Vulcan REF-1M Service Manual
MCDONALD'S ELECTRIC FRYERS
INSTALLATION, SERVICE
AND PARTS
MANUAL FOR MODELS
REF-1M and REF-2SM
VULCAN-HART COMPANY, P.O. BOX 696, LOUISVILLE, KY 40201-0696, TEL. (502) 778-2791
OPERATING, INSTALLATION AND SERVICE PERSONNEL
Operating information for this equipment has been prepared for use by qualified and/or authorized operating
personnel.
All installation and service on this equipment is to be performed by qualified, certified, licensed and/or
authorized installation or service personnel, with the exception of any marked with a c in front of the part
number.
Service may be obtained by contacting the Factory Service Department, Factory Representative or Local
Service Agency.
DEFINITIONS
QUALIFIED AND/OR AUTHORIZED OPERATING PERSONNEL
Qualified or authorized operating personnel are those who have carefully read the information in this manual
and are familiar with the equipment's functions or have had previous experience with the operation of the
equipment covered in this manual.
QUALIFIED INSTALLATION PERSONNEL
Qualified installation personnel are individuals, a firm, corporation or company which either in person or
through a representative are engaged in, and are responsible for:
1. The installation of gas piping from the outlet side of the gas meter, or the service regulator when the meter
is not provided, and the connection and installation of the gas appliance. Qualified installation personnel
must be experienced in such work, be familiar with all precautions required, and have complied with all
requirements of state or local authorities having jurisdiction. Reference in the United States of America National Fuel Gas code ANSI Z223.1 (Latest Edition). In Canada-Canadian Standard CAN1-B149.1 NAT.
GAS (Latest Edition) or CAN1-B149.2 PROPANE (Latest Edition).
2. The installation of electrical wiring from the electric meter, main control box or service outlet to the electric
appliance. Qualified installation personnel must be experienced in such work, be familiar with all
precautions required, and have complied with all requirements of state or local authorities having
jurisdiction. Reference: In the United States of America-National Electrical Code ANSI NFPA No. 70
(Latest Edition). In Canada-Canadian Electrical Code Part 1 CSA -C22.1 (Latest Edition).
QUALIFIED SERVICE PERSONNEL
Qualified service personnel are those who are familiar with Vulcan equipment who have been endorsed by
the Vulcan-Hart Corporation. All authorized service personnel are required to be equipped with a complete set
of service parts manuals and stock a minimum amount of parts for Vulcan equipment.
SHIPPING DAMAGE CLAIM PROCEDURE
For your protection, please note that equipment in this shipment was carefully inspected and packed by
skilled personnel before leaving the factory. The transportation company assumes full responsibility for safe
delivery upon acceptance of this shipment.
If shipment arrives damaged:
1. VISIBLE LOSS OR DAMAGE — Be certain this is noted on freight bill or express receipt and signed by
person making delivery.
2. FILE CLAIM FOR DAMAGES IMMEDIATELY — Regardless of extent of damage.
3. CONCEALED LOSS OR DAMAGE — If damage is unnoticed until merchandise is unpacked, notify
transportation company or carrier immediately, and file "concealed damage" claim with them. This should
be done within (15) days of date of delivery is made to you. Be sure to retain container for inspection.
We cannot assume responsibility for damage or loss incurred in transit. We will, however, be glad to furnish
you with necessary documents to support your claim.
PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE
IMPORTANT NOTES FOR ALL VULCAN APPLIANCES
1. These units are produced with the best possible workmanship and material. Proper installation is vital if best performance and
appearance are to be achieved. Installer must follow the installation instructions carefully.
2. Information on the construction and installation of ventilating hoods may be obtained from the "Standard for the installation of
equipment for the removal of smoke and grease laden vapors from commercial cooking equipment," NFPA No. 96 (latest
edition) available from the National Fire Protection Association, Battery March Park, Quincy MA 02269.
3. For an appliance equipped with a flexible electric supply cord, the cord is equipped with a three prong (grounding) plug. This
grounding plug is for your protection against shock hazard and should be plugged directly into a properly grounded three prong
recepticle. Do not cut or remove the grounding prong from this plug. If the appliance is not equipped with a grounding plug, and
electric supply is needed, ground the appliance by using the ground lug provided (refer to the wiring diagram).
(FOR GAS APPLIANCES ONLY)
4. Do not obstruct the air flow into and around the appliance. This air flow is necessary for proper combustion of gases and for
ventilation of the appliance. Provisions for ventilation of incoming air supply for the equipment in the room must be in accordance
with National Fuel Gas Code ANSI Z223.1 (latest edition).
5. Do not obstruct the flow of flue gases from the flue duct (when so equipped) located on the rear (or sides) of the appliance. It is
recommended that the flue gases be ventilated to the outside of the building through a ventilation system installed by qualified
personnel.
6. For an appliance equipped with casters, (1) the installation shall be made with a connector that complies with the Standard for
Connectors for Movable Gas Appliances, ANSI Z21.69 (latest edition), and Addenda, Z21.69a (latest edition), and a quickdisconnect device that complies with the Standard for Quick-Disconnect Devices for Use With Gas Fuel, ANSI Z21.41 (latest
edition), and Addenda, Z21.41 a (latest edition) and Z21.41 b (latest edition), and (2) adequate means must be provided to limit
the movement of the appliance without depending on the connector and the quick-disconnect device or its associated piping to
limit the appliance movement. If disconnection of the restraint is necessary, reconnect this restraint after the appliance has been
returned to its originally installed position.
7. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of 1/ 2 psig (3.45 k Pa).
8. The appliance must be isolated from the gas supply system by closing its individual manual shutoff valve during any pressure
testing of the gas supply system at test pressures equal to or less than 1/ 2 psig (3.45 k Pa).
CAUTIONS
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS
IN THE VICINITY OF THIS EQUIPMENT OR ANY OTHER APPLIANCE.
1. KEEP THE APPLIANCE FREE AND CLEAR FROM ALL COMBUSTIBLE SUBSTANCES.
2. IN THE EVENT A GAS ODOR IS DETECTED, SHUT UNIT(S) DOWN AT THE MAIN
SHUTOFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER
FOR SERVICE.
3. POST IN A PROMINENT LOCATION, INSTRUCTIONS TO BE FOLLOWED IN THE EVENT
THE SMELL OF GAS IS DETECTED. THIS INFORMATION MAY BE OBTAINED FROM A
LOCAL GAS SUPPLIER.
WARNING:
DO NOT SPRAY LIQUIDS OR VAPORS ON OR
NEAR EQUIPMENT UTILIZING ELECTRICITY
CAUTION
FROM THE TERMINATION OF THE APPLIANCE FLUE VENT TO THE FILTERS OF THE HOOD VENTING SYSTEM, AN 18
INCH MINIMUM CLEARANCE MUST BE MAINTAINED.
REFERENCE: ANSI/NFPA 96-1984 4-1.2.2.2. OF THE NATIONAL FIRE PROTECTION ASSOCIATION INC.,
BATTERYMARCH PARK, QUINCY, MASS. 02269, AND NATIONAL BUILDING CODE 1976 SEC. 1015.7b OF THE
AMERICAN INSURANCE ASSOCIATION ENGINEERING AND SAFETY SERVICE, 85 JOHN STREET, NEW YORK, N.Y.
10038.
IMPORTANT
THIS EQUIPMENT IS DESIGN CERTIFIED BY A NATIONALLY
RECOGNIZED TESTING LABORATORY TO THE
APPROPRIATE NATIONAL STANDARDS AS INDICATED ON
THE EQUIPMENT RATING PLATE. ANY MODIFICATION
WITHOUT WRITTEN PERMISSION OF VULCAN-HART
CORPORATION VOIDS THE CERTI FICATION AND WARRANTY
OF THIS UNIT.
115591-4
REF FRYER INSTALLATION, SERVICE &
PARTS MANUAL INDEX
Your Vulcan fryer is produced with the best possible workmanship and material. Proper usage and maintenance will
result in many years of satisfactory performance.
DESCRIPTION PAGE
DEFINITION OF PERSONNEL (Inside front cover) 115591-2
CAUTIONS, WARNINGS & IMPORTANT NOTATIONS 115591-2 THRU -5
SECTION 1 - INSTALLATION INSTRUCTIONS 115591-6
SECTION 11 - SERVICE 115591-7 THRU -13
SECTION III - TROUBLE SHOOTING 115591-14 THRU -15
SECTION IV - PARTS LIST & PHOTOS 115591-16 THRU -33
REVISION PAGE (Inside back cover) 115591-34
A RATING PLATE IS LOCATED ON THE INSIDE FRYER DOOR PANEL STATING THE MODEL NUMBER, SERIAL NUMBER,
VOLTAGE AND AMPERAGE. FRYER MUST BE INSTALLED AT LEAST 16 INCHES AWAY FROM OPEN TOP FLAME UNITS.
The manufacturer suggests that you thoroughly read this entire
manual and carefully follow all of the instructions provided.
A complete set of wiring diagrams are packaged separately and placed in the fryer tank for shipment. A wiring decal may also be
found mounted behind the contactor cover door of the unit.
115591-5
SECTION I INSTALLATION
DETAIL A
DETAIL B
115591
-
6
Place fryer as near to its' final position as possible. Connect 120V 60 Hertz electric supply to fryer barrier strip.
Barrier strip may be connected from rear of unit. To reach
barrier, remove electric cover plate from unit. After connecting 120V 60 Hertz electric supply to fryer barrier
strip, verify with a voltmeter that the following condition
exists. (See Details A & B).
1. Black to white 120V 60 Hertz.
2. Black to ground 120V 60 Hertz.
3. White to ground 0.00V 60 Hertz.
For each 15 1/2" section a high voltage line capable of
handling 16 KW at the unit's rated voltage (208, 240,
480) is required. If a fan interlock is needed, it should be
connected to 1 and 2 on the barrier strip. 1 and 2 go to a
set of dry contacts on the power switch.
SECTION II SERVICE___________________________________________
SWITCH PANEL OPERATION
DETAIL A1
1. MASTER SWITCH - Controls electric supply to unit. (Optional - ventilator interlock.)
2. POWER "ON" LIGHT - Light Indicates when electrical supply is on.
3. TEMPERATURE CONTROL - Maintains frying temperature by controlling power supply.
4. HEATING LIGHT
5. HIGH LIMIT TEST SWITCH - Bypasses temperature control for testing of high limit thermostats.
6. FIRST HIGH LIMIT LIGHT - When "On", indicates first high limit thermostat has shut down.
7. SECOND HIGH LIMIT LIGHT
8. TROUBLE LIGHT - Indicates unit has been shut down by second high limit thermostat.
- When "On", indicates temperature control is calling for power to
elements.
- When "On", indicates second high limit thermostat has shut down
unit. (reset required)
115591-7
SECTION II SERVICE (Continued)
CLEANING HEATING ELEMENTS & THERMOSTAT BULB
1. The kettle must be at operating temperature.
2. Turn master switch off.
3. Raise elements out of hot shortening with a lift rod and
allow shortening to drip off for five minutes.
CAUTION
4. Place cover(s) over kettle(s). To prevent fire and
preserve clean shortening.
5. Turn operating thermostat to 300°F. (148.8°C).
6. Turn master switch on. Do not leave the fryer
unattended. The second high limit will trip out
terminating the bum off cycle
7. Turn master switch off at termination of burn off cycle.
DETAIL C DETAIL C1
15591-8
8. Heating elements will heat up in excess of 600°F
(315.5°C) glowing red. If any do not glow, call service
agency. Some smoking, cracking sound and flames will
occur. This is normal. If excessive flaming occurs,
extinguish immediately to prevent damage to elements
and thermostat bulbs.
9. Allow elements to cool and press reset button on rear
of element head (See Detail C & C1).
10. Brush residue from elements and thermostat bulbs with
a stiff nylon brush. Care should be taken not to bend or
displace temperature controller bulbs.
11. Remove cover(s) from kettle(s) and lower elements into
shortening.
12. Proceed with filtering procedures.
SECTION II SERVICE (Continued)
THERMOSTAT CALIBRATION PROCEDURES
1. Thermostat calibration is factory set before unit shipment. Thermostat calibration should not be performed
unless unit temperature is registered within 5°F (15°C) plus or minus the thermostat setting.
Check thermostat calibration as follows:
NOTE: The following tools will be required: Digital pyrome-
ter and holder, 1/8" flatblade, screwdriver, maple
paddle.
1. The shortening must be at the proper level as indicated
by the indicator line on the vat wall.
2. Inset a digital pyrometer, alnor pyrometer or a deep fat
thermometer at the rear of the fryer exactly where the
computer probe would go.
3. Set the thermostat knob at the correct cooking temperature and turn on unit.
4. Allow the shortening temperature to stabilize by letting
the fryer cycle on and off after reaching the desired
temperature at least three times.
5. Agitate the shortening using maple paddle until step
6 is completed
6. After the stabilizing period, the instant the burner acates (as noted by the burners "On" light turning on),
the shortening temperature should be plus of minus
5°F (-15°C) of the thermostat setting.
7. If it is within ± 5°F (-15°C) you are finished
calibrating. If not follow steps 8 thru 11 for
recalibration.
8. Loosen the set screw in the temperature control
knob. Rotate knob without moving shaft and set the
knob to match the pyrometer reading.
9. Retighten the set screw. CAUTION: Do not
overtighten.
10. Turn the dial to the desired temperature.
11. Repeat steps 4,5 and 6.
NOTE: Do not calibrate using new shortening unless
you agitate the shortening as indicated in
step 5.
115591-9
SECTION II SERVICE (Continued)
DETAI
L
C2 115591
-
10
SERVICING MULTI-FUNCTION BOARD
NOTE: The multi-function board incorporates the follow
ing features utilizing a thermosistor probe to
sense fat melt cycle, fat melt temperature trip,
oil temperature and the first high limit tempera
ture trip.
A. Melt Cycle & Temperature
1. Set the temperature control knob to the frying
temperature and turn on the master switch.
2. After an initial off period of approximately 45
seconds, the elements will cycle on for 2 seconds
and off for 28 seconds until the shortening melts
and a temperature of 135°F (57°C) is obtained,
after which the operating thermostat will take over
and bring the unit to the set temperature. If the fat
melt cycle responds, but comes out of fat melt at
more than ± 10° of 135° F. (57°C) see fat melt
calibration procedures in item no. 3. If the fat melt
cycle fails to respond, see item 4 below.
3. Fat Melt Calibration
NOTE: This procedure should be performed by an
authorized service person only. If the unit is
coming out of the fat melt cycle at ± 10°F (-12°C),
try the following calibration procedure before
replacing the multi-function board.
A. Insert pyrometer in place of the computer
probe.
B. Turn unit "off" and allow unit to cool to below
135°F (57°C) or begin calibration from cold
start.
C. Remove (2) screws from upper corners
of control panel, drop control panel down, dis-
connect the electric harness and remove panel.
D. Locate defective multi-function board on
back wall of the control area.
E. Locate fat melt adjustment screw resting in the
bottom center of the board to the right of pin #12.
F. Remove the adjustment screw sealant by
gently chipping with screwdriver
G. Turn fat melt adjustment screw full clockwise.
H. Connect a DC voltmeter between pins 13 and 15.
I. Reconnect control panel wire harness while
holding panel assembly in hand. Turn power switch
"On" and set the potentiometer knob to frying
temperature.
J. Check DC voltmeter for a reading of 5 volts
K. When pyrometer reaches 135°F (57°C) and while
observing the voltmeter gently rotate fat melt
adjustment screw counterclockwise until DC
voltmeter reads 0 volts.
NOTE: It is advisable to secure adjustment screw
by placing a small drop of enameled paint or
fingernail polish in center of screw. Calibration is
now complete, remove voltmeter and replace
control panel.
4. If the fat melt cycle is inoperative, the multi-funcion
control board must be replaced.
NOTE: Field repair of the multi-function board is
not practical, therefore, when the board
malfunctions, it must be completely replaced. Ref.
to Detail C2
SECTION II SERVICE (Continued)
SERVICING MULTI -FUNCTION BOARD (Continued)
To replace multi-function board, disconnect unit
power and remove (2) screws in the upper comers
of the control panel. Fold down control panel as sembly. Disconnect electrical harness and remove
panel. The multi-function boards are located on
the back wall of the control box area. Ref. to
Detail C.
NOTE: Split vat units utilize (2) boards, (1) to the
right and (1) to the left upper wall. Single vat units
utilize (1) board mounted to the upper left wall.
Remove (4) screws securing defective board. Disconnect multi pinned plug. Remove the 11 wire
connections one at a time transfering each connector from the old board onto the new board.
Reconnect multi pinned plug and remount new
multi-function board. Reconnect wire harness and
close up control panel assembly. Reinstall (2)
screws to secure panel mounting.
SERVICE NOTE:
Harness connectors, in split vat fryers, which
serve the same purpose for left side or right sides,
have been identified by a "red" dot for "left" and a
"green" dot for "right". When reconnecting
harness insure that red dots connect to left hand
components and green dots to right hand
components.
6. Stop agitating and allow fryer to cycle On and Off
automatically three (3) times.
7. After the stabilizing period, the instant the element
actuates (as noted by the fryer "On" light turning
on), the shortening temperature should be plus
or minus 5°F. (-15°C) of the thermostat setting.
8. If it is within ± 5°F. (-15°C) you are finished
calibrating.
9. If not, loosen the set screw in the temperature
control knob. Rotate knob without moving shaft
and set the knob, to match the pyrometer
reading.
10. Retighten the set screw.
DO NOT OVERTIGHTEN.
11. Turn the dial to the desired temperature.
12. Repeat steps 6,7 and 8
13. If, after repeating steps 6 thru 7 oil temperature
calibration is not achieved, replacement of the
multi-function board will be required.
B. OIL TEMPERATURE
The fryer oil temperature is controlled by the multi
function board, monitored by the thermistor probe and
set by the potentiometer.
The following calibration check will help determine the
operational status of the temperature controller in the
multi function board.
NOTE: Best results can be obtained by not using new
shortening.
1. The shortening must be at the proper level as indicated by the indicator line on the vat wall.
2. Insert pyrometer, at the rear of the fryer exactly
where the computer probe would go.
3. Set the thermostat knob to the correct cooking
temperature and turn on unit.
4. Allow the shortening temperature to cycle off
after reaching the desired temperature.
5. Agitate the shortening using a maple paddle to
eliminate the cold zone in the bottom of the kettle.
115591-11
14. Replacement of the multi-function board is to be
performed only by a certified Vulcan service
agency. Service personnel should disconnect
unit power and follow board replacement
procedure outlined in item 3 of melt cycle and
temperature in Section II Service.
HIGH LIMIT CONTROL
The function of the high limit control is to shut the unit
down in the event of a thermostat failure which would
allow the cooking oil to be overheated. The operating
temperature of the high limit control is 35° or 60° higher
than the highest temperature allowed by the thermostat
when the thermostat is functioning properly.
In the event of a high limit 'Shut -Down" the entire control
system will be put out of operation.
DO NOT attempt to restart the fryer until the temperature
of the cooking oil has lowered to approximately 350°.
CAUTION
IF THIS SITUATION CONTINUALLY OCCURS, DO
NOTATTEMPT TO BYPASS THE HIGH LIMIT. SHUT
UNIT DOWN AND CONTACT A SERVICE AGENCY.
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