Service manual

ManualsBrandsVulcan-Hart ManualsFryerGRC35

MODEL ML MODEL ML

GRD25 052513 GRD35F 126732

GRD35 052080 GRD45F 126735

GRD45 052081 GRD65F 126738

GRD65 052082 GRD85F 126741

GRD85 052306 GRC35F 126733

GRC35 052083 GRC45F 126736

GRC45 052084 GRC65F 126739

GRC65 052085 GRC85F 126742

GRC85 052307

- 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. 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.

Reproduction or other us e of this Manual, without the express written consent

of Vulcan, is prohibited.

SERVICE MANUAL

GR SERIES GAS FRYERS WITH

TRIDELTA CONTROLS

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.

FORM 25114 Rev.A (07-03)

VULCAN-HART COMPANY, P.O. BOX 696, LOUISVILLE, KY 40201-0696, TEL. (502) 778-2791

Summary of content (47 pages)

PAGE 1
SERVICE MANUAL GR SERIES GAS FRYERS WITH TRIDELTA CONTROLS MODEL ML MODEL ML GRD25 GRD35 GRD45 GRD65 GRD85 GRC35 GRC45 GRC65 GRC85 052513 052080 052081 052082 052306 052083 052084 052085 052307 GRD35F GRD45F GRD65F GRD85F GRC35F GRC45F GRC65F GRC85F 126732 126735 126738 126741 126733 126736 126739 126742 - NOTICE This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified.
PAGE 2
GR SERIES GAS FRYERS TABLE OF CONTENTS GENERAL .......................................................................................................................................... 4 Introduction ................................................................................................................................... 4 Single Floor Model Fryers ............................................................................................................ 4 Model Designations ....................
PAGE 3
GR SERIES GAS FRYERS Computer Control ....................................................................................................................... 25 Operation .............................................................................................................................. 25 Service Programming ........................................................................................................... 25 Error messages ................................................................
PAGE 4
GR SERIES GAS FRYERS - GENERAL GENERAL INTRODUCTION This Service Manual covers specific service information related to the models listed on the front cover. Current production model fryers are built using a solid state control and computer control from Tridelta Industries (TDI). SINGLE FLOOR MODEL FRYERS Fryers with the Filter-Ready option installed, use the Mobile Filter. For service information related to the Mobile filter, refer to F24599 “MOBILE FILTERS”.
PAGE 5
GR SERIES GAS FRYERS - GENERAL KLEENSCREEN FILTERING SYSTEM The fryer battery still utilizes many of the same components as the Vulcan GR series fryers. The new Kleenscreen filtering system has been integrated into the GR Series fryer battery. The filter is housed in a pull-out drawer assembly at the base of the fryer. The filtering components in the drawer include a stainless steel filter tank, crumb-catch basket and a dual element mesh filter screen.
PAGE 6
GR SERIES GAS FRYERS - GENERAL SPECIFICATIONS Electrical • 120VAC supply. A 24VAC transformer provides power for the fryer controls, basket lift controls (if installed) and the filtering controls on Kleenscreen™ battery fryers. • Kleenscreen filter models require a separate 120VAC connection for the filter pump motor (5 amp draw). 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.
PAGE 7
GR SERIES GAS FRYERS - GENERAL CONTROL PANELS Solid State • Five product/programming keys: Left basket (up arrow); Right basket (down arrow); Temperature; Program and Boil. • Four digit display window that indicates fryer status, time left to cook, and actual or set point temperature. • Two LED lamps that illuminate when a basket timer is being programmed or blink to when a timer is activated (left or right basket). • Boil key for manual mode “boil out” cleaning of fry tank.
PAGE 8
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. Control Panel 1. Remove screws at top of control panel and rotate panel downwards. A. Lift upper cover over support rods and place cover to the side. 5. Remove screws securing lower cover to motor mounting base. 2.
PAGE 9
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS COOKING CONTROLS 3. Remove mounting nuts securing solid state control to mounting panel. WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. CAUTION: Certain components in this system are subject to damage by electrostatic discharge during field repairs. A field service ground kit is available to prevent damage.
PAGE 10
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS FILTER VALVE AND DISCARD VALVE SWITCHES WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. 1. Open the door to the fryer section being serviced. 2. Remove burners closest to the switch being serviced (if applicable) as outlined under “GAS BURNERS”. 3. Disconnect lead wire connector (2 pin) from the appropriate switch. 4.
PAGE 11
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 4. Disconnect pilot tube compression fitting. GAS ORIFICE 5. Disconnect gas inlet compression fitting. WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. 6. Separate the gas line union at gas outlet on the gas valve, then remove valve.
PAGE 12
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 5. Remove screws securing gas pilot to mounting bracket and remove pilot. TEMPERATURE PROBE WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. GAS PILOT FOR ELECTRONIC IGNITION SHOWN WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT. CAUTION: Do not sharply bend and kink the temperature probe or damage may occur. 1.
PAGE 13
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 2. Remove burners as outlined under “GAS BURNERS”. 3. Disconnect lead wires from high limit thermostat. 4. Remove screws securing the high limit to mounting bracket. 6. Remove screws securing probe mounting clips and probe to the fryer heat tube (inside tank) then remove probe. 5. Remove the capillary tube retaining and packing nuts, from the bottom of fry tank. 7. Reverse procedure to install. 8.
PAGE 14
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 7. Reverse procedure to install. POWER SUPPLY BOX WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. 7. Bring power supply box out from bottom of fryer. WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT. 8. To access components in power supply box, remove screws securing cover and lift from box.
PAGE 15
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 4. Reverse procedure to install and check for proper operation. BASKET LIFT TUBE WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. 1. Remove basket lift cover as outlined in “BASKET LIFT COVERS” under “COVERS AND PANELS”. 2. Remove nut securing lift bar to the lift tube. 3.
PAGE 16
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS BASKET LIFT CAM SWITCH WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. 1. Remove basket lift cover as outlined in “BASKET LIFT COVERS” under “COVERS AND PANELS”. 2. Remove basket lift tube as outlined under “BASKET LIFT TUBE”. 3. Disconnect lead wires from cam switch. 4. Remove screws securing cam switch to cam bracket. 5.
PAGE 17
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS BASKET LIFT CAM WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. THERE MAY BE MULTIPLE CIRCUITS. BE SURE ALL CIRCUITS ARE DISCONNECTED. 3. Remove burners from the right side fryer section above filter tank drawer as outlined under “GAS BURNERS”. 4. Disconnect the electrical connection to the motor. 5. Separate the swivel hose connections at the pump.
PAGE 18
GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 5. On battery fryer sections only, remove bolts securing the drain pipe flange to the manual drain valve. 6. Disconnect temperature probe and drain valve interlock switch (DVI) connector (6 pin) on the left. 7. Disconnect the following lead wire connectors: main control harness (right); gas combination valve and power supply box. 8. Disconnect ignitor cable and ground wire from gas pilot assembly. 9. Remove gas manifold and frame assembly.
PAGE 19
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS WARNING: 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, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. A. If the measured resistance values are within the allowable range, the probe is functioning properly. Reverse procedure to re-install.
PAGE 20
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS A. If the average temperature reading is within tolerance, cooking control is properly calibrated. Once the pilot flame is confirmed, a 24 volt output from terminal 1 will provide the ignition status input signal to the cooking control. When the cooking control calls for heat, the heat output is activated and power is applied to the heat control Triac on the Control Interface Board.
PAGE 21
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS 4. Set VOM to micro amp scale (DC) and connect meter leads at the same terminals. Negative (-) meter lead to the asterisk (*) terminal and positive meter lead to terminal 8. 4. Remove the gas pilot and check the following: A. Inspect the ceramic insulator on the ignitor/flame sense electrode for cracks or evidence of exposure to extreme heat, which can permit leakage to ground.
PAGE 22
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS B. If gas pilot lights but does not maintain an adequate flame during the trial for ignition (90 sec.), check pilot orifice for clogging. 5. Remove the adjustment screw cap to access the pressure adjustment screw. A. To increase pressure, turn the screw clockwise. To decrease pressure, turn the screw counterclockwise. CAUTION: If orifice is clogged with debris, clean with air or liquid only. C.
PAGE 23
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS BASKET LIFT ARM ADJUSTMENT 1. With frying oil at room temperature, verify the oil level is between MIN & MAX lines in fry tank. Add frying oil as needed. NOTE: Frying oil will expand when heated. Do not fill the fry tank past the MAX line. 2. Turn power switch on and set temperature to 350°F. Allow the frying oil to reach set temperature. 3. Check basket lift operation. A. If necessary, adjust as outlined below. 4.
PAGE 24
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS Use the following key sequence (password) to enter PROGRAM MODE: LEFT BASKET/UP; LEFT BASKET/UP; RIGHT BASKET/DOWN; RIGHT BASKET/DOWN. SOLID STATE CONTROL Operation Refer to the Installation & Operations manual for specific operating instructions. Error messages For information on solid state control error messages, refer to “SOLID STATE CONTROL” under “TROUBLESHOOTING”.
PAGE 25
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS COMPUTER CONTROL Operation Refer to the Installation & Operations manual for specific operating instructions. Service Programming The computer control’s “service programming” mode is used to perform system diagnostic tests or edit “program items” that affect the fryers operation. NOTE: If a product key is active (timing), service programming can not be entered.
PAGE 26
GR SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS Display, Led and Keypad Test 1. Press and hold the “5” key while turning power on to Initiate test. Release the “5” key during display of software revision level. 2. For each number key (1-9, & 0) pressed, the corresponding value is displayed in each character position on the left and right display. (i.e.”5" key shows “55555555” “55555555”). NOTE: Beeper chirp’s for as long as key is held. 3.
PAGE 27
GR SERIES GAS FRYERS - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION FRYER CONTROLS Solid State or Computer Cooking Controls (“D” or “C” Models) .................................... Monitors and evaluates input signals to the control.
PAGE 28
GR SERIES GAS FRYERS - ELECTRICAL OPERATION KLEENSCREEN FILTER CONTROLS Filter Power Switch .................................... Supplies 120VAC to pump motor. Filter valve switch or discard valve switch must be closed (valve handle extended). Pump Motor ................................................. Operates pump to circulate frying oil through filtering system. Filter Valve Switch ......................................
PAGE 29
GR SERIES GAS FRYERS - ELECTRICAL OPERATION COMPONENT LOCATION – 29 – F-25114 Rev.
PAGE 30
GR SERIES GAS FRYERS - ELECTRICAL OPERATION POWER SUPPLY BOX F-25114 Rev.
PAGE 31
GR SERIES GAS FRYERS - ELECTRICAL OPERATION 1) Pilot voltage (PV) N.O. contacts close, pilot valve energized at positive (+) terminal and opens for gas flow to pilot. SEQUENCE OF OPERATION Solid State or Computer, Cooking Control a. Pilot flame established. A micro amp “flame sense” current is rectified to ignition module through ignitor cable and sparking stops. Refer to schematic diagram 7411 for Cooking Control operation. FRY CYCLE - LIQUID FRYING OIL b. Main voltage (MV) N.O.
PAGE 32
GR SERIES GAS FRYERS - ELECTRICAL OPERATION 6. Cooking control cycles heat output on frying oil temperature until power switch is turned off; Ignition input status is removed; Drain valve interlock input status is removed; temperature probe input is outside acceptable limits or a high limit condition occurs. B. Power switch to fryer section turned off. C. Frying oil between 300°F and 350°F. D. Filter drawer assembly installed properly. E. Filter power switch turned off.
PAGE 33
GR SERIES GAS FRYERS - ELECTRICAL OPERATION F. When the oil filtering process is completed, close the manual drain valve to the fryer and allow the fry tank to refill. G. Press either “TIME” key to start filter timer countdown. 1) “FILTER” and the remaining filter time are displayed. NOTE: Drain valve interlock contacts close and the position of the drain valve is indicated to the cooking control. H.
PAGE 34
GR SERIES GAS FRYERS - ELECTRICAL OPERATION SCHEMATIC DIAGRAMS Electronic Ignition, Solid State or Computer Control F-25114 Rev.
PAGE 35
GR SERIES GAS FRYERS - ELECTRICAL OPERATION Electronic Ignition, Solid State or Computer Control – 35 – F-25114 Rev.
PAGE 36
GR SERIES GAS FRYERS - ELECTRICAL OPERATION WIRING DIAGRAMS Electronic Ignition, Solid State or Computer Control F-25114 Rev.
PAGE 37
GR SERIES GAS FRYERS - ELECTRICAL OPERATION – 37 – F-25114 Rev.
PAGE 38
GR SERIES GAS FRYERS - ELECTRICAL OPERATION Manual Pilot Ignition, Solid State or Computer Control F-25114 Rev.
PAGE 39
GR SERIES GAS FRYERS - ELECTRICAL OPERATION – 39 – F-25114 Rev.
PAGE 40
GR SERIES GAS FRYERS - ELECTRICAL OPERATION Junction Box, Kleenscreen Filtering System F-25114 Rev.
PAGE 41
GR SERIES GAS FRYERS - ELECTRICAL OPERATION Frymate (Dump Station) – 41 – F-25114 Rev.
PAGE 42
GR SERIES GAS FRYERS - TROUBLESHOOTING TROUBLESHOOTING ALL MODELS SYMPTOMS No spark to ignite pilot gas; Display lit. Sparks but gas does not ignite; Display lit. Gas pilot ignites but will not maintain flame. Gas burner(s) ignite but will not maintain flame. Excessive or low heat. Intermittent problems. No power to cooking control, fryer does not heat. High limit thermostat shutting off gas burner. POSSIBLE CAUSES 1. Drain valve switch open (alarm message displayed); or switch malfunction. 2.
PAGE 43
GR SERIES GAS FRYERS - TROUBLESHOOTING SOLID STATE CONTROL The following alarms take precedence over any other controller mode or function (except drain valve open). ALARMS OPEN PROBE DESCRIPTION If an open probe is detected, the heat demand (heat on) and basket lift outputs are disabled. Any cooking in progress is cancelled and all operator buttons are disabled. The display shows “Prob” and the electronic alarm will sound continuously. NOTE: A temperature of less than 40°F is an open probe equivalent.
PAGE 44
GR SERIES GAS FRYERS - TROUBLESHOOTING COMPUTER CONTROL The following alarms take precedence over any other controller mode or function (except drain valve open). ALARMS OPEN PROBE DESCRIPTION If an open probe is detected, the heat demand (heat on) and basket lift outputs are disabled. Any cooking in progress is cancelled and all operator buttons are disabled. The display shows “PROBE OPEN” and the electronic alarm will sound continuously. NOTE: A temperature of less than 40°F is an open probe equivalent.
PAGE 45
GR SERIES GAS FRYERS - TROUBLESHOOTING SOLID STATE OR COMPUTER CONTROL HARNESS PIN-OUTS PIN NO. INPUTS PIN NO. OUTPUTS3 E1-1 24VAC Hot E1-8 24VDC (+) Heat Demand E1-2 24VAC Neutral E1-9 Not used at this time2 E1-3 Probe High (red) E1-10 24VDC (+) Left Basket Lift E1-4 Probe Low (white) E1-11 24VDC (+) Right Basket Lift E1-5 Drain Valve Interlock (24VAC) N.O. E1-12 No connection E1-6 Ignition Status (24VAC) — — E1-7 Relay DC (-) Common — — NOTES: 1 1.
PAGE 46
GR SERIES GAS FRYERS - TROUBLESHOOTING KLEENSCREEN FILTERING SYSTEM SYMPTOM Oil not filtering, pump motor is on. POSSIBLE CAUSES 1. Filter screen plugged. 2. Clog in filter system lines. NOTE: If using solid shortening, when all filtered oil is returned to the fry tank and filter power switch is off, open the filter drawer approximately one inch. Allow the remaining shortening in the line to drain into the filter tank to prevent possible clogging after the shortening cools and solidifies.
PAGE 47
GR SERIES GAS FRYERS - CONDENSED SPARE PARTS LIST CONDENSED SPARE PARTS LIST KLEENSCREEN FILTER PART NUMBER DESCRIPTION NOTES 411496-B4 Lighted Rocker Switch, Filter 417792-1 Pump and Motor Assy, Kleenscreen™ Filter 411497-A3 Relay, Filter Circuit, 24v Coil GR SERIES GAS FRYERS WITH TDI CONTROLS PART NUMBER DESCRIPTION “D” “C” SERIES SERIES 427758-1 Cooking Computer 427757-1 Cooking Control, Solid State X 427759-1 Control Interface Board (TDI) X X 427755-G1 Rocker Switch Assy.