Fryer User Manual

ManualsBrandsVulcan Materials ManualsFryer1GR45A

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.

2GR45AF KLEENSCREEN

FRYER BATTERY

SERVICE MANUAL

GRA SERIES GAS FRYERS WITH

KLEENSCREEN PLUS®

FILTRATION SYSTEMS

MODEL ML MODEL ML

1GR45A 136647 3GR85AF 136655

1GR65A 136648 4GR45AF 136656

1GR85A 136649 4GR65AF 136657

2GR45AF 136650 4GR85AF 136681

2GR65AF 136651 2XGR45AF 136658

2GR85AF 136652 2XGR65AF 136659

3GR45AF 136653 2XGR85AF 136660

3GR65AF 136654

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.

A product of VULCAN-HART LOUISVILLE, KY 40201-0696

F25377 (March 2010)

Summary of content (36 pages)

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SERVICE MANUAL GRA SERIES GAS FRYERS WITH KLEENSCREEN PLUS® FILTRATION SYSTEMS 2GR45AF KLEENSCREEN FRYER BATTERY MODEL ML MODEL ML 1GR45A 136647 3GR85AF 136655 1GR65A 136648 4GR45AF 136656 1GR85A 136649 4GR65AF 136657 2GR45AF 136650 4GR85AF 136681 2GR65AF 136651 2XGR45AF 136658 2GR85AF 136652 2XGR65AF 136659 3GR45AF 136653 2XGR85AF 136660 3GR65AF 136654 This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly q
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GRA SERIES GAS FRYERS TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Floor Model Fryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GRA SERIES GAS FRYERS - GENERAL GENERAL INTRODUCTION SINGLE FLOOR MODEL FRYERS This Service Manual covers specific service information related to the models listed on the front cover. GRA series gas fryers come equipped with behind-the-door solid state controls. The features and operation of the cooking controls are the same for both single floor model fryers and kleenscreen battery fryers. Fryers with the Filter-Ready option installed, use the Mobile Filter.
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GRA SERIES GAS FRYERS - GENERAL KLEENSCREEN FILTRATION SYSTEM TOOLS Standard The Kleenscreen filtration system is integrated into the GRA 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. With the filter drawer closed, a self-seating oil return line provides the path to return the filtered shortening to the fry tank.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS SPLASH GUARD (KLEENSCREEN FRYERS ONLY) 1. Open fryer section doors. 2. Remove screws securing splash guard. 3. Remove splash guard. 4. Reverse procedure to install. 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.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 2. Pull filter drawer out, remove filter tank assembly and push the tank support arms back into place under the fryer. 3. Remove splash guard from base frame. 4. From underneath the fryer: 5. A. Disconnect the discard valve switch lead wire connector from power supply box. B. Remove switch mounting screws. 2. Remove cooking controls to access burner(s) if necessary. 3. Remove drain pipe to access burner(s) if necessary. 4.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 2. Reverse procedure to install and check for proper operation. GAS COMBINATION VALVE 6. Remove burner. 7. Reverse procedure to install and check for proper operation. GAS ORIFICE NOTE: If a gas combination valve is malfunctioning, do not attempt to disassemble the valve for repair. Install a replacement gas combination valve. 1. 1. Remove GAS BURNERS. 2. Disconnect lead wires from gas combination valve.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 3. Disconnect pilot tube from gas combination valve. 4. Disconnect gas line fittings then remove gas combination valve. A. 5. Remove gas line fittings from gas combination valve and install (in same orientation) on the replacement valve. Reverse procedure to install and check for proper operation. A. Clean the pipe threads and apply pipe joint compound to threads. Any pipe joint compound used must be resistant to the action of propane gases.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS and probe to the fryer heat tube (inside tank) then remove probe. TEMPERATURE PROBE Do not sharply bend and kink, or clamp down on the capillary tube or damage may occur. 1. Drain shortening from fryer tank. 2. Disconnect smaller, 6-pin male connector. (Temperature probe and drain valve interlock (DVI) connector) 7. Reverse procedure to install and check for proper operation. 8.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS POWER SUPPLY BOX COMPONENTS 4. Remove screws securing the high limit to mounting bracket. 5. Remove the capillary tube retaining and packing nuts. 6. 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.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 4. 5. Disconnect swivel pipe fitting at rear of fry tank. Reverse procedure to install and check for proper operation. FILL SOLENOID VALVE (KLEENSCREEN FRYERS ONLY) REAR VIEW SHOWN 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. 1. Open the fryer section doors above filter pan. 2.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 2. Open the fryer section doors above the filter tank drawer. 3. Pull filter drawer out, remove filter tank assembly and push the tank support arms back into place under the fryer. 4. Remove splash guard from base frame. 5. Disconnect pump motor lead wire connector. 6. From underneath the fryer: A. 7. 8. Disconnect flexible line fittings from pump. Remove pump motor assembly from fryer. A.
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GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS 6. Remove POWER SUPPLY BOX. 7. On battery fryer sections only, remove splash guard from base frame. 9. Disconnect swivel fitting from fry tank at the rear (shortening line inlet to fry tank). 10. Disconnect flexible gas line fitting at manual shutoff valve (gas supply inlet to valve). 11. Remove screws securing the top of fry tank to the flue wrap.
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GRA SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS TEMPERATURE PROBE TEST The temperature probe is an RTD (resistance temperature detector) of the thermistor type. As temperature increases the resistance value decreases. Probe Fault If a temperature probe fault occurs, red diagnostic LED on back of control assembly (inside control box cover) will flash. The heat demand outputs are de-activated. 3. Test the probe using a VOM to measure resistance.
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GRA SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS COOKING CONTROL CALIBRATION NOTE: Verify condition of temperature probe as outlined under TEMPERATURE PROBE TEST before proceeding. 1. Check the level of shortening in fry tank. The level must be between the MIN & MAX fill lines before proceeding. 2. Allow shortening to cool below 300EF. 3. Place a thermocouple in the geometric center of the fry tank one inch below the shortening surface. 4.
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GRA SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS control calls for heat, the heat output is activated and the main valve coil on the combination valve is then energized, allowing gas flow to the burners. Terminal Description 1 MV (main voltage) - 24VAC output will be present, providing the ignitor/flame sense electrode is sensing an adequate pilot fame. 2 MV/PV (common). 3 PV (pilot voltage) - 24VAC output will be present after the ignition module is powered.
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GRA SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS 3. 4. Turn the power switch on and verify the ignition control module is receiving power from the transformer. A. If 24VAC is present, then module is receiving power. Turn the power switch off and continue with procedure. B. If 24VAC is not present then find the source of the problem. ELECTRONIC IGNITION GAS PILOT SHOWN D. Disconnect power to the machine. 5. Verify all electrical connections on the ignition control module are secure. 6.
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GRA SERIES GAS FRYERS - SERVICE PROCEDURES AND ADJUSTMENTS adequate sizing. GAS MANIFOLD PRESSURE ADJUSTMENT 1. 2. B. Open the door(s) and remove drain pipe. 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. To measure the manifold pressure, remove plug and attach manometer to pressure tap in manifold. A. To increase pressure, turn the screw clockwise.
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION FRYER CONTROLS Cooking Control . . . . . . . . . . . . . . Monitors and evaluates input signals to the control: Activates heat output signal to maintain shortening temperature; and activates filter output signal to power the fill solenoid valve. Transformer . . . . . . . . . . . . . . . . . Supplies 24VAC to the cooking control ignition control module. Transformer is energized when power switch is turned on. Power Switch .
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION KLEENSCREEN FILTER CONTROLS Fill Solenoid Valve . . . . . . . . . . . . When energized by filter switch, the solenoid valve opens to allow the flow of shortening thru filtering system. Pump Motor . . . . . . . . . . . . . . . . . Operates pump to circulate shortening through filtering system. Start Switch . . . . . . . . . . . . . . . . . . Supplies power to temperature control module. Filter Switch . . . . . . . . . . . . . . . . .
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION POWER SUPPLY BOX COMPONENTS Page 21 of 36 F25377 (March 2010)
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION SEQUENCE OF OPERATION Refer to schematic diagram AI 2727 for Cooking Control operation. NOTE: Make sure melt select switch reflects type of shortening being used (solid/liquid). 1. 2. Conditions. A. Fryer connected to correct supply voltage and properly grounded. B. Gas supply is on and gas combination valve is open. C. Power switch to the fryer section in the off position. D.
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION Kleenscreen Filtering System Refer to schematic diagram AI 2728 for Kleenscreen Filter System operation. Refer to Installation & Operation manual and Kleenscreen Filtration System Supplement manual for specific instructions on filtering. NOTE: The discard valve handle is connected to a mechanical valve and magnetic reed switch assembly to route the flow of shortening in the filtering system and supply power to the pump motor. 1. Conditions. A.
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION SCHEMATIC DIAGRAMS Fryers Without KleenScreen Filtration System F25377 (March 2010) Page 24 of 36
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION Fryers With KleenScreen Filtration System Page 25 of 36 F25377 (March 2010)
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION WIRING DIAGRAMS Fryers Without KleenScreen Filtration System F25377 (March 2010) Page 26 of 36
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION Page 27 of 36 F25377 (March 2010)
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION Fryers With KleenScreen Filtration System F25377 (March 2010) Page 28 of 36
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION Page 29 of 36 F25377 (March 2010)
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GRA SERIES GAS FRYERS - ELECTRICAL OPERATION Frymate (Dump Station) F25377 (March 2010) Page 30 of 36
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GRA SERIES GAS FRYERS - TROUBLESHOOTING TROUBLESHOOTING ALL MODELS SYMPTOMS No spark to ignite pilot gas. POSSIBLE CAUSES 1. 2. 3. 4. 5. Drain valve switch open or switch malfunction. Shorted electrode or an improper ground on ignitor/flame sense. Ignitor cable open. Interconnecting wiring malfunction. Ignition Module malfunction. Sparks but gas does not ignite. 1. 2. 3. 4. 5. 6. 7. Service gas valve closed. Gas supply off or insufficient gas pressure.
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GRA SERIES GAS FRYERS - TROUBLESHOOTING IGNITION MODULE The ignition module has two LED's; one for flame sensing and one for ignition system status. • Flame LED (Yellow) - Indicates pilot burner flame presence and signal strength. • Status LED (Green) - Indicates ignition system operation status and error conditions. LED Flash Code Descriptions - Flame LED (yellow) or Status LED (green): • Fast Flash - Rapid blinking during startup and self check.
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GRA SERIES GAS FRYERS - TROUBLESHOOTING IGNITION SYSTEM STATUS LED CODES (GREEN) - PART NO. 857207-1 SINGLE TRY LOCKOUT IGNITION MODULE LED Flash Code OFF Indicates System Action Possible Causes No Call for Heat None None Fast Flash Startup - Pilot flame sense calibration Flame sense calibration automatically occurs immediately after pilot lights. None Heartbeat Normal operation None None 3 Restart ignition trial - Pilot flame failed while main burner on Trial for ignition auto re-starts.
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GRA SERIES GAS FRYERS - TROUBLESHOOTING IGNITION SYSTEM STATUS LED CODES (GREEN) - PART NO. 857207-1 SINGLE TRY LOCKOUT IGNITION MODULE LED Flash Code 8 Indicates System Action Possible Causes Low voltage to ignition module - Below 15.5 VAC Module will not proceed to trial for ignition. When fault is corrected, module resumes trial for ignition, after a one minute delay. 1. Check voltage to ignition module during trial for ignition. 2. Check supply voltage to machine.
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GRA SERIES GAS FRYERS - TROUBLESHOOTING FRYMATE (DUMP STATION) WITH OPTIONAL HEATER SYMPTOM No heat. POSSIBLE CAUSES 1. 2. 3. 4. Unplugged. Power switch off or inoperative. Main circuit breaker off or open. Malfunctioning heater assembly.
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GRA SERIES GAS FRYERS - TROUBLESHOOTING KLEENSCREEN FILTERING SYSTEM SYMPTOM POSSIBLE CAUSES Shortening not filtering, pump motor is energized. 1. Filter screen plugged. 2. Clog in filter system lines. NOTE: If using solid shortening, when all filtered shortening is returned to the fry tank and filter power switch is off, open the filter drawer approximately one inch.