Vulcan ERC50 Service Manual

SERVICE MANUAL

ER SERIES ELECTRIC FRYERS

WITH TRIDELTA CONTROLS

MODEL ML

ERD50 135541

ERD85 135543

ERC50 135545

ERC85 135547

ERD50F 135561

ERD85F 135563

ERC50F 135565

ERC85F 135567

ERC50 WITH DUAL BASKET

LIFTS SHOWN

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.

ERO15 135548

ERO21 135549

- NOTICE -

Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.

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

F35613 (September 2003)

ER SERIES ELECTRIC FRYERS

TABLE OF CONTENTS

GENERAL ................................................................................ 4

Introduction ............................................................................ 4

Single Floor Model Fryers ................................................................. 4

Model Designations ................................................................. 4

Models, Features and Options ......................................................... 4

Kleenscreen Filtering System .............................................................. 5

Model Designations ................................................................. 5

Models, Features and Options ......................................................... 5

Specifications ..........................................................................6

Tools ................................................................................. 6

Control Panels ......................................................................... 7

REMOVAL AND REPLACEMENT OF PARTS .................................................... 8

Covers and Panels ...................................................................... 8

Cooking Controls ....................................................................... 9

Filter Valve and Discard Valve Switches .................................................... 10

Temperature Probe .................................................................... 10

High Limit Thermostat .................................................................. 11

Power Supply Box Components ........................................................... 12

Heating Elements ...................................................................... 12

Lift Assist Springs ...................................................................... 13

Tilt Switch ............................................................................14

Basket Lift Tube ....................................................................... 15

Basket Lift Motor....................................................................... 15

Basket Lift Cam Switch.................................................................. 16

Pump and Motor ....................................................................... 16

SERVICE PROCEDURES AND ADJUSTMENTS ................................................. 17

Temperature Probe Test ................................................................ 17

Cooking Control Calibration .............................................................. 17

Lift Assist Spring Adjustment............................................................. 18

Basket Lift Arm Adjustment .............................................................. 18

Heating Element Test ................................................................... 19

Solid State Control ..................................................................... 20

Operation ........................................................................ 20

Error Messages ................................................................... 20

Programming ..................................................................... 20

Computer Control ...................................................................... 21

Operation ........................................................................ 21

Service Programming ............................................................... 21

Error messages ................................................................... 21

Enter Service Mode ................................................................ 21

Display, Led and Keypad Test ........................................................ 22

ELECTRICAL OPERATION .................................................................. 23

Component Function ................................................................... 23

Component Location ................................................................... 24

Power Supply Box ..................................................................... 25

Circuit Breaker/Supply Box ............................................................... 26

F35613 (September 2003) Page 2 of 48

ER SERIES ELECTRIC FRYERS

Sequence of Operation .................................................................. 27

Cooking Control, Solid State or Computer ............................................... 27

Filtering System ................................................................... 28

Schematic Diagrams ................................................................... 30

Single Floor Model Fryers & Filtering System Fryer Batteries, Non Pump Side Fryer Section(s) ..... 30

Filtering System Fryer Batteries, Pump Side Fryer Section .................................. 31

Heater Circuit ..................................................................... 32

Basket Lift Circuit .................................................................. 33

Wiring Diagrams ....................................................................... 34

Single Floor Model Fryers & Filtering System Fryer Batteries, Non Pump Side Fryer Section(s) ..... 34

Filtering System Fryer Batteries, Pump Side Fryer Section .................................. 36

Basket Lift ........................................................................ 38

Filtering System Fryers, Filter/Discard Switch Connections .................................. 39

Frymate (Dump Station) ............................................................. 40

TROUBLESHOOTING ...................................................................... 41

All Models ............................................................................ 41

Solid State Control ..................................................................... 42

Computer Control ...................................................................... 42

Solid State or Computer Control Harness Pin-Outs ............................................43

Control Interface Board Pin-Outs .......................................................... 43

Frymate (Dump Station) with Optional Heater ................................................ 43

Kleenscreen Filtering System ............................................................. 44

CONDENSED SPARE PARTS LIST ........................................................... 48

Page 3 of 48

F35613 (September 2003)

ER SERIES ELECTRIC 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.

An ERO Frymate (dump station) can be configured in a battery with fryers 15 1/2 inches or 21 inches in width.

Model Designations

Models, Features and Options

FEATURES OPTIONS

MODEL

ERD50 15 1/2 45-50 Full Solid State 0-99:59 Single or Dual

ERD85 21 85-90 Full Solid State 0-99:59 Single or Dual

ERC50 15 1/2 45-50 Full Computer 0-99:59 Single or Dual

ERC85 21 85-90 Full Computer 0-99:59 Single or Dual

ERO15

(Frymate)

ERO21

(Frymate)

FRYER WIDTH

(INCHES)

15 1/2

SHORTENING

CAPACITY (POUNDS)

FRY

TANK

COOKING

CONTROL

COOK TIMER

(MM:SS)

AUTOMATIC BASKET

LIFTS

F35613 (September 2003) Page 4 of 48

ER SERIES ELECTRIC FRYERS - GENERAL

KLEENSCREEN FILTERING

SYSTEM

The Kleenscreen filtering system has been integrated into the ER 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.

This system is designed to provide a thorough and easy method for filtering shortening.

Some of the benefits include:

• Self-contained system eliminating the use of external filter equipment.

• Paperless filtering system.

• Easy to clean and low maintenance.

The fryer battery still utilizes many of the same components as the Vulcan ER series fryers.

Kleenscreen fryer batteries are available in a minimum of two and a maximum of four fryer sections. The fryer size of each section is identical.

An ERO Frymate (dump station) can be included as one of the sections.

Model Designations

Models, Features and Options

MODEL

2ERD50F

2ERD85F

2ERC50F

2ERC85F

ERO15

(Frymate)

ERO21

(Frymate)

NOTES:

FRYER WIDTH

(INCHES)

42 45-50 130 Full Solid State 0-99:59 Single or Dual

42 85-90 130 Full Solid State 0-99:59 Single or Dual

31 45-50 130 Full Computer 0-99:59 Single or Dual

42 85-90 130 Full Computer 0-99:59 Single or Dual

15 1/2

1. For each additional fryer section, add 15 1/2 inches to the width. 2. For each additional fryer section, add 21 inches to the width.

FRYING OIL

CAPACITY

PER FRYER

(POUNDS)

FEATURES OPTIONS

FILTER PAN

CAPACITY (POUNDS)

FRY

TANK

COOKING CONTROL

COOK

TIMER

(MM:SS)

AUTOMATIC

BASKET LIFTS

Page 5 of 48

F35613 (September 2003)

ER SERIES ELECTRIC FRYERS - GENERAL

SPECIFICATIONS

MODELKWPER FRYER

SECTION

ERD50,

ERD50F

ERD85,

ERD85F

ERC50,

ERC50F

ERC85,

ERC85F

NOTES:

14 39 34 17

17 47 41 20

24 67 58 29

14 39 34 17

17 47 41 20

24 67 58 29

1. Amperage values in the table are nominal. Tolerance is +5/-10%.

2. 14kw is standard on all fryers except 85 lb. models which are 24kw.

AMPS - EACH FRYER

SECTION

(3 PHASE/ 60HZ)

PER LINE

208V 240V 480V

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).

Special

• Field service grounding kit P/N TL- 84919.

• Loctite 242 P/N 520228 or equivalent.

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

Single Floor Model Fryers

• Fryers with the Filter-Ready option installed, use a 120VAC power cord for the Mobile Filter.

• 208VAC, 240VAC or 480VAC (3 phase, 60HZ) to power the heating elements.

Kleenscreen Filtering System

Separate electrical connections are required for

section of the battery.

each

• 208VAC, 240VAC or 480VAC (3 phase, 60HZ) to power the heating elements.

• On 208VAC and 240VAC models, a transformer provides power for the fryer controls, basket lift(s) if installed, and Kleenscreen filtering controls.

• On 480VAC models, a 120VAC connection is required for each fryer section.

• All models require a separate 120VAC connection for the pump motor (5.0 amp draw).

F35613 (September 2003) Page 6 of 48

ER SERIES ELECTRIC 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.

Decimal point of first character indicates heat on when lit.

! 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 automatic or manual mode BOIL out cleaning of fry tank.

SOLID STATE CONTROL, D MODEL

Computer

! Eighteen product/programming keys allow individual product cooking times for up to ten different products:

Product/Programming keys 1 thru 0; Oil Temp to view actual temperature or set the desired product cooking temperature; L & R (Left & Right) basket selection; 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 preheat period.

! Two LED lamps on the OIL TEMP key that indicate heat on and ten individual LED lamps above each of the

ten product/programming keys: LED’s blink when a product key is activated, solid when using a key for programming.

! Boil key for automatic or manual mode BOIL out cleaning of fry tank.

COMPUTER CONTROL, C MODEL

Page 7 of 48

F35613 (September 2003)

ER SERIES ELECTRIC 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 lower panel.

2. Disconnect wiring harness then remove control panel.

3. Reverse procedure to install.

Element Head Cover

1. Remove basket hanger or lift arm(s) if basket lift option is installed.

2. Remove screws from rear of element head assembly.

4. Remove screws from the bottom of element head assembly.

5. Grasp heating elements and remove 2x4 lumber. Lift the elements and pull toward rear of fryer. Head cover will separate from element head base.

A. Lower the heating elements and place

them in fry tank.

NOTE: Heating elements remain attached to element head cover.

6. Reverse procedure to install.

Basket Lift Covers

NOTE: Applies to fryers with basket lift option only.

1. Access rear of fryer.

3. Raise heating elements and place 2x4 lumber under them for support.

F35613 (September 2003) Page 8 of 48

2. Remove basket lift arms from lift tubes.

3. Remove screws securing upper cover to fryer.

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

A. Lift the upper cover over support rods to

remove.

4. Remove screws securing lower cover to motor mounting base.

NOTE: The cover is flanged at the top & bottom and is held in place by an interference fit. The bottom flange is formed to secure the cover to fryer.

4. Reverse procedure to install.

COOKING CONTROLS

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. The field service grounding kit must be used anytime the control board is handled.

1. Remove the control panel as outlined under CONTROL PANEL.

2. Remove cooking control by removing mounting nuts securing the control and mounting panel to front control panel.

5. Reverse procedure to install.

Rear Door (Access Cover)

1. Access rear of fryer.

2. Remove basket lift covers if basket lift option is installed.

3. Remove access cover at the top.

Page 9 of 48

F35613 (September 2003)

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

3. Lift the cooking control with mounting panel attached, off the front control panel.

4. Remove switch cover and disconnect lead wires from switch.

5. Reverse procedure to install and check for proper operation.

NOTE: Switches are not adjustable.

4. Reverse procedure to install.

5. Re-connect power and turn power switch on.

6. Program the cooking control for the control type as outlined under SOLID STATE CONTROL or COMPUTER CONTROL in SERVICE PROCEDURES AND ADJUSTMENTS.

NOTE: If installing a replacement cooking control, program the control with the customers settings and products.

7. Check for proper operation.

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.

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.

CAUTION: Do not sharply bend and kink the temperature probe or damage may occur.

1. Raise heating elements.

2. Remove clamps from temperature probe.

1. Open the door to the fryer section being serviced.

2. Disconnect lead wire connector (2 pin) to the switch.

3. Remove switch mounting screws.

F35613 (September 2003) Page 10 of 48

3. Remove element head cover as outlined under

4. Disconnect temperature probe lead wires.

COVERS AND PANELS.

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

5. Remove temperature probe from the element head.

6. Reverse procedure to install.

NOTE: When installing, ensure grommet remains in place when inserting temperature probe thru the grommet in the element head.

3. Remove element head cover as outlined under COVERS AND PANELS.

4. Remove high limit from mounting bracket.

5. Disconnect high limit lead wires.

7. Check cooking control calibration as outlined in COOKING CONTROL CALIBRATION under SERVICE PROCEDURES AND ADJUSTMENTS.

HIGH LIMIT THERMOSTAT

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: Do not sharply bend and kink the capillary tube or damage may occur.

Raise heating elements.

2. Loosen clamps securing capillary tube and bulb to element.

6. Remove grommet from the element head assembly.

7. Remove the bulb, capillary tube and high limit from the element head assembly.

NOTE: When installing, slide grommet onto capillary tube then insert grommet into the capillary tube thru hole in the element head.

8. Reverse procedure to install.

Page 11 of 48

F35613 (September 2003)

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

POWER SUPPLY BOX

COMPONENTS

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 grounding kit is available to prevent damage. The field service grounding kit must be used anytime a control board is handled.

1. Remove the control panel as outlined under CONTROL PANEL.

2. Disconnect lead wires then remove the component being replaced.

5. Reverse procedure to install the replacement component and check for proper operation.

HEATING ELEMENTS

WARNING: DISCONNECT THE

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

A. If removing, contactor(s), transformer, or

filter relay, continue with procedure.

3. Remove screw securing control plate to box.

A. Grasp control plate on the right side at the

top, and pull out until left side holding tab clears slot.

CAUTION: Do not sharply bend and kink the capillary tube or the temperature probe, or damage may occur.

1. Remove basket hanger or lift arm(s) if basket lift option is installed.

2. Raise heating elements.

A. If replacing left

high limit bulb and capillary tube clamps. Remove high limit bulb and capillary tube from clamps then position away from element.

B. If replacing right

temperature probe clamps and position temperature probe away from element.

heating element, loosen

heating element, remove

4. Disconnect lead wires then remove the component being replaced.

F35613 (September 2003) Page 12 of 48

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

NOTE: When installing high limit, route the capillary tube and center the bulb between the clamps before tightening.

3. Remove element assembly clamps. Front clamps stiffen and secure both elements together. Rear clamps stiffen each individual element.

6. Remove screws from heating element mounting bracket and remove heating element.

7. Reverse procedure to install.

LIFT ASSIST SPRINGS

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 rear door (access cover) as outlined under COVERS AND PANELS.

4. Remove element head cover as outlined under COVERS AND PANELS.

5. Disconnect heating element lead wires.

NOTE: Each heating element assembly contains three individual elements (six lead wire connections total).

2. Raise heating elements and place 2x4 lumber under them for support. Heating elements are to remain upright.

3. Loosen all eye bolt mounting nuts to release tension on springs.

Page 13 of 48

F35613 (September 2003)

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

TILT 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 element head cover as outlined under COVERS AND PANELS.

2. Lower heating elements.

3. Disconnect lead wires from tilt switch.

4. Remove lift assist springs from the eye bolt hooks.

5. Remove lift assist springs from the hangers.

6. To install springs:

A. Attach spring hook to hanger thru rear

door opening.

B. Attach spring hook to eye bolt and tighten

eye bolt mounting nut.

4. Remove tilt switch from element head.

REAR VIEW SHOWN, ELEMENTS LOWERED

C. Remove 2x4 lumber and lower heating

elements.

7. Adjust spring tension as outlined under LIFT ASSIST SPRING ADJUSTMENT in SERVICE PROCEDURES AND ADJUSTMENTS.

F35613 (September 2003) Page 14 of 48

5. Reverse procedure to install and check for

NOTE: The tilt switch and magnet are mounted in fixed locations and are not adjustable.

FRONT VIEW SHOWN, ELEMENTS RAISED

proper operation.

ER SERIES ELECTRIC FRYERS - REMOVAL AND REPLACEMENT OF PARTS

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 covers as outlined under COVERS AND PANELS.

2. Remove nut securing lift bar to the lift tube.

3. Remove screws securing lift tube bracket to fryer then remove bracket and lift tube.

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 tube as outlined under BASKET LIFT TUBE.

2. Disconnect lead wires from cam switch and basket lift motor.

3. Loosen set screws securing crank arm assembly to the basket lift motor shaft.

4. Reverse procedure to install.

4. Remove screws securing motor mounting plate

Page 15 of 48

to fryer then remove motor from plate.

F35613 (September 2003)

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