Vulcan Hart 1VK85A Manuel de service

SERVICE MANUAL
VK and TR GAS FRYERS W/Wo KleenScreen PLUS
VK Series TR Series
- NOTICE -
This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified.
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.
A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222
F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS
TABLE OF CONTENTS
GENERAL .................................................................................................. 4
INTRODUCTION ....................................................................................... 4
MODEL AND ML NUMBERS ............................................................................ 4
MODELS, FEATURES AND OPTIONS .................................................................. 5
KLEENSCREEN PLUS FILTRATION SYSTEM: (KSP) ................................................... 5
SERIAL NUMBER LOCATION .......................................................................... 6
CONTROL PANELS .................................................................................... 6
INSTALLATION ........................................................................................ 7
OPERATION ........................................................................................... 7
CLEANING ............................................................................................. 7
TOOLS ................................................................................................. 7
SPECIFICATIONS ...................................................................................... 7
REMOVAL AND REPLACEMENT OF PARTS ............................................................... 9
COVERS AND PANELS ................................................................................ 9
CONTROL PANEL (SOLID STATE AND COMPUTER) .............................................. 9
BASKET LIFT COVERS ............................................................................ 9
ANALOG CONTROL .................................................................................. 10
INTERFACE CONTROL - D AND C SERIES ........................................................... 11
POWER SWITCH - D AND C SERIES ................................................................. 11
TEMPERATURE PROBE .............................................................................. 11
HIGH LIMIT THERMOSTAT ........................................................................... 12
POWER SUPPLY BOX ................................................................................ 13
POWER SUPPLY BOX COMPONENTS BEFORE 12/1/12 .............................................. 14
IGNITION MODULE ............................................................................... 14
BLOWER CONTROL BOARD ..................................................................... 14
TIME DELAY TIMERS ............................................................................. 14
BLOWER RELAY ................................................................................. 14
FILTER 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 INTERLOCK SWITCH (DVI) ............................................................ 21
FRY TANK ............................................................................................ 22
SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 24
ELECTRIC CONNECTIONS ........................................................................... 24
HARMONIC TONE .................................................................................... 24
TEMPERATURE PROBE FAULT CODES .............................................................. 24
TEMPERATURE PROBE TEST ....................................................................... 24
COOKING CONTROL CALIBRATION .................................................................. 25
FLAME SENSE CURRENT CHECK PRIOR TO 12/1/12 ................................................ 25
FLAME SENSE CURRENT CHECK AFTER 12/1/12 .................................................... 26
ELECTRONIC IGNITION CONTROL ................................................................... 26
IGNITION MODULE LOCKOUT .................................................................... 26
ELECTRONIC IGNITION SYSTEM ................................................................ 27
F45474 (0413) Page 2 of 55
VK and TR GAS FRYERS W/Wo KleenScreen PLUS
MODULATING GAS VALVE ADJUSTMENTS .......................................................... 27
BASKET LIFT ARM ADJUSTMENT .................................................................... 27
SOLID STATE CONTROL ............................................................................. 28
OPERATION ...................................................................................... 28
SERVICE PROGRAMMING ....................................................................... 28
ERROR MESSAGES .............................................................................. 28
ENTER SERVICE MODE .......................................................................... 28
ALARM MESSAGES .............................................................................. 30
COMPUTER CONTROL ............................................................................... 31
OPERATION ...................................................................................... 31
SERVICE PROGRAMMING ....................................................................... 31
ENTER SERVICE SETTING MODE ................................................................ 31
ALARM MESSAGES .............................................................................. 35
DISPLAY, LED AND KEYPAD TEST - COMPUTER CONTROL ......................................... 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
WIRING DIAGRAMS .................................................................................. 49
TROUBLESHOOTING ..................................................................................... 54
TROUBLESHOOTING ................................................................................. 54
© VULCAN 2013
Page 3 of 55 F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - GENERAL
GENERAL
INTRODUCTION
This service manual covers the specific service information related to the models listed in the chart below. The VK and TR series gas fryers come equipped with solid state analog (A), solid state digital (D) or programmable computer (C) controls. This manual covers single floor model fryers, battery fryers as well as fryers with the KleenScreen PLUS® Filtration System. All pictures and illustrations will be of a 2VK45A unless otherwise noted.
All of the information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing.
MODEL AND ML NUMBERS
MODEL ML # MODEL ML # MODEL ML #
1VK45A 136885 1VK45D 136886 1VK45C 136887
1VK65A 136888 1VK65D 136889 1VK65C 136890
1VK85A 136891 1VK85D 136892 1VK85C 136893
1VK45AF 136684 1VK45DF 136895 1VK45CF 136896
1VK65AF 136897 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
4VK65AF 136935 4VK65DF 136941 4VK65CF 136937
4VK85AF 136938 4VK85DF 136939 4VK85CF 136940
1TR45A 136946 3TR45CF 136959 3TR65CF 136972
1TR45AF 136947 4TR45CF 136960 1TR85A 136973
2TR45AF 136948 1TR65A 136961 1TR85AF 136974
3TR45AF 136949 1TR65AF 136962 2TR85AF 136975
4TR45AF 136950 2TR65AF 136963 3TR85AF 136976
1TR45D 136951 3TR65AF 136964 1TR85D 136977
1TR45DF 136952 1TR65D 136965 1TR85DF 136978
2TR45DF 136953 1TR65DF 136966 2TR85DF 136979
3TR45DF 136954 2TR65DF 136967 3TR85DF 136980
4TR45DF 136955 3TR65DF 136968 1TR85C 136981
1TR45C 136956 1TR65C 136969 1TR85CF 136982
F45474 (0413) Page 4 of 55
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - GENERAL
MODEL ML # MODEL ML # MODEL ML #
1TR45CF 136957 1TR65CF 136970 2TR85CF 136983
2TR45CF 136958 2TR65CF 136971 3TR85CF 136984
4TR65AF 136985 4TR65DF 136986 4TR65CF 136987
4TR85AF 136988 4TR85DF 136989 4TR85CF 136990
MODELS, FEATURES AND OPTIONS
MODELS, FEATURES AND OPTIONS
FEATURES OPTIONS
MODEL
1VK/TR45A /D / C / AF / DF / CF
1VK/TR65A / D / C AF / DF / CF
1VK/TR85A / D / C / AF / DF / CF
2VK/TR45AF / DF / CF
3VK/TR45AF / DF / CF
4VK/TR45AF / DF / CF
2VK/TR65AF / DF / CF
3VK/TR65AF / DF / CF
4VK/TR65AF / DF / CF
2VK/TR85AF / DF / CF
3VKTR85AF / DF / CF 63.0" 85 - 90 90,000 SINGLE OR DUAL
4VK/TR85AF / DF / CF
FRYER WIDTH
(INCHES)
15.5" 45 - 50 70,000 SINGLE OR DUAL
21.0" 65 - 70 80,000 SINGLE OR DUAL
21.0" 85 - 90 90,000 SINGLE OR DUAL
31.0" 45 - 50 70,000 SINGLE OR DUAL
46.5" 45 - 50 70,000 SINGLE OR DUAL
62.0" 45 - 50 70,000 SINGLE OR DUAL
42.0" 65 - 70 80,000 SINGLE OR DUAL
63.0" 65 - 70 80,000 SINGLE OR DUAL
84.0" 65 - 70 80,000 SINGLE OR DUAL
42.0" 85 - 90 90,000 SINGLE OR DUAL
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 filtering components in the drawer include a stainless steel filter tank, a stainless steel
SHORTENING
CAPACITY PER
FRYER (POUNDS)
mesh filter screen with a stainless steel insert, a suction tube and a knurled knob that holds the assembly together. In addition, the KSP comes with a second filtering system; a microfilteration fabric envelope (3), a dedicated stainless steel insert and stainless steel clip that holds the assembly together. With the filter drawer closed, a self-sealing oil return line provides the path to return the filtered shortening back into the fry tank.
BTU/HR/SECTION
AUTOMATIC
BASKET LIFTS
Page 5 of 55 F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - GENERAL
This system is designed to provide a through and easy method to filter the 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
Extends the life of the shortening
KSP fryer batteries are standard in single and up to a maximum of a four fryer battery in most cases. Batteries are made up of only fryers, no warming stations.
SERIAL NUMBER LOCATION
Serial number plate is attached to door of fryer.
Fig. 2
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 on fryer.
This serial number plate is attached to bottom rear support panel. This plate is pop riveted to support panel and should not come off.
CONTROL PANELS
F45474 (0413) Page 6 of 55
ANALOG CONTROL
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - GENERAL
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
SOLID STATE CONTROL
COMPUTER CONTROL
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
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.
Page 7 of 55 F45474 (0413)
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
unit). On fryers built after 12/1/12 an incoming gas pressure regulator is installed on the fryer.
VKINPUT BTU RATING
VK SERIES BTU/HR/SECTION
VK45A, VK45AF, VK45D, VK45DF, VK45C, VK45CF
VK65A, VK65AF, VK65D, VK65DF, VK65C, VK65CF
VK85A, VK85AF, VK85D, VK85DF, VK85C, VK85CF
TR INPUT BTU RATING
TR SERIES BTU/HR/SECTION
TR45A, TR45AF, TR45D, TR45DF, TR45C, TR45CF
TR65A, TR65AF, TR65D, TR65DF, TR65C, TR65CF
TR85A, TR85AF, TR85D, TR85DF, TR85C, VK85CF
70,000
80,000
90,000
70,000
80,000
90,000
F45474 (0413) Page 8 of 55
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
REMOVAL AND REPLACEMENT OF PARTS
COVERS AND PANELS
Disconnect the
electrical power to the machine and follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
Control Panel (Solid State and Computer)
1. Remove screws at top of control panel and rotate panel downwards.
Fig. 7
2. Disconnect wiring harness then lift panel off.
NOTE: The cooking control, control box, interface board and wiring harness are now accessible.
3. Reverse procedure to install.
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.
Fig. 8
A. Lift upper cover over support rods and place
cover to the side.
3. Remove screws securing lower cover to motor mounting base.
Fig. 9
4. Reverse procedure to install.
2. Remove screws securing upper cover to flue wrap.
Page 9 of 55 F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
ANALOG CONTROL
Disconnect the
electrical power to the machine and follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
1. Open the door.
2. Unplug wiring harnesses from bottom of control box.
3. Remove control box from frame of fryer.
4. Loosen set screw in control knob and remove from shaft.
Fig. 11
Fig. 10
5. Remove control box cover.
6. Disconnect lead wires as necessary to remove control.
Fig. 12
7. Remove screws from front of control panel and
F45474 (0413) Page 10 of 55
remove control.
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
INTERFACE CONTROL - D and C
SERIES
Disconnect the
electrical power to the machine and follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
1. Remove CONTROL PANEL.
2. Note lead wire locations and remove wiring.
3. Remove screws securing control to fryer and remove.
POWER SWITCH - D and C SERIES
Disconnect the
electrical power to the machine and follow lockout / tagout procedures.
NOTE: This procedure is 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. 13
4. Reverse procedure to install and check for proper operation.
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 machine.
TEMPERATURE PROBE
Disconnect the
electrical power to the machine and follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
1. Drain shortening from fryer tank.
Page 11 of 55 F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
2. Unplug temperature probe lead wire connector.
4. Install new probe making sure that probe is installed into bracket shown.
HIGH LIMIT THERMOSTAT
Disconnect the
electrical 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. 15
NOTE: This picture shows the probes with the burner
removed.
3. Loosen compression nut and remove probe from fryer.
Fig. 17
4. Remove the capillary tube retaining and packing nuts.
Fig. 16
F45474 (0413) Page 12 of 55
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
POWER SUPPLY BOX
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 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
Fig. 18
lower to clear bracket.
NOTE: This picture shows the probes with the burner removed.
5. Slide high limit probe out of fry tank.
Fig. 19
Fig. 20
2. Access front of fryer to slide power supply box toward rear of fryer to disconnect from front support bracket.
6. Reverse procedure to install and check for proper operation.
Page 13 of 55 F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 23
5. Reverse procedure to install.
POWER SUPPLY BOX
COMPONENTS BEFORE 12/1/12
Fig. 21
3. Unplug all connecters from power supply box and remove box from under fryer.
4. Remove cover to access power supply box components.
NOTE: The ignition module, blower control board and the time delay timers will not be available to the field any longer. If any one of these items fail, replace power supply box. However, 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 SUPPLY BOX.
2. Note location of all wiring to the relay and remove wiring.
3. Remove screw and remove relay from box.
Fig. 22
F45474 (0413) Page 14 of 55
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 24
4. Reverse procedure to install new relay.
5. Reinstall power supply box and check operation.
120 Volt Transformer
1. Remove POWER SUPPLY BOX.
2. Note location of wiring on 120 volt transformer and remove wiring.
3. Remove screws and remove transformer from the box.
Fig. 25
4. Reverse procedure to install new transformer.
5. Reinstall power supply box and check operation.
POWER SUPPLY BOX
COMPONENTS AFTER 12/1/12
NOTE: Power 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. Note location of all wiring and remove wiring from transformer.
3. Remove four screws and remove transformer from box.
Page 15 of 55 F45474 (0413)
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
5. Reinstall power supply box and check operation.
Filter Relays
1. Remove POWER SUPPLY BOX.
2. Note location of wiring to the relays and remove wiring.
Fig. 26
4. Reverse the procedure to install new transformer.
5. Reinstall power supply box and check operation.
Control Board
1. Remove POWER SUPPLY BOX.
2. Note location of wiring to relay control board and remove wiring.
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 not use an open flame.
1. Remove gas line from gas valve.
2. Remove electric plug connector from gas valve.
3. Unbolt high limit thermostat clamp from transfer
Fig. 27
3. Remove screws and remove from box.
4. Reverse the procedure to install new relay control board.
F45474 (0413) Page 16 of 55
tube.
VK and TR GAS FRYERS W/Wo KleenScreen PLUS - REMOVAL AND REPLACEMENT OF PARTS
5. Reverse procedure to reinstall burner.
GAS VALVE
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 not use an open flame.
The gas valve is considered part of the burner assembly. If the gas valve fails and needs to be replaced, you must order a complete blower/gas valve assembly (burner). The reason for this is every blower/ gas valve assembly (burner) is set up at the factory to
Fig. 29
4. Remove bolts and remove burner from fryer.
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 power to the machine and follow lockout / tagout procedures.
1. Remove
2. Remove nut securing lift bar to lift tube.
3. Remove screws securing lift tube bracket to fryer then remove bracket and lift tube.
BASKET LIFT COVERS.
Fig. 30
Page 17 of 55 F45474 (0413)
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