Vulcan-Hart GRC35 Service Manual Download Page 11

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F-25114 Rev.A (07-03)

GR SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

GAS ORIFICE

WARNING:

DISCONNECT THE

ELECTRICAL POWER TO THE
MACHINE AND FOLLOW LOCKOUT /
TAGOUT PROCEDURES. THERE MAY
BE MULTIPLE CIRCUITS. BE SURE
ALL CIRCUITS ARE DISCONNECTED.

WARNING:

SHUT OFF THE GAS BEFORE SERVICING

THE UNIT.

1. Remove gas orifice spud from orifice extension.

NOTE:

The spud screws into orifice extension. When

installing, do not over tighten the spud or damage to the
threads may occur.

2. Reverse procedure to install.

GAS COMBINATION VALVE

WARNING:

DISCONNECT THE

ELECTRICAL POWER TO THE
MACHINE AND FOLLOW LOCKOUT /
TAGOUT PROCEDURES. THERE MAY
BE MULTIPLE CIRCUITS. BE SURE
ALL CIRCUITS ARE DISCONNECTED.

WARNING:

SHUT OFF THE GAS BEFORE SERVICING

THE UNIT.

WARNING:

ALL GAS JOINTS DISTURBED DURING

SERVICING MUST BE CHECKED FOR LEAKS. CHECK
WITH A SOAP AND WATER SOLUTION (BUBBLES).
DO NOT USE AN OPEN FLAME.

NOTE:

Gas combination valves are not serviceable and

should not be disassembled. Once the problem has
been isolated to this control, replace it. Do not attempt to
repair the assembly.

1. Remove burners as outlined under “GAS BURNERS”.

2. Disconnect lead wires from gas combination valve.

3. Remove cotter pin securing handle to gas valve on/

off knob. Pull handle (with knob bracket attached)
away from valve assembly.

4. Disconnect pilot tube compression fitting.

5. Disconnect gas inlet compression fitting.

6. Separate the gas line union at gas outlet on the gas

valve, then remove valve.

GAS COMBINATION VALVE FOR ELECTRONIC

IGNITION SHOWN

NOTE:

Remove fittings on gas valve and install (in same

orientation) on the replacement valve.

7. Reverse procedure to install and check for proper

operation.

GAS PILOT

WARNING:

DISCONNECT THE

ELECTRICAL POWER TO THE
MACHINE AND FOLLOW LOCKOUT /
TAGOUT PROCEDURES. THERE MAY
BE MULTIPLE CIRCUITS. BE SURE
ALL CIRCUITS ARE DISCONNECTED.

WARNING:

SHUT OFF THE GAS BEFORE SERVICING

THE UNIT.

WARNING:

ALL GAS JOINTS DISTURBED DURING

SERVICING MUST BE CHECKED FOR LEAKS. CHECK
WITH A SOAP AND WATER SOLUTION (BUBBLES).
DO NOT USE AN OPEN FLAME.

1. Remove burners as outlined under “GAS BURNERS”.

2. Disconnect ignitor cable (at boot) from ignitor/flame

sense electrode on the gas pilot.

3. Disconnect ground wire from pilot bracket.

4. Disconnect pilot tube compression fitting.

Summary of Contents for GRC35

Page 1: ...e 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 ...

Page 2: ...as Orifice 11 Gas Combination Valve 11 Gas Pilot 11 Temperature Probe 12 High Limit Thermostat 13 Power Supply Box 14 Ignition Control Module 14 Basket Lift Tube 15 Basket Lift Motor 15 Basket Lift Cam Switch 16 Basket Lift Cam 17 Pump and Motor 17 Fry Tank Assembly 17 SERVICE PROCEDURES AND ADJUSTMENTS 19 Temperature Probe Test 19 Cooking Control Calibration 19 Electronic Ignition System 20 Flame...

Page 3: ...ng System 32 Schematic Diagrams 34 Electronic Ignition Solid State or Computer Control 34 Manual Pilot Ignition Solid State or Computer Control 35 Wiring Diagrams 36 Junction Box Kleenscreen Filtering System 40 Frymate Dump Station 41 TROUBLESHOOTING 42 All Models 42 Solid State Control 43 Computer Control 44 Solid State or Computer Control Harness Pin Outs 45 Interface Control Board Pin Outs 45 F...

Page 4: ...th Models Features and Options Model Designations FEATURES OPTIONS MODEL FRYER FRYING OIL FRY COOKING COOK TIMER AUTOMATIC BASKET WIDTH CAPACITY TANK CONTROL MM SS LIFTS INCHES POUNDS GRD251 10 1 2 25 30 Full Solid State 0 99 59 Single GRD35 15 1 2 35 40 Full Solid State 0 99 59 Single or Dual GRD45 15 1 2 45 50 Full Solid State 0 99 59 Single or Dual GRD65 21 65 70 Full Solid State 0 99 59 Single...

Page 5: ...ches to the width KLEENSCREEN FILTERING SYSTEM 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 With the filter drawer closed a self seating oil retu...

Page 6: ...2 W C battery units NOTE Propane or Natural gases 14 W C Max TOOLS Standard Standard set of hand tools VOM with AC current tester NOTE Any quality VOM with a sensitivity of 20 000 ohms per volt can be used Temperature tester thermocouple type U Tube Manometer Special Field service grounding kit P N TL 84919 Loctite 242 P N 520228 or equivalent Burndy pin extraction tool RX2025 GE1 Newark Electroni...

Page 7: ...Computer Fifteen product programming keys allow individual product cooking times for up to ten different products Product Programming keys 1 thru 0 Toggle Boil and two Timer keys Left Right Arrows used to initiate programming of time and checking stored values left 1 5 right 6 0 Left Right displays that indicate actual or set point temperature remaining times operating mode and completion of prehe...

Page 8: ...edure to install Basket Lift Covers WARNING SHUT OFF THE GAS BEFORE SERVICING THE UNIT WARNING ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS CHECK WITH A SOAP AND WATER SOLUTION BUBBLES DO NOT USE AN OPEN FLAME NOTE This procedure applies to fryers with automatic basket lift option only 1 Disconnect gas line at the fryer 2 Move fryer out from wall to access basket lift covers...

Page 9: ...vice grounding kit must be used anytime the control board is handled 1 Remove the control panel as outlined in CONTROL PANEL under COVERS AND PANELS 2 To Remove A Solid State Control proceed to step 3 B Computer Control Remove mounting nuts securing computer control and mounting panel to front control panel Proceed to step 4 3 Remove mounting nuts securing solid state control to mounting panel 4 L...

Page 10: ... 4 Remove switch mounting screws 5 Reverse procedure to install and check for proper operation NOTE Switches are not adjustable GAS BURNERS WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES THERE MAY BE MULTIPLE CIRCUITS BE SURE ALL CIRCUITS ARE DISCONNECTED WARNING SHUT OFF THE GAS BEFORE SERVICING THE UNIT 1 Open the door to the fryer section being servi...

Page 11: ... it Do not attempt to repair the assembly 1 Remove burners as outlined under GAS BURNERS 2 Disconnect lead wires from gas combination valve 3 Remove cotter pin securing handle to gas valve on off knob Pull handle with knob bracket attached away from valve assembly 4 Disconnect pilot tube compression fitting 5 Disconnect gas inlet compression fitting 6 Separate the gas line union at gas outlet on t...

Page 12: ...ERE MAY BE MULTIPLE CIRCUITS BE SURE ALL CIRCUITS ARE DISCONNECTED WARNING SHUT OFF THE GAS BEFORE SERVICING THE UNIT CAUTION Do not sharply bend and kink the temperature probe or damage may occur 1 Drain frying oil from fryer tank 2 Disconnect temperature probe drain valve interlock DVI connector NOTE The connector has 6 pin positions and is labeled G on the wiring diagram 3 Remove the temperatur...

Page 13: ...LOW LOCKOUT TAGOUT PROCEDURES THERE MAY BE MULTIPLE CIRCUITS BE SURE ALL CIRCUITS ARE DISCONNECTED WARNING SHUT OFF THE GAS BEFORE SERVICING THE UNIT CAUTION Do not sharply bend and kink the temperature probe or damage may occur 1 Drain frying oil from fryer tank 2 Remove burners as outlined under GAS BURNERS 3 Disconnect lead wires from high limit thermostat 4 Remove screws securing the high limi...

Page 14: ...nnect ground wire from pilot bracket 6 From rear of fryer A Disconnect wire harness connectors and power from the power supply box B Remove mounting bolts securing power supply box to fryer Access the bolts from the bottom of rear support channel frame 7 Bring power supply box out from bottom of fryer 8 To access components in power supply box remove screws securing cover and lift from box 9 Rever...

Page 15: ...securing lift bar to the lift tube 3 Remove screws securing lift tube bracket to fryer then remove bracket and lift tube 4 Reverse procedure to install BASKET LIFT MOTOR 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 CO...

Page 16: ...ds clear from moving 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 R...

Page 17: ...onnection to the motor 5 Separate the swivel hose connections at the pump NOTE When viewed from pump end the right side is the intake port and the left side is the discharge port 6 Remove motor mounting bolts 7 Remove the motor and pump pipe fittings attached from the fryer A If replacing the pump and motor remove the existing pipe assemblies and reuse 8 Reverse procedure to install NOTE Ensure th...

Page 18: ...olts securing gas line support bracket on the left side of gas manifold and frame assembly Allow gas line support bracket to swing out of way then replace bolts in the frame Hand tighten only 13 Remove screws securing the top of fry tank to the flue wrap 14 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 r...

Page 19: ...ween the MIN MAX fill lines before proceeding 2 Allow the oil to cool below 300 F 3 Place a thermocouple in the geometric center of the fry tank one inch below the oil surface 4 Set the cooking control to 350 F and turn the fryer on 5 Allow the frying oil temperature to stabilize normally 3 cycles NOTE Agitate the frying oil to eliminate any cold zones 6 Record the temperature reading from the met...

Page 20: ...erate a spark at the ignitor flame sense electrode If pilot is not established within the 90 second ignition trial time the ignition module locks out power to the gas valve A message is displayed by the control indicating ignition lockout keypad is disabled and the electronic alarm will sound continuously The system remains locked out until the power switch is cycled to reset the system and re sta...

Page 21: ...UPPLY BEFORE SERVICING THE UNIT WARNING ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS CHECK WITH A SOAP AND WATER SOLUTION BUBBLES DO NOT USE AN OPEN FLAME 2 Verify all electrical connections on the ignition control module are secure 3 Verify the ground wire connections on the ignition control module and the gas pilot mounting bracket are clean and secure The gas pilot should...

Page 22: ... valve and attach a manometer NOTE Gas manifold pressure can also be measured at the pressure tap in the manifold However the fryer drain pipe may need removed for access 3 Turn the gas supply gas combination valve and the main power switch to on A Verify burners light 4 Observe the manometer pressure reading and compare to the pressure chart near the end of this procedure A If other appliances ar...

Page 23: ...set temperature 3 Check basket lift operation A If necessary adjust as outlined below 4 When basket is in the up position the bottom of the basket should be out of the oil When basket is in the down position the bottom of the basket should clear the crumb screen and the product should be submerged A To adjust remove basket arm from lift shaft loosen stop nut and turn height adjustment bolt to rais...

Page 24: ...ntered 1 Press V key to enter programming mode If the PARAMETER LOCK feature is disabled PROGRAM MODE entry is immediate If the PARAMETER LOCK feature is enabled LoC will be displayed Use the following key sequence password to enter PROGRAM MODE LEFT BASKET UP LEFT BASKET UP RIGHT BASKET DOWN RIGHT BASKET DOWN NOTE If the proper key sequence is not entered within 6 seconds the controller exits PRO...

Page 25: ...tion on computer control error messages refer to COMPUTER CONTROL under TROUBLESHOOTING Enter Service Mode 1 Press V key and enter password default 1972 Use product key numbers 1 9 0 to enter values A SERVICE is displayed in left window the LED s above product key s 1 2 4 5 6 7 8 come on B Beeper chirp s on each successful keypress If a key is not pressed within 2 minutes the computer will automat...

Page 26: ...ng 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 For each function key pressed the following values are displayed in each character position on the left and right display PROGRAM V V TEMPERATURE T TOGGLE L BOIL B LEFT TIME RIGHT TIME 4 Turn power off to exit test GR SERIES GAS FRYERS SE...

Page 27: ... manifold pressure High Limit Thermostat Prevents the frying oil from reaching temperatures over 450 F auto reset 415 F Serves as a backup to the cooking control s high temperature alarm setting of 415 F normal operation resumes when temperature falls below this point Temperature Probe Senses temperature of frying oil Converts the temperature into a resistance valve which is monitored by the cooki...

Page 28: ...ed Filter power switch must be turned on When oil filtering is complete close the manual drain valve to the fryer and allow the fry tank to refill Return the switch to the N O position valve handle retracted when all filtered oil is returned to fry tank Discard Valve Switch Energizes pump motor to discard the frying oil from filter tank when switch is closed valve handle extended Filter power swit...

Page 29: ... 29 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION COMPONENT LOCATION ...

Page 30: ... 30 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION POWER SUPPLY BOX ...

Page 31: ...rk at ignitor 1 Pilot voltage PV N O contacts close pilot valve energized at positive terminal and opens for gas flow to pilot a Pilot flame established A micro amp flame sense current is rectified to ignition module through ignitor cable and sparking stops b Main voltage MV N O contacts close and provides ignition status input signal 24VAC to cooking control at pin E1 6 NOTE If pilot ignition is ...

Page 32: ...omplete then alert the operator to filter the frying oil shortening When the actual cooking count reaches the filter count setting FILTER will flash in the right display when fryer is idle Normal fryer operation continues without a cooking lockout This feature can also be disabled Refer to Installation Operation manual for specific instructions on filtering 1 Conditions A Fryer connected to correc...

Page 33: ... and the position of the drain valve is indicated to the cooking control NOTE Steps 5D thru 5G should be performed in immediate succession to start the filtering process and the filter timer D Turn filter power switch on 1 Switch pilot light comes on E Extend Filter valve handle of the same fryer section 1 Filter valve switch N O contacts close a Power supplied to pump motor F Pump motor circulate...

Page 34: ... 34 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION SCHEMATIC DIAGRAMS Electronic Ignition Solid State or Computer Control ...

Page 35: ... 35 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION Electronic Ignition Solid State or Computer Control ...

Page 36: ... 36 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION WIRING DIAGRAMS Electronic Ignition Solid State or Computer Control ...

Page 37: ... 37 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION ...

Page 38: ... 38 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION Manual Pilot Ignition Solid State or Computer Control ...

Page 39: ... 39 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION ...

Page 40: ... 40 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION Junction Box Kleenscreen Filtering System ...

Page 41: ... 41 F 25114 Rev A 07 03 GR SERIES GAS FRYERS ELECTRICAL OPERATION Frymate Dump Station ...

Page 42: ...as pressure 5 Incorrect polarity from transformer to Ignition module Gas burner s 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 Incorrect temperature offset selected 2 Temperature probe malfunction 3 Cooking control malfunction 4 Interface board malfunction 5 Gas pressure incorr...

Page 43: ...bled The display shows HI and the electronic alarm will sound continuously Normal fryer operation resumes when the temperature drops below the high temperature alarm level IGNITION STATUS If this input is not active 24VAC active the display will show FIrE OUt for gas pilot out If the input remains inactive for greater than 90 seconds the display will show Ign LoC for ignition lockout the electroni...

Page 44: ...tons are disabled The display shows HI TMP and the electronic alarm will sound continuously Normal fryer operation resumes when the temperature drops below the high temperature alarm level IGNITION STATUS If this input is not active 24VAC active the display will show PILOT OUT for gas pilot out If the input remains inactive for greater than 90 seconds the display will show Ign LoC for ignition loc...

Page 45: ...d Control P8 24VAC Left Basket Lift3 P4 Control Common P9 24VAC Right Basket Lift3 P5 Heat Demand Triac 24VAC P10 Relay Contacts 24VAC 1 NOTES 1 Relays connected internally 2 To TH Terminal on gas valve main 3 To basket lift relay coils PIN NO INPUTS PIN NO OUTPUTS3 E1 1 24VAC Hot E1 8 24VDC Heat Demand E1 2 24VAC Neutral1 E1 9 Not used at this time2 E1 3 Probe High red E1 10 24VDC Left Basket Lif...

Page 46: ...ilter 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 Close the filter drawer when complete 3 Frying ...

Page 47: ...0 12 Transformer 120 24v X 1 X 2 417980 1 Ignition Control Module X 1 X 2 419359 Ignitor Cable X 1 X 2 414287 231 Lead Assembly Ign Sensor X 1 X 2 410841 28 Gas Valve Nat Elect Ign X 1 X 2 410841 29 Gas Valve Lp Elect Ign X 1 X 2 419316 1 Pilot Nat Elect Ign X 1 X 2 419316 2 Pilot Lp Elect Ign X 1 X 2 418159 1 Cam Switch Basket Lift X 1 X 2 418156 1 Gear Motor Basket Lift X 1 X 2 416535 4 Relay ba...

Page 48: ... 48 F 25114 Rev A 07 03 NOTES GR SERIES GAS FRYERS ...

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