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Vulcan-Hart SG4D manual

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Table of contents for the manual

  • Page 1

    – 1 – Model SG4D SERVICE MANUAL SG4 & SG6 SERIES FULL SIZE GAS CONVECTION O VENS MODELS SG4D ML-114875 SG4C ML-114876 SG6D ML-114877 SG6C ML-114878 - NOTICE - This manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. If you have attended a Vulcan Service School for this[...]

  • Page 2

    – 2 – © VULCAN-HART, 2008[...]

  • Page 3

    – 3 – T ABLE OF CONTENTS GENERAL .............................................................................................................................................................. 5 Introduction ...........................................................................................................................................[...]

  • Page 4

    – 4 – TABLE OF CONTENTS (Cont.) Computer Controller (SG4C/SG6C) ......................................................................................................... 2 3 Operat ion ...................................................................................................................... ..................... 2 3 Setup Mode .....[...]

  • Page 5

    – 5 – INSTALLATION Generally, installations are made by the dealer or contracted by the dealer or owner. Detailed installation instructions are included in the Installation & Operation Manual which is sent with each unit. OPERATION Detailed operation instructions are included with each oven. CLEANING Detailed cleaning procedures are include[...]

  • Page 6

    – 6 – REMO V AL AND REPLA CEMENT OF P AR TS COMPONENT LOCATION DOOR SWITCH IGNITER & FLAME SENSE GAS BURNERS COMPONENT P ANEL COOLING FA N O VEN LIGHTS CONTROL P ANEL T OP VIEW BLO WER MO T OR TEMPERA TURE PROBE HIGH LIMIT GAS V AL VE PL-56044[...]

  • Page 7

    – 7 – COVERS AND PANELS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Top Front Cover 1 . The top front cover is secured with four screws, two on each side of cover. Remove these screws, then remove the cover from the oven. 2 . Reverse the procedure to install. Bottom Front Cover 1 . The bottom front cov[...]

  • Page 8

    – 8 – CONTROL PANEL COMPONENTS Procedure Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1 . Remove the control panel as outlined under Covers and Panels. 2 . Remove the component being replaced. 3 . Reverse the procedure to install the new component, then check oven for proper operation. MASTER SWITCH SG4[...]

  • Page 9

    – 9 – COMPONENT PANEL COMPONENTS Procedure Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1 . Remove the right side panel as outlined under Covers and Panels. 2 . Disconnect the wire leads to the component being replaced. 3 . Remove the component. 4 . Reverse the procedure to install the new component and[...]

  • Page 10

    – 10 – TEMPERATURE PROBE Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove the right-side panel as outlined under Covers and Panels. 2. Disconnect probe leads from the solid state temperature controller on the SG4D/SG6D or the computer controller on the SG4C/SG6C. 3. Remove the racks and right rack[...]

  • Page 11

    – 11 – GAS BURNERS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the oven. 1 . Remove the lower front cover as outlined under Covers and Panels. 2. There are two burners located on the bottom left and right side of the oven. Disconnect the ignition cable and the flame se[...]

  • Page 12

    – 12 – GAS ORIFICE Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the oven. 1 . Remove the lower front cover as outlined under Covers and Panels. 2 . Remove the bolts securing the gas manifold and place manifold aside. 3 . There are two gas orifices on the manifold. Remov[...]

  • Page 13

    – 13 – IGNITION CONTROL MODULE Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1 . Remove the right side cover as outlined under Covers and Panels. 2. Loosen the screws securing the mounting bracket to the component panel and remove the bracket. 3. Disconnect the lead wires and igniter cables from the igni[...]

  • Page 14

    – 14 – BLOWER AND MOTOR Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1 . Remove racks. 2. Remove the screws securing the snorkel and remove the snorkel. 3 . Remove screws securing baffle panel and remove the panel. 4 . If replacing: A. Blower Only - Loosen set screws on blower hub and using a bearing pu[...]

  • Page 15

    – 15 – 12 . Slide blower onto motor shaft until hub is flush with end of shaft, then tighten setscrews. 13 . Adjust motor position until blower is parallel to motor mounting plate as outlined in Blower Adjustment under Service Procedures and Adjustments. 14 . Position motor mounting plate on the rear wall and secure with nuts and washers. 15 . [...]

  • Page 16

    – 16 – 7 . The top and bottom bearings are now accessible for inspection and/or replacement if needed. A. If bearings are OK, proceed to step 8. B. If replacing the top bearing, remove the top bearing retainer and top bearing. C . If replacing the bottom bearing, remove it from the door shaft or the lower sill opening. 8 . Reverse procedure to [...]

  • Page 17

    – 17 – DOOR SWITCH Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove the top front cover as outlined under Covers and Panel. 2 . Disconnect the lead wires to the door switch. GLASS GLASS REMOVE SCREWS INNER DOOR PANEL ASSEMBLY PL-56053 2 . Remove the door handle, then remove the outer door panel. 3[...]

  • Page 18

    – 18 – Lamp Assembly 1. Remove the lens and bulb. 2. Remove the springs from the retaining tabs (two places) on the socket. 3. Depress the retaining tabs and pull the socket out from the oven, far enough to disconnect the lead wires. 4. Remove the socket from the oven. RETAINING TABS SPRING CROSS SECTIONAL VIEW PL-56055 3. Disconnect the lead w[...]

  • Page 19

    – 19 – COOLING FAN Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove the right side panel as outlined under Covers and Panels. 2 . Disconnect the lead wires to the fan motor by removing the wire nuts. 3. Remove the screws securing the air deflector to the fan, then loosen the tab screw holding the [...]

  • Page 20

    – 20 – SOLID STATE TEMPERATURE CONTROLLER TEST (SG4D/SG6D) Test Steps 1. Remove the right side panel as outlined under Cover and Panels in Removal and Replacement of Parts. 2. Place a thermocouple in the geometric center of the oven cavity. Oven temperature must be below 450°F. 3. Set the temperature control to the maximum setting. 4. Set the [...]

  • Page 21

    – 21 – SOLID STATE TEMPERATURE CONTROL CALIBRATION (SG4D/SG6D) Before attempting any calibration, see Section 8C of SOLID STATE TEMPERATURE CONTROLLER TEST (SG4D/SG6D) on previous page. Calibration Steps 1. Place a thermocouple in the geometric center of the oven cavity. 2. Set the ON/OFF/OVEN COOL switch to ON. 3. Set the temperature controlle[...]

  • Page 22

    – 22 – TEMPERATURE PROBE TEST (SG4D/SG6D) Disconnect the electrical power to the machine and follow lockout / tagout procedures. The temperature probe used in conjunction with the Solid State Temperature controller is an RTD (resistance temperature detector) of the Thermistor type. As temperature increases the resistance value decreases. Test S[...]

  • Page 23

    – 23 – COMPUTER CONTROLLER (SG4C/SG6C) Operation Refer to the Installation & Operation Manual for specific operating instructions. Setup Mode Use the setup mode to verify that the control is configured to the factory settings which result in the proper operation of the oven. If the CAL1 parameter is other than zero, see Computer Control Cal[...]

  • Page 24

    – 24 – Solid State Relay Test 1. Remove the right side panels as outlined under Covers and Panels in Removal and Replacement of Parts. 2. Turn the power switch to the ON position. 3. Check for +5 VDC on input side of SSR-1 in the normal heating mode (terminals 3 & 4) and SSR-2 in the roast and hold mode. A . If +5 VDC is present, continue t[...]

  • Page 25

    – 25 – GAS PRESSURE ADJUSTMENT Disconnect the electrical power to the machine and follow lockout / tagout procedures. Accurate gas pressure adjustments can only be made with the gas on and the burner lit. If the incoming line pressure to the valve is less than the minimum stated, then the manifold pressure cannot be set correctly. 1. Turn gas s[...]

  • Page 26

    – 26 – VERIFICATION OF SPARK AT IGNITOR Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the oven. 1 . Remove the bottom front cover as outlined under Covers and Panels in Removal and Replacement of Parts. 2. Disconnect the high voltage ignition cable from the spark igniter[...]

  • Page 27

    – 27 – Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1 . Remove the blower motor and mounting assembly as outlined under Blower and Motor in Removal and Replacement of Parts. 2. Loosen the motor mounting bolts. 3. Adjust the motor position until the blower is parallel to and 1 / 4 " inch away from t[...]

  • Page 28

    – 28 – Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1 . Check the doors to make sure they have an equal gap between them and that the vertical edge of the door is parallel to the vertical door seal. If the doors are not positioned in this manner, adjust the doors as described. EQUAL GAP EQUAL GAP PL-560[...]

  • Page 29

    – 29 – 6. Place a standard flat screwdriver through the opening in the top channel into the slot in the cylinder of the catch assembly. 7. Turn the screwdriver clockwise to increase the ball pressure or counterclockwise to decrease the pressure onto the door strike. The ball pressure should be tight enough to hold the door in place when the blo[...]

  • Page 30

    – 30 – ELECTRICAL OPERA TION Master Switch (S1) - Determines the mode of operation; ON, OFF or OVEN COOL Lights Switch (S2) - Controls the oven cavity lights. Fan Speed Switch Hi/Low (S3) - Controls blower motor speed between HI and LOW settings. Available on models SG4D/SG6D. Alarm/Buzzer - Signals the end of the normal cook cycle when cooking[...]

  • Page 31

    – 31 – Plug, Socket and Components (SG4D/SG6D) CONTR OL P ANEL (REAR VIEW) COMPONENT P ANEL (FR ONT VIEW) PORCELAIN BLOCK A SS EMBL Y PORCELAIN BLOCK A SS EMBL Y (PLUG S VIEWED FROM PIN S IDE) 2 1 3 5 4 6 8 7 9 11 10 12 2 3 1 5 6 4 8 9 7 11 12 10 OUT BUZZER ON HEA T NO IGNITION INDICA TOR LIGHT S NH IN 1T TRAN S FORMER 14 5 8 91 2 1 3 14 NH HEA[...]

  • Page 32

    – 32 – Plug, Socket and Components (SG4C/SG6C) 2 3 1 5 6 4 8 9 12 NO IGNITION 2J (FEMALE) 2J 3J 3J (FEMALE) PIN NUMBERS CONTROL P ANEL (REAR VIEW) COMPONENT P ANEL (FRONT VIEW) 1L T 4 1 5 2 6 1 10 7 22 21 24 23 18 17 20 19 14 13 16 15 10 9 12 11 6 5 8 7 2 1 4 3 11 8 12 9 7 123 456 789 10 7 4 11 8 5 12 9 6 1 2 3 OPER. TEMP . 0-30 DEG. C 1 EVENT [...]

  • Page 33

    – 33 – 2. Set temperature controller dial to desired temperature. A . Contacts J3 and J5 close. 3. Power switch (S1) is turned ON. NOTE : Power is available to the oven light switch A . Component cooling fan energized. B . ON light (amber) is lit. C . Power to timer terminal C. D. Transformer (T1) energized. 1 ) Power (24 VAC) to one side of th[...]

  • Page 34

    – 34 – 4. Heating circuit is powered. A . No ignition light (red) comes ON. B . Module performs a self diagnostic test for 4 seconds. C . Second valve (main) on the gas valve is energized. Gas starts to flow to burners. D . Sparking begins, the no ignition light goes out and burners light. NOTE: Sparking continues for up to 7 seconds or until a[...]

  • Page 35

    – 35 – 2. Power switch (S1) turned to COOL DOWN. A . Power to fan speed switch (S3). Set fan speed switch to either HI or LO. 3. If door is closed, power is supplied to one side of the following components: A . Power ON light (Amber) comes ON. B . Transformer (T1) energized. 1 ) Power (24 VAC) to one side of the following components: heat relay[...]

  • Page 36

    – 36 – C . Power to terminal 1 on solid state relay 1 SSR1-load side and solid state relay 2 SSR2-load side. D . Component cooling fan energized. E . Transformer (T1) is energized, 24 volt output. 1 ) Power (24 VAC) to one side of the following components: heat relay (R1) normally open (N.O.) contacts, high limit connected through the normally [...]

  • Page 37

    – 37 – 2 ) Oven heat LED on the control goes out. 3 ) Oven ready LED on the control comes ON. 4 ) Electronic beeper sounds momentarily. C . The oven will continue to cycle on the computer control until the doors are opened or power switch (S1) is turned to the OFF or COOL DOWN position. Temperature and Time Cycle (Normal Cooking) The computer&a[...]

  • Page 38

    – 38 – WIRING DIAGRAMS[...]

  • Page 39

    – 39 – WIRING DIA GRAM 734 COMPUTER CONTROL DU AL BURNER CONVECTION O VENS 120 & 200 V . 426574 Re v . C[...]

  • Page 40

    – 40 – SCHEMATICS POWER LEVEL C1-3 C1-4 C3-1 C3-2 OPEN DOOR SWITCH PROBE C1-6 NO IGNITION HEAT RELAY C M BK NC HOLD BUZZER WHT. LEAD 1 HOUR TIMER NO FROM FRONT ROTATION HEATING THERMOSTAT POWER ON SHOWN ON ON/OFF/COOL C2-3 C2-1 C2-2 1st VALVE TH GND. 24V. CHANNEL DUAL RED YELLOW BLUE YELLOW 24V. T2 BLACK C1-8 NC T1 2ed VALVE V1 MODULE IGNITION [...]

  • Page 41

    – 41 – GAS CONVECTION O VEN SG4 WITH W A TLO W 734 CONTR OL 426575-1 REV . C[...]

  • Page 42

    – 42 – TR OUBLESHOO TING S M O T P M Y S S E S U A C E L B I S S O P r o L O O C N E V O n i n u r t ' n s e o d r o t o m r e w o l B . n o i t i s o p N O . e g a t l o v e n i L . n o i t c n u f l a m h c t i w s r e t s a M / r e w o P . n o i t c n u f l a m h c t i w s n a F . n o i t c n u f l a m g n i r i w n o i t c e n n o c r [...]

  • Page 43

    – 43 – TR OUBLESHOO TING COMPUTER CONTROL MODELS ONLY M O T P M Y S S E S U A C E L B I S S O P . t a e h t o n s e o d n e v O . n e p o h c t i w s t i m i l h g i H . n o i t c n u f l a m e b o r P . n o i t c n u f l a m l o r t n o C . f f o o t t e s l o r t n o c l e v e l r e w o P . r e n r u b s a g f f o g n i t t u h s t a t s o m [...]

  • Page 44

    – 44 – FORM 35626 Rev. A (02-08) PRINTED IN U.S.A. ERROR CODES D N A E D O C M E L B O R P E S U A C E L B A B O R P N O I T U L O S k c e h c M O R - 1 0 r E r o r r e m u s n o i t c n u f l a m M O R l a n r e t n I. r e w o p e l c y C k c e h c M A R - 2 0 r E r o r r e m u s n o i t c n u f l a m M A R l a n r e t n I. r e w o p e l c y C[...]