Vulcan Materials 936RX User's Manual
Contents
1. 12 Continue to install in reverse order Page 7 of 16 _ F283 510 REMOVAL AND REPLACEMENT OF PARTS BURNER 2 electrical power to the machine follow lockout tagout procedures aw A WARNING Disconnect the Zy 7 UY iy WARNING Shut off the gas before servicing the unit WARNINGJAII gas joints disturbed during servicing must be checked for leaks Check with a soap and water solution bubbles Do not use an open flame 1 Remove FRONT PANEL and REAR PANEL 2 Disconnect gas supply at griddle 3 Remove screw securing burner to wall 4 Atrear of unit pull burner enough to disengage burner pin from frame and pull burner out 5 Install in reverse order 6 Adjust as outlined in BURNER ADJUSTMENT F25383 510 PILOT THERMOCOUPLE ASSEMBLY ake Disconnect the S electrical power to the machine and SS X follow lockout tagout procedures 9 4 WARNING Shut off the gas before servicing the unit 1 Remove FRONT PANEL 2 From underneath the front of the griddle remove screw securing pilot assembly bracket VIEW FROM REAR OF UNIT TO SEE PARTS 3 Carefully lift to disengage bracket from slot and work assembly down to access parts 4 Service assembly as required and assemble in reverse order being sure bracket is seated in slot for alignment Page 8 of 16 SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTM2. 3 INTFODUCHION deerme ogee eg daha alee deka a Syed paw alee da tan Beg 3 Installation Mets Bathe Sesame bathe tee eae heed Late Bendre Bae og 3 Operation alee elt alert aa ate age a hig Late Soh 3 Cleaning tel ke SA SAM odie NMA AGE 3 3 MOONS irate TTE E cutis ce EE E dati 4 Component LOCATON iiai enchants racine Gust aad 4 REMOVAL AND REPLACEMENT OF PARTS 5 Govers and Panels Creure naa i din a KE ab doe 5 Front PANG sasan Eevee antec E ete bs 5 Dack Panel e r a feet aged eel 5 Momentary Power Switch 900 5 El ctnic lgniter 900100 aetate wae dine Pad eee eee Pe ES eee edie bed i needing 6 BASO Safety Vales carat dhe neat 6 Thermostat Valve Assembly soar een ee Gone ba heaves 6 eects te dined dd mend eae ere ea elated wh
3. from unit Transfer fittings from old valve to new valve Use thread sealant on assembly 6 Install new valve to same measurement as step 2 7 Continue to install in reverse order THERMOSTAT VALVE ASSEMBLY A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures WARNING Shut off the gas before servicing the unit AWARNINGJAII gas joints disturbed during servicing must be checked for leaks Check with a soap and water solution bubbles Do not use an open flame 1 Remove FRONT PANEL 2 Disconnect gas line Page 6 of 16 REMOVAL AND REPLACEMENT OF PARTS 3 Remove screws securing thermostat mounting 10 Carefully insert orifice into burner and secure bracket to frame thermostat mounting bracket to frame 4 Pull capillary tube out from underneath griddle plate 5 Transfer fittings from old thermostat to new thermostat Use thread sealant 1 Inlet to burner must be straight Adjust thread on orifice and or extension to close gap 6 Transfer thermostat mounting bracket to new between orifice and burner to 1 16 thermostat 7 Remove insulator sleeve from old capillary tube and install on new thermostat 8 Secure end of insulator sleeve to thick end of capillary tube with metal tape as shown THIN CAPILLARY amp METAL 9 Slide capillary tube all the way into slot underneath griddle plate until it is fully seated
4. only Power cord RX only Thermostat Gas shut off valve RX only BASO pilot safety valve OL iD Pilot flame adjustment F25383 510 _ Page 4 of 16 REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS WARNING Disconnect the We electrical power to the machine and SS X follow lockout tagout procedures S WS amp Front Panel 1 Turn all thermostats to off position loosen set screw securing thermostat knobs and pull off knobs NOT IN OFF POSITION FOR VIEW Remove screws securing front panel to griddle Pull front panel forward and lay aside If servicing a 900RX lay front panel face down front of unit 4 Install in reverse order NOTE Before installing front panel check that line of sight through the front panel to see both pilot burners and griddle burners Move any flexible gas tubing or capillary tubing that may obstruct the sight holes Page 5 of 16 Back Panel WARNING Shut off the gas before servicing the unit WARNINGJAII gas joints disturbed during servicing must be checked for leaks Check with a soap and water solution bubbles Do not use an open flame NOTE It will be necessary to remove the back panel when changing a burner or to remove excessive grease build up from flue area 1 Disconnect gas supply at griddle 2 Remove screws securing back panel to griddle 3 I
5. 50 F One pilot safety for every two burners Manual shut off valve 3 wide stainless steel grease trough 120V 50 60Hz 1 Amp single phase electric ignition circuit Plug type is NEMA 5 15 USA 34 rear gas connection and gas pressure regulator A gas pressure regulator supplied with the unit must be installed Check and set the gas pressure after the regulator is installed Manifold pressure should be Natural Gas 4 0 W C Propane Gas 10 0 W C Incoming pressure should be 5 9 W C for Natural Gas and 11 0 W C for Propane Gas Incoming pressure should not exceed 14 0 W C F25383 510 GENERAL TOOLS Standard set of hand tools e with A C current tester any quality VOM with a sensitivity of at least 20 000 ohms per volt can be used Temperature tester thermocouple type U Tube or Digital Manometer Thread sealant suitable for use with natural or propane gas 924RX SHOWN e Aluminum Foil Tape McMaster Carr Part No 7631421 or equivalent Adapter to test thermocouple Johnstone Supply Part No H23 226 or equivalent JOHNSTONE SUPPLY H23 226 Burner assembly Electric igniter RX only Thermostat Orifice Thermostat capillary tube amp Pilot igniter RX only and thermocouple BASO pilot safety valve OO Oe CIN Ee Pilot adjustment valve COMPONENT LOCATION 924RX SHOWN 1 Pilot electric ignition system control switch RX
6. ENTS CALIBRATION Level The griddle must be level side to side and front to back during operation to ensure proper performance Improper leveling can result in uneven temperature distribution cold spots and possibly damage electrical components 1 Place a level on the griddle 2 Adjust legs by turning the bullet feet at the bottom of each leg Using pliers or a crescent wrench turn the feet counter clockwise to increase height and clockwise to decrease height until leveling is achieved Do not extend the legs more than 1 3 Calibrate 1 Each thermostat controls 12 zone of the griddle Using a Surface Probe temperature measurement device observe the temperatures at the center points of the cooking zones These points are located by starting 6 from the side splash left or right and every 12 across the width of the griddle with all points located 12 back from the front edge of the griddle plate NOTE Use of infrared thermometers is not recommended These devices are highly sensitive to surface color clean or dirty angle of reading and distance from the unit Page 9 of 16 2 Set thermostats to 350 F and allow to stabilize 3 Record the temperature tester readouts for each zone for 3 cycles Turn Off Temperature Temperature Tester turn off Tester turn on Turn On divide deg F deg F by 2 average Total averages divide by 3 deg F 4 Calculate total av
7. VULCAN SERVICE MANUAL HEAVY DUTY GAS GRIDDLES MODELS 924RX MSA24 936RX MSA36 948RX MSA48 960RX MSA60 972RX MSA72 948RX 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 For additional information on Vulcan Hart Company or to locate an authorized parts and service provider in your area visit our website at www vulcanhart com A product of VULCAN HART LOUISVILLE KY 40201 0696 F25383 510 GENERAL TABLE OF CONTENTS GENERAL ee aed Stn at Oh Sheds a Ried bods Gn tae
8. be of any model unless the picture or illustration needs to be model specific MSA griddles have a standing pilot that must be lit manually One pilot services two burners via a flame tube between the burners The 900RX utilizes a spark ignition system that has a momentarily switch that means the switch must be held down for sparking to take place and it ceases sparking when released The MSA and 900RX have BASO pilot safety valves that must be pressed to allow gas to feed the pilot burner For the 900RX the pilot buttons must be pressed at the same time the power switch is pressed in order to light the pilot INSTALLATION Generally installations are made by the dealer or contracted by the dealer or owner Detailed installation instructions are included in the Installation and Operation Manual that is sent with each unit However it should be noted that an improperly installed unit especially an unlevel unit can lead to premature electrical component failures A unit that is higher in the front will cause the flue gases to vent improperly and gather in the front near the electrical components All models must be installed with an externally mounted regulator OPERATION Detailed operation instructions are included in the Installation amp Operation Manual sent with each unit and are also available at WWW VULCANHART COM The 900RX models feature an electric ignition system that is controlled by a momentary power s
9. ees ed ee 8 Pilot Thermocouple Assembly 00 ce nee 8 SERVICE PROCEDURES AND ADJUSTMENTS 0 0 0000 cece 9 Calibration wane Sane Rake ele Berea Re et as E 9 Pilot ACJUStIMO I sera beet hte BSED a sae ee ede bee dar beet thee baat Star cM ees ee a 10 Gas Pressure Measurement teen ee 10 Gas Pressure Regulator Adjustment 0 00 ccc cette teens 10 Burr r2A CU SUIS rit es haa gee 11 Thermocouple Test reuso o eee 12 ELECTRICAL OPERATION 000 0c cen 13 Electrical Diagram eaan eas gt S o 13 TROUBLESHOOTING ate eo ade nada wae som leads 15 VULCAN 2010 F25383 510 _ Page 2 of 16 GENERAL GENERAL The griddle and its parts are hot Use care when operating cleaning or servicing the griddle INTRODUCTION This Service Manual covers specific service information related to the models listed on the front cover and built after March 2010 Procedures this manual will apply to all 900 models unless specified No procedure in this manual will require the removal or raising of the griddle plate Pictures and illustrations can
10. er F25383 510 _ Page 12 of 16 ELECTRICAL OPERATION ELECTRICAL OPERATION ELECTRICAL DIAGRAM SPARK MODULE NOTES 1 SPARK MODULE LEGS 1 2 3 8 4 ALL UNUSED LEGS MUST BE GROUNDED POWER CORD POWER SWITCH Al 2872 Page 13 of 16 _ F283 510 ELECTRICAL OPERATION F25383 510 Page 14 of 16 TROUBLESHOOTING TROUBLESHOOTING No spark to ignite pilot gas Power cord unplugged Igniter switch malfunction Shorted electrode on ignitor Ignitor cable malfunction Interconnecting wiring malfunction Electric Igniter Module malfunction Sparks but gas does not ignite 1 Service gas valve closed Gas supply not purged of air Depress pilot safety button until air is purged Gas supply off or insufficient gas pressure Adjust pilot valve to allow more gas flow Safety valve malfunction Gas pilot ignites but will not maintain flame Air blowing pilot out Prevent air flow from affecting unit Gas supply not purged of air Depress pilot safety button until air is purged Adjust pilot valve to allow more gas flow Thermocouple not sufficiently immersed in flame Adjust accordingly Thermocouple malfunction Refer to THERMOCOUPLE TEST Obstructed pilot orifice Insufficient gas pressure Safety valve malfunction Gas burners ignite but will not maintain flame Gas pressure i
11. erage temperature for that zone 5 The temperature should be 350 F 15 F If not continue to next step 6 Carefully loosen the knob set screw DO NOT allow the knob to turn Carefully remove the knob from the thermostat shaft exposing the temperature dial 7 Loosen screws on the temperature dial adjust it so that the temperature indicated by the knob arrow matches the griddle plate temperature reading Knob will have to be carefully placed back on the shaft to verify adjustment F25383 510 SERVICE PROCEDURES AND ADJUSTMENTS Never adjust the screw in the center of the thermostat shaft This will ruin the factory calibration the thermostat will no longer operate properly and will need to be replaced 8 Once calibration is achieved tighten the temperature dial screws and knob set screws 9 Repeat steps 3 thru 8 for each zone PILOT ADJUSTMENT Using a flathead screwdriver turn the slotted pilot adjustment screw clockwise to decrease the flame and counterclockwise to increase the flame F25383 510 GAS PRESSURE MEASUREMENT AWARNINGIAII gas joints disturbed during servicing must be checked for leaks Check with a soap and water solution bubbles Do not use an open flame 1 Turn the gas supply off at a manual shutoff valve Remove the control panel Remove the pressure tap plug and attach manometer 4 Turn gas back on Light pilot s 6 Turn all thermostats on t
12. ncorrect or fluctuating Obstructed flue Gas orifice obstructed improperly aligned spaced or incorrect Burner malfunction One or more burners have lower flame level than Check gas pressure the others External air flow or vent hood problems may agitate affected burners Gas orifice obstructed improperly aligned spaced or incorrect Adjust burner air shutter One burner has a delayed ignition a several gas pressure second lapse when the burner actually lights _ Check that burner is properly seated Check that burner ignition ports pilot flash tube and pilot burner are all aligned Gas orifice obstructed improperly aligned spaced or incorrect Check burner shutter adjustment Check pilot flame adjustment Excessive or low heat Gas shut off valve not completely open Thermostats need calibrated See CALIBRATION section Thermostat malfunction Gas pressure incorrect Unit s gas regulator not installed or malfunctioning Incorrect gas type Gas orifice obstructed or incorrect Heat does not come on when the thermostat Pilot burner lit is turned on Griddle shut off valve ON position Low gas pressure Thermostat malfunction Page 15 of 16 _ 25383 510 TROUBLESHOOTING F25383 510 Printed in USA
13. nstall in reverse order MOMENTARY POWER SWITCH 900RX SA A WARNING Disconnect the S electrical power to the machine and Y follow lockout tagout procedures ay Remove FRONT PANEL Label and disconnect wires from power switch Squeeze switch retainers and slide switch out through front of panel 1001 NOILINSI 6110000021 IVAOSUSZI OL 0110 4 Install in reverse order F25383 510 REMOVAL AND REPLACEMENT OF PARTS ELECTRIC IGNITER 900RX A W Disconnect the 9 S electrical power to the machine and gt follow lockout tagout procedures 1 Remove FRONT PANEL 2 Push tab to release igniter from frame and pull out of unit 3 Label and disconnect wires from electric igniter 4 Install in reverse order BASO SAFETY VALVE AWARNING Disconnect the electrical power to the machine and follow lockout tagout procedures WARNING Shut off the gas before servicing the unit WARNINGJAII gas joints disturbed during servicing must be checked for leaks Check with a soap and water solution bubbles Do not use an open flame 1 Remove FRONT PANEL F25383 510 2 Measure distance between manifold pipe and valve for reassembly later NOTE Ignition wires must be routed in front of valves as shown to prevent them from touching hot heat shield 3 Disconnect all gas lines and thermocouple from valve Remove valve
14. o the maximum setting so that all burners are on 7 Turn all the equipment the same supply line on Check gas pressure Gas pressure should read 4 W C for natural and 10 W C for propane gas If not correct refer to GAS REGULATOR ADJUSTMENT 10 Turn gas supply off disconnect manometer and reinstall pressure tap plug 924RX SHOWN GAS PRESSURE REGULATOR ADJUSTMENT A gas pressure regulator is supplied with the griddle and must be installed as close to the griddle on the gas supply line as possible Make sure that the arrow on the underside of the regulator is oriented in the direction of gas flow to the griddle and the regulator is positioned with the vent plug and adjustment screw upright Check that vent plug is not clogged by grease and debris Check and set the gas pressure after the regulator is installed The pressure should be set for 4 water column W C for natural gas and 10 W C for propane gas while all burners are on Page 10 of 16 SERVICE PROCEDURES AND ADJUSTMENTS The supply pressure upstream of the regulator should be 7 9 W C for natural gas and 11 12 W C for propane gas At no time should the griddle be connected to supply pressure greater than psig 3 45 kPa or 14 W C Graphic shows pressure plug location NOTE MSA models are in same locations There are no shut off valves BURNER ADJUSTMENT For efficient burner operation it is important that a pr
15. oper balance of gas volume and primary air supply is maintained to give complete combustion Insufficient air supply results in a yellow streaming flame Primary air supply is controlled by the air shutter on the front of the burner venturi Loosen the screw on the venturi and adjust the air shutter to just eliminate yellow tips on the burner flames Lock the air shutter in place in place by tightening the screw Repeat this procedure as necessary with all burners Page 11 of 16 _ F283 510 SERVICE PROCEDURES AND ADJUSTMENTS THERMOCOUPLE TEST 1 Unscrew thermocouple fitting from safety valve 2 Install thermocouple test adapter finger tight plus a quarter turn 3 Install thermocouple into test adapter finger tight plus a quarter turn NOTE Over tightening can cause thermocouple tip to short out 4 Set VOM to DC millivolt scale and connect meter lead to pin on thermocouple adapter and meter lead to thermocouple Light pilot flame Verify that thermocouple is sufficiently immersed in flame Adjust pilot valve to allow more gas flow if necessary 7 With thermostat off allow pilot to burn for 3 4 minutes to stabilize voltage output from thermocouple 8 Verify thermocouple output voltage A 125 35 millivolts is measured the thermocouple is functioning properly If less than 17 millivolts is measured install a replacement thermocouple 9 Remove test adapt
16. witch The power switch turns the electric ignition system off and on only and will only supply power to the igniters when held down in the ON position The burners and pilots will continue to work with the power switch in the OFF position until the gas supply to the unit is cut off or the griddle gas shut off valve is turned to the OFF position The pilots are Page 3 of 16 monitored by thermocouples and pilot safety valves If the pilot goes out the safety valve will shut off the gas supply to the pilot and main burners In the event of a failure of the electronic ignition system it is possible to ignite the pilots with an outside source such as a lit taper You will have to reach under the front of the unit and through the pilot cutout to ignite the pilots while again depressing the corresponding red button CLEANING Detailed cleaning procedures are included in the Installation amp Operation manual sent with each unit SPECIFICATIONS Stainless steel front sides and front top ledge Fully welded stainless and aluminized steel body frame 11 low profile cooking height on 4 legs 1 thick polished steel griddle plate with 12 gage 4 stainless steel back and tapered side splashes Grease chute is fully welded to stop grease migration One 27 000 BTU hr U shaped aluminized steel burner and mechanical snap action thermostat for each 12 of griddle width Chrome thermostat knob guards Temperature adjusts from 200 to 5
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