Vulcan-Hart VSX24D Service Manual Download | Manualshive

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A product of VULCAN-HART LOUISVILLE, KY 40201-0696

Form 24627 (12/98)

- 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.

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.

Reproduction or other use of this Manual, without the express
written consent of Vulcan, is prohibited.

VSX24G SHOWN

SERVICE MANUAL

VSX BOILER BASE SERIES

CONVECTION STEAMERS

(GAS, ELECTRIC, DIRECT AND REGENERATED)

VSX24G

ML-52163

VSX24D

ML-52827

VSX36G

ML-52360

VSX36D

ML-52830

VSX42GT

ML-52376

VSX42DT

ML-52834

VSX24E

ML-52164

VSX36R

ML-52831

VSX36E

ML-52829

VSX42RT

ML-52835

VSX42ET

ML-52833

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2
3
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Summary of Contents for VSX24D

Page 1: ...s 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 Reproduction or other use of this Manual without the express written consent of Vulcan is prohibited VSX24G...

Page 2: ...evel Controls Low Level Cut Off and Differential 16 Water Level Gauge Assembly 17 Pressure Switches Gas and Electric Models 17 High Limit Thermostat 18 Removing The Boiler Assembly 18 Fill and Cold Water Solenoid Valves 18 Water Not Being Supplied to Boiler 19 Blowdown Solenoid Valve Does Not Drain 19 Steamer Achieves Pressure Slower Than Normal 20 Inlet Water Strainer 21 Gas Models 21 Pilot Therm...

Page 3: ...rols VSX24E 36E AND 42ET 54 Auto Blowdown Standard Controls 54 Auto Blowdown Cal Code Controls 55 Auto Blowdown Standard Controls 56 Auto Blowdown Cal Code Controls 57 Wiring Diagrams Electric Steamers Boiler Controls VSX24E 36E AND 42ET 58 Auto Blowdown Standard Controls 58 Auto Blowdown Cal Code Controls 60 Auto Blowdown Standard Controls 62 Auto Blowdown Step Down Transformer Standard Controls ...

Page 4: ...s are listed below Cal Code Construction Redundant controls in the electrical safety circuits that if tripped must manually be reset after the condition causing the trip subsides These controls consist of 1 dual function water level cycling and low level cut off control and 1 single function low water level cut off control Aux LLCO and a high pressure relief switch in conjunction with a mechanical...

Page 5: ... 240 415V VSX24E 24 116 100 67 58 29 34 VSX36E 24 67 58 29 34 36 100 87 44 50 42 117 48 116 58 67 VSX42ET 24 67 58 29 34 36 100 87 44 50 std Steam Supply Dry steam must be provided to the steamer If the steam is heavy with condensate a Ball Float Trap must be used in the line and plumbed in before the pressure reducing valve To ensure rapid heat up of heavy cold loads the steam supply line must be...

Page 6: ...nd coat the inside of the boiler heating elements thermostat bulbs and water level probes Because of the high temperature of these surfaces the precipitated minerals bake onto them and become very difficult to remove This causes several problems 1 Reduce the heat transfer efficiency of the heating system 2 Cause premature failure of Electric heaters 3 Water level probes will give false readings 4 ...

Page 7: ...out wait 5 minutes before relighting Turn knob on gas combination control valve to ON If the water level in the boiler has reached the minimum level burners will ignite and begin to heat the water in the boiler After approximately 15 minutes steam should be present for cooking product Observe that the boiler pressure gauge indicates steam pressure of 8 10 psi B On Models with Automatic Ignition Th...

Page 8: ... and the blowdown solenoid valve will close Models equipped with a manual ball type blowdown valve need to be closed for the boiler to fill The boiler should fill in approximately 15 minutes Observe water level gauge glass to verify that water is in boiler and that the level in the gauge glass is about half full Both valves on the gauge glass assembly must be open to fill the gauge When the water ...

Page 9: ...his condition will not be seen 1 With both timer knobs at the off position open the compartment doors and observe that no steam has entered the cooking compartments then close the doors 2 Set both timer knobs at 2 minutes The ready lights will go off the cooking lights will come on and steam will begin to enter the compartments 3 After one minute open each door and observe that steam has ceased to...

Page 10: ...rain Cycling Pressure Switch controls boiler pressure between prescribed limits by turning the heat source on and off High Limit Pressure Switch a switch of identical design to the cycling pressure switch but used as a high limit The pressure settings are at higher and lower limits than the cycling pressure switch in order to turn off the heat source before the boiler pressure reaches its limit an...

Page 11: ...ed to remove calcium lime and rust build up See BOILER under SERVICE PROCEDURES Standing Pilot Gas Boilers should always remain lit to light the main burners upon a call for heat unless the steamer will not be in use for an extended period If the pilot flame goes out wait 5 minutes before relighting Main Burners Gas Boilers heats the water in the boiler to generate steam Combination Control Valve ...

Page 12: ...VSX SERIES STEAMERS COMPONENT FUNCTION AND LOCATION Page 12 of 80 ...

Page 13: ...VSX SERIES STEAMERS COMPONENT FUNCTION AND LOCATION Page 13 of 80 ...

Page 14: ...ng compartment but only after the boiler has reached its operating pressure Also energizes the buzzer when time expires Buzzer signals end of a cook cycle must be turned off manually Door Switch removes electrical power to the timer Steam Solenoid Valve when energized opens to allow steam into the cooking compartment normally closed valve Compartment Pressure Switch supplies power to the controls ...

Page 15: ...d remove all loose scale from boiler shell The loose material must be either scooped from the boiler or flushed through the drain 5 Check probe canister and float valve assembly regenerated models for a scale build up and clean as necessary 6 Check drain hole for obstructions 7 Install two new descalers 8 Mix the deliming solution according to the instructions for the chemical in use then add solu...

Page 16: ...ain valve Open the deliming assembly valve and pour the deliming solution into the port Mix the solution in accordance with the instructions on its container Close the deliming assembly valve and proceed to step 3 3 Top compartments are to be in the OFF position Turn the boiler switch ON and open water valve if necessary 4 Boiler is to operate under pressure for 90 minutes or per the instructions ...

Page 17: ...with a wrench Be careful to note the location of each probe and the number of the wire connected to it Incorrectly connected wires will cause the controls to malfunction 4 Clean probe thoroughly removing ALL deposits from the insulator Do not use an abrasive on the insulator use a soft cloth 5 Inspect through the probe socket for the presence of water Water must drain from the probe housing If in ...

Page 18: ...ompartment top to the boiler base The bolts are located behind the small louvered access panels on the left and right side of the steamer Lift the top off the boiler base and place to the side Remove the remaining plumbing and electrical connections from the boiler to the controls Remove the bolts securing the boiler to the frame and lift it out Reverse procedure to install a new boiler Older Stea...

Page 19: ...r may not seat properly to close off the opening If this symptom is suspect remove the solenoid as outlined in FILL AND COLD WATER SOLENOID VALVES Remove any debris found on sealing surfaces reassemble and install If the solenoid valve still does not function properly replace it with a new valve and check for proper operation Older steamer models have a movable blade and when closed the blade reac...

Page 20: ... period of time gas burners can accumulate carbon in their ports or become clogged by food and grease debris from kitchen cleaning restricting performance To clean burners remove them from burner box and boil in water for 10 15 minutes to dislodge clog Clean out any remaining debris from the gas ports using a wire brush scribe or pic type metal instrument Remove any other foreign objects that appe...

Page 21: ...unusually strong floor drafts are not interfering with proper heating of the thermocouple by the pilot flame The pilot flame should be a steady blue flame that envelopes the thermocouple tip The flame should be about one inch long with half its length extending beyond the outer edges of the pilot shield If the pilot flame does not appear to be this length and color then an adjustment is necessary ...

Page 22: ... to each burner Set each burner air shutter opening just large enough to eliminate any yellow tip in the burner flame To remove main burners lift burner and slide it to the rear just enough to clear the gas orifice hood Lower the front end of burner and bring it forward under the manifold pipe When reinstalling burners ensure that locating pin is in the hole for proper positioning and to prevent b...

Page 23: ...ed insulation 3 Check unit for proper operation Gas Combination Control Valve Replacement 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 WARNING SHUT OFF THE GAS SUPPLY BEFORE SERVICING THE UNIT WARNING ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS CHECK WITH A SOAP AND WAT...

Page 24: ...nit for proper operation ELECTRIC MODELS Magnetic Contactor 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 The contactor can be serviced by removing the cover of the contactor box A noisy contactor hum or chatter is generally due to enough dust or dirt on the armature pole faces or around the ar...

Page 25: ...ife DO NOT immerse elements in a chemical solution to descale 4 After new element is installed check unit for proper operation VOLTAGE TOTAL KW NUMBER OF ELEMENTS KW PER ELEMENT AMPERAGE PER LINE RESISTANCE PER ELEMENT OHMS 1 PH 3 PH 208 18 2 9 87 50 14 42 240 18 2 9 75 44 19 20 480 18 2 9 22 76 80 220 380 240 415 18 2 9 25 19 20 208 24 4 6 116 68 21 63 240 24 4 6 100 58 28 80 480 24 4 6 29 115 20...

Page 26: ...NECT POWER ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST Controls For access to compartment controls remove the right side compartment panel Check for failure of the control circuit in the following order 1 Ensure that voltage is reaching control circuit through compartment pressure switch when the main power switch is turned ON 2 On electric heat models with a transformer check step down transf...

Page 27: ... heat up until steamer ready light comes on Turn both cooking timers on and allow boiler to cycle 2 to 3 times then proceed to step 6 5 Turn both cooking timers on 6 Monitor the boiler until heat source turns off 7 At that time adjust the intake shut off valve until the manifold pressure gauge reads 9 1 psi The valve setting should be made while the boiler pressure is at the upper cycling limit 8 ...

Page 28: ...e screws from the top and bottom of the door 3 Pull the inner door panel out from the door housing with the gasket plate and gasket still attached 4 Remove the nuts and spacers from the handle screws and remove the handle from the door NOTE When installing the spacers the smaller diameter fits into the slot in the door and the latch lever must rest on top of the handle latch screw 5 Reverse proced...

Page 29: ...ny burrs on the striker that may cause the latch to stick Reinstall the striker and adjust so door will not jam To adjust 1 Reinstall the striker with the slot pointing upwards and hand tighten nut only 2 Close the door to center the striker in the oval mounting hole 3 Open the door and check the strikers slot for horizontal alignment The slot on the striker must be kept horizontal in order for th...

Page 30: ...and ILR 2 N C contacts in their shelf state When the main power switch is turned ON power is supplied to the WLC board which energizes the high level HL relay and illuminates the HL relay LED With the HL 3 contacts closed the boiler fill solenoid is energized and water begins filling the boiler When the water level reaches the low level cut off LLCO probe the LLCO relay is energized and illuminate...

Page 31: ...ide of the transformer secondary 12VAC is attached to the control that directs power to the other side of the internal relay LLCO As water enters the boiler it becomes part of the auxiliary water level control s circuit When the water level in the boiler reaches the LLCO probe the circuit is completed When the main power switch is turned ON power is supplied to the auxiliary WLC board but no switc...

Page 32: ... solenoid is then energized through the normally closed contacts terminals 3 4 on the differential level control and water begins filling the boiler When the water level reaches the low level cut off LLCO probe the internal contactor coil on the low water level control is energized With the contacts on terminals 7 8 now closed the heat source is then energized The internal contactor coil will rema...

Page 33: ...winding 300 VAC will provide power to the internal contactor coil through a series path going from one side of the secondary winding through the contactor coil through the water level control probe through the water in the boiler and to the boiler for ground The other side of the transformer secondary is attached to the LLCO probe which directs power to the other side of the internal contactor coi...

Page 34: ...d the safety circuit de energized until the water level in the boiler reaches the low level cut off probes minimum level for the water level control the auxiliary low level cut off control and the manual reset switch is pressed The gas burners will not light until these conditions are satisfied D Water level control WLC is powered 1 High level HL relay is energized HL 3 N O contacts close and HL L...

Page 35: ...be closed and the water level in the boiler must be above the low level cut off probes in order for LLCO 2 N O contacts to close C Auxiliary gas solenoid valve is energized and opens to allow gas flow D As long as the ignition control module is sensing a pilot flame the internal main valve MV contacts close N O on the ignition control module The main gas valve is energized and gas begins flowing E...

Page 36: ...is energized D Compartment steam solenoid valve energized and steam begins to enter the compartment NOTE Burners will re light after the boiler pressure drops below the low pressure set point limit 8 psi and will stay on until the high pressure set point 10 psi is reached As long as steam pressure is within limits even while cooking burners can go off The boiler is able to re pressurize to the upp...

Page 37: ...ater condenser CWC thermostat N O to one side of the power ON OFF switch 2 L2 NEUTRAL to in line fuse 10 amp to the other side of the primary on the step down transformer H2 from the other side of the secondary winding X1 to the other side of the cooking compartment controls to the other side of the cold water condenser CWC solenoid valve to the other side of the power ON OFF switch E Unit properl...

Page 38: ...essures this condition will not be seen 8 Boiler steam pressure reaches upper limit set point pressure of 13 PSI Approximately 15 min A Cycling pressure switch opens heater contactors de energize and power to heating elements is removed B As boiler heats up and builds steam pressure some by pass water steam is produced which runs in to the steam drain box This causes the cold water condenser CWC s...

Page 39: ... B Alarm Buzzer de energized and stops buzzing 5 Steamer reverts to preheat cycle until time is dialed into timer and the door is shut water level drops below low level cut off probe or the power switch is turned OFF WATER REFILL AFTER INITIAL FILL 1 Water level drops below low level probe LL A Power is removed from terminal 2 on the water level control 1 The inverse latching relay is de energized...

Page 40: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 40 of 80 PAGE PURPOSELY LEFT BLANK ...

Page 41: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 41 of 80 SCHEMATICS GAS STEAMERS BOILER CONTROLS VSX24G 36G AND 42GT Manual Ignition Standard Controls ...

Page 42: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 42 of 80 Electronic Ignition Standard Controls ...

Page 43: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 43 of 80 Manual Ignition CSD 1 Code Controls ...

Page 44: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 44 of 80 Electronic Ignition CSD 1 Code Controls ...

Page 45: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 45 of 80 ...

Page 46: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 46 of 80 WIRING DIAGRAMS GAS STEAMERS BOILER CONTROLS VSX24G 36G AND 42GT Manual Ignition Standard Controls ...

Page 47: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 47 of 80 ...

Page 48: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 48 of 80 Electronic Ignition Standard Controls ...

Page 49: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 49 of 80 ...

Page 50: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 50 of 80 Manual Ignition CSD 1 Code Controls ...

Page 51: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 51 of 80 ...

Page 52: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 52 of 80 Electronic Ignition CSD 1 Code Controls ...

Page 53: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 53 of 80 ...

Page 54: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 54 of 80 SCHEMATICS ELECTRIC STEAMERS BOILER CONTROLS VSX24E 36E AND 42ET Auto Blowdown Standard Controls ...

Page 55: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 55 of 80 Auto Blowdown Cal Code Controls ...

Page 56: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 56 of 80 Auto Blowdown Standard Controls ...

Page 57: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 57 of 80 Auto Blowdown Cal Code Controls ...

Page 58: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 58 of 80 WIRING DIAGRAMS ELECTRIC STEAMERS BOILER CONTROLS VSX24E 36E AND 42ET Auto Blowdown Standard Controls ...

Page 59: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 59 of 80 ...

Page 60: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 60 of 80 Auto Blowdown Cal Code Controls ...

Page 61: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 61 of 80 ...

Page 62: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 62 of 80 Auto Blowdown Standard Controls ...

Page 63: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 63 of 80 ...

Page 64: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 64 of 80 Auto Blowdown Step Down Transformer Standard Controls ...

Page 65: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 65 of 80 ...

Page 66: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 66 of 80 Auto Blowdown Step Down Transformer Cal Code Controls 2 contactors ...

Page 67: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 67 of 80 ...

Page 68: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 68 of 80 Auto Blowdown Step Down Transformer Cal Code Controls 4 contactors ...

Page 69: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 69 of 80 ...

Page 70: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 70 of 80 WIRING DIAGRAMS ELECTRIC HEATER CIRCUITS VSX24E 36E AND 42ET Standard and Cal Code CSD 1 Controls Newer Models ...

Page 71: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 71 of 80 Standard and Cal Code Controls Older Models ...

Page 72: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 72 of 80 3 Phase 4 Wire Older Models ...

Page 73: ...ION Page 73 of 80 SCHEMATIC DIRECT STEAMERS CABINET BASE VSX24D 36D AND 42DT See SCHEMATIC ALL MODELS COMPARTMENT CONTROLS WIRING DIAGRAM DIRECT STEAMERS CABINET BASE VSX24D 36D AND 42DT See WIRING DIAGRAM ALL MODELS COMPARTMENT CONTROLS ...

Page 74: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 74 of 80 WIRING DIAGRAMS REGENERATED STEAMERS BOILER CONTROLS VSX36R AND 42RT OLDER MODELS Manual Blowdown ...

Page 75: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 75 of 80 Auto Blowdown ...

Page 76: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 76 of 80 SCHEMATIC ALL MODELS COMPARTMENT CONTROLS ...

Page 77: ...VSX SERIES STEAMER ELECTRICAL OPERATION Page 77 of 80 WIRING DIAGRAM ALL MODELS COMPARTMENT CONTROLS ...

Page 78: ... not fully closing clogged or dirty See FILL AND COLD WATER SOLENOID VALVES in SERVICE PROCEDURES 2 Timer contacts 1 3 closed Heat coming on without water in boiler Dry firing 1 Dirty water level probes shorted to ground 2 Retention of water in probe canister assembly 3 Water level control malfunction Pressure relief valve opening or leaking 1 Cycling pressure switch set to high See PRESSURE SWITC...

Page 79: ...nes leaking badly Unit leaks water 1 Loose water steam or drain line connections top or base 2 Boiler hand hole gasket not sealing 3 Leak at gauge glass Boiler water level too high 1 Fill solenoid does not shut off 2 High level probe dirty open circuit 3 Water level control malfunction Boiler does not fill 1 Water supply not on 2 Fill solenoid not opening or plugged 3 Water level control malfuncti...

Page 80: ...RES Burner won t stay lit 1 Gas pressure low See MANIFOLD PRESSURE ADJUSTMENT in SERVICE PROCEDURES 2 Ignition module malfunction 3 Check gas orifice for obstruction Pilot not lit or goes out 1 Gas not on 2 Low incoming gas pressure 3 Check thermopile millivolts 4 Pilot going out due to drafts excess steam from drain or unit not level Improper venting can direct the pilot flame away from thermopil...

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