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Vulcan-Hart ML-136059 manual

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  • Page 1

    A product of VULCAN-HART LOUISVILLE, KY 40201-0696 F35453 (July 2008) - NOTICE - This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. If you have attended a Vulcan Service School for this product, you may be qualified to perform all the procedures described in this manual.[...]

  • Page 2

    MODEL C24EA F35453 (July 2008) Page 2 of 68 TABLE OF CONTENTS G E N E R A L ................................................................................ 3 C O V E R S A N D P A N E L S ..................................................................... 5 D O O R .................................................................................[...]

  • Page 3

    MODEL C24EA - GENERAL F35453 (July 2008) Page 3 of 68 GENERAL INTRODUCTION This manual is applicable to the models and ML numbers listed on the cover page. Procedures apply to all models unless specified otherwise. Steam Cooking Convection steamers offer an efficient way to produce many foods in either small portions or larger batches. Convection s[...]

  • Page 4

    MODEL C24EA - GENERAL F35453 (July 2008) Page 4 of 68 Other chemical properties in water supplies can also affect good steam generation and vary from within each state and locality. The water level probes in the steam generator use ions in the water to detect the water level. Do not use fully demineralized or de-ionized water since it is non-conduc[...]

  • Page 5

    MODEL C24EA - COVERS AND PANELS F35453 (July 2008) Page 5 of 68 COVERS AND PANELS FRONT BASE PANEL 1. Remove screws from the bottom of panel. 2. Pull bottom of panel out and slide down to clear tabletop cover. 3. Reverse procedure to install. RIGHT AND LEFT SIDE BASE PANELS NOTE: Removal of left side panel is identical to the procedure for the righ[...]

  • Page 6

    MODEL C24EA - COVERS AND PANELS F35453 (July 2008) Page 6 of 68 REAR BASE PANEL 1. Remove electrical power connection to machine. 2. Turn off water supply and disconnect plumbing to machine. 3. Remove screws securing water valves to panel. 4. Remove screws from the bottom of panel. 5. Pull bottom of panel out and slide down to clear tabletop cover.[...]

  • Page 7

    MODEL C24EA - DOOR F35453 (July 2008) Page 7 of 68 DOOR REMOVAL 1. Close door. 2. Remove COOKING COMPARTMENT LEFT SIDE PANEL as outlined under COVERS AND PANELS. 3. Remove nuts from upper hinge located inside front panel. 4. Open door slightly, and while holding door, pull upper hinge away from front panel. 5. Pull upper hinge out of upper door hin[...]

  • Page 8

    MODEL C24EA - DOOR F35453 (July 2008) Page 8 of 68 DOOR HANDLE Removal 1. Open door. 2. Remove screws from top and bottom of door assembly. 3. Pull outer door housing away from inner door panel starting at the hinge side of door to separate the door halves. NOTE: The smaller radius of the step spacers fit into the slots of the outer door housing an[...]

  • Page 9

    MODEL C24EA - DOOR F35453 (July 2008) Page 9 of 68 LATCH ASSEMBLY Removal and Disassembly 1. Separate outer door housing assembly from inner door panel as outlined under DOOR HANDLE. 2. Remove screws securing latch assembly to inner door panel and remove latch mechanism. 3. Remove E-clip from latch assembly pins and pull pins from latch mechanism. [...]

  • Page 10

    MODEL C24EA - DOOR F35453 (July 2008) Page 10 of 68 Installation 1. Install latch assembly onto inner door panel with spring pin toward bottom of door panel. A. Apply Loctite 271 to threads of screws before assembly and secure latch assembly to inner door panel. 2. Install outer door housing assembly as outlined under DOOR HANDLE. 3. Check opening [...]

  • Page 11

    MODEL C24EA - DOOR F35453 (July 2008) Page 11 of 68 B. Locate the striker that catches on door latch near steam chamber on front panel. C. Remove the nut from striker and this should release it from the panel. D. Open door. 2. Remove striker. 3. Remove any burrs on striker that may cause latch to stick. 4. Apply Loctite 271 to threads of striker. 5[...]

  • Page 12

    MODEL C24EA - THERMOSTATS AND HIGH LIMITS F35453 (July 2008) Page 12 of 68 THERMOSTAT AND HIGH LIMITS HEAT EXCHANGER HIGH LIMIT 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. 2. Remove RIGHT SIDE BASE PANEL as outlined under COVERS AND PANELS. 3. Disconnect electrical lead wires from heat exchanger high limit. [...]

  • Page 13

    MODEL C24EA - THERMOSTATS AND HIGH LIMITS F35453 (July 2008) Page 13 of 68 8. Remove capillary tube from heating element. Installation 1. Route capillary bulb through the opening in heating element mounting plate. Ensure there are no sharp bends in capillary tubing while installing. A. Insert capillary bulb into the holding tube on heating element.[...]

  • Page 14

    MODEL C24EA - TIMERS F35453 (July 2008) Page 14 of 68 TIMERS REMOVAL AND REPLACEMENT NOTE: When the timer reaches zero, an external buzzer will sound and steam will stop entering the cooking compartment. The constant steam setting allows for continuous steam operation. 1. Remove COOKING COMPARTMENT RIGHT SIDE PANEL as outlined under COVERS AND PANE[...]

  • Page 15

    MODEL C24EA - HEATING ELEMENTS AND CONTACTORS F35453 (July 2008) Page 15 of 68 HEATING ELEMENTS AND CONTACTORS REMOVAL AND REPLACEMENT Heating Elements 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. A. Turn off water supply. 2. Remove FRONT BASE PANEL as outlined under COVERS AND PANELS. 3. Remove top screw sec[...]

  • Page 16

    MODEL C24EA - HEATING ELEMENTS AND CONTACTORS F35453 (July 2008) Page 16 of 68 Contactors 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. 2. Remove FRONT BASE PANEL as outlined under COVERS AND PANELS. 3. Remove top screw securing cover to high voltage box. 4. Note electrical connections for the contactor being [...]

  • Page 17

    MODEL C24EA - HEATING ELEMENTS AND CONTACTORS F35453 (July 2008) Page 17 of 68 3. If unable to check current draw, a resistance check may indicate a malfunctioning element. A. Turn power switch off and disconnect power to machine. B. Disconnect heating element lead wires and check t he individual element resistance using a VOM. C. If resistance rea[...]

  • Page 18

    MODEL C24EA - HEAT EXCHANGER ELEMENTS AND RELAYS F35453 (July 2008) Page 18 of 68 HEAT EXCHANGER ELEMENTS AND RELAYS REMOVAL AND REPLACEMENT Heat Exchanger Elements 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. A. Turn off water supply. 2. Remove FRONT BASE PANEL and RIGHT SIDE BASE PANEL as outlined under COV[...]

  • Page 19

    MODEL C24EA - HEAT EXCHANGER ELEMENTS AND RELAYS F35453 (July 2008) Page 19 of 68 6. Reassemble parts removed in reverse order. Apply pipe thread sealant to threads of heat exchanger element before assembly. 7. Check steamer for proper operation and leaks around heat exchanger element. Heat Exchanger Relays (K10, K12) 1. Turn off machine to drain s[...]

  • Page 20

    MODEL C24EA - HEAT EXCHANGER ELEMENTS AND RELAYS F35453 (July 2008) Page 20 of 68 3. If unable to check current draw, a resistance check may indicate a malfunctioning element. A. Turn power switch off and disconnect power to machine. B. Disconnect heat exchanger element lead wires and check resistance using a VOM. C. If resistance is not correct, r[...]

  • Page 21

    MODEL C24EA - WATER LEVEL CONTROL COMPONENTS F35453 (July 2008) Page 21 of 68 WATER LEVEL CONTROL COMPONENTS WATER LEVEL CONTROL - LOW LEVEL CUT-OFF AND DIFFERENTIAL OPERATION The steamer is equipped with three water level sensing probes (high, low and low level cut-off) and a water level control. The water level control performs two functions: 1. [...]

  • Page 22

    MODEL C24EA - WATER LEVEL CONTROL COMPONENTS F35453 (July 2008) Page 22 of 68 WATER LEVEL CONTROL 1. Remove FRONT BASE PANEL as outlined under COVERS AND PANELS. 2. Squeeze tab on plastic standoffs (5) to release water level control. 3. Note electrical connections then disconnect lead wires from water level control (WLC). Refer to the machine schem[...]

  • Page 23

    MODEL C24EA - WATER LEVEL CONTROL COMPONENTS F35453 (July 2008) Page 23 of 68 DUAL WATER VALVES SHOWN FILTERED AND NON-FILTERED DUAL WATER SOLENOID VALVES NOTE: The filtered and non-filtered water solenoid valves are constructed as dual water valve assemblies. The two water valve assemblies used on the steamer have different flow rates and should n[...]

  • Page 24

    MODEL C24EA - WATER LEVEL CONTROL COMPONENTS F35453 (July 2008) Page 24 of 68 6. Remove screws (2) securing dual water solenoid valve to rear panel. 7. Reassemble parts removed in reverse order. 8. Verify water supply is connected to the correct dual water solenoid valve (filtered or non filtered). 9. Check steamer for leaks and proper operation. M[...]

  • Page 25

    MODEL C24EA - WATER LEVEL CONTROL COMPONENTS F35453 (July 2008) Page 25 of 68 NOTE: When installing, align the flat on delime valve stem and the locking pins on delime valve to the motorized control assembly. NOTE: The two electrical plugs on the motorized control assembly are identical. If the electrical wiring is not connected correctly, the moto[...]

  • Page 26

    MODEL C24EA - SWITCHES, SOLENOIDS, RELAY, AND BUZZER F35453 (July 2008) Page 26 of 68 SWITCHES, SOLENOIDS, RELAYS AND BUZZER POWER AND DELIME SWITCHES 1. Remove COOKING COMPARTMENT RIGHT SIDE PANEL as outlined under COVERS AND PANELS. 2. Locate switch on front panel. 3. Disconnect electrical plug from the switch being replaced. 4. Remove switch fro[...]

  • Page 27

    MODEL C24EA - SWITCHES, SOLENOIDS, RELAY, AND BUZZER F35453 (July 2008) Page 27 of 68 Installation 1. Verify E-clip is installed on door switch linkage in groove nearest front panel. 2. Loosely install door switch onto door switch mounting bracket. A. Close door. B. Push switch up against switch linkage as far as possible. C. Tighten switch mountin[...]

  • Page 28

    MODEL C24EA - SWITCHES, SOLENOIDS, RELAY, AND BUZZER F35453 (July 2008) Page 28 of 68 Check NOTE: Pressure can be checked with the small air pocket that exists between the delime port cap and water level probe housing in the delime hose. Make certain that no leaks exist in the steam generator connections or pressure gauge fittings. 1. Turn off mach[...]

  • Page 29

    MODEL C24EA - SWITCHES, SOLENOIDS, RELAY, AND BUZZER F35453 (July 2008) Page 29 of 68 B. Check cut-out pressure after making adjustment. Repeat Check and Adjustment as necessary until cut-out pressure is within 3.5 to 3.7 psi. PRESSURE SWITCH (2PAS) 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. 2. Remove FRONT[...]

  • Page 30

    MODEL C24EA - SWITCHES, SOLENOIDS, RELAY, AND BUZZER F35453 (July 2008) Page 30 of 68 COMPARTMENT STEAM SOLENOID 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. 2. Remove RIGHT SIDE BASE PANEL as outlined under COVERS AND PANELS. 3. Locate compartment steam solenoid connected to cooking compartment. 4. Disconnec[...]

  • Page 31

    MODEL C24EA - SWITCHES, SOLENOIDS, RELAY, AND BUZZER F35453 (July 2008) Page 31 of 68 BUZZER 1. Remove COOKING COMPARTMENT RIGHT SIDE PANEL as outlined under COVERS AND PANELS. 2. Locate buzzer on the door switch mounting bracket. 3. Disconnect electrical wiring from the buzzer and door switch. 4. Remove door striker. 5. Remove remaining hardware s[...]

  • Page 32

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 32 of 68 CONTROL BOARD REMOVAL AND REPLACEMENT 1. Remove FRONT BASE PANEL as outlined under COVERS AND PANELS. 2. Disconnect electrical connectors from control board. 3. Squeeze tab on plastic standoffs (10) to release control board. 4. Reassemble parts removed in reverse order. 5. Check steamer f[...]

  • Page 33

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 33 of 68 LAYOUT AND LED LEGEND The control board provides a central location for wire harness connections and power transfer through board relays (K1-K9, and K11) and time delay relays (delime 1, delime 2 and drain) to the steamer controls. Also, provides a condition or component troubleshooting i[...]

  • Page 34

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 34 of 68 STEAM GENERATOR OPERATIONAL STATUS (LED INDICATORS) Use the tables below to determine the operational stat us of a component or condition by utilizing the LED indicators on the board. The sections are divided according to their operational step. NOTE: If steamer power switch is off when l[...]

  • Page 35

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 35 of 68 Water Level at LLCO Probe • LLCO LED is on (water level control) (LED is on until water drops below LLCO probe). • All contactors energized (steam generator begins heating). • Water fill of the steam generator changes to slow fill rate. LED STATUS COMPONENT DESCRIPTION ON OFF 1 X Sa[...]

  • Page 36

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 36 of 68 Steam Generator at Operating Pressure • Ready lights (1LT) (green) lit for the upper and lower compartments. • All contactors de-energized (heating stops). LED STATUS COMPONENT DESCRIPTION ON OFF 1 X Same as Starting Conditions 2X Same as Water Level at LLCO Probe Limiting contactor ([...]

  • Page 37

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 37 of 68 Timers Reach Zero (Upper and lower Compartments) • Buzzer sounds until timer turned to off, constant or additional time is set. • Cook lights (2LT) (red) turn off and cooking compartment steam solenoids de-energize. • Heat exchanger heating elements de-energize. • LED 3 and 4 will[...]

  • Page 38

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 38 of 68 DELIMING CYCLE STATUS (LED INDICATORS) • Conditions same as listed under STARTING CONDITIONS. • Delime time delay relay 2 (TDR) and drain time delay relay (TDR) jumpers on the control board are set at their default times as shown on the schematic. • Delime valve closed. • Delime s[...]

  • Page 39

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 39 of 68 Water Level at LLCO Probe • LLCO LED is on (water level control) (LED is on until water drops below LLCO probe). • All contactors energized (steam generator begins heating). • Water fill of the steam generator changes to slow fill rate. LED STATUS COMPONENT DESCRIPTION ON OFF 1 X Sa[...]

  • Page 40

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 40 of 68 Steam Generator at Operating Pressure • All contactors de-energized (heating stops). LED STATUS COMPONENT DESCRIPTION ON OFF 1 X Same as Starting Conditions 2X Same as Water Level at LLCO Probe Limiting contactor (1CON) remains energized with the water level satisfied (LLCO probe). 3X R[...]

  • Page 41

    MODEL C24EA - CONTROL BOARD F35453 (July 2008) Page 41 of 68 LED STATUS COMPONENT DESCRIPTION ON OFF 1 X Same as Starting Conditions 3X Regulating contactor 1 (2CON) de- energized. Power removed from heating elements. 5 X Relay (K1) de-energized. Pressure switch (1PAS) contacts close. 9X Drain (TDR) energized thru K4-6/2 contacts. 120VAC output fro[...]

  • Page 42

    MODEL C24EA - HEAT EXCHANGER F35453 (July 2008) Page 42 of 68 HEAT EXCHANGER REMOVAL AND REPLACEMENT 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. A. Turn off water supply. 2. Remove FRONT and RIGHT SIDE BASE PANELS as outlined under COVERS AND PANELS. 3. Disconnect heat exchanger element wiring as outlined un[...]

  • Page 43

    MODEL C24EA - HEAT EXCHANGER F35453 (July 2008) Page 43 of 68 MOTORIZED DELIME VALVE NOTE: The motorized delime valve (normally closed) can be opened or closed manually by pushing in on the manual override knob on top of the valve to disengage the gear set. Rotate knob CW to open the valve (slot in knob vertical); or CCW to close the valve (slot in[...]

  • Page 44

    MODEL C24EA - STEAM GENERATOR F35453 (July 2008) Page 44 of 68 STEAM GENERATOR REMOVAL AND REPLACEMENT 1. Turn off machine to drain steam generator. Allow steamer to complete drain cycle. A. Turn off water supply. 2. Remove FRONT, LEFT and RIGHT SIDE BASE PANELS from generator base and COOKING COMPARTMENT RIGHT SIDE PANEL as outlined under COVERS A[...]

  • Page 45

    MODEL C24EA - STEAM GENERATOR F35453 (July 2008) Page 45 of 68 C. Remove four bolts securing high voltage control box to frame. 12. Remove low voltage control box from steamer. A. Disconnect wiring harness connector leading to cooking compartment controls. B. Disconnect delime valve and drain valve harness connectors from control board. C. Remove f[...]

  • Page 46

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 46 of 68 ELECTRICAL OPERATION COMPONENT FUNCTION STEAM GENERATOR CONTROLS W a t e r L e v e l C o n t r o l ( W L C ) ............... Controls water level by monitoring conditions of the three water level probes H, L and LLCO. P r o b e ( H ) ............................. High water level p[...]

  • Page 47

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 47 of 68 S o l e n o i d , D e l i m e V a l v e .................. Controlled by delime relay K7 and drain circuit operation. When energized by 24VAC, valve opens to allow deliming of the heat exchanger and elements during a delime cycle. Switch (1PAS), Pressure ................. Pressure [...]

  • Page 48

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 48 of 68 R e l a y ( K 9 ) , C a v i t y ...................... Controlled by lower cooking compartment timer. When timer is set, relay is energized and power is provided thru K8-1/5 N.C. contacts to cavity condensate solenoid and heat exchanger relay (K11). Heat exchanger element (2) energ[...]

  • Page 49

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 49 of 68 COMPONENT LOCATION Steam Generator Base[...]

  • Page 50

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 50 of 68[...]

  • Page 51

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 51 of 68 Water Level Control Cooking Compartment Controls[...]

  • Page 52

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 52 of 68 SMART CYCLE POWER MANAGEMENT Reduces energy use by not powering all the heating elements in steam generator and heat exchanger when the steamer is at operating pressure and one cooking compar tment in use. When both cooking compartments are in use, all of the heating elements in th[...]

  • Page 53

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 53 of 68 K. Pressure switch (1PAS) closed. L. Drain valve closed and steam generator is empty. M. Delime valve closed and heat exchanger empty. 1) Delime valve end switch N.O. contacts are open. N. Water level control (WLC) and steam generator properly grounded. 2. Power switch turned on (1[...]

  • Page 54

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 54 of 68 a) Ready lights (1LT) (green) are lit for the upper and lower compartments. b. K1-5/1 N.C. contacts open. a) LED 4 off. Regulating contactor 2 (3CON) de-energized. 2) LED 3 off. Regulating contactor 1 (2CON) de-energized. B. Power removed from heating elements. Steam generator heat[...]

  • Page 55

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 55 of 68 2) HL LED off. High level (HL) coil de-energized by ILR-2 contacts opening. a. WLC (HL) contacts open. Slow fill solenoid (4SOL) de-energized. 2. Timers reach zero (Upper & Lower Compartments). A. Upper compartment - Timer contacts 11/13 and 21/23 open. 1) LED 6 off. Upper cavi[...]

  • Page 56

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 56 of 68 6. LED 13 Lit. Power to delime 1 (TDR). Time delay relay has no output from load terminal until input trigger voltage is received by delime switch (2S) at the start of a delime cycle. 7. Water level drops below low level (L) probe. A. Internal latching relay coil (ILR) on WLC de-en[...]

  • Page 57

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 57 of 68 a. Delime relay (K2) remains powered. LED 15 remains lit from pressing delime switch (2S). b. Power to heating circuit, power light (3LT) (amber) and WLC thru K4-5/3 closed contacts (N.O.). a) Steam generator fills and operates as outlined in steps 2A thru 7B under Initial Fill and[...]

  • Page 58

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 58 of 68 SCHEMATIC DIAGRAMS[...]

  • Page 59

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 59 of 68 - THIS PAGE INTENTIONALLY LEFT BLANK -[...]

  • Page 60

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 60 of 68 Steam Generator Base[...]

  • Page 61

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 61 of 68[...]

  • Page 62

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 62 of 68 WIRING DIAGRAMS Heating Element Wiring[...]

  • Page 63

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 63 of 68[...]

  • Page 64

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 64 of 68[...]

  • Page 65

    MODEL C24EA - ELECTRICAL OPERATION F35453 (July 2008) Page 65 of 68 Cooking Compartment[...]

  • Page 66

    MODEL C24EA - TROUBLESHOOTING F35453 (July 2008) Page 66 of 68 TROUBLESHOOTING Before performing any of the troubleshooting checks lis ted below, remove the front generator base panel and check the LED’S on the control board for the status of the condition or component in the operating sequence. By utilizing the troubleshooting LED’S, the Servi[...]

  • Page 67

    MODEL C24EA - TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES F35453 (July 2008) Page 67 of 68 Steamer will not heat. 1. Check incoming voltage. 2. Steam generator not filled. See Symptom - Steam generator not filling or is slow to fill. 3. Power switch (1S) malfunction. 4. Steam generator high limit (2TAS) open. 5. Heat exchanger high limit (3TAS) open. 6[...]

  • Page 68

    MODEL C24EA - TROUBLESHOOTING F35453 (July 2008) Printed in U.S.A. - N O T E S -[...]