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AccuTemp Accu-Steam G2 Series, Service Manual

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Accu-Steam™ G2 Gas Service Manual

2

SP8042-1911

Table of Contents

1.0 Warnings and Cautions

 

1.1 Warning Symbol Definitions
1.2 Safety Precautions

2.0 Griddle Specification

2.1 Equipment Data Plate

3.0 Sequence of Operation

4.0 Troubleshooting Guide

4.1 Troubleshooting Flowchart
4.2 Diagnosis Table

5.0 Digital Controller

5.1 Operation
5.2 Managers Mode
5.3 Set RTD Probe Offset

6.0 Main Component Identification

7.0 Removal and Replacement of Components

7.1 R&R of Voltage Supply Components
7.2 R&R of Control Boards
7.3 R&R of Ignition System Components
7.4 R&R of Temperature Sensors

8.0 Extended Troubleshooting

8.1 Griddle Surface Temperature Measurement
8.2 Ignition System Testing

9.0 Planned Maintenance

10.0 Wiring Schematic

11.0 Limited Warranty

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DOCUMENT HISTORY 

CURRENT 
REVISION

DATE

PRIOR 
REVISION

DATE

CHANGE

1911

11/05/2019

1609

09/14/2016

Review and update of manual

Summary of Contents for Accu-Steam G2 Series

Page 1: ...AccuTemp Products Inc 8415 North Clinton Park Fort Wayne IN 46825 800 210 5907 accutemp net SP8042 1911 ACCU STEAM GAS G2 GRIDDLE SERVICE MANUAL ...

Page 2: ...present in concentrations that would pose a significant risk to the consumer when the equipment is installed operated and maintained as follows 1 Installed in accordance with all local codes or in the absence of local codes with the current National Fuel Gas Code Z223 1 latest addenda 2 Installed under a properly designed and operating exhaust hood 3 Connected to the type of gas for which the unit...

Page 3: ...fset 6 0 Main Component Identification 7 0 Removal and Replacement of Components 7 1 R R of Voltage Supply Components 7 2 R R of Control Boards 7 3 R R of Ignition System Components 7 4 R R of Temperature Sensors 8 0 Extended Troubleshooting 8 1 Griddle Surface Temperature Measurement 8 2 Ignition System Testing 9 0 Planned Maintenance 10 0 Wiring Schematic 11 0 Limited Warranty 3 3 4 5 6 7 9 9 10...

Page 4: ...spect they deserve for safe operation Symbol Icons Below are definitions of the symbol icons used in this manual CAUTION HOT SURFACE DANGEROUS VOLTAGE EARTH GROUND DANGER Indicates an imminently hazardous situation which if unchanged will result in death or serious injury CAUTION Indicates a potentially hazardous situation which if unchanged will result in minor or moderate injury NOTE Advises the...

Page 5: ...PER installation adjustment alteration service or maintenance can cause personal injury or death and or property damage Read the installation operation and service maintenance instructions thoroughly before installing or servicing this equipment Only QUALIFIED service technicians electricians should perform the equipment installation to ensure that all electrical and safety requirements are met an...

Page 6: ...44 1118 44 1118 Effective Cooking Area 717 sq in 574 sq in 1077 sq in 862 sq in 1437 sq in 1150 sq in Grease Pan Capacity 5 qt 5 qt 6 qt 6 qt 6 qt 6 qt NEMA Plug 5 15 5 15 5 15 5 15 5 15 5 15 MM5208 1803 C COOKING DEPTH 3 54 22 75 COOKING HEIGHT E 13 24 19 44 B COOKING WIDTH D UNIT DEPTH 4 84 F Notes 1 Dimensions in brackets are metric 2 3 4 NPT gas connection 90 elbow provided 3 5 120 volt power ...

Page 7: ...850 A is the base model N Natural Gas P Propane B is the model configuration CCC is the supply Voltage D is the number of phases 1 or 3 E is the depth F is the width G is the special configuration Fig 2 C The Serial Number is also stamped into the upper right corner of the front plate above the grease tray Fig 2 D ...

Page 8: ...AC to be sent to the ignition control DC relay and to the pilot valve coil of the gas combination valve opening the pilot valve 8 If the reading from the Hi Limit RTD Resistive Thermal Device is 425 F or higher an output relay in the Hi Limit controller will be opened causing the 24VAC to be cut off from the ignition control DC relay and to the pilot valve coil of the gas combination valve closing...

Page 9: ...nded to start the ignition cycle 24VAC is present on both the red and the blue harnesses and the timer is deactivated 16 If the ignition module fails to see a sufficiently high enough DC voltage level through the flame sense circuit the ignition module will disable 24VAC from the red harness and the timer will see the voltage potential from the chassis ground yellow system harness side of the tran...

Page 10: ...N YES YES NO NO FAULT LIGHT ERROR CODE D E OVERTEMP YES HEAT ON H I NO UNIT HEATING UP HEAT LIGHT ON YES NO NO ERROR CODE E001 E002 PROPER TEMPERATURE UNIT OPERATING NORMAL J YES NO NO YES YES YES YES NO FAULT LIGHT FLASHING F FAULT LIGHT ON G YES NO NO YES 4 1 Flowchart UNIT POWER ON PLEASE REFER TO SELECTED LETTER IN THE NEXT SECTION 4 2 DIAGNOSIS TABLE ...

Page 11: ...age check for poor crimps or loose wires at the terminals Fuses Check for loose or blown fuses Wiring Inspect wiring for damage opens and or shorts Inspect ground and wire to wire connections NOTE Unit has a digital controller if voltages fuses and wiring appear to be in order try cycling power Transformer Check for 24 Volts from secondary side of transformer If input to transformer is present and...

Page 12: ... is continually calling for heat replace temperature controller If Control RTD and control board are operating normally check Hi Limit RTD for proper values at current temperature If temp resistance values match RTD replace Over Temp Thermostat If values do not match RTD replace Over Temp RTD SCHEMA G2 GRID AT2T 39 A YEL ORN BRN VIO BRN YEL BLU RED ORN YEL 100 O PRTD 1000O PRTD N O N C COM 7 4 1 N...

Page 13: ...uTemp Products Inc AT2T 3912 1 120V 240V ACCU STEAM G2 GAS GRIDDLE YEL ORN BRN VIO BRN YEL BLU RED ORN YEL 100 O PRTD 1000O PRTD N O N C COM 7 4 1 N O N C COM 8 5 2 3 6 RLY 2 DC COIL BRN WHT GRAY GRY WHT BRN WHT BRN OVER TEMP VIO L1 L2 N C N O COM RTD RESET HIGH LIMIT CONTROLLER BRN ZR1 38V ZR2 38V PV MV GAS VALVE 1 2 3 4 5 6 SPARK MODULE GRN HV IGNITOR BURNER RED BLU HEAT 1 2 J2 POWER INPUT DIGIT...

Page 14: ... pilot gas valve and the valve has turned on check for proper gas supply and pressures If there is no 24VAC on the brown wire at the pilot gas valve check for poor or loose connections or broken brown wire at the gas valve the OT indicator lamp and the OT thermostat and the demand relay Repair as necessary J Inaccurate Temperature If display temperature is greater than 50 degrees different than me...

Page 15: ...ameters may be adjusted using Manager s Mode Reset Pressing and holding the DOWN S4 arrow key and the ON OFF S5 key for five seconds will reset the software back to the factory default settings Error Codes The control will display error codes for the following conditions E001 Displays when controller detects an Open Sensor E002 Displays when controller detects a Shorted Sensor 9999 No calibration ...

Page 16: ... when there is a key press 0 00 rdY Set Point Temperature Set Point Temperature 1 00 Set Point Tempera ture Set Point Temperature Actual Temperature 2 00 rdY rdY rdY 3 00 Set Point Set Point Temperature Set Point Temperature This chart illustrates the programming logic and program level indication Programming Example Adjusting the Default Temp 1 Press and hold the DOWN arrow key and the Asterisk k...

Page 17: ...seconds to enter Manager s mode while the unit is on In Manager s mode the first field displayed will be the Parameter 1 DEFAULT COOK TEMP Scroll to the probe offset mode using the UP arrow key or DOWN arrow key Hand held field temperature meter that shows a higher temperature than the griddle displayed temperature Press the Preset 2 key to increase the offset number by the number of degrees off T...

Page 18: ...heat to the griddles steam chamber Supplies flame for flame sensor Flame Sensor AT2E 4717 1 When in direct contact with the flame the sensors gives off a DC Micro amp signal to the ignition module Igniter AT2T 5035 1 Receives voltage from ignition module Ignites burners 1 8 3 16 Gap AT2E 1806 2 Natural Gas Valve 5 WC H20 AT2E 1806 3 Liquid Propane Valve 10 WC H20 Regulates incoming gas pressure 1 ...

Page 19: ... Hi Limit RTD approximatively 425 or 1820Ω Temperature Sensor RTD AT0E 5062 1 1000 OHM The RTD provide temperature reference information to the Temperature Control This RTD is a 1000Ω Hi Limit Temperature Sensor RTD AT0E 5062 1 1000 OHM SN 18182 and above When replacing under SN 18181 order kit AT2A 5063 1 The RTD provides temperature reference information to the Hi Limit Board When replacing unde...

Page 20: ...rews in the upper corners of the panel 3 Locate transformer and note the location of the wires and their terminals disconnect wires 4 On the inside of the unit remove the retaining nut on the threads of the Power Cord Cable Fitting pullout the Power Cord Fig 7C 5 Reinstall in reverse order 7 1 Voltage Supply Components 1 Unplug from wall receptacle 2 Lower front access panel by removing the screws...

Page 21: ...ntrol Board AT0E 3880 1 1 Unplug from wall receptacle 2 Lower front access panel by removing the screws in the upper corners of the panel 3 Locate the Hi Limit control board Take note of wires and their terminals remove wires 4 Remove nuts and washers securing board to panel remove panel Fig 7 2B 5 Reinstall in reverse order Failure to unplug the unit before pulling wires from the board could resu...

Page 22: ...500 3 1 Unplug from wall receptacle 2 Lower front access panel by removing the screws in the upper corners of the panel 3 Locate the Fault timer take note of wire location and remove wires Fig 7 3C 4 Remove hardware securing timer 5 Remove timer 6 Reinstall in reverse order 7 Set timer pot to 6 seconds Control Relay AT0E 2825 6 1 Unplug from wall receptacle 2 Lower front access panel by removing t...

Page 23: ...ctions 1 Unplug from wall receptacle 2 Turn off gas supply and disconnect the unit from supply hose 3 Lower front access panel by removing the screws in the upper corners of the panel 4 Take note of or mark wire location and remove wires 5 Disconnect brass gas lines from cross fitting 6 Disconnect union and remove assembly 7 Remove cross fitting 8 Reinstall in reverse order applying new pipe dope ...

Page 24: ... wall receptacle 2 Lower front access panel by removing the screws in the upper corners of the panel 3 Remove igniter wire 4 Remove two nuts and igniter Fig 7 3H 5 Reinstall in reverse order 6 Set new igniter gap between 1 8 3 16 Fig 7 3H Fig 7 3G Ignition Cable AT2E 1804 4 1 Unplug from wall receptacle 2 Lower front access panel by removing the screws in the upper corners of the panel 3 Remove ig...

Page 25: ...e the grease tray and remove the two 8 32 X 3 8 screws at the top corners of the front plate The front plate will hinge down allowing access to control chamber 4 To allow for easy removal of the burner s the bottom panel of the control chamber should be removed which also requires the removal of the grease trough 5 Remove the nut above the grease trough and pull the grease trough out Fig Fig 7 3K ...

Page 26: ...urner and install on new burner in reverse order Remember to angle the elbow correctly to ensure gas line can be reattached 12 Remove plastic protection tape on burner before installing 13 Install burner back in place on griddle Line up burner with front studs and slide into place then lift rear of burner into place 14 Hand tighten rear fasteners back into place Then use a socket wrench to snug fr...

Page 27: ...remove RTD wires attached to the Hi Limit control Board 4 Remove nut securing RTD to griddle 5 Reinstall in reverse order RTD Resistance Chart Disconnect RTD wires from board and test resistance across the wires RTD Testing Temp Hi Limit Sensor 100 Ω Temp Sensor 1k Ω Temp Hi Limit Sensor 100 Ω Temp Sensor 1k Ω 70 108 22 1082 25 100 114 68 1146 82 300 156 91 1569 10 125 120 03 1200 38 325 162 08 16...

Page 28: ...und placed between the griddle surface and the sensor surface to improve thermal contact Fig 8 B The oil works by filling microscopic voids between the griddle surface and the sensor surface allowing improved heat transfer and therefore more uniform temperatures between the griddle and sensor On the other hand dirt or food residue of any kind act as an insulating barrier between the griddle and se...

Page 29: ...rner is lighting determine if the sensing signal level is0 12µA or higher A If the reading is less than 0 12µA check for proper gas pressures to the dual valve For natural gas the pressures must be 5 water column for the main gas valve For propane gas the pressures must be 10 water column B If the gas pressures are good but the sensing signal level is still poor check burner orifice for obstructio...

Page 30: ...ast 200 F First check the main burner regulator pressure Remove the rubber hose and replace with the manometer tube The pressure should be 5 WC for natural gas and 10 WC for propane If the outgoing pressure does not meet this value remove the cap on the main burner pressure regulator and adjust it to the necessary value 4 Replace the hose fittings with original plug The internal dual gas valves ar...

Page 31: ...r emery cloth Caution DO NOT use any abrasive that contains silica This will leave a coating on the flame sensor that could cause the unit not to ignite X X Clean all burner orifices making sure that each orifice is clear and unobstructed It may be necessary to use a drill the same size of the orifice if very soiled X X Inspect the burner venturi tubes for foreign particulate Wipe out with a mild ...

Page 32: ... YEL BLU HEAT RED RED BLK WHT 240V 208V 120V COM 24V RED ORN 75 A F2 75 A F1 IGN FAULT BLU WHT FAULT TIMER 1 2 3 1 2 J2 POWER INPUT DIGITAL CONTROLLER ON OFF 1 2 3 4 5 6 J7 24V GND 1 2 J3 SENSOR INPUT 1 2 3 4 5 ISSP YEL VIO GRN 1 2 J1 3 4 OPTIONAL REMOTE TIMER AT0A 2779 5 TRANSFORMER ASSEMBLY AT0E 3625 5 Control Board AT0E 3880 1 HI LIMIT CONTROL AT0E 2825 6 Relay DC AT0E 1800 2 PILOT LAMP RED AT2...

Page 33: ...ctory service to perform the repair or replacement This warranty includes travel time not to exceed two hours and mileage not to exceed 50 miles 100 miles round trip but does not include post start up assistance or training tightening of loose fittings or external electrical connections minor adjustments gaskets maintenance or cleaning AccuTemp will not reimburse the expense of labor required to r...

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