Vulcan-Hart VL3GAS, VL3GMS, VL3GPS, VL2GMS, VL2GAS User 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).

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)

Page 5 of 88

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 compartment reaches 180°F to close the switch.

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

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

manual) Use to set desired cookin

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

Si except manual)

A normal ly open v alve that allows full com par tment ventin condensate up to 180°F durin vent in 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 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

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

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

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

izes the steam exhaust solenoid valve one minute

compartment controls.

cycle. (All models except

cycle time between 0-60 minutes. Energizes

of air and

compartment heat up and “limited free

e state and de-energize the valve to

compartment.

ate v alves.

compartments.

it to return to its rear position. This

ate v alve and opens the steam exhaust gate

Thermal S witch

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

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

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

Controls power to the preheat cycle components. Turns the cookin on, ener cookin 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 manual models use one steam one additional steam

Exhausts air and condensate from c ompartm ent durin compartment temperature reaches approx imately 180(F. The bel lows then close, stoppi n

izes the steam exhaust solenoid valve and energizes the

timer motor to start timing, aft er the compartment reaches

compartment through the inlet steam gate v alve when

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

ate v alve as the steam inlet. The automatic, standar d and

ate v alve to exhaust the steam and

ate v alve as the steam inlet.

preheat until the

the exhaust. ( all models except prevent)

light

h the

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)

2. Autom atic same as prevent except does not

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

4. Manual manual and exhaust steam

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

valve but does traps.

Includes two steam t r aps.

ht. Does not use a steam tr ap.

include an exhaust steam gate v alve and two steam

Page 16 of 88

ate v alve, steam exhaust sol enoid

include steam exhaust solenoi d

ate v alves and a manual timer.

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

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

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

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

s with its core completely below the

free. The descaler m ust not contact the bottom of the boiler shell, elect r ic heatin

enerating steam coils.

element s or

Page 23 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

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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

gaug

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

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

g g

If t he blowdown operation appears to function slu

ishly or not at all, c onsi der able scalants may

be lod

ed in the drai n pipe and/or the valve. Disconnect the valve f r om the drain line and inspect both the valve and the drain pipe fixed to the boi ler. If consi der able scalants or lime build up is apparent, then not only the valve, but also the boil er and water level probes must be thor ou

hly cleaned. See “FILL AND COLD WATER SOLENOID VALVES” for an inspection and cleanin

procedure of a sol enoid valve and "B OILER” f or a pr oc edur e on boiler inspection, c lean out and deli ming.

1. If your steamer has an automat ic blowdown

drain valve. A. Newer M odels

1) Are equipped with normally open solenoid valves that close when ener

ized by the main power switch. When the main power switch i s turned off, the solenoid valve is deener

ized and the boi ler blowdown valve re- opens.

B. Older Models

1) Turn the power switch(s) OFF and press the blowdown timer button. This activates the boiler blowdown timer and ener

izes (opens) the solenoid valve. Timer oper ates approximately four minutes then shuts off.

2. If your steamer has a manual blowdown drain valve.

A. Turn the power switch(s) OFF then open

the v alve to blowdown the boiler. Close the v alve at the end of t he blowdown sequence so boiler will be ready to fill.

BOILER SLOW TO PRESSURIZE

NORMAL OPERATING STEAMER PRESSURES (PSI)

CONTROL

TYPE

With

Compartment

Pressure

Regulating Valve

With-Out

Compartment

Pressure

Regulating Valve

MODELS

PS AS SS

CYCLING HIGH LIMIT ON OFF ON OFF

9 11615

46215SS

1. All Models (With Boiler) A. Check for low water pressure input, line

strainer clo

ed or fill solenoid valve malfunction. See “FILL AND CO LD WATER SOLENOID VALVES”.

B. B oiler blowdown solenoid valve may be

clo

ed and not fully closi ng. Check for a slow leak out of steamer drain. If not able to v er ify, then proceed to step 1C. If blowdown solenoid valve appear s to be functionin

properly, then proceed to step

1D.

C. Turn power swi tch OFF, disconnect lead

wires from blowdown solenoid and remove it for inspection.

D. A heav y build-up of scalants has possibly

coated the interior of the boiler . The insulatin

effect of the scalants hampers heat transfer . Unbolt and remove t he hand hole cover plate and

asket assembly. Exam ine interior of boi ler and if scalants and/or li me build up is apparent, perform a boiler inspection, clean-out and deli min procedure. See “BOILER”. If considerabl e scalants are evident, t hen both the boiler blowdown solenoid valve and the water level probes must al so be examined.

2. Gas Models

If t he boiler requi r es more than 15 minutes (20 minut es for re operatin followin

enerated models) to achieve normal

pressure as listed in below, t hen c hec k the

conditi ons.

A. Low incomin

reduced BTU output . Check incomin and manifold “GAS MANIFOLD PRESSURE

as pressure causes

line

as pressures as outlined in

ADJUSTMENT.”

B. Gas combination control valve

malfunction. Check incomin

and manifold

as pressures as outlined in “GAS MANIFOLD PRESSURE ADJUSTMENT.” If pressure adjustments are made and manifold pressure remains low, replace the combination valve and check for proper operation.

Page 28 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gging

C. Gas burner ports clogged or obstruction

around air shutter. After a per iod of time,

as burners can accumulate carbon in

their port s or become clo

rease debris from kitchen c leaning, restrictin remove them from bur ner box and boil in water for 10 -15 minutes to di sl od Clean-out any remainin

as ports using a wire brush, scribe or pi c type met al instrum ent. Remove any other forei obstructin

D. Gas orifice clo

air shutter. It is possible for debris to become lod openin orif ice usin the same hole diameter or sl i Clean as needed. If clo the orifice should be removed, cleaned and reinstalled. Remove any other forei objects that appear to be obstructin

as orifice or air shutter s.

3. Electric Mo dels A. One or more el ec tric heatin

malfunctionin ELEMENTS”

B. One or more heater c ontactors not pullin

in to power heating element s.

C. If steamer operates under three phase

power, then check line for all phases.

D. Heavy scale build up on heatin

causes reduced heatin

4. Direct Steam Models A. Buildin B. Cook in

valve malf unc tion.

C. Steam pr essure re

low.

D. Clo

supply.

5. Regenerated (Steam Coil) Steamers A. Heavy scale build up inside c opper steam

coil. B. Buildin C. Cookin

valve malf unc tion.

performance. To clean burners,

n objects that appear to be

the gas ports or air shutters.

ed or obstructed around

ed in the small gas orifice

over time. Clean-out the gas

a round metal instrument of

. See “HEATING

steam supply pressure low.

compartment steam sol enoid

ulator adj usted too

in the steam line reduces steam

steam supply pressure low

compartment steam sol enoid

ed by food and

debris from the

htly sm aller.

reappears,

element s

e clog.

the

element

INLET WATER STRAINER

The in-l ine Y strainer should be located upstream of the fill valve solenoid. Shut off the water suppl y . Unscrew the cap from the body on the le that should be pointin Remove the screen and any f or ei trapped in the openin to remove accumulated debri s and replace the screen in the valve body. If screen can not be thorou Reinstall the cap and ensure that the Y strainer is positioned with the cap pointi n debris.

The pressure re clo steam models. Remove the hex nut on the bottom of the pressure re and valve seat.

hly cleaned, replace it with a new one.

ed if dirty steam lines are connected t o direct

downwards toward the floor.

n particles

. Rinse the screen thoroughly

downward to catch

ulating valve strainer will become

ulating valve t o c lean the strainer

of the Y

PILOT AND THERMOCOUPLE

ASSEMBLY ( GAS MODELS)

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.

WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT.

The pilot thermocouple when heated, supplies a DC millivolt si

as combination control valve. T his solenoid valve is desi main burner s i n c ase of a malfuncti on in the system. When ener valve is held in the open posit ion to permit The pilot burner flame is contr olled by an adjustable needle valve located under a sm all cap screw on the combination contr ol valve.

When experiencin pilot flame for the pr oper c ontact on thermocouple and the flame color . Also, check t o see that excessive air drafts are not int er ferin heatin

The pilot flame should be a steady blue flam e that envelopes the thermocouple tip. The flame should be about one inch l on beyond the outer edges of the pilot shield. If the pilot flame does not appear to be this len then adjust as necessary. See the dia an example of unsati sfactory pi lot flames. Turn clockwise countercloc k wise

nal to an internal solenoid valve on the

ned to shut off the gas flow to the pilot and

ized by the t her mocouple voltage, the

as flow.

pilot outages, visually check

with proper

of the t her mocouple by t he pilot flame.

with half its length extendin

th and color,

ram below for

to decrease pilot flame and

to increase.

Page 29 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

NOTE: If adjustments in

s are made, always replac e the adjustment

settin cover screw to assure proper

as or pilot pressure

as control operation.

Check the thermocouple output volta

e as foll ows:

1. Turn the power switch OFF and disconnect the

thermocouple from the

as combination control

valve.

2. Check the thermocouple DC m illivolt output

with a VOM. If a m eter is not available, replace the therm oc ouple with a new one and check operation a

ain.

A. Install a ther mocouple adaptor into the

connection on t he

as combination control val ve. Screw the thermocouple in to t he adaptor then connect the meter leads to it. See “TOOLS” under “GENERAL” for infor mation on t her mocouple adaptor . If a thermocouple adaptor is not available then turn the power switch OFF, disconnect the thermocouple from the

as combination

control valve and proceed to step 2D.

B. Turn the power switch ON and li

ht the pilot. Allow the pi lot to heat t he thermocouple for one t o two minutes and take a closed readin

circui t reading. Compare t he

s with the chart bel ow.

If t he adjustment does not resul t in a pil ot flame of proper size, then to the pilot. Check for a plu kinked or pl u

as might not be f lowing properly

ed pilot or ifi c e, a

ed pilot gas supply tube and for low

as supply pressure. The pilot operates unregulated

as supply pressures while the pressure regulator

at in the combination c ontrol valve re

ulates pressure to the main burners only. Visually check the thermocouple tip (hot end) and tube lead for k inks or pinches that mi

ht be causing a short between the tube and the wire insi de. Also, check t he threaded connector tip for corr osi on, tarnish or dir t which can cause a poor connection. If the t her mocouple shows either of these si

ns, it should be replaced with a

new one. NOTE: The connection of the tubi n

from the thermocouple tip to the control valve is an elec trical connection and must be clean. Do not use any sealin threaded connection. Fin turn with a wrench. Over ti crush the insulator, shortin

compound on the t hr eads or over tighten the

er tighten the nut pl us 1/4

htening the nut could the therm oc ouple.

1) If the readin

is less than the minimum or thermocoupl e is not operatin

as described, replace the thermocouple as outlined under “PILOT A ND THERMOCOUPLE ASSEMBLY (GAS MODELS)” in “REMOVAL AND REPLACEMENT OF PARTS ” then check for pr oper operation.

2) If the readin

is within the range listed in the chart below then thermocouple is operatin thermocouple to the

properly. Rec onnec t the

as combination

control valve.

3) If after r eplacin

thermocouple, the pilot or main burners are still not functionin in the

properly, then a problem

as combination control valve exists as well. Replace the combination control valve as outlined under “GAS COM B INATION CONTROL VALVE” in “REMOVAL AND REPLACEMENT OF PARTS” then check for proper operati on.

C. Turn the power switch OFF and

disconnect the t her mocouple adaptor from

as combination control valve and

the thermocouple.

If t he pilot flame is correct and there ar e no dr afts, then the problem is in the thermocoupl e output

e or the gas solenoid v alve in the combination

volta control.

Page 30 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

g g

D. W ith the thermocouple di sconnected,

connect the meter leads to the tube and threaded end. Turn the power switch ON and li

ht the pilot. Hold down the OFF/PILOT/ON knob and allow the pilot t o heat the thermocouple for one to two minut es. Take an open

circui t reading and

compare with the chart below.

1) If the readin

is less than the minimum or thermocoupl e is not operatin

as described, replace the thermocouple as outlined under “PILOT A ND THERMOCOUPLE ASSEMBLY (GAS MODELS)” in “REMOVAL AND REPLACEMENT OF PARTS ” then check for pr oper operation.

3. If after checkin

and/or replacin thermocouple, the pilot or main burners are still not functionin

properly, then a problem in the

as combination control valve ex ists as well. Replace the combinati on c ontrol valve as outlined under “ GAS COMBINA TION CONTROL VALVE” in “REMOVAL AND REPLACEMENT OF PARTS” then check for proper operation.

NOTE: Gas combination control valves are not servi c eable and should not be disassembled. Once you have isolated the problem to this control, replace it. Do not

attempt to repair t he assembly.

THERMOCOUPLE

DC MILLIVOLT

READINGS

3. Loosen the set screw on the burner bein adjusted. Closi ng the air shutter will decrease primar y air to the burner and opening the shutter will increase

primar y air the burner.

4. Monitor t he bur ner flame and set the air shutter openin

as follows:

A. Open up the air shutter until the inner

portion (blue) of the flame lifts off the burner port and then t ur n the air shutter back until the flame touches the burner port a

ain. A slight tinge of orange and yellow in t he flame is acceptable. An extremely yel low flame indicat es too little primary air (oxy burnin

characteri stics and the heatin

en), producing poor

efficiency dr ops off. A by pr oduc t of this would be soot (carbon).

Factory air shutter settin

s are: natural

gas - open approxim ately ½ inc h; propane gas - fully open.

5. After the air shutter adjustment i s made, ti

hten

the set screw.

Inspection

Remove

as burners by lifting burner up and slidi n it to t he r ear just enough to clear t he gas orifice hood. Lower the front end of burner and brin forward under the for clo

ed or damaged ports. Clean or replace as necessary. W hen r einstallin locatin

pin is in t he hole for proper posi tioning and

to prevent burner from rollin

as manifold pipe. Inspect burner

burners, assure that

over.

CLOSED CIRCUIT

(CONNECTED)

Typical 15

Range 10 - 20 20 - 35

OPEN CIRCUIT

(DISCONNECTED)

GAS BURNERS

The mai n gas burners are located under the boiler for heatin the steamer model. They ar e made of aluminized steel with lanc ed type ports and hav e adjustable air shutters in the front. Fixed ori fice t y pe hoods extend from the mani fold to establish burner.

Air Shutter Adjustment

1. I

2. Verify the manifold pr essure as outlined under

and number five to seven depending on

as flow to each

nite the burner s and al low to heat up for at

least five minutes.

“GAS MANIFOLD PRESSURE ADJUSTMENT”.

AUTOMATIC IGNITION SYSTEMS

(GAS MODELS)

When the main power switch i s tur ned ON and the

nition c ontrol modules reset switch is in the O N

i position, the i with 24VAC between terminals f ive and si x.

h voltage is sent from terminal nine t o the spark

Hi electrode and an out put of 24 volts is sent from terminals two and three to the pilot coi l in the combination valve, allowin The sparkin the flame sensor has confir med that an adequate pilot flame is present.

nition c ontrol module is energized

as to flow to the pilot.

will continue f or 90 seconds or until

Page 31 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

Once the pilot flame is confirmed, a 24 v olt output from terminal one will be sent, allowin valve (cyclin

) coil of the combination valve to

operate at the request of the cyclin

the mai n

pressure

switch.

A. Chec k to ensure that all electric al terminal

connections on the i and the i

nitor are clean and tight. If loose

nition c ontrol module

connections are found, make the necessary adjustments.

B. Verify that the i

nitor have good ground wire

the i connections. T he i should have to its m ountin

C. Remove the pilot i

followin

1) The round clip shoul d be

the approximately 1/8 inch. If the

nition c ontrol module and

nitor mounting bracket

ood metal to metal c ontact

surface.

nitor and check the

ap between the spark probe and

ap appears to be excessive or poor sparkin

is occurring then adjust.

Terminals:

1. Main Valve #1 with the pilot sensin

- 24VAC will be present on terminal electrode sensing an

adequate pilot fam e. This output will remain present as lon

as the pilot flame remains

adequate.

2. Common (MV/PV).

3. Pilot Valve #3 at the instant an input volta the modul e. This volta terminal #3 providin

- 24VAC will be present on terminal e is supplied to

e will remain present on

an adequate pilot flame is established withi n 90 seconds. I n the event that an adequate pilot flame is not established within 90 seconds this output volta

e will drop

out.

4. Ground (burner).

5. 24VAC Neutral (

round).

6. 24VAC Input.

7. Hi

h Voltage to spark electr ode ( The pilot flame current is sensed by the I via the spark electr ode hi

nitor Module

h voltage wire and

terminal #9).

Spark Ignition Control Test

2) Inspect t he c er amic flame r od insulator for cracks or evidence of exposure to ex treme heat, whic h c an permit leaka

e to ground. If either of these conditi ons exist, then replace the pilot i

3) Check the i or dama

nitor and re-test.

nition c able for t ightness

ed insulati on. If t he ignition cable appears to be dam a replace it and re-test.

2. Install the pilot i

nitor and attach ignition c able.

A. Turn the main power switch ON and ver ify

nition c ontrol modules re-set switch

the i is ON. Observe spark condit ion from

nitor.

1) If a spark from i nites the gas from the pilot and

nitor i s present and

burner then the system is workin properly.

ed, then

1. If t he i to be sparkin followin

nition c ontrol module does not appear

to ignite gas, perform the

Page 32 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gh g

g ag

2) If a spark from ignitor i s present but does not i

nite gas before the ignition control module lock s out, (90 sec.) there may not be enou line for i and

nition. Verify the gas supply

as combination control valve are both on. Turn the i modules re-set switch OFF then ON to reset the m odule. Sparki n then resume to i module may need reset sever al times before i

3) If i

nition takes place.

nitor is still not sparking proceed

to step 3.

3. Check the i

nition c ontrol module and

transformer. A. Turn the i

nition c ontrol modules re-set switch OFF then ON to eliminate a lockout conditi on.

B. Chec k for 24VAC output on the i

control module transformer.

1) If 24VAC is present between

terminals 5 & 6 on the i module but i then replace i

nitor i s not sparking,

nition c ontrol module

and re-test.

as in the

nition c ontrol

nite gas. The

nition c ontrol

should

nition

4. After the burner li pressure readin

hts, compare the manometer

to the pressure chart near t he

end of this procedure. A. If other appliances are connected to the

same manometer pressure readin

as line, tur n them all ON and check

ain. If the pressure drops ½ inch water column or more, t hen the incomin be checked. then t he be checked by the local

as company f or adequate sizing.

B. If no other

to the

as line or the pressure does not

as appliances are connected

pressure should

as supply needs to

as line installer or the

drop as described abov e but the mani fold pressure still requires adj ustment, proceed to step 5.

5. Remove the adjustment screw cap to access the pressure adjustment screw.

2) If 24VAC is not present t hen ensure that transformer i s receivin input. If i

nition c ontrol module

transformer is receivin

e, then replac e ignition c ontrol

volta

120VAC

proper

module t r ansformer and re- test.

4. After makin

the necessary component adjustment s or replacements, c hec k for proper operation.

GAS MANIFOLD PRESSURE

ADJUSTMENT

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. Open the f r ont cabinet doors and turn the

2. To measure the manif old pressure, remove the

DISCONNECT THE ELECTRICAL

SHUT OFF THE GAS SUPPLY

combination control valve off.

1/8 inch NPT plu

(pressure tap) on the outl et

side of the valve and attach a manometer .

6. After the burner li

hts, set the pressure as

outlined below. A. To increase pressure, turn the screw

clockwise

B. To decrease pressure, turn the screw

countercloc k wise

NOTE:

Accurate

be made with the

GAS TYPE MANIFOLD

Natural 4.0 7.0 5.0

Propane 10.0 11.0 11.0

as pressure adjustments can only

as ON and the burner lit.

PRESSURE READINGS

(INCHES W.C.)

LINE

RECOMMENDED MIN MAX

3. Turn the

as combination control valve and the

main power switch to ON.

NOTE

: If the incomin

line pressure is

minimum stated, then the manifold pressure can not

less than

the

be set correctly.

Page 33 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gaug

ge g

ging

7. Once the correc t pressure has been set, turn the power switch OFF, replace the adjustm ent screw cap and 1/8 inch NPT plu on the outlet si de of the valve.

8. Check for pr oper oper ation.

(pressure tap)

DIRECT STEAM MODELS

These models consist of a pressure regulator and

e that run off a buildings potable steam supply .

The re should be set for a dischar maximum input pressure to the re 15 psi. Incomin compartment controls is supplied f r om a junction box in t he base.

ulator used will be of the adjustable type and

e pressure of 10 psi. The

ulator should be

power (120VAC) for the

REGENERATED STEAM

(OLDER MODELS)

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.

The contactor c an be serviced by r emov in cover of the contac tor box.

A noisy contact or ( hum or chatter ) is to excessive dust or dirt on the armat ur e pole faces or around the arm ature core preventin coil from pullin sealed position. This can usually be cor r ec ted by blowin electrical contacts, remove cover at top of contactor by removin Replace contactor if the electrical contacts appear to be severely pitt ed or bur ned.

DISCONNECT THE ELECTRICAL

the

enerally due

the magnet

the armature into a completely

or wiping the pole faces clean. To inspect

two screws which hold it in plac e.

HEATING ELEMENTS

The steam coils on a regenerated type steamer are intended for use at a steam supply pressure of 15 psi maximum. A pressure re available as opti onal equipment for steamers where a buildin The re should be set for a dischar for monit or ed by the supplied pressure re (steam solenoi d valve is open). If steam is heavy with condensate, install a ball float trap in the steam line before the pressure re

WARNING:

BEFORE SERVICING THE UNIT. To remove a steam c oil, di sconnect union in steam

supply line to the coil s and i n the condensate dischar supplies steam to c oils by disconnectin each coil. In same way, rem ove coi l condensate collection header. Remove four bolts clampin coil flan flan mate with

Turn steamer power switch O N, allowin

eneration and, c onsequently, pressure to rise to normal oper atin OFF for a final pur lines. St eamer is now ready for use.

s steam supply pressure exceeds 15 psi.

ulator used will be of the adjustable type and

ood steam generation. This pressure can be

ulator should be set, only when steam is f lowin

SHUT OFF THE STEAM SUPPLY

e line from the c oils. Remove header that

e in place and pull coil forward. Use a new

asket when replacing coil. The faces that

asket must be cl ean.

level and then turn power switch

of boiler and steam supply

ulating valve is

e pressure high enough

e. The

ulating valve.

union at

each

steam

WARNING:

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

1. Measure the v olta terminals and ver ify it a volta

A. If volta

B. If volta

C. If c ur r ent draw is correct then heat in

D. If c ur r ent draw is not correct t hen r eplace

NOTE:

new surfaces which contact the removed elem ent shows a pronounced scale build-up on its heatin should be removed and mechanically c leaned to remove the scale. This will prolon NOT immerse elements in a chem ical solution to descale.

2. Check for pr oper oper ation.

THE FOLLOWI NG ST EPS REQUIRE

e at the heati ng element

ainst the data plate

e is incorrect, find the source of

the problem.

e is correct, check current draw

(amps) throu

See table below for proper

wires.

values.

element is ok.

the elem ent and proceed to step 3.

When r eplacin

asket and ensure that the flange and tube

h the heating element lead

an element , always use a

asket are clean. If

tubes, the other elements

their l ife. DO

Page 34 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

TOTAL

VOLTAGE

208 18 2 9 87 50 14.42 240 18 2 9 75 44 19.20 480 18 2 9 22 76.80

*220/380

240/415

208 24 2 12 116 68 10.82 240 24 2 12 100 58 14.40 480 24 2 12 29 57.60

*220/380

240/415

208 36 4 9 100 14.42 240 36 4 9 87 19.20 480 36 4 9 44 76.80

*220/380

240/415

18 2 9 25 19.20

24 2 12 34 14.40

36 4 9 50 19.20

NUMBER

ELEMENTS

PER

ELEMENT

AMPERAGE

PER LINE

1 PH 3 PH

RESISTANCE

PER

ELEMENT

(OHMS)

208 42 4 10.5 117 12.36 240 48 4 12 116 14.40 480 48 4 12 58 57.60

*220/380

240/415

NOTES:

1. Values in the t able are nomi nal. Toler anc e is +/-10 %.

2. Asterisk (*) i ndicates 3 phase/4wire.

3. Each heater has three i nternal elements.

48 4 12 67 14.40

Page 35 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

gaug

gauge g

THERMAL SWITCH - PREVENT

AND AUTO MATIC MODELS

The load compensator is a therm al switch in a stainless steel housin

(newer models) on the left side wall of the

fittin compartment. The switc h c ontacts should close when the compartment tem per ature reaches 180(F, supplyin valve, pilot li

The correct adjustment or veri ficat ion of the load compensator can best be made by usin thermometer and thermocouple to sense the compartment temperature.

power to the steam exhaust solenoid

ht and cooking timer motor.

Newer Model s

A. This switch is NON-ADJUS TABLE. Check

to see if the switch is operatin described below. If the switch is suspected to be mal functi onin for proper oper ation.

Older Models

A. The switch can be adjusted by tur nin

slotted screw. Turn the screw clockwise lower the closin countercloc k wise temperat ur e. Check the operation of the switch as described below. These models are ½ NPT.

that screws into a 3/8 NPT

properly as

, replace it and check

the

temperat ur e and

to raise the closin

a digital

D. If the cookin

the red li an abnormal amount of time elapses before they c ome on, then the load compensator i s set too hi tim er stops, the red li buzzer does not sound after the compartment has exhausted the steam or if the tim e is set as usual for the product and the product i s overcooked or if the tim e is set as usual for the product and the product is overcooked.

E. If there is too short a time between startin

and the red light coming on, or if it comes on immediatel y , the load compensator is set too low. Also, if the time is set as usual for the pr oduc t and the product i s undercooked.

cycle is started normally, but

ht and timer do not com e on or

h. Also, if the

ht goes out, and the

WATER LEVEL GAUGE

ASSEMBLY

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

2. Unscrew the packin of the

3. Slide t he of the t ube is clear of the fittin

e assembly.

nuts at the top and bottom

lass tube.

lass tube upwards, until t he bottom

and lift it out.

1. Position t he thermocoupl e near the exposed bulb of the load compensator inside the compartment.

2. Close and seal the com par tment. P ull the steam control arm handl e forward, set the timer and turn the compartment power switch O N.

3. Monitor t he thermocoupl e temperature, and adjust or verify (as applicable) the load compensator temperature.

A. The red li

should li 185 ±7 (F.

B. After the cookin

compartment temperature lowers, the thermal switch should then re-open at 165 ±7 °F.

C. If the load compensator c an not be

adjusted correct ly or the temperature is out side the allowable limits, then r eplace thermal switch and check f or pr oper operation.

ht of t he c ompartm ent switch

ht when the thermoc ouple reads

cycle ends and the

4. Reinstall the tube and use new sealin washers. Do not over tighten the packi ng nuts, it coul d br eak the

5. Open the top and bottom valves fully.

6. Check for pr oper oper ation.

lass.

Page 36 of 88

VL SERIES STEAMER - SERVICE PROCEDURES AND ADJUSTMENTS

STEAM GATE VALVE(S)

On all models, each cooking compartment has its own mechanical steam steam to the c ook in control arm handle is pul led forward. T he P r event models use a solenoid valve to exhaust steam f r om the compartment whereas the Automatic, S tandard and Manual models use an additional steam valve t o exhaust steam when the steam c ontrol arm handle is returned to the rear. These a standard type and can be disassembl ed for cleanin

If steam leaks are noti c ed ar ound the packin and stem durin until the steam leak c eases. Rel ease steam control arm to ensure i ts automati c r eturn. If arm does not return freely or steam is still leakin inspection or adjustments are necessary. T ur n the tim er and c ompartm ent power switch OFF and blowdown the boiler. Remov e the control arm bracket and packin out the old strin then be re-packed usin steam service.

and gasket replacement.

cooking, tighten the packi ng nut

packing. The valve stems may

ate v alve that supplies

compartment when the steam

ate

ate v alves are

nut

, then f ur ther

nut from the stem and c lean

a string packing suitable for

Replace the packin

hten the packi ng nut finger tight plus ½ turn and

Ti check for pr oper oper ation. If steam cont inues to leak, ti increm ents until i t stops and re-check operati on of the steam cont r ol arm.

NOTE:

linka to return the steam control ar m to the fully c losed position.

For other service to these valves, remove t he stem assembly and cap at t he top of the valve. Check the valve linka

The steam simple and there funct ion easily seen. The inlet and exhaust steam the inlet valve is open and the exhaust valve closed when the steam control arm handle is pulled forward and rever ses when the control arm is released.

NOTE:

power fail ur e, the steam cont r ol arm can be operated manually on automatic models.

hten the packi ng nut in additional ½ t ur n

Do not ov er ti

e system must be free enough for the sprin

e for l oose or binding parts.

ate v alve linkage for these cont r ols are

In the event of an electric al component or a

nut and control ar m bracket.

hten packing glands, the

ate v alves must be positioned so

Page 37 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

ELECTRICAL OPERATION

WATER LEVEL CONTROLS

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

The steamer is equipped with three water l evel sensin a sin control board per forms two functions:

1. Prov ide low level cut-off pr otection to shut off

2. Performs as a differential level control to

The water level contr ol (WLC) has input volta (120VAC) across term inals 11 and 12 which powers the transfor mer. On one side of the transformer secondary, power is provided to the control by a series path throu The other side of the transf or mer secondary (12VAC) supplies power to one side of the int er nal relays LLCO, HL and I LR. As water enters the boiler, it becomes part of the water level c ontrol’s circui t. When the water level in the boiler reac hes a probe, that circuit is complet ed.

The inverse latchin ener contacts in t heir shelf state.

When the main power switch i s tur ned ON, power is supplied to the WLC board which ener level (HL) rel ay and illuminates the HL relay LED. With the HL-3 cont ac ts closed, the boiler fi ll solenoid is ener boiler.

When the water level reaches the low level c ut-off (LLCO) probe, t he LLCO relay is ener illuminates the LLCO LED. With the LLCO-2 contacts closed the heat source is then ener The LLCO relay will remain ener will stay lit until the water level in the boiler drops below the LLCO probe.

When the water level reaches the low level ( LL) probe, power to terminal 2 on the WLC board is present but no switchin

After the water level reaches the hi probe, the inverse lat c hin ener (LL) and ILR-1 contac ts. With ILR-2 cont ac ts open, this de-ener out. With t he HL- 3 c ontacts open, the boiler fill solenoid is de-ener into the boiler.

probes (high, low and low level cut- off) and

le water level cont r ol board. The water l evel

the heat source in case the water level drops below the low level cut- off ( LLCO) probe.

maint ain the water level between the low and

h water level probes.

h cha ssis ground (term inal 10).

relay of the board is de-

ized, l eaving the ILR-1 (N.O.) and ILR-2 (N.C.)

izes the high

ized and water begins filling the

ized and

ized.

ized and it s LED

occurs.

h level (HL)

relay of the board is

ized and lock ed through the low level probe

izes the HL relay and the HL LED goes

ized, stoppi ng the flow of water

When the water level drops below the low level (LL) probe, power is removed f r om the inverse latc hin relay, t he HL r elay energizes through ILR-2 and HL contacts chan

h HL-3 to refill the boiler and the HL LED is lit .

throu The HL relay and LED will to

a cooking cycle as needed.

durin

e state. The fill solenoid is energized

le ON and OF F

Page 38 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Solid State - Auxiliary Low Level Cut-Off

This control serves as a safety bac k up to the mai n water level control (W LC) boar d to meet Cal - Code and CSD-1 code requirements. The aux iliary control provides auxiliary low level cut-off protection to shut off the heat source in case the water level drops below the low level cut- off ( LLCO) probe. A sin LLCO probe is connected to the auxiliary control.

The auxiliary water level control (WLC) has input

e (120VAC) across term inals L1 and L2 to

volta power the transformer primary. On one side of the transformer secondary, power is provided to t he control by a series path throu other side of the transformer secondary (12VAC) supplies power to one side of the internal r elay LLCO. As water enters the boi ler, it bec omes part of the auxiliary water level control’s circuit. When the water level in the boiler reaches the LLCO pr obe, the circuit is completed.

When the main power switch i s tur ned ON, power is supplied to the auxiliary WLC board but no switchin level indicator li comes on.

occurs. On CSD-1 models, the l ow water

ht (amber) on the boiler control box

h cha ssis ground. The

When the boiler stops fillin button on the boi ler control box. On CSD-1 models, this ener water li control. On Cal-Code models, this closes and lock s the manual r eset switc h c ontacts to ener heat source auxiliary control.

izes the low water relay , turns off the low

ht and energizes the heat source auxiliary

, press the manual r eset

ize the

When the water level reaches the low level c ut-off (LLCO) probe, t he LLCO relay is ener illuminates the LLCO LED. With the LLCO-2 contacts closed the auxiliary heatin

ized. The LLCO relay will remain energized

ener and its LED will stay lit until the water level in the boiler drops bel ow the LLCO pr obe.

ized and

control is then

Page 39 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

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

The steamer is equipped with three water l evel sensin

probes (high, low and low level cut- off) , a differenti al level control (1G1GO) and a low level cut-of f control (1D1DO). The low-lev el cut-off is an additional control that is identical to t he differential level control but serves as the saf ety backup to shut off the heat source in case the water level drops below the low level cut- off ( LLCO) probe. The differential level control maintains the water level between the low and hi

Each control is powered by input volta

h water level probes.

e (120VAC) on terminals 1 and 2 which also connect t o the primar y si de of the internal transformer. The transformer secondary (300VAC) will provide power to the int er nal contactor c oil throu

h a series path

oing from one side of the secondary winding,

h the contactor c oil, thr ough the water level

throu control probe, throu the boiler for transformer secondary is attac hed to

h the water in the boiler and to

round. The other si de of the

round.

When the main power switch i s tur ned ON, both water level controls are ener solenoid is then ener

ized through the normally

ized. The boiler fill

closed contacts (t er minals 3 & 4) on the differenti al level control and water be

ins filling the boiler .

When the water level reaches the low level c ut-off (LLCO) probe, t he internal contactor coil on the low water level control is ener

ized. Wit h the contacts on terminals 7 & 8 now closed, the heat source is then ener remain ener

ized. The internal contactor coil will

ized unti l the water level i n the boiler

drops below the LLCO probe. When the water level reaches the low level ( LL)

probe, power to terminal 7 on the differential level control will be present but no switchin

After the water level reaches the hi

occurs.

h level (HL)

probe, the differ ential cont r ol contactor c oil is

ized and the normally c losed contacts on

ener terminals 3 & 4 open, which de-ener

izes the boiler fill solenoid and stops the flow of water into the boiler. The internal contactor coil will have a lockin path through contacts 7 & 8 to t he low level probe to keep the coil ener below the hi

ized af ter the water level drops

h level probe.

When the water level drops below the low level (LL) probe, the internal contactor coil is de-ener returnin closed state and ener

contacts 3 & 4 back t o their norm ally

izing the boiler fill solenoid to

ized,

refill the boiler. The water level must then fill to the

h level probe again, to energize the i nternal

hi contactor coil. The differential control will to and OFF durin

a cooking cycle as needed.

le ON

Page 40 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Electro Mech anical - Auxiliary Low Level Cut-Off

This control serves as a safety bac k up to the mai n low level cut-off (LLCO) c ontrol to meet Cal-Code requirem ents. The operation of the auxiliary control is identical to the mai n low level cut-off contr ol but perf or ms

le function: 1) Provide auxiliary low level cut-off protection to shut off the heat source in case the water

a sin level drops below the low level cut-off (LLCO) probe. A si n main low level cut-of f control is connected to t he auxiliary control.

le LLCO probe i dentical t o the LLCO probe on the

The auxiliary control is powered by input volta primar y si de of the internal transformer. The transformer secondary windin internal contactor coil throu coil, throu side of the transform er secondary is attached to

When the main power switch i s tur ned ON, the auxiliary low level control is ener When the water level reaches the low level c ut-off (LLCO) probe, the internal c ontactor coil on the low level

control is ener until the water level in the boiler drops below the LLCO pr obe.

When the boiler stops fillin manual reset switc h c ontacts to ener

h the water level contr ol probe, through the water in the boiler and to the boiler for ground. The other

ized, closing the contacts on terminals 7 & 8. The internal contactor coil will remain energized

h a series path going from one side of the secondary winding, through the contactor

, press the manual r eset button on the boiler control box. Thi s closes and locks the

ize the heat source auxiliary control.

e (120VAC) on terminals 1 and 2 which al so connect to the

(300 VAC) will provide power to the

round.

ized but no switching occurs.

Page 41 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

SEQUENCE OF OPERATION

GAS MODELS

This sequence of operation is writt en for steamer s with electr onic i controls, CSD- 1 ( c ode) boiler contr ols option and with Prevent cookin to schematic dia boiler control schemat ic and 3962 for a schematic and wirin compartment controls.

Initial Fill and Preheat

1. Conditions. A. Power switch OFF. B. I C. Cookin D. Compartment power switches OFF. E. Unit connected t o c or r ec t volta

1) L1 (HOT ) to one side of the c ook in

2) L2 (NEUTRA L) to one side of the

F. Unit pr oper ly

level control share a common G. Water supply valve on. H. Gas supply valve on. I. Gas combinati on c ontrol valve ON. J. Control (cyclin K. Hi L. Cold water condenser (CWC) thermostat

open. M. Blowdown solenoid val ve (drain) open and

boiler empty. N. Compartment doors open.

2. Power switch turned ON. (located on boiler control box)

A. Power switch indicator li

on.

B. Hi pressure indicator li

on.

C. Low water level indicator li

comes on.

nition, solid state water l evel

compartment controls. Refer

ram num ber s 3928 and 3929 for a

diagram on Prevent cookin

nition module reset switch O N

timers off.

compartment controls; to one side of the cold water condenser ther mostat; to one side of the power ON/OFF switch.

cookin side of the c old water condenser (CW C) sol enoid valve; to one side of the power ON/OFF switch.

h limit pressure switch closed.

compartment controls; to one

rounded. (Boiler and water

) pressure switch closed.

ht (red) comes

ht (amber) comes

ht (amber)

e .

round)

NOTE:

on and the safety c ircuit de- ener steam pressure is within oper ational l imits (hi pressure switch closed) and the manual reset button is pressed. The low water indic ator li on and the safety c ircuit de- ener level in the boiler reaches the low level cut-of f probes (minimum level) for the water level control, the auxiliary low level cut-off control and the manual reset switch is pressed. The light until these conditi ons are satisfied.

NOTE:

position, no sparkin while idlin out and not re-i pressu re switch.

The hi

D. W ater level control (WLC) is powered.

E. Auxiliary low water level cut-off control is

F. With t he HL- 3 and ILR-2 contacts cl osed,

G. Blowdown solenoid valve is ener

H. I

If t he modules re-set switch i s i n the OFF

h pressure indicator light will remain

ized unti l boiler

h limit

ht will remain

ized unti l the water

as burners will not

1) Hi

2) The i nverse lat c hin

powered, LLCO-2 (N.O.) contacts remain open.

the fill solenoid is ener boiler be

closes.

pilot after a 3 second delay .

1) If pilot i

2) If pilot i

or cooking, then pilot and burners will go

h level (HL) rel ay is energized, HL-3 (N.O.) contacts close and HL LED li

board remai ns de-ener the ILR-1 (N.O.) and ILR-2 (N.C.) contacts in t heir shelf state.

nition module begins sparking to light

then a mi c r o amp flame sense current is sent back to the i control module throu cable. Spark in lit and is ready to i

90 seconds, sparkin i power to the combination (pilot valve and m ain valve r emain closed). The module rem ains locked out until the reset switch on the i switched to OFF then ON to re- star t the i

hts up.

relay of the

ized, l eavin

ized and water

ins filling.

ized and

nition is established (pilot lit)

nition

h the ignition

stops, pilot remains

nite burners.

nition is not established after

stops and the

nition c ontrol module locks out

as valve

nition c ontrol module box is

nition trial cycle.

will occur or if it’s turned OFF

nite upon call for heat by the cyclin

Page 42 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

ging

3. Water level reaches LLCO (low water level cutoff) probe for the water level control and to the auxiliary LLCO probe for the auxiliary low level cut-off control.

A. P ower to terminal 9 on the water level

control.

1) LLCO relay ener contacts close and LED li

izes, LLCO-2 (N.O.)

hts.

B. P ower to terminal LLCO on the auxiliary

low water level cut-off control.

1) LLCO relay ener contacts close and LED li

NOTE: LLCO relays will remain ener

izes, LLCO-2 (N.O.)

hts.

ized and LLCO LED’S will remain lit until the water level drops below the LLCO probes or the power switch is turned OFF.

4. Water reaches LL (low level) probe. A. P ower to terminal 2 on the water level

control is present but no switchin

5. Water reaches HL (hi

h level) probe.

occurs.

A. Power to terminal 6 on water level control.

1) The i nverse lat c hin board is ener

relay of the

ized, changing the state of ILR-1 (N.O.) and ILR-2 (N.C.) contacts. The inver se l atchin will rem ain ener alternate latchin

ized through the

path of I LR- 1

relay

contacts unti l the water level recedes below the low level probe.

2) With I LR- 2 c ontacts open, HL relay is de-ener open and HL LED

3) Water fill solenoid is de-ener

ized, HL-3 (N.O.) contacts

oes out.

ized.

(boiler fill time approx. 11 mi n.)

6. Manual re-set switch is pressed, ener coils on the hi

A. Contacts 1 & 9 on the hi

chan and turn off the hi li

ht. Concurrent ly, Contact s 1 & 9 on t he

low water relay chan

h limit and low water rel ay s.

h pressure relay

e state and lock from N. C. to N.O.

h pressure indicator

e state and lock from

izing the

N.C. to N.O. and turn off the low water indicator li

B. Contacts 5 & 9 on the hi

chan supplyin of the auxiliary

ht.

h pressure relay

e state and lock from N.O. to N.C.,

power (NEUTRAL) to one side

as solenoid v alve. Concurrently , Contacts 5 & 9 on the l ow water relay chan N.O. to N.C., supplyin other side of the auxiliary

e state and lock from

power (L1) to the

as solenoid

valve.

NOTE: For both relays to ener

ize, the high pressure switch must be closed and the water level in the boiler must be above the low level c ut-off probes in order f or LLCO-2 (N.O.) contacts to close.

C. Auxiliary

and opens to allow

D. As lon

sensin

as solenoid v alve is energized

as flow.

as the ignition c ontrol module is

a pilot flame, the int er nal main valve (MV) contacts close (N.O.) on the i

nition c ontrol module. The m ain gas

valve is ener

E. Burners li

ized and gas begins flowing.

ht and water in boiler begins to

heat up.

7. Boiler steam pressure reaches upper limit set point of 11 PSI. (Appr oxim ately 15 min.)

A. Cycli n

solenoid valve de-ener shuts off and bur ner s

pressure switch opens, main gas

izes, gas flow

o out.

B. A s boi ler heats up and builds pressure,

some by-pass water/steam i s produced which runs into the steam drain box . This causes the cold water condenser (CWC) solenoid to cycle, coolin

the drain water. This solenoid is powered by the CWC thermostat .

NOTE: S team should not be seen enterin

a compartment unti l the manual steam control arm i s pulled forward and locked.

8. Boiler steam pressure drops below lower limit

set point of 9 PSI and the cyclin

pressure

switch closes. A. B oiler steam pr essure is maintained by the

cyclin

of the pressure switch between the upper and lower set point limits. The cyclin ener solenoid valve startin flow of

pressure switch continues to

ize and de-energize the main gas

and stopping the

as, which in turn, cycles the burners on and off. This sequence continues unti l one of the foll owin

occurs:

1) Boiler pressurizes to 15 PSI, causin

the high limit pressure switch to open. At that time, the auxiliary de-ener

izes, shutting off the gas flow to t he bur ner s and the hi failure li

ht will come on. This light

as valve

h limit

will stay lit until the pressure drops below the lower li mit set point of 6 PSI and the manual re-set switch i s pressed.

2) Boiler water level drops below the LLCO probes for t he water level and the auxiliary low level cut-off controls which then de-ener relays, chan

izes the LLCO

the contact state of LLCO-2 (N.O.) back to open. This deener

izes the main and auxiliary gas

solenoid valves. The

as solenoid valves will remain off and the low water level li

ht will come on and stay lit until the water level rises above the LLCO probes and the manual re-set switch is pressed.

Page 43 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Cook Cycle

1. A Cook cycle should not be started, until the initial fill and preheat is complet ed, in order for the boiler steam pressure to be within operational limits.

A. Insert product into steamer. B. Compartm ent door is closed and screw

handle ti

htened down.

C. Compartment steam c ontrol arm is pulled

forward and lat c hes, allowin

steam to

enter compar tment.

NOTE: Cool air and condensate exit t hr ou

h the steam exhaust sol enoid valve ( N.O.) until compartment temperature reaches 180°F.

D. Time is dialed on t imer (past 5 minutes).

1) Mic r o switc h S W1 cont ac ts chan state from N.C. to N.O.

2) Mic r o switc h S W2 cont ac ts also chan

e state from N.C. to N.O.

E. Compartm ent power switch is turned ON.

1) L1 (HOT ) to one side of the thermal switch.

NOTE: L2 (NEUTRAL) i s connected to the other side of the buz z er , steam exhaust sol enoid valve, trip solenoid, pilot li

ht and timer motor .

F. Once compartm ent temperat ur e r eac hes

approximately 180°F therm al switch closes and supplies power L1 (HOT) to:

1) Steam exhaust solenoi d valve (N.O.) ener

ized and closes.

NOTE: Even thou is closed, a small openin blade of the valve t o allow “limited free ventin condensate durin

2) Pilot li

h steam exhaust sol enoid valve

exists in the “guillotine”

” of

a cook cycle.

ht (red) comes on indicatin

tim ed c ook ing at 180°F has started.

3) Ti mer mot or ener

2. Cookin

Tim er times down to approx imately

ized

one minut e before zero. A. Micro switch SW 2 contacts chan

e state from N.O. back to N.C. (normal startin position).

1) Steam exhaust solenoi d valve is de-

ener

ized and opens to exhaust steam and pressure from the compartment.

2) Steam trip solenoid is ener

ized and unlatches steam c ontrol arm allowin it to return to the rear. S team supply the compartment i s shut off.

3. Cookin

timer reaches zero.

A. Micro switch SW 1 contacts chan

e state from N.O. back to N.C. (normal startin position)..

4. Cookin

tim er is manuall y turned off.

5. Compartment power switch is turned OFF, buzzer is de-ener

ized and power is removed

from the common side of micro switch SW1.

6. Steamer reverts to preheat cycle until: A. A cookin

cycle is started. i.e. compartment door is closed and screw handle ti

htened down, time is dialed into tim er ( past 5 minutes) and the compartment power switch is turned O N.

B. Water level drops below low level cut-off

probe.

C. Power switch is turned OFF.

NOTE: Burners will re-li

ht aft er the boiler pressure drops below the low pressure set point limit ( 9 psi ) and will stay on until the hi psi) is reached. As l on limits, even while cookin

h pressure set point (11

as steam pressure is within

, burners can go off. The boiler is able to re-pressurize t o the upper set point limit even with all compartments in cook mode.

NOTE: The cold water condenser thermostat remains closed and cold water condenser solenoid stays ener

ized while cooking. If main water is shut off after boiler fill, then no cold water is present t o condense steam/hot water and steam vapor s exit the floor drain.

Water Refill (After Initial Fill)

1. Water level drops below low level probe (LL) .

A. P ower i s removed from terminal 2 on the

water level control .

1) The i nverse lat c hin ener

ized, returning ILR-1 (N.O.) and

relay is de-

ILR-2 (N.C.) c ontacts back to their

inal state.

ori

B. HL r elay is ener

ized.

1) Contact s HL-3 close.

2) HL LED comes on.

3) Fill solenoid is ener

ized and water

flows into tank.

2. Water reaches LL (low level) probe. A. P ower to terminal 2 on the water level

control is present but no switchin

3. Water reaches hi A. The inverse latchin

level control is ener

h level probe.

relay of the water

ized, changing the

occurs.

state of ILR-1 (N.O.) and ILR-2 (N.C.) contacts.

B. HL r elay is de-ener

ized.

Page 44 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

1) HL-3 opens.

2) Fill solenoid de-ener stops flowin

3) HL LED

4. The water refill cycle will occur whenever the water level is below the l ow level pr obe and will not affect the operation of either the preheat or cook cycle.

Boiler Blowdown/drain

1. Main power switch turned OFF. A. B oiler blowdown sequence starts. B. The blowdown solenoid valve ( N.O.) is de-

ized and valve opens to drain the

ener boiler.

C. Power is removed fr om all c omponents

except cold water condenser (CWC) thermostat and sol enoid valve. The CWC thermostat cycles as necessary to lower the dischar and condense steam

into tank.

oes out.

e temperat ur e of the water

ized and water

oing into the drain.

ELECTRIC MODELS

This sequence of operation is writt en for steamer s with electr o mechanical water level controls, CalCode boiler controls option and wit h P r event cookin dia and 3962 for a schem atic and wirin Prev ent cookin

INITIAL FILL AND PREHEAT

1. Conditions.

compartment controls. Refer t o schematic

ram num ber 3941 for a boiler control schematic

diagram on

compartment controls.

A. Power switch OFF. B. M anual reset switch OFF. C. Cookin D. Compartment power switches OFF. E. Unit connected t o c or r ec t volta

1) L1 to one side of the boiler fi ll

timers off.

e supply.

solenoid valve; to one side of the main and auxiliary contactor(s); to one side of the power on l i to one side of the heat on li (amber); to one side of the timer motor; to one side of the c old water condenser solenoid valve; to one side of the blowdown solenoid valve; t o terminal 1 on the auxiliary low level control t hen jumpers connect L1 to terminal 1 on the differ ential and l ow level controls; to the com par tment controls.

ht (red);

2) L2 to the c ommon ter minal on the blowdown timer relay; to pi n 4 on the boiler ON/OFF switch; to one side of the manual r eset switc h; to one side of the auxiliary switch(s) mounted on the side of the auxiliary contactor(s); to the com par tment cont r ols.

F. Unit pr oper ly

level control share a common G. Water supply valve on. H. Control (cyclin I. Hi J. Cold water condenser (CW C) thermostat

K. B lowdown solenoid val ve (drain) closed

L. Compartment doors open.

2. Power switch turned ON. (located on boiler control box)

A. P ower to terminal 2 on the different ial

B. Power switch indicator li

C. Boiler fill solenoid valve is ener

NOTE: The safety circuit r emains de-ener until the water level in the boiler reaches the low level cut-off probe ( minimum l evel) for the auxiliary low level cut-off control and the manual reset switc h is pressed. Also, until the water level in the boiler reaches the low level cut-of f probe (m inimum level) for the low level cut-of f control, the low level cut-off control remains de-ener will not pressed these conditions are satisfied.

3. Water level reaches LLCO (low water level cutoff) probe for the low level cut-off control and to the auxiliary LLCO probe for the auxiliary low level cut-off control.

A. P ower to terminal 10 on the low level cut -

h limit pressure switch closed.

open.

and boiler empty.

water level control then jum per s connect to term inal 2 on both the low level cut-off and auxiliary low level cut-off water level controls.

on.

boiler be

come on until the m anual rest switch is

off and on the auxiliary low lev el cut-off control is present. The inter nal contactor coil on t he water level controls are t hen ener

ized.

1) The normally open c ontacts on terminals 7 and 8 for bot h the main and auxiliary low level cut-off controls close.

2) The main heater cont ac tor(s) are then ener

rounded. (Boiler and water

round)

) pressure switch closed.

ht (red) comes

ized and

ins to fill.

ized

ized. The heating element s

ized.

Page 45 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

NOTE: P ower the internal contactors on the low level cut- off and auxiliary low level cut-off will remain, until the water level drops below the LLCO probes or the power switch is turned OFF.

4. Manual reset switch is pressed (momentary). A. The aux iliary heater contactor is ener

supplyin and the heat li

power to the heating element s

ht (amber) comes on.

ized

1) Water in boiler heats up.

B. Internal relay on manual r eset switc h is

ized.

ener

1) Norm ally open contac ts close and lock to provide power to the auxiliary heater contact or and the heat li

after the reset switch is released.

5. Water reaches LL (low level) probe. A. P ower to terminal 7 on the different ial

level control is present but no switchin occurs.

6. Water reaches HL (hi

h level) probe.

A. P ower to terminal 10 on the different ial

level control.

1) The i nternal contactor coil on the differenti al level controls is ener

ized.

a. The normally closed cont ac ts on

terminals 3 and 4 open, deener

izing the boiler fill solenoid

and the boiler stops fillin

NOTE: The internal contactor coil has a lockin

path through contacts on terminals 7 & 8 to the low level pr obe to keep the coil ener below the hi

ized af ter the water level drops

h level probe.

7. Boiler steam pressure reaches upper limit set point of 11 PSI. (Appr oxim ately 15 min.)

A. Cycli n

contactor(s) de-ener heatin

NOTE: S team should not be seen enterin

pressure switch opens, heater

ize and power to the

element s i s removed.

a compartment unti l the manual steam control arm is pul led forward and loc k ed.

8. Boiler steam pressure drops below lower limit set point of 9 PSI and the cyclin

pressure

switch closes. A. B oiler steam pr essure is maintained by the

cyclin

of the pressure switch between the upper and lower set point limits. The cyclin ener

pressure switch continues to

ize and de-energize the heatin element contactor(s), which in turn, cycles the heatin

element s on and off. This sequence continues until one of the followin

occurs:

1) Boiler pressurizes to 15 PSI, causin the high limit pressure switch to open. At that time, the auxiliary heatin element c ontactor(s) are deener

ized, shutting off power to the

heatin

element s. The pressure switch will remain open until the pressure drops below the lower limit set point of 6 PSI. Boiler water level drops below the LLCO (low water level cut-off) pr obes for the low level cut-of f and the aux iliary low level cutoff controls, de-ener

izing the internal contactor on bot h c ontrols. Thi s deener

izes the main and auxiliary heater contact or s, shuttin to the heati n

element s. The heatin

off power

elements will remain off until the water level rises above the LLCO probes and the manual r e- set switc h is pressed.

COOK CYCLE

1. A Cook cycle should not be started, until the initial fill and preheat is complet ed, in order for the boiler steam pressure to be within operational limits.

A. Insert product into steamer. B. Compartm ent door is closed and screw

handle ti

htened down.

C. Compartment steam c ontrol arm is pulled

forward and lat c hes, allowin

steam to

enter compar tment.

NOTE: Cool air and condensate exit t hr ou the steam exhaust solenoid valve (N.O.) under “Full Free Ventin

” until the compartment temperat ur e r eac hes 180°F. When the solenoid valve ener continue to exhaust throu

izes and closes, condensate will

h a small openin the v alve under “ Limited Free Venti ng” until the solenoid valve de-ener

izes and re-opens, one

minute before the end of a cook cycle. D. Time is dialed on t imer (past 5 minutes).

1) Mic r o switc h S W1 cont ac ts chan state from N.C. to N.O.

2) Mic r o switc h S W2 cont ac ts also chan

e state from N.C. to N.O.

E. Compartm ent power switch is turned ON.

1) L1 (HOT ) to one side of the thermal switch.

NOTE: L2 (NEUTRAL) i s connected to the other side of the buzzer, steam exhaust solenoid valve, tri p sol enoid, pil ot li

ht and

timer motor.

Page 46 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

F. Once compartm ent temperat ur e r eac hes

approximately 180°F therm al switch closes and supplies power L1 (HOT) to:

1) Steam exhaust solenoi d valve (N.O.) ener

ized and closes.

NOTE: Even thou

h steam exhaust solenoid valve is closed, a small openin exists in the “guillotine” blade of the valve to allow “l imited free ventin condensate durin

2) Pilot li

a cook cycle.

ht (red) comes on indicatin

” of

tim ed c ook ing at 180°F has started.

3) Ti mer mot or ener

2. Cookin

Tim er times down to approx imately

ized

one minut e before zero. A. Micro switch SW 2 contacts chan

e state from N.O. back to N.C. (normal startin position).

1) Steam exhaust solenoi d valve is de-

ener

ized and opens to exhaust steam and pressure from the compartment.

2) Steam control sol enoid (trip) is ener

ized and unlat c hes steam

control arm allowin

it to return to the rear. Steam supply the compartment is shut off.

3. Cookin A. Micro switch SW 1 contacts chan

timer reaches zero.

e state from N.O. back to N.C. (normal startin position).

B. B uz z er is ener

4. Cookin

tim er is manuall y turned off.

ized.

5. Compartment power switch is turned OFF, buzzer is de-ener

ized and power is removed

from the common side of micro switch SW1.

6. Steamer reverts to preheat cycle until: A. A cookin

cycle is started. i.e. compartment door is closed and screw handle ti

htened down, time is dialed into tim er ( past 5 minutes) and the compartment power switch is turned O N.

B. Water level drops below low level cut-off

probes.

C. Power switch is turned OFF.

NOTE: Heatin

elements will come back on, after the boiler pr essure drops below the l ow pressure set point limit (9 psi) and will stay on until the hi pressure set point (11 psi) i s reached. As lon

as steam pressure is within limits, even while cookin heatin

element s can go off. The boiler is able to repressurize to the upper set point limit even with al l compartments in cook mode.

WATER REFILL (AFTER INITIAL FILL)

1. Water level drops below low level probe (LL) . A. P ower i s removed from terminal 7 on the

differential water level control.

1) The i nternal contactor coil is deener

ized returning contacts 3 and 4 back to there ori ener

izing the boiler fill solenoid to

inal state and

refill the boiler.

2. Water reaches LL (low level) probe. A. P ower to terminal 2 on the water level

control is present but no switchin

3. Water reaches HL (hi

h level) probe.

occurs.

A. P ower to terminal 10 on the different ial

level control.

1) The i nternal contactor coil on the differenti al level controls is ener

ized.

a. The normally closed cont ac ts on

terminals 3 and 4 open, deener

izing the boiler fill solenoid

and the boiler stops fillin

NOTE: The internal contactor coil has a lockin

path through contacts on terminals 7 & 8 to the low level pr obe to keep the coil ener below the hi

ized af ter the water level drops

h level probe.

4. The water refill cycle will occur whenever the water level is below the l ow level pr obe and will not affect the operation of either the preheat or cook cycle.

BOILER BLOWDOWN/DRAIN

1. Main power switch turned OFF. A. Power switch indicator li

ht (red) goes out and power is removed form all boiler controls ex c ept the blowdown timer .

2. Blowdown timer switc h is pressed. A. The normally open timer contacts close,

ener

izing the blowdown solenoid valve

and the cold water condenser valve.

B. Boil er be

ins blowing down and drainin until timer “ times out” after approximately 4 minut es.

C. Timer contacts re-open and power is then

removed from the blowdown solenoid valve and t he c old water condenser valve.

Page 47 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

PAGE PURPOSELY LEFT BLANK

Page 48 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

SCHEMATICS, GAS ST EAMERS, BOILER CONTROLS

VL2G AND VL3G - PREVENT, AUTOMATIC, STANDARD AND MANUAL

Manual Ignition, Standard Controls

Page 49 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Electronic Ignition, Standard Controls

Page 50 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Manual Ignition, CSD-1 Code Controls

Page 51 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Electronic Ignition, CSD-1 Code Controls

Page 52 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Page 53 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

WIRING DIAGRAMS, GAS STEAMERS, BOILER CONTROLS

VL2G AND VL3G - PREVENT, AUTOMATIC, STANDARD AND MANUAL

Manual Ignition, Standard Controls

Page 54 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Page 55 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Electronic Ignition, Standard Controls

Page 56 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Page 57 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Manual Ignition, CSD-1 Code Controls

Page 58 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Page 59 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Electronic Ignition, CSD-1 Code Controls

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

SCHEMATICS, ELECTRIC STEAMERS, BOILER CONTROLS

VL2E AND VL3E - PREVENT, AUTOMATIC, STANDARD AND MANUAL

Auto Blowdown, Standard Controls

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VL SERIES STEAMER - ELECTRICAL OPERATION

Auto Blowdown, Cal-Code Controls

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VL SERIES STEAMER - ELECTRICAL OPERATION

WIRING DIAGRAMS, ELECTRIC STEAMERS, BOILER CONTROLS

VL2E AND VL3E - PREVENT, AUTOMATIC, STANDARD AND MANUAL

Auto Blowdown, Standard Controls (contactor - 1 std.)

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

Auto Blowdown, Standard Controls (contactors - 2 std.)

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

Manual Blowdown, Cal-Code Controls (contactors - 1 std. 1 aux.)

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

Auto Blowdown, Cal-Code Controls ( contactors - 1 std. 1 aux.)

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

Auto Blowdown, Cal-Code Controls (contactors - 2 std. 2 aux.)

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

Manual Blowdown, Cal-Code Controls (contactors - 2 std. 2 aux.)

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VL SERIES STEAMER - ELECTRICAL OPERATION

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VL SERIES STEAMER - ELECTRICAL OPERATION

WIRING DIAGRAMS, ELECTRIC HEATER CIRCUITS

VL2E AND VL3E - PREVENT, AUTOMATIC, STANDARD AND MANUAL

Standard and Cal-Code/CSD-1 Controls

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VL SERIES STEAMER - ELECTRICAL OPERATION

SCHEMATIC AND WIRING D IA GRA MS, DIRECT STEAMERS, CABINET BA SE VL2D AND VL3D - PREVENT, AUTOMATIC, STANDARD AND MANUAL

See “SCHEMATIC AND WIRING DIAGRAMS - COMPARTMENT CONTROLS”

Page 77 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

WIRING DIAGRAMS, REGENERATED STEAMERS, BOILER CONTROLS

VL2R AND VL 3R - PREVENT, AUTOMATIC, ST ANDARD AND MANUAL

Manual Blowdown (Older Models)

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VL SERIES STEAMER - ELECTRICAL OPERATION

Auto Blowdown (Older Models)

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VL SERIES STEAMER - ELECTRICAL OPERATION

SCHEMATIC AND WIRING DIA GRAMS - COMPARTMENT CONTROLS

Prevent

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Automatic

VL SERIES STEAMER - ELECTRICAL OPERATION

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Standard

VL SERIES STEAMER - ELECTRICAL OPERATION

Page 82 of 88

VL SERIES STEAMER - ELECTRICAL OPERATION

Manual

NO ELECTRICAL COMPONENTS ARE USED WITH THE MANUAL COMPARTMENT CONTROLS OPTION.

THE CONTROLS CONSIST OF A MANUAL COOKING TIMER AND MANUAL STEAM CONTROL ARM TO CLOSE AND OPEN THE STEAM GATE VALVES.

Page 83 of 88

VL SERIES STEAMER - TROUBLESHOOTING

TROUBLESHOOTING

ALL MODELS

WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TESTS OR

SYMPTOM POSSIBLE CAUSES

Compartment leaks water around door. 1. Drai n screen c logged.

2. Drain line obstructed or not t o an open

3. Steamer not level.

4. Excessive cookin A. On models equipped with the compartment pressure

ulating valve, veri fy the compartment pressure is 6 psi durin pressure re COMPARTMENT PRESSURE ADJUSTMENT” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

B. On models with out the compartment pressure

ulating valve, veri fy the compartment pressure is 6 psi durin cyclin AND HIGH LIMIT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

compartment pressures.

cooking. If pressure is higher then adjust the

ulating valve and re- c hec k . See

cooking. If pressure is higher then adjust the

pressure switch and re-check. See “CY CLING

ap drain.

Cold water condenser not operatin properly.

Steam leaks around door. 1. Compartment door not properly sealed.

Steam when timer or c ompartm ent power switch is OFF.

Heat comin (Dry firin

Pressure relief valve openin

enerated inside compartm ent

on without water in boiler

or leaking. 1. Pr essure rel ief valve malfunction.

1. Water supply not on.

2. Plu

3. Cold water condenser solenoid inoperative or plu

4. Cold water condenser thermostat mal functi on or needs

5. No power to cold water condenser solenoid.

2. Wor n or dama

3. Drain line obstructed or not t o an open dr ain.

1. Steam

1. Lime scal e ( moist) on LLCO water level probe or probe

2. Retention of water in probe canister assembly.

3. Water level control malfuncti on.

2. Cyclin

ed spray nozzle.

adjustment .

ed gasket.

ate v alve not fully closing (clogged, dirty or malfunctionin PROCEDURES”.

damaged (shorted to ground).

pressure switch set to high. See “CYCLING A ND HI LIMIT PRESSURE SWITCHES (GAS AND ELECTRIC MODELS)” in “SERVICE PROCEDURES”.

). See “STEAM GATE VALVE” in “SERVICE

ed.

Page 84 of 88

VL SERIES STEAMER - TROUBLESHOOTING

gging

gauge g

SYMPTOM POSSIBLE CAUSES

Boiler base will not heat or buil d pressure.

Steam out put low or slow cookin

1. Check incoming voltage.

2. Boiler not f illed - check fill solenoid for power, c lo malfunction.

3. Water Level Control malf unc tion. HL-3 relay not ener or contacts not closing to power boiler fill solenoid.

4. Water too “pure” for probes to properly c onduc t electricity.

5. Contactor malfunc tion (electric only ) .

6. Heatin

7. Cyclin cyclin

8. Hi

9. Problem with auto blowdown timer ( older model s).

10. Power switch malfuncti on.

11. Pressure reducin (direct or r e

12. Low or no steam supply to steamer (direct or re models only ) .

. 1. S team gate v alve not fully opening or blocked.

2. Cyclin

3. Steam header line (supply) blocka

4. Heavy amount of c ondensate in the pressure controls steam supply line.

5. Pressure relief valve leakin

6. Steam supply lines leaki n

element inoperative (elec tric only ) .

pressure switch open or set too high. Steam er is

on high limit.

h limit thermostat open.

valve malf unc tion or needs cleaned

enerated models only).

pressure switch malfunction or needs adj ustment.

izin

enerated

Boiler leaks water. 1. Loose water, steam or drai n line connections (top or base).

2. Boiler hand hole

3. Leak at

Boiler fill solenoid cyclin

Boiler water level too hi

Boiler does not fill or slow to fill. 1. Water supply not on or pressure too l ow.

to frequent ly. 1. LL probe lim e scal ed over (dry) or dam aged and not sensin

water.

2. Water level control malfuncti on.

h. 1. Fill solenoid does not shut off .

2. Hi

3. Water level control malfuncti on. HL-3 relay not de- ener

2. Line strainer c lo

3. Fill solenoid not malfuncti onin

4. A Hi

5. Water level control malfuncti on. HL-3 relay not ener

h lev el probe lime scaled over (dry) or damaged and is

not sensin

or contacts not opening.

the fill solenoid val ve not t o open. See ”BOILER NOT FILLING WITH WATER” i n “SERVI CE PRO CEDURES AND ADJUSTMENTS”.

contacts not closin

water (open circuit).

h pressure pocket in the supply line to the boiler causes

asket not sealing.

lass.

izin

ed.

or plugged.

izing or

to power boiler fill solenoid.

Page 85 of 88

VL SERIES STEAMER - TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSES

Cooking tim er motor does not run. 1. Tim er not getting power.

2. Tim er motor inoper ative.

Buzzer not operat in

Compartment red li come on; excessive time elapses before they come on; tim er stops, the red li

oes out, and the buzzer does not sound after c ompartm ent exhausts steam; time is set as usual for the pr oduc t and the product is overcooked.

Short a ti me between startin

ht coming on; red light comes on

li immediatel y ; tim e is set as usual for the product and the product is undercooked.

Cookin inoperati ve

Compartment Control s

. 1. Cooking tim er malfunction.

ht and timer do not

and the red

2. Buzzer malfunct ion.

1. Thermal switch (load compensator) is set too hi

1. Thermal switch (load compensator) is set too low.

1. Ensure that voltage is reaching control circuit through compartment power switch when turned ON.

2. On electr ic heat models with a transformer, check step down transformer (locat ed in the contact or box) for pr oper operation.

3. Check cookin “SCHEMATIC AND WIRING DIAGRAMS COMPARTMENT CONTRO LS” under “ELECTRICAL OPERATION”.

4. Check that timer motor operates when connected to power. I f a problem is found in t imer, r eplace it, do not take timer apart.

5. On prevent and automatic models check the load compensator for mal functi on.

6. Check wirin

7. Check that al l connections and ter minals are securely fastened. (no open c ircuits)

8. Check that al l connections are made accordin compartment control wirin

tim er functi on and c ontact positi on. See

for damaged insulati on. (no short circuit)

diagram.

Cookin of cook cycle (Prevent m odels) or when manual steam control ar m is released.

Compartment not venting at end

1. Steam control arm not returnin standard and manual models).

A. Broken or missin B. Packin C. Steam c ontrol (trip) solenoid malfunc tion (prevent and

automatic model s).

2. Steam exhaust solenoid valve mal functi onin models).

Page 86 of 88

nut on steam gate v alve to tight.

return spring.

after unlatching (automat ic,

(prevent

VL SERIES STEAMER - TROUBLESHOOTING

g g

GAS MODELS ONLY

SYMPTOM POSSIBLE CAUSES

Burner won’t li

ht. 1. Gas not on.

nition c ontrol module reset switch in the OFF position or

2. I malfunctionin

nition module not rec eiving power. Check ignition module

3. I transformer for 24V A C output to module on automat ic i

nition systems.

4. Steamer not properly power is incorrect on automati c ignition systems.

5. Low incomin PRESSURE ADJUSTMENT” in “SERVICE PROCEDURES”.

6. I

nition module m alfunct ion.

7. Gas combination control valve malf unc tion.

8. Boiler not f illin malfunction.

9. Water level control malfuncti on. HL-3 relay not ener or contacts not closing to power boiler fill solenoid.

10. W ater too ”pure” for probes to properly c onduc t electricity.

11. Hi

12. Hi

13. Cycli n

h limit thermostat open (if equipped). h limit pressure switch open.

pressure switch open or set too high. Steam er is cyclin PRESSURE SWITCHES (GAS AND ELECTRIC MODELS) in SERVICE PROCEDURES”.

on high limit. See “ CY CLING AND HI LIMIT

rounded and/or polarity of incomi n

as pressure. See “GAS MANIFOLD

. Check fill solenoid for power, clogging or

izin

Burner won’t stay li t. 1. Gas pressure low. See “GAS MANI FOLD PRESSURE

ADJUSTMENT” in “SERVICE PROCEDURES”.

2. Check

3. I

as orifice for obstruc tion.

nition module m alfunct ion.

Page 87 of 88

VL SERIES STEAMER - TROUBLESHOOTING

g g

SYMPTOM POSSIBLE CAUSES

Pilot not lit or goes out. 1. Gas not on.

2. Pilot

3. Low incomin

4. Pilot not adjusted correct ly. See “PI LOT AND

5. Check thermopile millivolts. See “PILOT AND

6. Burners i

7. If aut o i

8. Wr on

oing out due to drafts, excess steam from drain or steamer not level. Impr oper ventin flame away from thermopile or f lame sensor.

PRESSURE ADJUSTMENT” in “SERVICE PROCEDURES”.

THERMOCOUPLE ASSEMBLY (GAS MODELS)” in “SERVICE PROCEDURES AND ADJUSTMENTS”.

steamer. See “GAS MANIFOLD PRESSURE ADJUSTMENT” in “SERVICE PROCEDURES”.

nition and no sparking - ignition module

malfunction.

pilot assembly used.

can direct the pilot

as pressure. See “GAS MANIFOLD

nite too violently. Chec k gas pressure to the

Spark I

nitor not sparking. 1. Poor ground between pilot br ac k et and burner.

2. Loose, broken or dama from i

3. I causing excessive ignition voltage leakage.

4. Ceramic flame rod insulator on i from extreme heat.

5. Incorrect spark SYSTEMS (GAS MODELS)” in “SERVICE PROCEDURES”.

6. I i

7. I

nition module to ignitor.

nitor boot on ignition c able loose, damaged or missin

ap setting. See “AUTOMATIC IGNITION

nition module not rec eiving power. Check to ensure the

nition c ontrol module reset switch is ON.

nition module m alfunct ion.

ed lead wires (including ground)

nitor crac k ed or damaged

Form 24650 (M ay 1999) Printed in U.S.A.

Vulcan-Hart VL3GAS, VL3GMS, VL3GPS, VL2GMS, VL2GAS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual