SERVICE MANUAL INDUCTION COOKERS MODEL ML VI2 114713 VI3 114714 VI22 114715 VI33 114716 VI23 114717 Model VI22 shown - 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.
TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Distinguish a Usable Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDUCTION COOKERS - GENERAL GENERAL INTRODUCTION Model Model Model Model Model VI2 is a single 2.2KW cooker. VI3 is a single 3KW cooker. VI22 is a double 2.2KW cooker. VI33 is a double 3KW cooker. VI23 is a double cooker with one 2.2KW cooker and one 3KW cooker. The induction cooktop will not heat the way a resistance heater conducts to the pan. A magnetic induction coil is beneath the ceramic top. This coil creates a magnetic field that requires a steel or iron pan to complete the magnetic loop.
INDUCTION COOKERS - GENERAL Recommended Pans Pans made of cast iron, enameled iron, or stainless steel with an iron inner layer are recommended. Stainless steel pans with 18-0, 18-8, 18-10, and 18-Cr material are acceptable if a magnet will attach itself to the pan and if the shape of the pan is acceptable. Pans with a flat bottom 5" to 10½" in diameter are recommended. Thin pans may deform during heating; a thicker wall and bottom are recommended.
INDUCTION COOKERS - GENERAL Unusable Pans Pans made of porcelain, earthenware, heat-resistant glass, copper, or aluminum are not recommended because they do not transfer heat from the magnetic induction field. LOCATION TOOLS • • • • & & Standard set of hand tools VOM with AC current tester (Any VOM with a sensitivity of at least 20,000 ohms per volt can be used.
INDUCTION COOKERS - GENERAL SPECIFICATIONS MODEL VOLTAGE PLUG TYPE MAX. AMPS BREAKER SIZE VI2 208/60/1 220/240/60/1 6-20P 10.6 9.1/9.1 15 15 VI3 208/60/1 220/240/60/1 6-20P 14.6 12.3/12.5 15 15 VI22 208/60/1 220/240/60/1 6-30P 21.2 18.2/18.2 30 30 VI23 208/60/1 220/240/60/1 6-30P 25.2 21.4/21.6 30 30 VI33 208/60/1 220/240/60/1 6-30P 29.2 24.6/25.0 30 30 CLEANING WARNING: DISCONNECT ELECTRICAL POWER BEFORE CLEANING.
INDUCTION COOKERS - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS TOP COVER 6. Remove controller board and potentiometer as outlined in “CONTROLLER BOARD, LED AND POTENTIOMETER”. WARNING: UNPLUG UNIT BEFORE SERVICING. 7. Remove six screws securing inverter assembly to the base. 8. Reverse procedure to install. 9. Apply a liberal amount of thermal compound to thermistor in center of inverter coil to contact top cover as noted in “TOP COVER”. 1.
INDUCTION COOKERS - REMOVAL AND REPLACEMENT OF PARTS FAN MOTORS WARNING: UNPLUG UNIT BEFORE SERVICING. 1. Remove the top cover as outlined under “TOP COVER”. 2. Disconnect the lead wire plug for the fan motor being removed. Units Built Before 11/14/97 1. 2. Intake fan only: A. Snap off filters located underneath unit. B. Remove screws securing fan housing to base. Current Production Units C. Remove fan housing. 1. D. Remove fan from fan housing. Discharge fan: A. Remove fan. 2.
INDUCTION COOKERS - REMOVAL AND REPLACEMENT OF PARTS CONTROLLER BOARD, LED AND POTENTIOMETER KNOB GASKET WARNING: UNPLUG UNIT BEFORE SERVICING. WARNING: UNPLUG UNIT BEFORE SERVICING. CAUTION: Certain components in this system are subject to damage due to electro-static discharge during field repairs. A Field Service Kit is available to prevent this damage. This Field Service Kit must be used anytime a component or circuit board is handled. Specific instructions are included with the kit. 1.
INDUCTION COOKERS - REMOVAL AND REPLACEMENT OF PARTS 3. Position the inverter coil on its side to access the lead wires. 4. Disconnect the lead wires from the high voltage board. NOTE: The lead from the inner portion of the inverter coil connects to the “L” terminal and the lead from the outer portion connects to the “M” terminal. These leads must also be twisted and then connected properly. 5. Remove thermistor, tension spring and support as outlined in “THERMISTOR, TENSION SPRING AND SUPPORT” 6.
INDUCTION COOKERS - REMOVAL AND REPLACEMENT OF PARTS EMI BOARD THERMISTOR, TENSION SPRING AND SUPPORT WARNING: UNPLUG UNIT BEFORE SERVICING. CAUTION: Certain components in this system are subject to damage due to electro-static discharge during field repairs. A Field Service Kit is available to prevent this damage. This Field Service Kit must be used anytime a component or circuit board is handled. Specific instructions are included with the kit. 1.
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE THE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. NOTE: Make sure all plugs are properly connected before applying power. Circuit boards have a special coating on them so handle carefully.
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS E. 6. A reading greater than 2 meg ohms should be observed. It may take 10 to 15 seconds to reach this value. F. To check collector/base of TR1 and TR2, keep VOM positive lead on the heatsink and connect the VOM negative lead to pin 6 of WF5 on the board. G. A reading of more than 0 meg ohms should be observed. 3. Unplug power cord. 4. Remove the top cover as outlined under “TOP COVER”. 5.
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS AMPERE DRAW AT SPECIFIC VOLTAGES FOR 208/60/1 UNITS @ #9 SETTING. NOTE: Chart is for single coil. UNITS WITH 208V/60HZ DATA PLATES SUPPLY VOLTAGE 220 216 208 198 188 KW RATING OF COOKTOP ZONE 3 2.2 3 2.2 3 2.2 3 2.2 3 2.2 DEMEYERE APOLLO SERIES FRYING PAN 26CM TOP X 24CM BOTTOM. AMPS @ #9 SETTING. 14.7 10.7 14.8 10.6 14.6 10.6 14.4 10.4 12.7 10 NOTE: 208V units must have a nominal line voltage of 208V.
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS AMPERE DRAW AT SPECIFIC VOLTAGES FOR 220/240/60/1 UNITS AT @9 SETTING. NOTE: Chart is for single coil. UNITS WITH 220/240/60HZ DATA PLATES SUPPLY VOLTAGE 264 240 230 220 208 KW RATING OF COOKTOP ZONE 3 2.2 3 2.2 3 2.2 3 2.2 3 2.2 DEMEYERE APOLLO SERIES FRYING PAN 26CM TOP X 24CM BOTTOM. AMPS @ #9 SETTING. 12.8 9.3 12.5 9.1 12.4 9.2 12.3 9.1 12 9 NOTE: 220/240V units must have a nominal line voltage of 220/240V.
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS 10. Turn the potentiometer on the low voltage board to obtain the correct current for the applied voltage measured in Step 2. ACCESS HOLE MODIFICATION NOTE: Do not exceed current for applied voltage for specific test pan. Damage to unit will result. A. NOTE: For units made prior to 11/14/97. To adjust if unit has potentiometer access hole in base: WARNING: UNPLUG UNIT BEFORE SERVICING. 1) Remove pan from cooker. 1. Remove top cover.
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS 17
INDUCTION COOKERS - SERVICE PROCEDURES AND ADJUSTMENTS TRANSFORMER TEST 5. Apply power to unit and check voltage at transformer secondary plug as shown in diagram. 6. If test is not correct, replace the transformer. 7. Assemble in reverse order. WARNING: UNPLUG UNIT BEFORE SERVICING. 1. Remove inverter coil as outlined in “INVERTER COIL”. 2. Remove high voltage board as outlined in “HIGH VOLTAGE BOARD”. 3. Unplug transformer secondary from plug WF1 on the low voltage board. 4.
INDUCTION COOKERS - ELECTRICAL OPERATION COMPONENT LOCATION Units built before 11/14/97 have fans mounted inside the fan housing as illustrated below. Current production units have fans mounted directly to the base and a fan air deflector which directs air flow across the inverter assembly as shown in pictures.
INDUCTION COOKERS - ELECTRICAL OPERATION SEQUENCE OF OPERATION 1. Cooktop has power applied. 2. A. Circuit boards have power applied to them all the time the unit is plugged in and the receptacle is live. B. Low voltage board is monitoring input from controller board. Turn control knob clockwise to desired cooking level. A. Cooling fans turn on. B. If indicator light blinks, it indicates no pan is detected and cooktop will shut off after 3 minutes. C. 3.
INDUCTION COOKERS - ELECTRICAL OPERATION PLUG LAYOUT 21
INDUCTION COOKERS - ELECTRICAL OPERATION NOTE: To avoid EMI interference all wire leads should be routed as far away as possible from the inverter. Do not run power leads parallel to the control leads.
INDUCTION COOKERS - ELECTRICAL OPERATION Single Heater NOTE: To avoid EMI interference all wire leads should be routed as far away as possible from the inverter. Do not run power leads parallel to the control leads.
INDUCTION COOKER - TROUBLESHOOTING TROUBLESHOOTING NOTE: Visually check boards for arcing or burn marks that could indicate a problem. SYMPTOM Indicator light blinks and then goes off after 2-3 minutes. Indicator light blinks intermittently and turns back on, cooks when light is not blinking. (Cooker may overheat and shut down.) Reduced heat. No heating, indicator continues to flash. Cooker does not operate, indicator light is off. Cooker does not operate, indicator light is on.
