Service Manual

ManualsBrandsVulcan-Hart ManualsGas HeaterSG66 Gas Heater

SG SERIES GAS CONVECTION

OVENS

MODELS SG4

SG6

STACKED

MODELS

SG44

SG66

- NOTICE -

This Manual is prepared for the use of trained Vulcan Service

Technicians and should not be used by those not properly

qualified.

This manual is not intended to be all encompassing. If you have

not attended a Vulcan Service School for this product, you should

read, in its entirety, the repair procedure you wish to perform to

determine if you have the necessary tools, instruments and skills

required to perform the procedure. Procedures for which you do

not have the necessary tools, instruments and skills should be

performed by a trained Vulcan Service Technician.

The reproduction, transfer, sale or other use of this Manual,

without the express written consent of Vulcan, is prohibited.

This manual has been provided to you by ITW Food Equipment

Group LLC ("ITW FEG") without charge and remains the property

of ITW FEG, and by accepting this manual you agree that you will

return it to ITW FEG promptly upon its request for such return at

any time in the future.

SERVICE MANUAL

A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222

F45525 Rev. A (0315)

Summary of content (33 pages)

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SERVICE MANUAL SG SERIES GAS CONVECTION OVENS MODELS STACKED MODELS SG4 SG6 SG44 SG66 - NOTICE This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. This manual is not intended to be all encompassing.
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SG SERIES GAS CONVECTION OVENS TABLE OF CONTENTS SERVICE UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE UPDATES - SG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SG SERIES GAS CONVECTION OVENS - SERVICE UPDATES SERVICE UPDATES SERVICE UPDATES - SG March 2015 Updated Photos in Data Modules • GAS BURNER • GAS ORIFICE • ROLLER LATCH ASSEMBLY • HIGH LIMIT THERMOSTAT Updated Specifications • SPECIFICATIONS F45525 Rev.
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SG SERIES GAS CONVECTION OVENS - GENERAL GENERAL INTRODUCTION Procedures in this manual will apply to all models unless specified. Pictures and illustrations can be of any model unless the picture or illustration needs to be model specific. MODELS FEATURES OPTIONS MODEL CAVITY DEPTH TEMPERTURE CONTROL DOORS (50/50) COOK TIMER CASTERS BLOWER 208/240/60/1 SG4 26.5" Solid State Independent 1-Hour Dial Optional Optional SG6 30.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS Disconnect the electrical power to the machine and follow lockout / tagout procedures. SHUT OFF THE GAS BEFORE SERVICING THE UNIT. Top Front Cover 1. The top front cover is secured with four (4) screws, two on each side of cover. Remove these screws then remove the cover from the oven. Fig.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS CONTROL PANEL COMPONENTS COMPONENT PANEL COMPONENTS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Disconnect the electrical power to the machine and follow lockout / tagout procedures. Removable Components Procedure 1. Remove the CONTROL PANEL. Removable Components Procedure 2. Remove the component being replaced. 1. 3.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS NOTE: If right side panel is not accessible, this component can be serviced by removing the CONTROL PANEL. 2. Disconnect the probe leads from the solid state temperature control. 3. Remove the racks and right rack support. 4. Remove the probe guard. Fig. 7 5. Remove probe by pushing it through the oven wall and into the control panel area. Fig.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 2. Disconnect the ignition cable and the flame sense lead wire. Fig. 12 6. Fig. 9 3. Disconnect the ignition cable and the flame sense lead wire. Reverse procedure to install the replacement burner. NOTE: Ensure that burner positioning bracket (U shaped end) is inserted into slot at the rear of the burner chamber. 7. Check for proper operation. GAS ORIFICE Fig. 10 4.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS Fig. 14 4. Reverse procedure to install and check for proper operation. GAS SOLENOID VALVE Fig. 15 Disconnect the electrical power to the machine and follow lockout / tagout procedures. 4. Loosen the bolts securing the valve and bracket assembly then remove the screws securing the valve to the bracket. SHUT OFF THE GAS BEFORE SERVICING THE UNIT. All gas joints disturbed during servicing must be checked for leaks.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS Fig. 17 Fig. 19 6. Reverse the procedure to install the replacement gas valve. 7. Check pressure as outlined under GAS VALVE PRESSURE CHECK. IGNITION CONTROL MODULE Disconnect the electrical power to the machine and follow lockout / tagout procedures. SHUT OFF THE GAS BEFORE SERVICING THE UNIT. 1. Fig. 18 A. To change gas type unscrew and reverse cap to show the proper gas type.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 2. Fig. 22 Fig. 20 3. Remove the screws securing the ignitor and flame sense to burner then remove the assembly. Disconnect the lead wires and igniter cable from the ignition module board. 3. Reverse the procedure to install the assembly and check for proper operation. NOTE: Check to ensure the spark gap distance is approximately 1/8". If the gap appears to be excessive or poor sparking is occurring then adjust.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 2. Remove screws securing the “snorkel” and remove the snorkel. 5. Fig. 27 Fig. 25 3. 6. Remove screws securing baffle panel and remove the panel. 7. Blower Only - Loosen set screws on blower hub and using a bearing puller, remove blower from motor shaft. Place a piece of cardboard on the bottom of the oven cavity to protect its surface from any damage during motor assembly removal. 8.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 11. Position the replacement motor on the motor mounting plate and install mounting bolts and washers. Hand tighten mounting bolts only. OVEN DOORS AND BEARINGS (INDEPENDENT DOORS) 12. Reconnect lead wires at the motor, replace conduit and junction box cover. Disconnect the electrical power to the machine and follow lockout / tagout procedures. NOTE: Check data plate on motor for wiring schematic.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS DOOR WINDOW Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove the screws at the top and bottom of door. Fig. 32 C. 8. If replacing the bottom bearing, remove it from the door shaft or the lower sill opening. Reverse procedure to install door assembly and check for proper adjustment as outlined under DOOR ADJUSTMENT and DOOR SWITCH ADJUSTMENT.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS Fig. 36 4. Reverse procedure to install the replacement switch and check for proper adjustment as outlined under DOOR SWITCH ADJUSTMENT. HIGH LIMIT THERMOSTAT Disconnect the electrical power to the machine and follow lockout / tagout procedures. Fig. 35 5. 1. Take out racks from the oven. 2. Remove the high limit thermostat cover/mounting plate from inside the oven cavity at the top.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 1. Remove the lens and bulb. 2. Remove the springs from the retaining tabs (2 places) on the socket. Fig. 38 NOTE: Remove the old RTV from the cover and mating surfaces inside the oven cavity and apply new RTV before installing. 4. Reverse procedure to install. Fig. 40 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. 5.
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SG SERIES GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS Fig. 41 4. Reverse the procedure to install the replacement fan and check for proper operation. NOTE: The fan must be installed so air is pulled from the rear of the oven and blown into the control area. The arrow on the fan body indicates “air flow” direction and should be pointing toward the controls. NOTE: Ensure fan is seated “squarely” against the air tube and the oven bottom.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS SERVICE PRODCEDURES AND ADJUSTMENTS Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times and follow Arc Flash procedures. If test points are not easily accessible, disconnect power and follow Lockout/Tagout procedures, attach test equipment and reapply power to test. 8.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS 6. SOLID STATE TEMPERATURE CONTROL TEST Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times and follow Arc Flash procedures. If test points are not easily accessible, disconnect power and follow Lockout/Tagout procedures, attach test equipment and reapply power to test. 1. 7. Remove the RIGHT SIDE PANEL.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS TEMP (°F) OHMS* TEMP (°F) OHMS* 320 1,332 475 266 340 1,041 Disconnect the electrical power to the machine and follow lockout / tagout procedures. (*) Resistance in ohms ± 10% b. Replace the temperature control and check calibration as outlined under SOILD STATE TEMPERATURE CONTROL CALIBRATION. GAS VALVE PRESSURE CHECK Disconnect the electrical power to the machine and follow lockout / tagout procedures.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS PRESSURE READINGS (IN W.C.) GAS TYPE LINE MANIFOLD RECOMMENDED MIN Natural 5.0 8.0 6.0 Propane 10.0 11.0 11.0 MAX 14.0 NOTE: If the incoming line pressure to the valve is less than the minimum stated, then the manifold pressure will not be maintained VERIFICATION OF SPARK AT IGNITOR Disconnect the electrical power to the machine and follow lockout / tagout procedures. SHUT OFF THE GAS BEFORE SERVICING THE UNIT. Fig. 45 1.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS Fig. 46 Fig. 47 4. Install the top front cover. 5. Apply power to the oven and check for proper operation. 4. Reverse the procedure to install. DOOR ADJUSTMENT BLOWER ADJUSTMENT Disconnect the electrical power to the machine and follow lockout / tagout procedures. Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. SHUT OFF THE GAS BEFORE SERVICING THE UNIT. 1.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS 4. Move the door until proper alignment is achieved then tighten the screws on the upper door bearing hardware. 5. Repeat step 3 and 4 on the opposite door, if necessary. DOOR STRIKE ADJUSTMENT (INDEPENDENT DOORS) NOTE: For units with serial number starting with 48 made after 8/12/07 and serial number starting with 54 made after 8/26/07. Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1.
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SG SERIES GAS CONVECTION OVENS - SERVICE PRODCEDURES AND ADJUSTMENTS 4. Each oven door should open with a force of 8 to 25 pounds when pulled at the handle. The adjustments must allow the doors to remain closed during normal operation and allow opening without exertion by the user. Page 25 of 33 F45525 Rev.
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SG SERIES GAS CONVECTION OVENS - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION Power Switch (S1) . . . Determines the mode of operation; ON, OFF, or COOL DOWN. Oven Light Switch (S2) ........................ Controls the oven cavity lights. Fan Speed Switch Hi/ Low (S3) . . . . . . . . . . . . . Controls blower motor speed between Hi and Low settings. Bake Mode Switch (S4) ........................ Selects the cooking mode of the oven between Normal and Gentle Bake.
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SG SERIES GAS CONVECTION OVENS - ELECTRICAL OPERATION COMPONENT LOCATION Fig. 51 Page 27 of 33 F45525 Rev.
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SG SERIES GAS CONVECTION OVENS - ELECTRICAL OPERATION Fig. 52 SEQUENCE OF OPERATION SG4, SG6 (Solid State Temperature Control) Schematic diagram AI3691 will be used to explain the electrical sequence of operation. Normal Cycle 1. F45525 Rev. A (0315) Page 28 of 33 Conditions.
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SG SERIES GAS CONVECTION OVENS - ELECTRICAL OPERATION A. Oven connected to correct voltage. a. 1) L1 (HOT) to power switch (S1). 2) L2 (NEUTRAL or SECOND LINE) to one side of the following components: power ON light, heat light, temperature control board terminal T2 (120VAC) or terminal T3 (208- 240VAC), oven cavity lights, buzzer, "Cook" timer motor, heat relay coil (R3), convection fan motor common ©), transformer primary (T1), motor speed (Hi/Low) switch and the component cooling fan. B.
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SG SERIES GAS CONVECTION OVENS - ELECTRICAL OPERATION d) 4. C. Doors are open. D. 2. Door switch contacts OPEN Cook timer in the OFF position. Power Switch (S1) turned to COOL DOWN. NOTE: With door switch contacts OPEN (doors open), the convection fan motor will still run and continue to cool the oven. However, power would be removed from the following components: Power ON light (goes out), transformer T1 (de-energized) and to the component cooling fan. A. Power to motor speed switch (Hi/Low).
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SG SERIES GAS CONVECTION OVENS - ELECTRICAL OPERATION SCHEMATICS Fig. 53 WIRING DIAGRAM See Wiring Diagram AI3692 Page 31 of 33 F45525 Rev.
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SG SERIES GAS CONVECTION OVENS - TROUBLESHOOTING TROUBLESHOOTING Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times and follow Arc Flash procedures. If test points are not easily accessible, disconnect power and follow Lockout/Tagout procedures, attach test equipment and reapply power to test. ALL MODELS SYMPTOMS POSSIBLE CAUSES 1. 2. Blower motor doesn’t run with 1S in “Cool Down” or “On” 3. position.
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SG SERIES GAS CONVECTION OVENS - TROUBLESHOOTING SYMPTOMS Excessive or low heat. POSSIBLE CAUSES 1. Temperature probe malfunction. 2. Temperature control board malfunction. 3. Gas pressure Insufficient. 4. Gas orifice plugged or obstructed. 1. Interconnecting wiring malfunction. Mechanical Timer inoperative or not functioning properly. 2. Component cooling Fan does not run. 3. Timer malfunction. 1. Motor inoperable. 2. Interconnecting wiring malfunction. 1.