Vulcan-Hart SG4D Service Manual
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Vulcan-Hart SG4D Service Manual

Sg4 series; sg6 series full size gas convection ovens;
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See also: Operation & Installation Manual
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.
A product of Vulcan-Hart
SERVICE MANUAL
SG4 & SG6 Series Full Size Gas
Convection Ovens
SG4D
SG4C
SG6D
SG6C
- NOTICE -
3600 North Point Blvd Baltimore, MD 21222
ML-114875
ML-114876
ML-114877
ML-114878
F35626 Rev. B (1118)

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Summary of Contents for Vulcan-Hart SG4D

  • Page 1 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. A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222 F35626 Rev. B (1118)

  • Page 2: Table Of Contents

    SOLID STATE TEMPERATURE CONTROLLER TEST (SG4D/SG6D) ........
  • Page 3 SG4 & SG6 Series Full Size Gas Convection Ovens TROUBLESHOOTING ..................53 TROUBLESHOOTING .

  • Page 4: Service Updates

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE UPDATES SERVICE UPDATES SERVICE UPDATES • BLOWER AND MOTOR Starting at Serial Number 481913936 • OVEN DOORS (INDEPENDENT DOORS) Starting at Serial Number 481907146 • INTERIOR LIGHTS (Rear Mounted, Round) •...

  • Page 5: General

    TOOLS 15,0000 BTU/hr to 60,000 BTU/hr. Models SG4D and SG6D are equipped with solid Standard state-controls and a 60-minute timer (a 5-hour timer is optional). Models SG4C and SG6C have a computer •...

  • Page 6: Removal And Replacement Of Parts

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COMPONENT LOCATION Fig. 1 COVERS AND PANELS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Top Front Cover The top front cover is secured with four screws, two on each side of cover.
  • Page 7 SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Reverse the procedure to install. Disconnect the temperature probe leads from the solid state temperature controller. Bottom Front Cover Unplug the wire harness connector to the control The bottom front cover is secured with six panel components.

  • Page 8: Control Panel Components

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS CONTROL PANEL COMPONENTS Fig. 6 F35626 Rev. B (1118) Page 8 of 56...
  • Page 9 SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Fig. 7 Procedure Disconnect the electrical power to the machine and follow lockout / tagout procedures. Remove the control panel as outlined under Covers and Panels. Remove the component being replaced.

  • Page 10: Component Panel Components

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS COMPONENT PANEL COMPONENTS Fig. 8 F35626 Rev. B (1118) Page 10 of 56...
  • Page 11 SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Fig. 9 Procedure Disconnect the electrical power to the machine and follow lockout / tagout procedures. Remove the right side panel as outlined under Covers and Panels. Disconnect the wire leads to the component being replaced.

  • Page 12: Temperature Probe

    Remove the right-side panel as outlined under Covers and Panels. Disconnect probe leads from the solid state temperature controller on the SG4D/SG6D or the computer controller on the SG4C/SG6C. Fig. 12 Remove the racks and right rack support.

  • Page 13: Gas Orifice

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS GAS ORIFICE Disconnect the electrical power to the machine and follow lockout / tagout procedures. Fig. 13 Remove the bolts securing the gas manifold and Shut off the gas before servicing the oven.

  • Page 14: Ignition Control Module

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Disconnect the lead wires. Verify gas pressure as outlined under the Gas Pressure Adjustment in Service Procedures and Disconnect compression fittings from the valve. Adjustments. Check for proper operation. IGNITION CONTROL MODULE Disconnect the electrical power to the machine and follow lockout /...

  • Page 15: Spark Igniter And Flame Sense

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Reverse the procedure to install the replacement ignition module board. Check for proper operation. SPARK IGNITER AND FLAME SENSE Fig. 24 Reverse the procedure to install the assembly and check for proper operation.
  • Page 16 SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Reverse procedure to install and adjust blower position as outlined under the Blower Adjustment in Service Procedures and Adjustments section. Motor - Perform step 4A and continue procedure.

  • Page 17: Blower And Motor Starting At Serial Number 481913936

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS BLOWER AND MOTOR Starting at Serial Number 481913936 Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit and follow lockout / tagout procedures.

  • Page 18: Oven Doors And Bearings Ending At Serial Number 481907145

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Fig. 33 13. Reverse procedure to install. 14. Verify operation. Fig. 31 OVEN DOORS AND BEARINGS Remove motor mounting plate nuts (1, Fig. 31). Ending at Serial Number 481907145 Place a piece of cardboard on bottom of oven cavity to protect its surface from any damage during motor assembly removal.

  • Page 19: Oven Doors (Independent Doors) Starting At Serial Number 481907146

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS The door assembly is heavy and will drop down once the last screw is removed. If removing the door assembly without assistance, the ignition cable, flame sense lead and gas manifold should also be removed to avoid damage to these components.

  • Page 20: Door Catch Roller Assembly (Independent Doors)

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS DOOR WINDOW Disconnect the electrical power to the machine and follow lockout / tagout procedures. Disconnect the electrical power to Remove the screws that attach roller latch the machine and follow lockout / assembly to door.

  • Page 21: Interior Lights (Rear Mounted, Round)

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Fig. 43 Replace bulb then reverse procedure to install. Disconnect the electrical power to the machine and follow lockout / tagout procedures. Lamp Assembly Remove lens and bulb. Remove springs from retaining tabs (2 places) on the socket.
  • Page 22 SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Remove racks and right-side hand rack guide. Pull lamp cover off. Grasp lamp using a clean cloth and remove from lamp assembly.

  • Page 23: Door Switch

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS NOTE: Verify gasket (1, Fig. 49) is flat on lamp cover and not damaged. Fig. 49 Fig. 47 Pull lamp housing out of oven cavity. DOOR SWITCH Disconnect wires.

  • Page 24: High Limit Thermostat

    SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Reverse procedure to install the replacement switch and check for proper adjustment as outlined in Door Switch under Service Procedures and Adjustments. HIGH LIMIT THERMOSTAT Disconnect the electrical power to the machine and follow lockout / tagout procedures.
  • Page 25 SG4 & SG6 Series Full Size Gas Convection Ovens - REMOVAL AND REPLACEMENT OF PARTS Fig. 53 Reverse the procedure to install the replacement fan and check for proper operation. Fan Installation Tips • The fan must be installed so air is pulled from the rear of the oven and blown into the control area.

  • Page 26: Service Procedures And Adjustments

    SERVICE PROCEDURES AND ADJUSTMENTS If incorrect, the problem is not in the SOLID STATE TEMPERATURE temperature control (see Troubleshooting). CONTROLLER TEST (SG4D/SG6D) Check for voltage to the switching output. For 120 VAC controls, check across terminals J3 and J4 for input voltage and...

  • Page 27: Solid State Temperature Control Calibration (Sg4D/Sg6D)

    Before attempting any calibration, see Section 8C of If the average oven temperature is not within SOLID STATE TEMPERATURE CONTROLLER +/- 5°F, calibration is recommended. TEST (SG4D/SG6D) on previous page. Loosen the set screw on the temperature Calibration Steps controller and carefully remove the knob from the Place a thermocouple in the geometric center of shaft, without rotating the shaft.

  • Page 28: Temperature Probe Test (Sg4D/Sg6D)

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS TEMPERATURE PROBE TEST (SG4D/SG6D) 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, discern power, attach test equipment and reapply power to test.

  • Page 29: Computer Controller (Sg4C/Sg6C)

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS Guard Band 4000 COMPUTER CONTROLLER (SG4C/ Temperature SG6C) tcnP Compenstaion Input Type 1 InP1 Range Low 1 Certain procedures in this section require Range High 1 electrical test or measurements while power is applied to the machine.

  • Page 30: Computer Control Calibration (Sg4C/Sg6C)

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS If 120 VAC is present, component is Advance through the menu until CAL1 functioning properly. (calibration offset) appears. Reassemble oven and check for proper If the thermocouple reading is higher operation.

  • Page 31: Verification Of Spark At Ignitor

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS Remove the plug from the manifold pressure Remove adjustment screw cap from the gas port. valve and turn gas supply to the oven back on. The following steps require power to be applied to the unit during test.

  • Page 32: Door Switch Adjustment

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS DOOR SWITCH ADJUSTMENT 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, Fig.
  • Page 33 SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Remove screws securing right side of the top front cover, bottom front cover and control panel. Remove right side panel mounting screws.
  • Page 34 SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS Fig. 63 Set the oven to call for heat and measure the Micro Amps reading. Micro Amp reading from the flame sensor should measure a minimum of 0.7 Micro Amps to maintain burner ignition.

  • Page 35: Blower Adjustment

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS BLOWER ADJUSTMENT DOOR STRIKE ADJUSTMENT (INDEPENDENT DOORS) Certain procedures in this section require electrical test or measurements while power is Certain procedures in this section require applied to the machine.

  • Page 36: Door Catch Roller Adjustment

    SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS Replace roller latch if malfunctioning as outlined under ROLLER LATCH ASSEMBLY (INDEPENDENT DOORS) and adjust as outlined in this procedure. Each oven door should be open with a force of 8 to 25 pounds when pulled at the handle.
  • Page 37 SG4 & SG6 Series Full Size Gas Convection Ovens - SERVICE PROCEDURES AND ADJUSTMENTS Fig. 69 Figure shown below (Left Side) is starting at Serial Number 481907146. Fig. 70 Move the door until proper alignment is achieved Fig. 68 then tighten the screws/bolts on the upper door bearing hardware.

  • Page 38: Electrical Operation

    Also, counts the time of the product and signals the Power On Light (SG4D/SG6D) - Lit whenever the electronic alarm at the end of the cook cycle. Master Switch (S1) is turned to ON or OVEN COOL mode.
  • Page 39 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION Plug, Socket and Components (SG4D/SG6D) Fig. 71 Page 39 of 56 F35626 Rev. B (1118)
  • Page 40 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION Plug, Socket and Components (SG4C/SG6C) Fig. 72 F35626 Rev. B (1118) Page 40 of 56...
  • Page 41 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION STARTING AT SERIAL NUMBER 481913936 (STANDARD) Page 41 of 56 F35626 Rev. B (1118)

  • Page 42: Sequence Of Operations

    SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION STARTING AT SERIAL NUMBER 481913936 (COMPUTER) Schematic 424373-1 will be used to explain the SEQUENCE OF OPERATIONS electrical sequence of operation. Cook Cycle SG4D/SG6D with Solid State Temperature Controller Conditions F35626 Rev. B (1118) Page 42 of 56...
  • Page 43 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION Oven connected to correct voltage. First valve (safety) on the gas valve energized. Gas does not flow to the L1 (HOT) to power switch (S1). burner until the 2nd valve (main) is L2 (neutral or second line) to one side energized.
  • Page 44 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION The oven will continue to cycle on the Power (24 VAC) to one side of the temperature controller until the doors are opened following components: heat relay (R3) or master switch (S1) is turned to the OFF or normally open (N.O.) contacts, high OVEN COOL position.
  • Page 45 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION Oven cavity temperature below 140°F. When the convection fan motor reaches operating speed: Power switch (S1) turned ON. The blower switch (N.O.) on the Power (120 VAC) to computer control pin 3 motor closes.
  • Page 46 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION The oven will continue to cycle on the Power (120 VAC) is removed from computer control until the doors are opened convection fan motor high speed or power switch (S1) is turned to the OFF or terminal.

  • Page 47: Wiring Diagrams

    SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION WIRING DIAGRAMS Fig. 75 Page 47 of 56 F35626 Rev. B (1118)
  • Page 48 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION STARTING AT SERIAL NUMBER 481913936 F35626 Rev. B (1118) Page 48 of 56...
  • Page 49 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION Fig. 77 Page 49 of 56 F35626 Rev. B (1118)

  • Page 50: Schematics

    SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION SCHEMATICS Fig. 78 F35626 Rev. B (1118) Page 50 of 56...
  • Page 51 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION Fig. 79 Page 51 of 56 F35626 Rev. B (1118)
  • Page 52 SG4 & SG6 Series Full Size Gas Convection Ovens - ELECTRICAL OPERATION STARTING AT SERIAL NUMBER 481913936 F35626 Rev. B (1118) Page 52 of 56...

  • Page 53: Troubleshooting

    SG4 & SG6 Series Full Size Gas Convection Ovens - TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING SYMPTOMS POSSIBLE CAUSES Line voltage. Power/Master switch malfunction. Blower motor doesn't run in OVEN COOL or ON position. Fan switch malfunction. Interconnection wiring malfunction. Door switch malfunction. Blower motor doesn't run in the ON position.
  • Page 54 SG4 & SG6 Series Full Size Gas Convection Ovens - TROUBLESHOOTING SYMPTOMS POSSIBLE CAUSES Temperature probe malfunction. Temperature control board malfunction. Excessive or low heat. Gas pressure insufficient. Gas orifice plugged or obstructed. Power level may be set to low. Interconnecting wiring malfunction.

  • Page 55: Ignition Module Diagnostics

    SG4 & SG6 Series Full Size Gas Convection Ovens - TROUBLESHOOTING CODE AND PROBLEM PROBABLE CAUSE SOLUTION Er02 - RAM check sum error Internal RAM malfunction Cycle power. Check ambient temperature at the Er03 - Ambient sensor error Ambient temperature is below 32°F control.
  • Page 56 SG4 & SG6 Series Full Size Gas Convection Ovens - TROUBLESHOOTING NUMBER OF LED FLASHES INDICATES POSSIBLE CAUSE Ignition module could not “Prove” flame after three tries for ignition within the lockout time timing provided. Check for gas supply to burner.

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