Vulcan-Hart TR Series Page 7 Service Manual Download

Page: 7 / 55

SOLID STATE CONTROL

COMPUTER CONTROL

USB Port

INSTALLATION

Refer to the Instruction Manual for detailed installation
instructions.

OPERATION

Refer to the Instruction Manual for specific operating
instructions.

CLEANING

Refer to the Instruction Manual for specific cleaning
instructions.

TOOLS

STANDARD

•

Standard set of hand tools.

•

VOM with A.C. current tester (any quality VOM
with a sensitivity of at least 20,000 ohms per volt
can be used).

SPECIAL

•

Temperature tester (thermocouple type)

•

Manometer.

•

Combustion Analyzer

•

Set of Metric Hex Wrenches (must include a 2
mm wrench)

•

Set of jewelers screwdrivers

•

Field service grounding kit P/N TL- 84919.

•

Burndy pin extraction tool RX2025 GE1; Newark
Electronics Catalog Number 16F6666. Used for
removing pin terminals on Burndy connectors.

•

Thumb Drive (part number 443444) (Customer to
supply program for uploading menu items)

SPECIFICATIONS

ELECTRICAL:

•

120VAC supply.

•

Filter motor/pump

•

Basket lift motors

•

Transformer

•

24VAC transformer

•

Fryer controls

•

Basket lift relays

•

Filter relay

MANIFOLD GAS PRESSURES (per fryer section)

•

Natural - 0.08" W.C.

•

Propane - 0.08" W.C.

BUILDING SUPPLY PRESSURE (MAX)

•

Natural Single Fryer - 6" W.C.

Natural Battery Fryer - 8" W.C.

•

Propane Single and Battery Fryers - 11" W.C.

NOTE:

Natural and propane gases listed above are

maximum supply pressures. On fryers built before
12/1/12 a separate gas regulator must be used for
pressures exceeding maximum (not supplied with

VK and TR GAS FRYERS W/Wo KleenScreen PLUS - GENERAL

Page 7 of 55

F45474 (0413)

Summary of Contents for TR Series

Page 1: ...s 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 th...

Page 2: ...TER RELAYS 24 VAC AND 120 VAC 14 120 VOLT TRANSFORMER 15 POWER SUPPLY BOX COMPONENTS AFTER 12 1 12 15 120 VOLT TRANSFORMER 15 CONTROL BOARD 16 FILTER RELAYS 16 BURNER ASSEMBLY 16 GAS VALVE 17 BASKET LIFT TUBE 17 BASKET LIFT MOTOR 18 BASKET LIFT CAM SWITCH 19 BASKET LIFT CAM 19 FILL SOLENOID VALVE KSP 19 FILTER HOSE SWITCH KSP 20 FILTER PUMP AND MOTOR KLEENSCREEN FRYERS ONLY 20 DRAIN VALVE INTERLOC...

Page 3: ... 36 BLOWER CONTROL BOARD SETTINGS 36 HIGH LOW FIRE TIMER SETTING 36 AIR FILTER 37 SPARK GAP SETTING BEFORE 12 1 12 37 SPARK GAP SETTING AFTER 12 1 12 38 ELECTRICAL OPERATION 40 COMPONENT FUNCTION FRYER CONTROLS 40 COMPONENT FUNCTION KLEENSCREEN FILTER CONTROLS 41 COMPONENT LOCATION 41 SEQUENCE OF OPERATION A SERIES AFTER 12 1 12 42 SEQUENCE OF OPERATION D AND C SERIES 43 SCHEMATIC DIAGRAMS 45 WIRI...

Page 4: ...897 1VK65DF 136898 1VK65CF 136899 1VK85AF 136900 1VK85DF 136901 1VK85CF 136902 2VK45AF 136903 2VK45DF 136904 2VK45CF 136905 2VK65AF 136906 2VK65DF 136907 2VK65CF 136908 2VK85AF 136909 2VK85DF 136910 2VK85CF 136911 3VK45AF 136912 3VK45DF 136913 3VK45CF 136914 3VK65AF 136915 3VK65DF 136916 3VK65CF 136917 3VK85AF 136918 3VK85DF 136919 3VK85CF 136920 4VK45AF 136921 4VK45DF 136922 4VK45CF 136923 4VK65A...

Page 5: ...TR65AF DF CF 84 0 65 70 80 000 SINGLE OR DUAL 2VK TR85AF DF CF 42 0 85 90 90 000 SINGLE OR DUAL 3VKTR85AF DF CF 63 0 85 90 90 000 SINGLE OR DUAL 4VK TR85AF DF CF 84 0 85 90 90 000 SINGLE OR DUAL KLEENSCREEN PLUS FILTRATION SYSTEM KSP The KleenScreen PLUS filtration system is integrated into the VK Series fryer battery The filter is housed in a pullout drawer assembly at the base of the fryer The f...

Page 6: ...ER LOCATION Serial number plate is attached to door of fryer Fig 1 This serial number plate supplies more than the serial number It also contains electric requirements gas requirements clearances and agency approvals This plate is pop riveted to the door and should not be removed However the door sometimes comes off and can become misplaced If that happens there is a second serial number location ...

Page 7: ...urndy pin extraction tool RX2025 GE1 Newark Electronics Catalog Number 16F6666 Used for removing pin terminals on Burndy connectors Thumb Drive part number 443444 Customer to supply program for uploading menu items SPECIFICATIONS ELECTRICAL 120VAC supply Filter motor pump Basket lift motors Transformer 24VAC transformer Fryer controls Basket lift relays Filter relay MANIFOLD GAS PRESSURES per frye...

Page 8: ...K45C VK45CF 70 000 VK65A VK65AF VK65D VK65DF VK65C VK65CF 80 000 VK85A VK85AF VK85D VK85DF VK85C VK85CF 90 000 TR INPUT BTU RATING TR SERIES BTU HR SECTION TR45A TR45AF TR45D TR45DF TR45C TR45CF 70 000 TR65A TR65AF TR65D TR65DF TR65C TR65CF 80 000 TR85A TR85AF TR85D TR85DF TR85C VK85CF 90 000 VK and TR GAS FRYERS W Wo KleenScreen PLUS GENERAL F45474 0413 Page 8 of 55 ...

Page 9: ...nstall Basket Lift Covers Shut off the gas before servicing the unit 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 Remove basket assembly lift arms from support rods 2 Remove screws securing upper cover to flue wrap Fig 8 A Lift ...

Page 10: ...m bottom of control box 3 Remove control box from frame of fryer 4 Loosen set screw in control knob and remove from shaft Fig 10 5 Remove control box cover Fig 11 6 Disconnect lead wires as necessary to remove control Fig 12 7 Remove screws from front of control panel and remove control VK and TR GAS FRYERS W Wo KleenScreen PLUS REMOVAL AND REPLACEMENT OF PARTS F45474 0413 Page 10 of 55 ...

Page 11: ...for solid state and computer controls Power switch for analog controls is part of the analog control box 1 Open fryer door to access power switch Fig 14 2 Unplug power switch connector 3 Reach behind power switch and press tabs on both sides of power switch to remove switch NOTE Power switch is removed from front of the panel 4 Reverse procedure to install new power switch 5 Check operation of mac...

Page 12: ...trical power to the machine and follow lockout tagout procedures Shut off the gas before servicing the unit Do not sharply bend or kink the high limit capillary tube or damage may occur 1 Drain shortening from fryer tank 2 Disconnect lead wires from high limit thermostat 3 Remove screws securing high limit to mounting bracket Fig 17 4 Remove the capillary tube retaining and packing nuts VK and TR ...

Page 13: ... Check with a soap and water solution bubbles Do not use an open flame NOTE The power supply box must be removed to access the following components ignition module all 24 volt relays blower control board both time delay timers 120 volt transformer 1 Access rear of fryer and remove screw holding power supply box to support bracket The box will lower to clear bracket Fig 20 2 Access front of fryer t...

Page 14: ...the filter relays and the transformer are still available and can be replaced in the field Ignition Module Replace with updated Power Supply Box Assembly Blower Control Board Replace with updated Power Supply Box Assembly Time Delay Timers Replace with updated Power Supply Box Assembly Blower Relay Replace with updated Power Supply Box Assembly Filter Relays 24 VAC and 120 VAC 1 Remove POWER SUPPL...

Page 15: ...wer supply boxes built after 12 1 12 have different components in them The 24 volt electronic ignition relay blower control board ignition module and both time delay relays are replaced by a single control board NOTE The new ignition module will not have a separate flame sense rod and wire Ignition module will rectify flame through high voltage wire 120 Volt Transformer 1 Remove POWER SUPPLY BOX 2...

Page 16: ...ing Fig 28 3 Remove screws and remove from box 4 Reverse the procedure to install new relays 5 Reinstall power supply box and check operation BURNER ASSEMBLY Disconnect the electrical power to the machine and follow lockout tagout procedures Shut off the gas before servicing the unit All gas joints disturbed during servicing must be checked for leaks Check with a soap and water solution bubbles Do...

Page 17: ... valve assembly burner The reason for this is every blower gas valve assembly burner is set up at the factory to operate at the most efficient level possible This set up procedure cannot be duplicated in the field If you feel that the gas valve is not set up correctly or not operating correctly call product service and they will help solve the problem BASKET LIFT TUBE Disconnect the electrical pow...

Page 18: ... motor 3 Loosen set screws securing crank arm assembly to basket lift motor shaft Fig 32 4 Remove screws securing basket lift motor to cam bracket then remove motor from bracket Fig 33 5 Reverse procedure to install and check for proper operation NOTE After reinstalling motor keep all wire leads clear from moving parts VK and TR GAS FRYERS W Wo KleenScreen PLUS REMOVAL AND REPLACEMENT OF PARTS F45...

Page 19: ...IFT COVERS 2 Remove nut securing lift bar to cam assembly 3 Loosen cam set screw 4 Remove screws securing cam to the crank arm assembly Fig 35 5 Reverse procedure to install FILL SOLENOID VALVE KSP Disconnect the electrical power to the machine and follow lockout tagout procedures Shut off the gas before servicing the unit 1 Remove filter tank from fryer 2 Access fill solenoid valve 3 Loosen union...

Page 20: ... of switch and push out front of fry cabinet 4 Reverse procedure to install new switch FILTER PUMP AND MOTOR KLEENSCREEN FRYERS ONLY Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Access rear of fryer 2 Remove four bolts holding serial plate bracket and carefully lower bracket 3 Disconnect both hoses from filter pump VK and TR GAS FRYERS W Wo KleenScreen PLUS...

Page 21: ...n fryer section door 2 Locate drain valve switch 3 Remove nut holding drain valve handle and remove handle Fig 39 NOTE Make sure drain handle is in closed position If fry tank is full of shortening carefully remove drain handle Make sure you do not turn handle to open position Doing so will allow shortening to drain on floor or you 4 Remove drain valve interlock switch bracket from valve 5 Remove ...

Page 22: ...cked for leaks Check with a soap and water solution bubbles Do not use an open flame 1 Remove BURNER ASSEMBLY 2 Remove both HIGH LIMIT THERMOSTAT and TEMPERATURE ROBE 3 Remove DRAIN VALVE INTERLOCK SWITCH 4 Remove drain assembly from drain valve A Remove hose clamp from rubber boot B Remove drain piping from drain valve Fig 41 5 Remove drain valve from fry tank Fig 42 6 Loosen and disconnect the o...

Page 23: ... pried off B Order a replacement plate prior to replacing fry tank 9 If basket lifts are installed they will have to be removed from rear of tank 10 Remove tank from fryer Fig 46 11 Reverse order of this procedure to install new fry tank VK and TR GAS FRYERS W Wo KleenScreen PLUS REMOVAL AND REPLACEMENT OF PARTS Page 23 of 55 F45474 0413 ...

Page 24: ...and the computer control The 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 or high temperature condition occurs a fault message will be displayed and the electronic alarm will sound continuously The heat demand and basket lift outputs are de activated If a cooking cycle is in p...

Page 25: ...emperature reading when the heat lamp goes out to the temperature reading when the heat lamp comes on divide this answer by 2 Temp Lamp off Temp lamp on 2 Average Temp Example 360 340 2 350 F The average temperature should be 350 F 5 F A If the average temperature reading is within tolerance cooking control is properly calibrated B If the average temperature reading is out of tolerance perform the...

Page 26: ...ower and follow lockout tagout procedures attach test equipment and reapply power to the test 1 Remove cover from power supply box 2 Locate two pins FC and FC on side of the ignition blower control board Fig 49 3 Set your multi meter for Microamps and place meter leads on two pins 4 Restart the fryer and read the microamps as the fryer is sparking NOTE The only time you will be able to read the mi...

Page 27: ...o not use an open flame The modulating gas valve is adjusted at the factory and requires no adjustments If the modulating gas valve needs to be replaced the new gas valve from the parts depot will be adjusted property and will only need to have the gas pressure verified coming into the gas valve All fryers built after 12 1 12 will have gas regulators installed on the incoming gas line The gas pres...

Page 28: ...s PROGRAM key and hold for 1 second Fryer returns to normal operation and display shows the current heating mode based on shortening temperature MELT L liquid default or Melt S solid if shortening temperature is below 135 F HEATING if no melt is selected and shortening temperature is below set point Fryer set point temperature if actual shortening temperature is within set point range Control Prog...

Page 29: ...ase melt cycle time 3 Gas Fryers Adjustment Range Melt ON 0 to 20 seconds Melt OFF 0 to 30 seconds MLTG 1 16 Liq 08 Sol Melt ON MLTG 0 18 Liq 26 Sol Melt OFF Electric Fryers Adjustment Range Melt ON 0 to 2 seconds Melt OFF 10 to 30 seconds MLTE1 04 Liq 02 Sol Melt ON MLTE0 11 liq 13 Sol Melt OFF Proportional Offset Press left basket to increase or press right basket to decrease proportional offset...

Page 30: ...und continuously NOTE A temperature of 460 F is an open probe equivalent SHORTED PROBE If a shorted 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 alternates SHORTED PROBE and the electronic alarm will sound continuously NOTE A temperature of 460 F or greater is a shorted probe eq...

Page 31: ...disabled The display will show DRAINING When the drain valve is closed the DVI switch contacts close and the 24VAC input to the controller is restored The heat demand heat on and all operator buttons will remain disabled and the display will show FILL VAT HIT TEMP To resume operation allow the tank to fill with shortening between the MIN and MAX lines Press TEMP key Display will ask VAT FULL HIT T...

Page 32: ... value The current selection will be blinking C Press PROGRAM key to save the selection Blinking stops D Access the other service settings as necessary 4 To enter DIAGNOSTICS mode press product number key 7 on the control panel Fig 55 Fig 56 A Press the desired product number key 1 2 3 4 6 on the control panel that corresponds to the diagnostic test number on the display screen to check the output...

Page 33: ...ITEM FLASHES1 DESCRIPTION 1 Brand Press 1 to change brand name Press toggle key to select HOBART or VULCAN Press PROGRAM Key to save the selection VULCAN Brand name at power on 2 Celsius Press 2 to change temperature scale Press toggle key to select NO or YES Press PROGRAM Key to save the selection NO Temperature F C No Fahrenheit Yes Celsius 3 Mode Press 3 to change fryer mode Press toggle key to...

Page 34: ... cooking timers remain off ___ DIAGNOSTICS shown on display screen 1 L Basket Press 1 to toggle left basket lift output to lower the lift DOWN Lowers basket Press 1 again to raise the lift UP Raises basket 2 R Basket Press 2 to toggle right basket lift output to lower the lift DOWN Lowers basket Press 2 again to raise the lift UP Raises basket 3 Heater Press 3 to turn heat output ON for 3 seconds ...

Page 35: ...ALARMS DESCRIPTION PROBE FAULT If a temperature probe fault occurs the alarm sounds continuously and the display shows PROBE on the left display and either OPEN or SHORT on the right display This alarm state will remain until the fault clears or power switch is cycled OPEN Probe detects temperature less than 40 F SHORTED Probe detects temperature greater than 460 F IGNITION STATUS GAS Selected und...

Page 36: ... the following adjustments are correct 1 SW2 Set the SW2 potentiometer to the number 2 setting 2 SW4 Set the SW4 potentiometer to the number 4 setting 3 Dip switches Set the fourth switch the one closest to the potentiometers to the up position Fig 58 NOTE For fryers built after 12 1 2012 there are no adjustments for blower settings The Ignition Blower control board is preprogrammed If a fryer bui...

Page 37: ...rely To clean the air filter remove the filter by pulling it off The clamp is only hand tightened Clean air filter in dishwasher or in sink with hot soapy water Make sure air filter is completely dry prior to reinstalling making sure that the filter is snug onto the blower intake Make sure NOT to tighten the clamp more than hand tight Fig 60 SPARK GAP SETTING BEFORE 12 1 12 Fig 61 The spark ignite...

Page 38: ...GAP SETTING AFTER 12 1 12 1 Insure the spark igniter is installed properly on the burner 2 The spark igniter rod should be set touching mesh or with a maximum gap between rod and burner mesh of 1 16 of an inch Fig 63 3 There should be a gap of 1 8 to 3 16 of an inch between igniter rod and ground rod Fig 64 4 This igniter sparks to the ground rod To insure we have a proper ground we put a wire on ...

Page 39: ...Fig 65 VK and TR GAS FRYERS W Wo KleenScreen PLUS SERVICE PROCEDURES AND ADJUSTMENTS Page 39 of 55 F45474 0413 ...

Page 40: ...flame when gas valve coil is energized High Limit Thermostat Prevents the shortening 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 shortening Converts the temperature into a resistance valve which is mo...

Page 41: ...d 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 key supplies 120VAC to pump motor and fill solenoid valve thru R2 fill relay N C contacts R2 Fill Relay When 24VAC relay coil is energized by filter key supplies 24VAC to the fill solenoid valve ...

Page 42: ...s above 135 F and control calls for heat A 3 sec prepurge B Spark sent to igniter 7 sec trial for ignition If flame not detected after 8 sec Lockout NOTE System remains locked out until the power switch is cycled to reset system and restart trial for ignition cycle Wait 5 minutes for gas to dissipate 2 sec after flame detected burner blower motor in low speed and low fire initiated C Once burner f...

Page 43: ...heck the control displays an error message for the problem disables keypad and sounds the electronic alarm continuously Refer to SOLID STATE CONTROL ALARMS OR COMPUTER CONTROL ALARMS 4 24VAC to P5 of interface board 5 Control calls for heat A 25 VDC to P3 on interface board B Triac on interface board supplies 24VAC to ignition module to P6 on interface board 6 If shortening temp is below 135 F the...

Page 44: ...tes NOTE If using solid shortening once it has melted stir the shortening to eliminate any sold shortening in cold zone of the fry tank 3 Open drain valve to fryer section in need of filtering and drain shortening into filter tank A Display indicates draining B Drain valve interlock switch contacts open and position of drain valve is indicated to cooking control NOTE If using solid shortening allo...

Page 45: ...SCHEMATIC DIAGRAMS Analog Controls No Options VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION Page 45 of 55 F45474 0413 ...

Page 46: ...Analog Controls Kleenscreen VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION F45474 0413 Page 46 of 55 ...

Page 47: ...Solid State or Computer Control No Options VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION Page 47 of 55 F45474 0413 ...

Page 48: ...Solid State of Computer Control Kleenscreen VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION F45474 0413 Page 48 of 55 ...

Page 49: ...WIRING DIAGRAMS VK Fryer C and D Models VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION Page 49 of 55 F45474 0413 ...

Page 50: ...Power Supply Box Before 12 1 12 VK Fryer with basket lifts and Kleenscreen VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION F45474 0413 Page 50 of 55 ...

Page 51: ...Power Supply Box Before 12 1 12 VK Fryer without basket lifts and Kleenscreen VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION Page 51 of 55 F45474 0413 ...

Page 52: ...VK Fryers with Electronic Ignition and Analog Control and Kleenscreen VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION F45474 0413 Page 52 of 55 ...

Page 53: ...g Control VK TR D C Fryer Wiring Diagram VK TR Analog Control W Kleenscreen Fryer Wiring Diagram VK TR Analog Control W E I Stand Alone Fryer Wiring Diagram VK and TR GAS FRYERS W Wo KleenScreen PLUS ELECTRICAL OPERATION Page 53 of 55 F45474 0413 ...

Page 54: ...shut off 1 Grounding status 2 Check electrode No spark no blower 1 Harness connections check for flashing light in A control 2 Probe lead wires 3 Open probe 4 Controller 5 Open fuse on ignition blower control board Puffing during initial start up 1 Air Filter dirty 2 Incorrect gas pressure 3 Vent hose closed off or restricted 4 Cracked electrode 5 Electrode gap exceeding 3 16 Burner lights but wil...

Page 55: ...s loose No power to cooking control fryer does not heat 1 Power switch off or malfunction 2 Main circuit breaker off 3 Transformer inoperative 4 Interconnecting wiring malfunction High limit thermostat shutting down system 1 Shortening level below minimum fill line 2 Probe malfunction 3 Control malfunction Excessive time to melt shortening more than 45 minutes 1 Melt cycle timing incorrect 2 Insuf...

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