenoid as outl ined in “FI LL A ND COLD WATER SOLENOID VALVES”. Remove any debris found on seali n the solenoid valve still does not function properly, replace it with a new val ve and check for proper operation.

Older steamer models have a movable blade and when closed, the blade reacts as a should be free t o mov e full y down into the v alve pocket (proj ec tion at bott om of valve) so that t he pierced hole in the blade al i body openin bottom of the valve pocket, then the blade will not move into the pocket completely. If this symptom is suspect, remove the solenoi d as outlined in “FILL AND COLD WATER SOLENOID VALVES”.

NOTE:

assembly bolt s hol din remove the loose internal parts. Remove any debr is found on seali n the solenoid valve still does not function properly, replace it with a new val ve and check for proper operation.

has not been performed.

through an open boiler

, a burned out coi l or partic les of

er type rod that

er may not seat pr oper ly to close

. If this symptom is suspect, remove

surfaces, reassembl e and install. If

uillotine that

ns perfectly with the

. If debr is has accumulated in the

On this valve body, remove t he two

the brass body together and

surfaces, reassembl e and install. If

BOILER BLOWDOWN DRAIN

SOLENOID VALVE

The water contained in the boil er , being under pressure, should be blown throu noticeabl y visi ble exhaustin Daily boiler blowdown is essential operation and component li fe by rem ovin and scalants that may be lod the boiler .

h this valve and be

out the steamer dr ain.

to proper

sediment

ed in the chamber of

Page 27 of 88

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