SERVICE MANUAL
Heavy Duty Gas Griddles
MODEL
MLS
24RRG
36RRG
48RRG
60RRG
ML-135339-00024
ML-135340-00036
ML-135341-00048
ML-135342-00060
48RRG
ITW Food Equipment Group, LLC
3600 North Point Blvd.
Baltimore, MD 21222
FORM F-36986 (Rev. 11-08)
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BURNER…………………………………………………………………..15
BURNER TROUBLESHOOTING……………………………………….15
BURNER REMOVAL……………………………………………………. 15
BURNER ADJUSTMENT……………………………………………….. 16
GAS REGULATOR……………………………………………………… 17
REGULATOR TROUBLESHOOTING………………………………….17
SYMPTOM-UNIT WILL NOT MAINTAIN CONSISTENT GAS
PRESSURE………………………………………………………………. 17
GAS PRESSURE MEASUREMENT…………………………………...17
PRESSURE TAP LOCATION………………………………………….. 18
SEQUENCE OF OPERATION…………………………………………. 18
WIRING DIAGRAMS……………………………………………………. 19
24-INCH GRIDDLE……………………………………………………….19
36-INCH GRIDDLE……………………………………………………….20
48-INCH GRIDDLE……………………………………………………….21
60-INCH GRIDDLE……………………………………………………….22
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GENERAL
INTRODUCTION
This manual is prepared for the use of trained service technicians and should only be used by those
who are properly qualified. This manual is not intended to be all encompassing. You should read, in
it'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 not be attempted.
Disconnect the electrical power and follow lockout / tagout procedures
Certain procedures in this manual require electrical test or
measurements while power is applied to the machine. Exercise extreme caution at all
times when attempting these procedures. Before testing, disconnect electrical power
and follow lock/out tagout procedures, then attach test equipment and reapply power to
test.
Procedures in this manual will apply to all RRG models unless specified. No procedure in this
manual will require the removal or raising of the griddle plate. Pictures and illustrations can be of any
model unless the picture or illustration needs to be model specific.
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 RRG models must be
installed with an externally mounted regulator.
OPERATION
Detailed operation instructions are included in the Installation & Operation Manual sent with each
unit and are also available at WWW.VULCANHART.COM .
CLEANING
Detailed cleaning procedures are included in the Installation & Operation manual sent with each
unit.
LUBRICATION
No lubrication is required on this equipment.
SPECIFICATIONS
All RRG models operate on 120 volt, 60 hertz, single phase at 1.0 amps. All models are equipped
with electric solid state thermostats, automatic spark igniters and pilot safety circuit. All models are
equipped with 27,500 BTU/HR burners as standard equipment. One burner is used for every 12 inches
of griddle surface. Natural gas models are to operate at 5.0" W.C. manifold pressure and LP models at
10.0" W.C. manifold pressure with all burners on.
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COMPONENT LOCATION
GAS MANIFOLD
720122
PRESSURE CHECK PLUG
PILOT SPARK ASSEMBLY
713930
¼” FLEX TUBE
BURNER ORIFICE
TEMPERATURE
CONTROLLER
498438
SAFETY IGNITION MODULE
498443
DUAL SOLENOID VALVE
713656
KNOB
498438-1
3/8” FLEX TUBE
PILOT ADJUSTMENT VALVE
719194
INDICATOR LIGHT
720017
POWER SWITCH
810280-1
36RRG CONFIGURATION SHOWN
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EXTERIOR PANELS
CONTROL PANEL
FLUE
Disconnect the electrical
power and follow lockout
/ tagout procedures
BACK PANEL
BULLNOSE
The Control Panel holds the
thermostats, indicator lights
and power switch.
REMOVAL
1. Remove the four screws
securing the front of the
control panel. There are
two screws at each end
of the panel.
2. Remove the screws that
secure the bottom of the
control panel to the
underside of the chassis.
3. Pull the control panel
forward and lay face
down directly in front of
the unit while servicing.
4. Reverse the procedure to
install.
CONTROL PANEL
IDENTIFICATION PLATE
BACK PANEL
BULLNOSE
Disconnect the electrical power and
follow lockout / tagout procedures
It will be necessary to remove the back panel when changing a
burner, temperature probe or to remove excessive grease build up
from the flue area.
REMOVAL
1. Disconnect gas supply at griddle.
2. Remove all screws from rear of griddle securing the back panel.
3. Reverse the procedure to install.
Disconnect the electrical
power and follow
lockout / tagout
procedures
The Bullnose acts as a front
rail or shelf during griddle
operation.
REMOVAL
1. Remove the Control
Panel.
IDENTIFICATION PLATE
2. The bullnose assembly is
secured with several
screws, one at each end
of the bottom of the
assembly and several
more (depending on
size) facing the griddle
plate.
The identification plate contains the unit’s full model and serial
number along with BTU rating and clearance information. The
identification plate is located on the right side panel towards the
front of the unit.
FLUE
The flue is the outlet for gases left over from combustion and
excess heat. The flue should never be blocked or covered.
3. Reverse the procedure
to install.
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THERMOSTAT
WIRING CONFIGURATION
FRONT VIEW
The thermostat is a solid state control. The thermostat supplies power to the burner solenoid valves
and indicator lights when turned on or until the temperature setpoint is reached.
Disconnect the electrical power and follow lockout / tagout procedures
THERMOSTAT TROUBLESHOOTING
SYMPTOM – BURNER WILL NOT COME ON
1. Check for loose or excessively greasy/dirty connections at thermostat terminals
2. Check that thermostat is set higher than griddle plate surface temperature.
A. Check for 120 voltage going to L1 terminal on thermostat
B. If no voltage, check wiring and power switch.
3. Check safety ignition module.
4. Check for resistance (approx. 50 Ω) from L2 wire to ground when safety circuit should be made.
A. If no resistance, check that pilot is lit and check safety ignition module.
SYMPTOM – GRIDDLE SURFACE TEMPERATURE IS MORE THAN ±5°F OF THERMOSTAT SET
POINT
1. Ensure that you are using a high quality, calibrated surface temperature measuring device.
A. Do not use an infrared thermometer – these are highly inaccurate on a griddle plate.
B. Refer to instructions on page 8 for proper placement of probe and method.
2. Check that burners are properly adjusted.
3. Check that burner valves are operating correctly.
4. Check that there are no burner orifice obstructions
5. Check that the high temp. thermostat probe wire insulation is completely covering the wire. If
you have found no problems in steps 1 – 5, proceed page 9 for calibration instructions.
6. If thermostat will not calibrate after all previous steps – replace thermostat.
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Disconnect the electrical power and follow lockout/tagout procedures
THERMOSTAT REMOVAL
1. Remove the control panel
2. Remove the knob
3. Label and disconnect the wires
4. Remove the thermostat retaining nut on the knob shaft.
5. Reverse procedure to install while being careful to install the thermostat in the same orientation.
TEMPERATURE PROBE
The temperature probe is an embedded K
type thermocouple assembly.
498432-A
Disconnect
power and
lockout/tagout procedures
the
follow
electrical
TEMPERATURE PROBE REMOVAL
1. Remove the control panel
2. Remove the back panel
3. Label and disconnect the lead wires at
the temperature controller
4. Unthread the probe retaining nut and
remove the probe from the back of the
unit.
TEMPERATURE PROBE INSTALLATION
1. Insert lead wires from back of heatshield
through to temperature controller.
2. Apply a thin coating of high temp(500°
F min. rated),copper based heat transfer
and anti-seize compound to the probe tip
and retaining nut.
3. Insert probe end into plate socket and
hand tighten probe retaining nut.
4. Tighten the probe an additional ½ turn
only with a wrench. Over tightening can
strip threads and damage probe tip.
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ADJUSTMENTS
CALIBRATION
1. Each temperature controller controls a 12” zone
of the griddle. Using Surface Probe
a
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.
2. Set thermostats to 350°F and allow to stabilize,
allowing the indicator light to cycle ON and
OFF at least two times.
3. Watch for indicator light to cycle OFF, then
measure the temperature for that zone. The
temperature should be 350°F ±5°F. If not,
continue to Step 4.
4.
a. Set the temperature controller to
350° F. DO NOT allow the knob to
turn. Carefully remove the knob
from the temperature control
shaft.
Step 4a. Set knob &
check temperature.
Remove knob
b. Loosen screws on the back of
knob and turn the transparent ring
around the black knob to the
desired position. Knob will have to
be placed back on the shaft to
verify adjustment.
Step 4b. – Adjust
the position of outer
knob ring relative to
black knob body &
verify temperature
setting
IMPORTANT: NEVER ADJUST THE
SCREW ON THE BACK SIDE OF THE
TEMPERATURE CONTROLLER. This
will ruin the factory calibration; the
temperature controller will no longer
operate properly and will need to be
replaced.
Step 4c. –Replace
knob and verify the
reading. Carefully
remove the knob &
tighten screws
5. Once calibration is achieved, tighten the
knob screws.
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# 3 TERMINAL
# 2 TERMINAL
TEMPERATURE
CONTROLLER
# 1 TERMINAL
POWER
SWITCH
INDICATOR
LIGHT
POWER ON/OFF SWITCH
The Power Switch controls the power supply to all other electronic components.
Disconnect the electrical power and follow lockout / tagout procedures
POWER SWITCH TROUBLESHOOTING
SYMPTOM – NO POWER BEING SUPPLIED TO THE UNIT
1. Check for loose or excessively greasy/dirty connections at terminals.
2
With power wires disconnected check for continuity/resistance between the 1 and 2 terminals
A. If continuity/resistance with switch in OFF position – replace switch
B. If no continuity/no resistance with switch in ON position – replace switch
3. Check for 120 voltage from #2 terminal to ground
A. If no voltage – check main wiring from j box and power cord/plug
B. If getting voltage to #2 terminal – check voltage to #1 terminal to ground with switch in
“on” position.
1. If no voltage – replace switch
POWER SWITCH REMOVAL
1. Remove the control panel.
2. Label and disconnect the wires to the power switch.
3. Squeeze the switch retainers and slide the switch out through the front of the
control panel.
4. Reverse the procedure to install and check for operation.
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INDICATOR LIGHT
The indicator light illuminates fully to indicate that the corresponding thermostat and burner have turned
on and gas is flowing through the corresponding solenoid valve. The indicator light will illuminate at a
lower intensity when the pilot safety circuit is being made (pilot lit) but the corresponding burner
solenoid valve and thermostat are not on. The indicator light will exhibit no illumination if the pilot safety
circuit is not made (pilot not lit).
INDICATOR LIGHT TROUBLESHOOTING
SYMPTOM – LIGHT DOES NOT COME ON WHEN THERMOSTAT AND BURNER ARE ON.
1. Check for loose or excessively greasy/dirty terminal connections
2. Check for approx. ½ line voltage between the two indicator light terminals with the
corresponding burner and thermostat off.
A. If no voltage – check wires coming in from the corresponding safety ignition module to the
solenoid to the light for shorts or breaks.
3. With thermostat on and corresponding burner lit – check for 120 voltage between both wires
at the light.
A. If no voltage – check wires coming from the corresponding thermostat to the solenoid to the
light for shorts or breaks. Check thermostat and safety ignition module
B. If you have 120V – replace indicator light.
Disconnect the electrical power and follow lockout / tagout procedures
INDICATOR LIGHT REMOVAL
1.
2.
3.
4.
Remove the control panel
Label and disconnect wires to the light
Squeeze the light retainers and slide the light out through the front of the control panel
Reverse the procedures to install and check for proper operation
SAFETY IGNITION MODULE
The safety ignition module is a direct
spark ignition control that utilizes a
microprocessor circuit for ignition and
flame sensing. The flame sensing is
achieved via flame rectification. The unit
will continue to spark and keep the
corresponding solenoid valves locked out
until a minimum flame current of 1.0 μA is
achieved.
Pin 1
Pin 2
Pin 3
Pin 4
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Disconnect the electrical power and follow lockout / tagout procedures
SAFETY IGNITION MODULE TROUBLESHOOTING
SYMPTOM – NO SPARK BETWEEN PILOT HEAD AND ELECTRODE
1. Check for loose or greasy/dirty connections at all terminals (including electrode wire)
2. Check for 120 voltage from pin 4 wire to ground.
a. If no voltage check on/off switch and wiring for shorts or breaks
3. Check electrode wire for damage and continuity – if damaged or no continuity change
spark/pilot assembly
a. Check spark gap between electrode and pilot head. The spark gap should be between
.094” to 0.156” – or approx. 1/8”.
4. If component has passed above checks and is not sparking – then replace ignition module.
SYMPTOM – ELECTRODE CONTINUALLY SPARKS AFTER PILOT IS LIT
1. Check that electrode is engulfed by pilot flame
2. Increase pilot flame height
3. Check electrode and electrode wire for damage
4. Check that power cord grounding wire is securely attached to J box.
5. Check that ground wire from pin 1 is securely grounded to chassis.
SYMPTON – BURNER SOLENOID VALVE OPENS WITHOUT ESTABLISHED PILOT FLAME
1. Check burner solenoid valve.
2. Check for voltage from pin 2 wire of safety ignition module
a. Replace safety ignition module if voltage
IGNITION MODULE REMOVAL
1. Remove the control panel.
2. Label and disconnect the wires from the igniter module.
3. Disconnect the electrode wire and control wire harness.
4. Remove the two mounting bolts.
5. Remove the safety ignition module.
6. Reverse the procedure to install and check for proper operation.
SOLENOID VALVES
The RRG series griddles use both single and dual solenoid valves in differing applications. A single
or dual valve can be either a pilot valve or main burner valve. Pilot valves can be identified by the fact
that they will have adjustment screws for the pilot flame at the output of the valve body. Pilot solenoid
valves will receive power and remain on as long as the power switch is in the ON position. Main burner
solenoid valves will remain on until the thermostat set point has been satisfied.
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INPUT GAS LINE
IN BACK CENTER
RETAINING SCREW
OUTPUT
GAS LINES
DOUBLE SOLENOID VALVE
Disconnect the electrical power and follow lockout / tagout procedures
SOLENOID VALVE TROUBLESHOOTING
SYMPTOM – NO GAS FLOW TO BURNER
1. Check terminals for loose or greasy/dirty connections
2. Check gas pressure – check for orifice obstructions.
3. With thermostat, indicator light and power switch on – check for 120 voltage between the two
terminals on the solenoid.
A. On pilot solenoid if no voltage – check wiring and on/off power switch
B. On main burner solenoid if no voltage – check wiring, safety ignition module and
thermostat
4. If you have 120 voltage between the two terminals after performing steps 1- 3, replace the
solenoid valve.
5. Check for a shorted coil by checking resistance between the two terminals with the wires
disconnected. Readings of 100 ohms or less would indicate a shorted coil, replace the
solenoid.
SOLENOID VALVE REMOVAL
Shut off gas supply
1. Remove the control panel.
2. Label and disconnect the wires to the solenoid terminals.
3. Remove the two retaining screws that are holding the valve body in the bracket.
4. Disconnect the input compression fitting and the output compression fitting(s).
5. Remove the solenoid valve
6. Reverse the procedure to install. Be careful to attach the input lines to the ports on the valve
body that are stamped IN
7. Verify gas pressure and check for proper operation.
All gas joints disturbed during servicing must be checked for leaks.
Check with a soap and water solution. Do not use an open flame.
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PILOT
The RRG Series Griddles utilize a solenoid valve with
a brass pilot valve to control gas flow to pilot burners.
One to three pilot flames can be fed by one valve –
one leg of which may be branched.
BRASS PILOT
VALVE
PILOT TROUBLESHOOTING
SYMPTOM – PILOT WILL NOT LIGHT
1. Check pilot adjustment at solenoid valve
2. Check that power switch is on
3. Check that pilot solenoid valve is working
4. Check that safety ignition module and power switch are working
5. Check gas pressure
6. Check for air in the line
PILOT ASSEMBLY REMOVAL
Disconnect the electrical power and follow lockout / tagout procedures
Shut off gas supply
1. Remove control panel. Reaching
underneath the front of the unit,
remove the pilot tube fitting and
disengage the pilot tube from the pilot.
2. Reaching underneath the front of the
unit, remove the pilot bracket retaining
screw(#2 Phillips) and remove the
entire assembly out through the pilot
access cutout and out from under the
unit.
3. Disconnect the electrode wire from the
from the safety ignition module.
4. Remove the pilot from the bracket.
5. Reverse procedure to install
6. Verify gas pressure and check for
proper operation
BRACKET RETAINING SCREW
PILOT ASSEMBLY
ELECTRODE
PILOT
ACCESS
CUTOUT
All gas joints disturbed during servicing must be checked for leaks.
Check with a soap and water solution. Do not use an open flame.
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HELPFUL HINT – If the unit is attached to a flexible gas line, you can extend the bullet feet out to their
fullest extension to raise the griddle and allow yourself more clearance while reaching under the unit.
Remember to relevel the unit if you chose to do this.
BURNER
The RRG Series Griddle utilizes U-shaped burners with a single center inlet for every 12 inches of
griddle width. Each burner is rated for 27,500 BTU/hr.
Disconnect the electrical power and follow lockout / tagout procedures
BURNER TROUBLESHOOTING
SYMPTOM – ALL BURNERS HAVE A LOWER OR HIGHER FLAME THAN NORMAL.
1. Check gas pressure
SYMPTOM – ONE OR MORE BURNERS HAVE LOWER FLAME LEVEL THAN THE OTHERS.
1. Check gas pressure
2. Check burner orifice for obstructions
3. Adjust burner air shutter
4. Check solenoid valve
SYMPTOM – ONE BURNER HAS A DELAYED IGNITION; A SEVERAL SECOND LAPSE BETWEEN
THE INDICATOR LIGHT TURING ON AND WHEN THE BURNER ACTUALLY LIGHTS.
1. Check gas pressure
2. Check that burner locater pin is properly seated with retaining clip attached
3. Check that burner ignition ports, pilot flash tube and pilot burner are all aligned.
4. Check burner shutter adjustment
5. Check pilot flame adjustment
6. Check thermostat, safety ignition module and solenoid valve operation.
BURNER REMOVAL
Shut off gas supply
1. Remove the back panel
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2. Reach through the back of the unit. Squeeze the burner retaining clip and slide off burner
retaining pin.
3. Lift the burner up so the retaining pin clears the corresponding hole in the chassis, then pull
the burner out through the back of the unit.
4. Replace by inserting the burner through the rear of the unit and engaging the burner venturi
onto the burner orifice at the front of the unit.
5. Seat the retaining pin in the hole in the chassis and attach the retaining clip.
6. Remove the control panel to check that the venturi is properly fitted over the orifice.
7. Reassemble the control and back panels, then check for proper operation.
BURNER ADJUSTMENT
For efficient burner operation, it is important that a proper 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.
BURNER CLIP
(UNDERNEATH)
FLASH TUBE
PILOT ASSY
IGNITION PORTS
AIR SHUTTER
ORIFICE
MAIN BURNERS
These photos are for reference – it should not be necessary to remove the griddle top to perform the
procedures listed in this manual.
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GAS REGULATOR
The RRG series units must have an
exterior machine gas regulator installed. The
units are shipped with a regulator that has a
vent limiter.
installed as close as possible to the unit in a
horizontal, upright position for optimal
These regulators must be
VENT LIMITER
ADJUSTMENT
COVER
performance.
They are adjusted by
removing the adjustment cover – then by
turning the adjustment screw clockwise to
increase and counter clockwise to decrease.
The regulator and griddle can be damaged
by gas pressures that exceed 14” W.C. or ½
psig.
Natural Gas Regulator 408279-25
LP Gas Regulator
408279-21
REGULATOR INSTALLED IN A HORIZONTAL,
UPRIGHT POSITION
REGULATOR TROUBLESHOOTING
SYMPTOM – UNIT WILL NOT MAINTAIN CONSISTENT PRESSURE
1. Check that vent limiter is not clogged by grease and debris
2. Check store gas pressure before regulator with all equipment on that line turned on and
consuming gas
A. For natural gas should be between 7” and 14” W.C.
B. For propane gas should be between 12” and 14” W.C.
3. Check that regulator is installed in a horizontal, upright position
4. If no problems found in steps 1 – 3, replace the regulator
GAS PRESSURE MEASURMENT
1. Set the power on/off switch to the OFF position.
2. Turn the gas supply off at a manual shutoff valve.
3. Remove the control panel.
4. Remove the pressure tap plug from the far left/#1 burner port and attach manometer
5. Turn gas back on and turn power switch to the ON position
6. Turn all thermostats on to the maximum setting so that all burners are on.
7. Turn all the equipment on the same supply line on.
8. Check gas pressure
9. Gas pressure should read 5” W.C. for natural and 10” W.C. for propane gas.
10. Turn off the power switch.
11. Turn gas supply off, disconnect manometer and reinstall pressure tap plug.
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12. Turn power switch and gas supply back on.
All gas joints disturbed during servicing must be checked for leaks.
Check with a soap and water solution. Do not use an open flame.
PRESSURE TAP AT #1 BURNER
SEQUENCE OF OPERATION
Operation is the same for all size griddles. The neutral wire from the power source is directly
connected to each thermostat and each safety ignition module.
1. The power on/off switch is set to the ON position.
2. Voltage is applied to the following terminals
A. Terminal L1 on each thermostat.
B. Pin 4 terminal of each safety ignition module.
C. Both terminals of the pilot solenoid – energizing the solenoid.
3. The igniter electrode sparks against the pilot head and lights the pilot burner
4. When the pilot flame is sensed – the igniter stops sparking and the igniter safety module allows
voltage to pass to one terminal of each of the corresponding burner solenoid valves and one
terminal of each indicator light – the indicator light illuminates at dim.
5. If the griddle plate temperature is lower than the thermostat set points - the thermostat(s) will
send voltage to the remaining burner solenoid terminal and remaining indicator light terminal.
A. The solenoid will then energize - gas flows to the corresponding burner and is ignited
by the pilot flame.
B. The corresponding indicator light will go from dim to full illumination.
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WIRING DIAGRAMS
WIRING DIAGRAM – 24-INCH GRIDDLE
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WIRING DIAGRAM – 36-INCH GRIDDLE
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WIRING DIAGRAM – 48-INCH GRIDDLE
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WIRING DIAGRAM – 60-INCH GRIDDLE
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