SERVICE MANUAL VC4E & VC6E SERIES FULL SIZE ELECTRIC CONVECTION OVENS MODEL ML VC4ES 126743 VC4ED 126744 VC4EC 126745 VC6ES 126746 VC6ED 126747 VC6EC 126748 VC4ED SHOWN - 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.
FULL SIZE ELECTRIC CONVECTION OVENS TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FULL SIZE ELECTRIC CONVECTION OVENS VC4EC, VC6EC Computer Control, 208-240V (Roast & Hold Standard) . . . . . . . . . . . . . . . . . . . . . . VC4EC, VC6EC Computer Control, 480V (Roast & Hold Standard) . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VC4ES, VC6ES with Mechanical (KX) Control, 208-240V . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FULL SIZE ELECTRIC CONVECTION OVEN - 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 MODEL VC4ES 4 VC4ED VC4EC VC6ES 4 VC6ED VC6EC NOTES: FEATURES CAVITY TEMPERATURE DOORS COOK DEPTH CONTROL (50/50) TIMER 26.5" Mechanical (KX) Independent 1, 2 1-Hour Dial 1, 3 1-Hour Dial 26.5" Solid State Independent 1, 3 26.
FULL SIZE ELECTRIC CONVECTION OVEN - GENERAL SPECIFICATIONS Electrical AMPERAGE - 3 PHASE/ 60HZ MODEL VC4ES VC4ED VC4EC VC6ES VC6ED VC6EC NOTES: TOTAL POWER (KW) 12.5 RECOMMENDED CIRCUIT PROTECTION 2 PER LINE 1 208V 240V 480V 208V 240V 480V 35 33 15 45 40 20 1. Amperage values in the table are nominal. Tolerance is +5/-10%. 2. Complied in accordance with National Electric Code, ANSI/NFPA 70, latest edition.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED. 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.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS Left Side Panel 1. Remove the screws which secure the left side of the top front cover, bottom front cover and control panel. 2. Remove the seven screws securing the left side panel. 3. Pull the left side panel out at the bottom then down to remove. 4. Reverse the procedure to install. CONTROL PANEL COMPONENTS WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS COMPONENT PANEL COMPONENTS WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED. Removable Components 1. Remove the right side panel as outlined under "COVERS AND PANELS". NOTE: If right side panel is not accessible, this component can be serviced by removing the control panel as outlined under "COVERS AND PANELS". 2.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS A. 4. 5. Measure the current draw of the heating elements as outlined under "HEATING ELEMENT TEST" in "SERVICE PROCEDURES AND ADJUSTMENTS". From inside the oven cavity, remove the perforated panel from the same side of the element being replaced. Remove probe by pushing it through the oven wall and into the control panel area.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS 3. LEFT SIDE ELEMENTS SHOWN 4. If the element is on the right side: A. Remove the top panel and pull back the insulation to expose the element terminals. B. Remove the lead wires from the element being replaced. From the same element, remove the two clamps holding the element vertical, the screw’s securing mounting bracket at the top, and then remove the element.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS 1) B. 4. Reverse procedure to install and adjust blower position as outlined under "BLOWER ADJUSTMENT" in "SERVICE PROCEDURES AND ADJUSTMENTS". 10. Reconnect lead wires at the motor, replace conduit and junction box cover. NOTE: Check data plate on motor for wiring schematic. The motor must rotate clockwise when viewed from the shaft end. Motor - perform step 3A and continue procedure.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS 4. 1) Lift out the inner door panel and window assembly. 2) If replacing window on the right door, remove the screws along the inside edge (if applicable) of the door then remove the inner door panel and window assembly. 4. Remove the screws securing the window “tabs” to the door bracket and lift the window assembly out from the door frame. 5. Reverse procedure to install the replacement window.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS 3. Remove the lower door seal strip to expose the mounting screws of the door assembly. 4. Remove the two (2) lower sill bolts by the lower door shaft and the four (4) counter-sunk screws from the lower sill. OVEN DOORS (SIMULTANEOUS DOORS) WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS 5. Lift up on the door assembly and swing the right side out then move the assembly to the left to clear the slots in the upper door sill. 6. Lay the door assembly on a flat cushioned surface for disassembly. 7.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS NOTE: When installing probe guard, the probe should not extend beyond the guard. 4. Remove the thermostat bulb from the oven cavity by pushing it through the oven wall and into the control panel area. NOTE: The hole in the oven cavity wall does not line up straight with the oven cavity outer shell, therefore the probe must be removed at an angle. 5. Reverse the procedure to install. 6.
FULL SIZE ELECTRIC CONVECTION OVEN - REMOVAL AND REPLACEMENT OF PARTS 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. Attach the lead wires to the replacement socket. 6. Insert the socket into the hole in the oven and push until the socket is held in place by the retaining tabs. 7. Install the light bulb and lens. 8. Check for proper operation.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. SOLID STATE TEMPERATURE CONTROL CALIBRATION A.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS d. Rotate the knob to the lowest temperature setting then back to 350°F. e. Repeat the average temperature calculation in step 7. 2) a. 7. C. If the average temperature still differs more than 10 °F from the dial setting, adjust the thermostat calibration until the average temperature is within tolerance. Install a replacement thermostat and check calibration.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS A. After the final adjustment is made and the average temperature is within tolerance, remove the knob and apply a nonpermanent type sealer around the head of the set screw. 7. 10. If the above adjustment cannot be obtained: A. A. If correct, proceed to step 7. B. If incorrect, problem is not with the temperature control. See "TROUBLESHOOTING". Check relay voltages on the board: A. Turn the power switch OFF.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS TEMPERATURE PROBE TEST (SOLID STATE CONTROL) HEATING ELEMENT TEST WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED. NOTE: The temperature probe used in conjunction with the Solid State Temperature control is an RTD (resistance temperature detector) of the Thermistor type. As temperature increases the resistance value decreases. 1.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS BLOWER ADJUSTMENT WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED. 1. Remove the blower motor and mounting assembly by following steps 1 through 7 as outlined under "BLOWER AND MOTOR" in "REMOVAL AND REPLACEMENT OF PARTS". 2. Loosen the motor mounting bolts. 3.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS DOOR ADJUSTMENT 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. 2. Remove the top front cover. 3. Loosen the screws that secure the upper door bearings and related hardware, just enough to allow door movement.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS 6. With the doors closed, observe the position of the catch roller "ball" in relation to the door strike. A. Ensure the catch roller "ball" is centered (left to right) to the door strike. 1) B. Open the right side door and view the left side door catch roller and strike. Ensure the door catch roller "ball" is resting upon the angular surface of the door strike. Repeat on the opposite door. 1) 2) 7.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS A. Turnbuckles should be 5 to 5 ½ inches apart. B. Short eye bolt should be connected to the end of the chain that goes to the front of the sprocket. C. 2 links of the chain should not be engaged at the rear of the sprocket. D. Chain must be tight enough that the doors move simultaneously when opened or closed. E. When the doors are opened, the turnbuckles will move away from each other. F. 3. B.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS MENU ALTERNATING ON DISPLAY PARAMETER DATA C_F F gb 4000 Temperature Compensation tcnP OFF Input Type 1 InP1 J Range Low 1 rL1 75 Range High 1 rH1 500 Hysteresis HYS1 3 Calibration Offset CAL1 0 Celsius_Fahrenheit Guard Band Exit Setup Mode and return to Operation Mode. set point temperature is displayed or if call for heat, dashes (----) displayed.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS 7. A. If voltage is correct, SSR is functioning properly. B. If no voltage is present on the load side of SSR terminal 2, the SSR is not functioning properly. Turn the power switch OFF. 1) If the thermocouple reading is higher than set point temperature, press the down arrow key and enter a negative offset value that is equal to the number of degrees above the 5°F tolerance.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Listed below are the parameters and data you should find in the calibration Mode. ALTERNATING ON DISPLAY MENU PARAMETER DATA CALY no Calibrate (must display no) Logic Output Test (see step 3) LgOt* *g displays as a 9 Logic Inputs "LI" (Factory Only) LI 3. Press the Rack 1 key to accept the default "no" under the "CALY" (calibrate) parameter and advance the display menu to the "LgOt" (logic output) test.
FULL SIZE ELECTRIC CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS B. If the code displayed is not correct for the key pressed, then the keyboard is malfunctioning. 1) 9. Turn the power switch OFF. WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AT THE MAIN CIRCUIT BOX. PLACE A TAG ON THE CIRCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED. C. Replace the computer control and check for proper operation. 5. Press the Rack 1 key to advance the display menu to the "dISP" (display) test.
FULL SIZE ELECTRIC 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 (S3) . . . . . . . . Controls blower motor speed between High and Low settings (VC4ES/6ES and VC4ED/6ED only). Alarm/Buzzer . . . . . . . . . . . . . . . . Signals the end of a "Cook" cycle when cooking time expires.
FULL SIZE ELECTRIC CONVECTION OVENS - ELECTRICAL OPERATION Temperature Probe . . . . . . . . . . . Mechanical Temperature Control KX thermostat . . . . . . . . . . . . . . . Senses the oven temperature for the solid state temperature control or the computer control. On oven models using the solid state control, converts the temperature into a resistance valve which is monitored by the temperature control board. The probe is an RTD (resistance temperature detector) of the Thermistor type.
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FULL SIZE ELECTRIC CONVECTION OVENS - ELECTRICAL OPERATION Cook Cycle SEQUENCE OF OPERATION 1. Conditions. VC4ES, VC6ES with Mechanical KX Thermostat A. Schematic diagram 6532 will be used to explain the electrical sequence of operation. Oven connected to correct voltage and is properly grounded. B. Power switch (S1) OFF. Cook Cycle C. Temperature dial set to lowest temperature (fully CCW). D. High limit thermostat CLOSED. E. Oven doors closed (door switch contacts CLOSED). F.
FULL SIZE ELECTRIC CONVECTION OVENS - ELECTRICAL OPERATION 4. Timer Cycle, Cooking (KX Thermostat or Solid State Control) NOTE: The "Cook" timer operates independently of the heating cycle. Additional time can be set or the timer can be turned OFF throughout the cooking cycle. 1. 2. With the power switch turned ON, power is supplied to "Cook" timer terminal 1.
FULL SIZE ELECTRIC CONVECTION OVENS - ELECTRICAL OPERATION 1) C. At the end of the "Cook" time, the electronic beeper sounds momentarily to indicate the end of first stage cooking (oven operates normally at the temperature and time selected until time expires). 4. Computer control de-activates the output from pin C3-2. The display flashes HOLD as the oven enters HOLD mode. This is also considered second stage cooking (oven heating stops but product continues to cook on residual heat). 1) A.
FULL SIZE ELECTRIC CONVECTION OVENS - ELECTRICAL OPERATION SCHEMATICS VC4ES, VC6ES with Mechanical (KX) Controls, 208-240V Page 37 of 60 F25105 (December 2001)
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FULL SIZE ELECTRIC CONVECTION OVENS - ELECTRICAL OPERATION WIRING DIAGRAMS F25105 (December 2001) VC4ES, VC6ES with Mechanical (KX) Control, 208-240V Page 44 of 60
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FULL SIZE ELECTRIC CONVECTION OVENS - TROUBLESHOOTING TROUBLESHOOTING WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TESTS OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. ALL MODELS SYMPTOMS POSSIBLE CAUSES Blower motor doesn’t run with power switch in “ON” “COOL DOWN” or position. 1. 2. 3. 4. 5. Line voltage incorrect.
FULL SIZE ELECTRIC CONVECTION OVENS - TROUBLESHOOTING SYMPTOMS POSSIBLE CAUSES No power to oven controls. 1. 2. 3. 4. Main circuit breaker OPEN. Control circuit fuses OPEN. Power switch (S1) inoperative. Transformer (T2) inoperative (480V only). No heat, convection fan motor runs. 1. 2. 3. 4. High limit thermostat OPEN. Heating element malfunction. Contactor malfunction. Temperature control malfunction. No power to temperature control. 1. 2. Power switch (S1) in “Cool Down”.
FULL SIZE ELECTRIC CONVECTION OVENS - TROUBLESHOOTING Error Codes In the display window, the error code will alternate between the code and the oven cavity temperature or dashes if the oven is calling for heat (heat light on). The exact error code displayed will depend on the priority assigned to the problem in the EPROM’S software. The lower the error code number, the higher the priority.
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FULL SIZE ELECTRIC CONVECTION OVENS - CONDENSED SPARE PARTS LIST CONDENSED SPARE PARTS LIST VC4E & VC6E SERIES OVENS PART NUMBER DESCRIPTION VC4ES* VC4ED VC4EC VC6ES* VC6ED VC6EC X X X 358516-2 Blower Motor 2sp, 1/3hp 424846-1 Computer Controller 411497-C5 Contactor, 40A X X X 426635-1 Element, 208 volt X X X 426635-2 Element, 240 volt X X X 424940-2 Fan, Cooling X X X FE 19-40 Fuse, 15 amp X X X 346357-1 High Limit Thermostat X X X 821875-2 SST Relay, 50amp 3