Vulcan-Hart LG300, LG400, ML-136643, LG500, ML-136258 Service Manual

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SERVICE MANUAL
LG Series Fryer
LG300 ML-136528 LG400 ML-136622 LG500 ML-136643
- NOTICE -
This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified.
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.
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
F45691 (1117)
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LG Series Fryer
TABLE OF CONTENTS
GENERAL .................................................................................................. 3
INTRODUCTION ....................................................................................... 3
INSTALLATION, OPERATION AND CLEANING ......................................................... 3
TOOLS ................................................................................................. 3
SPECIFICATIONS ...................................................................................... 3
REMOVAL AND REPLACEMENT OF PARTS ............................................................... 4
COVER PANELS ....................................................................................... 4
BURNERS ............................................................................................. 5
THERMOSTAT ......................................................................................... 5
HIGH LIMIT THERMOSTAT ............................................................................ 6
THERMOPILE .......................................................................................... 7
PILOT .................................................................................................. 8
PILOT ORIFICE ........................................................................................ 9
COMBINATION VALVE ............................................................................... 10
FRY TANK ............................................................................................ 11
SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 12
TURNING FRYER OFF ................................................................................ 12
LIGHTING PILOT ..................................................................................... 12
DRAIN FRYER TANK ................................................................................. 13
MILLIVOLT CONTROLS TEST ........................................................................ 13
THERMOSTAT CALIBRATION ........................................................................ 14
PILOT ADJUSTMENT ................................................................................. 14
BURNERS, NOZZLES AND ORIFICES ................................................................ 15
COMBINATION VALVE REGULATOR ADJUSTMENT ................................................. 16
EXTENDED SHUT-DOWN ............................................................................ 17
DIAGRAMS ............................................................................................... 18
SCHEMATIC .......................................................................................... 18
WIRING DIAGRAM .................................................................................... 19
ELECTRICAL OPERATION ................................................................................ 20
CONTROL SYSTEM DESCRIPTION ................................................................... 20
SYSTEM CONDITION QUICK CHECK PROCEDURE .................................................. 20
COMPONENT FUNCTION ............................................................................ 21
TROUBLESHOOTING ..................................................................................... 22
TROUBLESHOOTING ................................................................................. 22
© VULCAN 2017
F45691 (1117) Page 2 of 23
Page 3
LG Series Fryer - GENERAL
GENERAL
INTRODUCTION
This manual is applicable only to models listed on the cover page. Procedures in this manual will apply to all models unless specified. Pictures and illustrations can be of any model unless they need to be model specific.
INSTALLATION, OPERATION AND
CLEANING
For detailed installation, operation and cleaning instructions, refer to the Installation & Operation Manual sent with each unit. The manual is also available online at www.vulcanequipment.com.
TOOLS
Standard
Standard set of hand tools.
VOM with minimum of NFPA-70E CATIII 600V, UL/CSA/TUV listed. Sensitivity of at least 20,000 ohms per volt. Meter leads must also be rated at CAT III 600V.
Temperature tester (thermocouple type).
ESD (Electrostatic discharge) Protection Kit.
Special
Manometer.
SPECIFICATIONS
Gas Data
Model No. Tubes BTU/HR
LG300 3 90,000
LG400 4 120,000
LG500 5 150,000
Page 3 of 23 F45691 (1117)
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
REMOVAL AND REPLACEMENT OF PARTS
COVER PANELS
Door
Be prepared to catch door when bottom hinge is removed.
1. Remove door hinge screws while supporting door.
Fig. 3
4. Reverse procedure to install.
Back Panel
1. Remove rear panel mounting screws.
Fig. 1
2. Reverse procedure to install.
Heat Shield
1. Remove DOOR.
2. Remove heat shield mounting screws.
Fig. 2
3. Angle heat shield to remove.
Fig. 4
2. Reverse procedure to install.
Flue Wrap
1. Remove screws securing flue wrap.
F45691 (1117) Page 4 of 23
Page 5
LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
3. Push up on burner while pulling bottom of burner
Fig. 5
forward to clear burner nozzle.
Fig. 7
2. Reverse procedure to install.
Flue Box
1. Remove FLUE WRAP.
2. Remove screws securing flue box.
Fig. 6
3. Reverse procedure to install.
BURNERS
4. Reverse procedure to install.
THERMOSTAT
Oil may be hot when draining fryer tank.
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
1. DRAIN FRYER TANK .
NOTE: Steps to remove Heat Shield can be skipped if back of fryer is accessible. Remove BACK PANEL to access thermostat probe packing nut.
2. Remove HEAT SHIELD.
3. Remove LEFT BURNER.
4. Pull thermostat knob (1, Fig. 8) off thermostat shaft.
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
1. Remove HEAT SHEILD.
2. Loosen mounting bolts at top of burner being removed.
Page 5 of 23 F45691 (1117)
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
Fig. 10
8. Remove thermostat bulb from clamp.
Fig. 8
5. Remove thermostat mounting screws (Fig. 8) and bracket.
6. Note and disconnect thermostat wiring.
Fig. 11
9. Remove thermostat assembly.
10. Reverse procedure to install.
Take care not to kink thermostat capillary when installing. Wrap threads of packing nut with teflon tape to prevent leakage.
HIGH LIMIT THERMOSTAT
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
1. DRAIN FRYER TANK .
Fig. 9
7. Loosen packing nut (1, Fig. 10) and remove holding nut (2, Fig. 10).
F45691 (1117) Page 6 of 23
2. Remove HEAT SHIELD.
3. Remove LEFT BURNER.
4. Remove high limit mounting bracket.
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
6. Loosen packing nut (1,Fig. 14 ) and remove holding nut (2, ).
Fig. 12
5. Note wires and disconnect.
Fig. 14
7. Reverse procedure to install.
8. Check for leaks.
THERMOPILE
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
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 pilot assembly bracket.
Fig. 13
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
Fig. 15
2. Note and disconnect thermopile to high limit switch wiring.
Fig. 16
3. Loosen thermopile holding nut (1, Fig. 17).
Fig. 17
4. Remove thermopile from bracket.
5. Reverse to install.
PILOT
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
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 HEAT SHIELD.
2. Remove pilot assembly bracket.
F45691 (1117) Page 8 of 23
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
Fig. 18
3. Remove pilot nut at bottom of pilot assembly.
Fig. 20
Fig. 19
4. Disconnect pilot tubing.
5. Remove THERMOPILE.
6. Remove pilot bracket screws.
7. Reverse procedure to install.
PILOT ORIFICE
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
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 HEAT SHIELD.
2. Remove pilot assembly bracket.
Page 9 of 23 F45691 (1117)
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
Fig. 21
3. Remove the nut at bottom of pilot to expose the orifice.
COMBINATION VALVE
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
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. Disconnect fryer from main gas supply.
2. Remove RIGHT BURNER.
3. Note and disconnect wires (1, Fig. 24) from combination valve (2, Fig. 24).
Fig. 22
4. Pull orifice (1, Fig. 23) out and replace.
Fig. 23
5. Reverse procedure to install.
F45691 (1117) Page 10 of 23
4. Disconnect pilot tubing (3, Fig. 24) from
5. Disconnect combination valve union and
Fig. 24
combination valve.
pressure fitting.
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LG Series Fryer - REMOVAL AND REPLACEMENT OF PARTS
3. DRAIN FRYER TANK .
4. Remove HEAT SHIELD.
5. Remove FLUE WRAP.
6. Remove FLUE BOX.
7. Remove BACK PANEL.
8. Remove BURNERS and manifold bracket (Fig.
26).
Fig. 26
Fig. 25
6. Remove all pipe fittings from old valve if new valve is not supplied with fittings.
7. Reverse procedure to install.
FRY TANK
Oil may be hot when draining fryer tank.
9. Remove THERMOSTAT.
10. Remove HIGH LIMIT THERMOSTAT.
11. Remove pilot assembly bracket.
Fig. 27
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
1. Disconnect fryer from main gas line.
2. Remove all baskets, fryer basket hanger and crumb screen.
12. Lift tank up and out of cabinet.
13. Remove drain valve from tank.
14. Reverse procedure to install.
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LG Series Fryer - SERVICE PROCEDURES AND ADJUSTMENTS
SERVICE PROCEDURES AND ADJUSTMENTS
TURNING FRYER OFF
1. Turn thermostat off.
Fig. 28
2. Keep pilot lit by turning gas valve to the "L" in pilot.
LIGHTING PILOT
Before lighting pilot make sure tank is filled with liquid shortening. Make sure gas supply to the fryer is on.
1. Turn thermostat off.
Fig. 30
Fig. 29
3. Turn gas valve to OFF position to shut gas off to the system, including pilot.
2. Turn gas control valve knob to PILOT.
3. Wait five minutes for unburned gas to vent.
4. Push and turn the gas control valve to "L" in pilot.
Fig. 31
F45691 (1117) Page 12 of 23
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LG Series Fryer - SERVICE PROCEDURES AND ADJUSTMENTS
5. While still holding knob in, light the pilot with a flame. Continue to depress knob until pilot remains lit (approximately 30 seconds), then release knob.
6. Depress and turn gas control valve knob to ON.
NOTE: If gas supply is interrupted, repeat all steps.
DRAIN FRYER TANK
Oil may be hot when draining fryer tank.
1. Turn thermostat off.
2. Turn gas valve to "L" in PILOT to keep pilot lit.
Fig. 32
3. Place container under drain valve (1, Fig. 33) to drain shortening into.
Fig. 33
4. Open the drain valve.
5. Close drain valve when fryer tank is emptied.
MILLIVOLT CONTROLS TEST
1. Verify proper gas (natural or propane) is present.
2. Check for correct wiring and secure connections.
3. Verify pilot flame is adjusted properly as outlined in PILOT ADJUSTMENT.
NOTE: If the pilot is not lit, light pilot. Refer to: LIGHTING PILOT.
4. Allow pilot to burn for 3 to 4 minutes to stabilize.
A. If pilot remains lit, proceed to step 6.
B. If pilot will not remain lit, proceed to step 5.
5. Connect DC voltmeter to terminals TH-TP and TH of combination valve. Relight pilot, hold gas control valve knob in, and allow pilot to burn for 3 to 4 minutes to stabilize.
A. lf voltage measures 450 millivolts or greater
and pilot will not stay lit, replace combination valve.
B. lf voltage is less than 450 millivolts, measure
voltage at terminals NO and C of high limit.
C. If the voltage is less than 500 millivolts,
disconnect lead wire from terminal TH-TP on combination valve and remeasure voltage at the high limit.
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LG Series Fryer - SERVICE PROCEDURES AND ADJUSTMENTS
If voltage is less than 500 millivolts, replace thermopile.
If voltage is 500 millivolts or more, replace combination valve.
6. Connect DC voltmeter to terminals TP and TH of combination valve.
7. Turn gas control valve knob to ON. Turn thermostat to a setting higher than the shortening temperature.
A. If voltage measures 150 millivolts or more
but the burners do not ignite, replace combination valve.
B. If voltage is less than 150 millivolts,
measure voltage between terminals NO on high limit and TP on combination valve.
If voltage is 200 millivolts or greater and burners do not light, replace thermostat.
If voltage is less than 200 millivolts and burners do not light, replace combination valve.
THERMOSTAT CALIBRATION
3. Allow temperature to stabilize and recheck temperature. Repeat until the temperature falls within the limits as stated in step 3 under Thermostat Calibration - Check.
4. Install thermostat knob and set dial to 350°F
5. Allow temperature to stabilize at new setting and compare temperature tester to dial setting. Recalibrate if the temperature does not fall within the range of 330°F to 370°F.
6. If temperature does not fall within the limits at both settings, replace thermostat.
7. Seal the adjustment screw after calibration is complete.
NOTE: Glyptal or ordinary Nail polish is acceptable to use as sealant.
PILOT ADJUSTMENT
NOTE: Verify the proper gas type (natural or propane)
is being supplied to fryer before proceeding.
1. Turn control thermostat to off.
2. LIGHT PILOT burner and leave gas combination valve knob/extension arm in pilot position.
Oil may be hot.
If oil is present, verify it is at proper fill mark.
Check
1. Place temperature tester in center of fry tank, one inch below the surface of the oil.
2. Set thermostat to 300°F and allow temperature to stabilize.
3. Check temperature tester reading against the thermostat dial reading. If there is a variance of more than +/- 20°F (208°F to 320°F), calibration is required.
Calibration
1. Remove thermostat knob from shaft.
2. Using a small screwdriver, rotate setscrew inside the hollow shaft counterclockwise to increase temperature or clockwise to decrease temperature (1/4 turn equals approximately 18°F).
Allow pilot to burn for 3-4 minutes to stabilize flame. If pilot burner is not lighting or does not remain lit when gas combination valve knob/extension arm is released, see TROUBLESHOOTING. Wait 5 minutes between pilot burner lighting attempts for unburned gas to vent.
NOTE: Connect meter to thermopile leads at high limit and monitor millivolt output, with pilot properly adjusted millivolt reading should be 500mV. increase or decrease pilot flame height to achieve 500mV.
3. Verify flame does not extend beyond the outer edges of pilot shield ½", or extends more than ½", (Fig. 34). If adjustment is necessary continue with procedure.
F45691 (1117) Page 14 of 23
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LG Series Fryer - SERVICE PROCEDURES AND ADJUSTMENTS
Fig. 34
4. Remove the cap covering pilot adjustment screw from combination valve.
If main burners do not light or pilot burner goes out, proceed to
MILLIVOLT CONTROLS TEST.
BURNERS, NOZZLES AND
ORIFICES
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
Burners
1. Remove BURNERS.
2. Check burners for cracks or clogged ports.
If burner ports become clogged fryer will not operate properly. If burner is cracked, it must be replaced.
Fig. 35
Turn counterclockwise to increase the size
of flame.
3. Wash burners in warm, soapy water.
4. Hand-turn a drill bit into hole with obstruction as needed to remove blockage.
Nozzles and Orifices
1. Remove BURNERS.
2. Hold burner nozzle with channel locks and remove orifice.
Turn clockwise to increase size of flame.
5. Verify pilot burner is lit.
6. Turn gas combination valve knob/extension arm to on and set control thermostat to call for heat.
Page 15 of 23 F45691 (1117)
Fig. 36
3. Check orifice for obstructions or damage.
4. Wash orifice in warm, soapy water.
5. Clean orifice with an orifice cleaning tool. Remove obstruction as needed to remove blockage.
Page 16
LG Series Fryer - SERVICE PROCEDURES AND ADJUSTMENTS
6. Reverse procedure to install new burner, nozzle and orifice.
COMBINATION VALVE
REGULATOR ADJUSTMENT
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
NOTE: Accurate gas pressure adjustments can only
be made with gas on and burner lit. If incoming line pressure to valve is less than the minimum stated, then pressure cannot be set correctly.
Combination valve is preadjusted for natural or propane gas as specified on the rating plate. Natural gas rating is 4" W.C., and propane rating is 10" W.C.
1. Turn gas control valve knob to OFF.
Fig. 38
3. Turn on gas and LIGHT PILOT.
Fig. 37
4. Turn gas control valve knob to ON.
5. Set thermostat so burners will come on.
6. Check pressure reading. Manifold Manometer should match pressure rating on data plate. Perform adjustment as necessary.
Adjustment
A. Remove adjustment screw cap.
B. Turn adjustment screw (1, Fig. 39):
2. Remove plug from submanifold and install Manometer at this point.
F45691 (1117) Page 16 of 23
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LG Series Fryer - SERVICE PROCEDURES AND ADJUSTMENTS
Fig. 39
Counterclockwise to decrease pressure.
Clockwise to increase pressure.
7. Install cap and check for proper operation.
EXTENDED SHUT-DOWN
Oil may be hot.
1. Turn thermostat off.
2. Push pilot knob in and turn to OFF.
3. DRAIN FRYER TANK .
4. Clean fryer.
5. Turn off main gas shutoff valve.
Shut off the gas before servicing the unit and follow lockout / tagout procedures.
Page 17 of 23 F45691 (1117)
Page 18
LG Series Fryer - DIAGRAMS
DIAGRAMS
SCHEMATIC
Fig. 40
NOTE: High limit shown tripped.
F45691 (1117) Page 18 of 23
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LG Series Fryer - DIAGRAMS
WIRING DIAGRAM
Fig. 41
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LG Series Fryer - ELECTRICAL OPERATION
ELECTRICAL OPERATION
CONTROL SYSTEM DESCRIPTION
1. The thermopile (TH) provides total control voltage for this system.
A. One side of thermopile is connected to
common (C) of high limit (HL).
B. The other side of the thermopile is
connected to normally open (NO) contacts (wire 4) of high limit.
C. The common of high limit (below high limit
trip temp) is connected through normally closed (NC) contacts of high limit, through wire 3 (wire 3 goes to TH/TP terminal on gas valve) to combination valve pilot connection common.
D. The other side of pilot valve is connected
through wire 4 (wire 4 goes to NO terminal on high limit with red wire from thermopile) to wire 1 (wire 1 goes from thermostat to high limit common terminal with white wire from the thermopile) to high limit normally open contacts which hold pilot valve open.
NOTE: If high limit trips, connection is made from common to normally open contacts, turning off pilot valve voltage. The gas valve closes.
2. Thermostat Control
A. One side of millivolt supply is connected
through high limit system, as described above, to thermostat common (wire 2) of combination valve.
B. The other side of thermopile is connected
from normally open (common terminal on high limit) contacts of high limit to thermostat through wire 1 (common terminal on high limit).
C. When the thermostat calls for heat (closed
circuit) power from thermopile, it is then connected to other combination valve thermostat connection through wire 2 (to TH terminal on gas valve).
3. Total Shutdown
A. When high limit trips, 0.0 millivolts will read
across both coils of the combination valve, causing both valves to close.
B. Pilot relight cannot be accomplished until oil
cools sufficiently to allow high limit to close.
C. If any wire in the system is shorting, cut or
broken, the system will shut down.
SYSTEM CONDITION QUICK
CHECK PROCEDURE
1. Use the Pilot Lighting procedure and check millivolts (mV) at wires 3 and 4.
A. lf the pilot lights, then pilot combination
valve and high limit are good.
B. If the pilot will not stay lit, check high limit
and open the thermopile circuit. It should read 500 mV; if there are Ø volts, check high limit. If the high limit is good, replace combination valve.
C. Check for voltage at disconnected
thermopile. It should read 500 mV; if there are Ø volts, replace thermopile. Check high limit. If the high limit is good, replace combination valve.
2. Turn on thermostat; burners should light.
A. If burner does not light, check voltage at
combination valve at wires 2 (TH) and 4 (TP).
B. If correct voltage is present, then check
combination valve.
C. If there are Ø volts, check voltage between
wire 3 of combination valve and wire 1 of thermostat. If correct voltage is present, then check resistance of the thermostat contacts and continuity of wires 3 & 2.
D. If high limit trips, thermopile is connected
across zero ohms, the output voltage of thermopile drops to 0.0 millivolts, and the thermostat coil of combination valve drops out, shutting the thermostat valve.
F45691 (1117) Page 20 of 23
Page 21
LG Series Fryer - ELECTRICAL OPERATION
COMPONENT FUNCTION
Thermostat ........... Millivolt type with capillary bulb, single-throw break on temperature rise. Temperature
range of 200°F to 400°F.
Thermopile ........... Millivolt control with 24" capillary. Rated to generate 500 millivolts.
Combination Valve ... Regulates gas flow to burner and pilot. Provides pilot safety.
High Limit ............ Prevents overheating of fryer in the event of thermostat failure. Opens at 465°F and
automatically resets at 415°F.
Page 21 of 23 F45691 (1117)
Page 22
LG Series Fryer - TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
SYMPTOM CAUSE REMEDY
1. Insufficient gas supply to unit.
1. Adjust gas supply at gas combination valve.
2. Relocate fryer.
3. Adjust loads accordingly.
The temperature of shortening drops, or excessive recovery time is required.
2. Ventilation system pulling heat out of heat exchanger and flue box.
3. Overloading fryer capacity.
Pilot won’t stay lit. Fryer shuts off.
Rapid shortening breakdown, crumbs and specks in frying compound.
4. Check thermostat calibration and reaction times.
1. Malfunctioning thermopile or loose/dirty connection in thermopile.
2. Gas supply turned off or disconnected.
3. Pilot burner orifice and air openings need cleaning.
4. Possible shorted combination valve.
5. High limit is open.
1. Excessive temperature settings (over 375°F).
2. Shortening not being filtered regularly.
3. Incorrect preparation of breaded food.
4. Calibrate or replace thermostat.
1. Check thermopile function and connections. Adjust or replace as required.
2. Clean burner orifice and air openings as required.
3. Check each post on combination valve to ground. If zero resistance, replace combination valve.
4. Check high limit, are NC contacts open?
1. Adjust temperature setting.
2. Adjust filtering schedule.
3. Do not use salt.
4. Allow breading time to adhere to food.
5. Do not allow loose flour to fall into shortening from hands.
6. Do not add straining or drippings from meat fats to shortening.
7. Use correct shortening and follow temperature recommendations.
F45691 (1117) Page 22 of 23
8. Take out 10% to 15% of the shortening.
9. Check thermostat settings with thermometer periodically.
Page 23
LG Series Fryer - TROUBLESHOOTING
SYMPTOM CAUSE REMEDY
Leaking tank.
Pilot burner flames adjusted properly, but fluctuates to very low and blows out easily.
1. Foam-over by depleted shortening permits oil to drip from the tank surface, giving appearance of leaking.
2. Careless draining procedures.
3. Carbon buildup causes rapid attack on tank by promoting acid formulation.
1. Gas pressure too low.
2. Gas pressure too low at submanifold.
1. Replace shortening.
2. Gas control valve knob should be in PILOT or OFF position before draining oil. Burners heating an empty tank will damage tank joints.
3. Clean tank surfaces.
1. Check gas pressure on submanifold fitting when fryer is in operation.
2. Check other equipment attached to same gas line.
3. Adjust gas pressure at submanifold to not less than 4.0" W.C. (natural and mixed gas) or
10.0" W.C. for propane gas.
Page 23 of 23 F45691 (1117)
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