Vulcan-Hart 136647, Service Manual

Page 1: ... 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 2GR45AF KLEENSCREEN FRYER BATTERY SERVICE MANUAL GRA SERIES GAS FRYERS WITH KLEENSCREEN PLUS FILTRATION SYSTEMS MOD...

Page 2: ...een Fryers Only 11 Fry Tank Assembly 12 SERVICE PROCEDURES AND ADJUSTMENTS 14 Temperature Probe Test 14 Cooking Control Calibration 15 Electronic Ignition System 15 Flame Sense Current Check 16 Electronic Ignition Control Test 16 Gas Manifold Pressure Adjustment 18 ELECTRICAL OPERATION 19 Component Function 19 Power Supply Box Components 21 Sequence of Operation 22 Kleenscreen Filtering System 23 ...

Page 3: ...r to F24599 MOBILE FILTERS A GRO Frymate dump station can be configured in a battery with fryers 15 1 2 inches or 21 inches in width Model NO OF HEAT TUBES EACH FRY TANK BTU HOUR EACH FRY TANK FRYER WIDTH INCHES SHORTENING CAPACITY LBS EACH FRY TANK 1GR45A 4 120 000 15 5 45 50 1GR65A 5 150 000 21 0 65 70 1GR85A 5 150 000 21 0 85 90 2GR45AF 4 120 000 31 0 45 50 3GR45AF 4 120 000 46 5 45 50 4GR45AF ...

Page 4: ...uded as one or more of the sections SPECIFICATIONS Electrical 120VAC supply A 24VAC transformer provides power for the fryer controls and the filtering controls on Kleenscreen battery fryers Gas Pressures Manifold per fryer section Natural 4 W C Propane 10 W C Building supply pressure Min Natural 5 W C 7 W C battery units Propane 11 W C 12 W C battery units NOTE Propane or Natural gases 14 W C Max...

Page 5: ...e to install COOKING CONTROLS 1 Open fryer section door s 2 Remove connections to cooking controls 3 Remove screws securing controls 4 Remove cooking controls 5 Disconnect lead wires from the component being replaced then remove from control box 6 Reverse procedure to install and check for proper operation DISCARD VALVE SWITCH KLEENSCREEN FRYERS ONLY 1 Open the fryer section doors above filter pan...

Page 6: ...ting screws 5 Reverse procedure to install and check for proper operation GAS BURNERS 1 Open the door to the fryer section being serviced 2 Remove cooking controls to access burner s if necessary 3 Remove drain pipe to access burner s if necessary 4 Remove gas burner shipping ties if installed 5 Lift gas burner up and tilt the top of burner toward fryer tank until it clears the gas orifice at the ...

Page 7: ...e extension When installing do not over tighten the spud or damage to the threads may occur 2 Reverse procedure to install and check for proper operation GAS COMBINATION VALVE NOTE If a gas combination valve is malfunctioning do not attempt to disassemble the valve for repair Install a replacement gas combination valve 1 Remove GAS BURNERS 2 Disconnect lead wires from gas combination valve F25377 ...

Page 8: ...e resistant to the action of propane gases GAS PILOT 1 Remove GAS BURNERS as necessary 2 Remove pilot burner assembly and bracket from pilot bracket stand off on the fry tank 3 Remove wire tie and disconnect ignitor cable from ignitor flame sense electrode on the gas pilot 4 Disconnect pilot tube from gas pilot 5 Remove screws 2 securing gas pilot to mounting bracket A To remove gas orifice from p...

Page 9: ... Remove GAS BURNERS as necessary 5 Remove the probe retaining and packing nuts 6 Remove screws securing probe mounting clips and probe to the fryer heat tube inside tank then remove probe 7 Reverse procedure to install and check for proper operation 8 Check COOKING CONTROL CALIBRATION under SERVICE PROCEDURES AND ADJUSTMENTS HIGH LIMIT THERMOSTAT Do not sharply bend and kink or clamp down on the c...

Page 10: ...S NOTE The power supply box must be removed to access the following components Ignition control module transformer R1 pump motor relay R2 fill relay 1 Disconnect all wiring harness connectors and power cords from power supply box 2 From rear remove screw securing power supply box to mounting bracket NOTE Power supply box is slotted at the front and secured by a hanging bracket loose fit 3 Remove c...

Page 11: ...er 3 Remove splash guard 4 Disconnect swivel pipe fitting at rear of fry tank 5 Disconnect fill solenoid valve lead wire connector 4 pin from power supply box 6 Remove screws 2 securing the solenoid valve body flange to pipe tee then remove the assembly from fryer A Remove pipe fittings from solenoid valve and install on replacement valve 7 Reverse procedure to install and check for proper operati...

Page 12: ...gs from the pump and install on replacement pump 8 Reverse procedure to install and check for proper operation FRY TANK ASSEMBLY 1 Drain shortening from fryer tank 2 Disconnect the gas supply line to allow access to fryer from all sides 3 Remove fryer baskets crumb screen and basket hanger NOTE If the fryer is a battery section remove grease strip and split the silicone seal between the fryer sect...

Page 13: ... lead wires and wiring harnesses as necessary before removing fry tank and when removing components from fry tank for reuse 12 Grasp the fry tank at the top by flue and front lip then lift fry tank assembly from the fryer body Place the assembly on floor or table for removal of components 13 Remove GAS PILOT 14 Remove TEMPERATURE PROBE 15 Remove HIGH LIMIT THERMOSTAT 16 On battery fryer sections o...

Page 14: ... can be caused by a lead break or a lead short To Check 1 Turn power switch off 2 Disconnect the temperature probe the drain valve interlock DVI connector 3 Test the probe using a VOM to measure resistance Connect the meter leads to pins 1 3 on the male connector A If the measured resistance values are within the allowable range the probe is functioning properly Reverse procedure to install B If t...

Page 15: ...libration potentiometer 1 Adjust calibration potentiometer clockwise to increase temperature and counterclockwise to decrease temperature a If over 25E of adjustment is necessary replace cooking control 7 Repeat the average temperature calculation for up to three attempts Allow the cooking control to cycle at least two times between adjustments before performing the calculation 8 If calibration is...

Page 16: ...C hot input FLAME SENSE CURRENT CHECK 1 Turn the power switch OFF 2 Access the ignition control module in the power supply box and locate the EnviraCom port 3 Connect the QuickLook 72 meter to the EnviraCom port Turn power switch ON 4 Meter reading should be above 1 0 micro amp minimum and steady A If reading is greater than or equal to the value given then flame sense current is within tolerance ...

Page 17: ... 1 8 inch If the gap is outside of this dimension bend the ground clip as necessary to make the adjustment D Check the ignitor cable connection for tightness and damaged insulation If the ignitor cable appears to be damaged then install a replacement ignitor cable 8 With gas pilot installed and the ignitor cable connected reconnect power and turn the gas supply on 9 Turn power switch on and observ...

Page 18: ...is observed then the gas supply needs to be checked by the gas line installer or the local gas company for adequate sizing B If adjustment is necessary continue with procedure 5 Remove burners as necessary 6 Remove the adjustment screw cap to access the pressure adjustment screw on gas combination valve A To increase pressure turn the screw clockwise To decrease pressure turn the screw countercloc...

Page 19: ...mperature falls below this point Temperature Probe Senses temperature of shortening Converts the temperature into a resistance which is monitored by the cooking control The probe is an RTD resistance temperature detector of the Thermistor type As temperature increases the resistance value decreases Ignition Control Module Controls and monitors gas pilot ignition Energizes pilot valve coil on the c...

Page 20: ...Valve Switch A magnetic reed switch mounted on the mechanical discard valve that closes when discard valve handle is extended to discard the shortening Prevents R2 filter relay N C contacts from suppling power to the fill solenoid valve when filter key is pressed R1 Pump Motor Relay When 24VAC relay coil is energized by filter switch supplies 120VAC to pump motor and fill solenoid valve thru R2 fi...

Page 21: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION POWER SUPPLY BOX COMPONENTS F25377 March 2010 Page 21 of 36 ...

Page 22: ...ition module locks out power to gas valve 1 The system remains locked out until the power switch is cycled to reset the system and re start the ignition trial cycle wait 5 minutes for gas to dissipate 4 Cooking control evaluates input signals from Ignition status Drain valve interlock and temperature probe A Main valve coil energized and valve opens for gas flow to burners 1 Burners light and heat...

Page 23: ...liminate any solid shortening in cold zone of the fry tank 3 Open the drain valve to the fryer section in need of filtering and drain the shortening into filter tank A Drain valve interlock contacts open and the position of the drain valve is indicated to the cooking control NOTE If using solid shortening allow hot shortening to stand in filter tank for approximately 6 minutes prior to filtering 4...

Page 24: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION SCHEMATIC DIAGRAMS Fryers Without KleenScreen Filtration System F25377 March 2010 Page 24 of 36 ...

Page 25: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION Fryers With KleenScreen Filtration System F25377 March 2010 Page 25 of 36 ...

Page 26: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION WIRING DIAGRAMS Fryers Without KleenScreen Filtration System F25377 March 2010 Page 26 of 36 ...

Page 27: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION F25377 March 2010 Page 27 of 36 ...

Page 28: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION Fryers With KleenScreen Filtration System F25377 March 2010 Page 28 of 36 ...

Page 29: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION F25377 March 2010 Page 29 of 36 ...

Page 30: ...GRA SERIES GAS FRYERS ELECTRICAL OPERATION Frymate Dump Station F25377 March 2010 Page 30 of 36 ...

Page 31: ...module malfunction Gas burners ignite but will not maintain flame 1 Gas pressure incorrect 2 Gas orifice obstructed or incorrect 3 Burner malfunction 4 Gas pilot malfunction Excessive or low heat 1 Cooking controls need calibrated 2 Temperature probe malfunction 3 Gas pressure incorrect 4 Gas orifice obstructed or incorrect 5 Cooking control malfunction 6 Interface board malfunction Intermittent p...

Page 32: ...l Ignition system will operate reliably but flame signal is less than desired NOTE Code may flash temporarily just after pilot burner lights then operate normally after flame signal stabilizes Check the following 1 Gas supply 2 Pilot burner flame 3 Spark flame sense wiring 4 Flame sense electrode contaminated or out of position 5 Pilot burner ground 1 Marginal pilot flame signal less than 2 µA Ign...

Page 33: ...upply 2 Pilot burner 3 Spark flame sense wiring 4 Flame sense electrode contaminated or out of position 5 Pilot burner ground 4 Pilot flame sensed out of sequence If ignition system self corrects within 10 seconds ignition module returns to normal operation If flame sense out of sequence continues module changes to Flash Code 6 4 1 Check pilot burner A If pilot flame present replace gas valve If n...

Page 34: ...ailures while main burner was on during the same Call for Heat Remains in lockout until power is cycled If pilot burner fails to light on next trial for ignition check 1 Gas supply 2 Pilot burner 3 Spark flame sense wiring 4 Flame sense electrode contaminated or out of position 5 Pilot burner ground 6 4 Flame sensed out of sequence longer than 10 seconds When pilot flame is no longer sensed pilot ...

Page 35: ...ESHOOTING FRYMATE DUMP STATION WITH OPTIONAL HEATER SYMPTOM POSSIBLE CAUSES No heat 1 Unplugged 2 Power switch off or inoperative 3 Main circuit breaker off or open 4 Malfunctioning heater assembly F25377 March 2010 Page 35 of 36 ...

Page 36: ...he line to drain into the filter tank to prevent possible clogging after the shortening cools and solidifies Close the filter drawer when complete 3 Shortening below 300 F to thick 4 Discard valve switch malfunction N O contacts not closing to energize R2 fill relay coil 5 R2 fill relay malfunction contacts remain closed NOTE The fill solenoid valve should not be energized during discard operation...