Vulcan Materials 2GR45AF, 2GR85AF, 1GR65A, 3GR85AF, 3GR65AF User Manual

...

SERVICE MANUAL

GRA SERIES GAS FRYERS WITH

KLEENSCREEN PLUS®

FILTRATION SYSTEMS

MODEL ML MODEL ML

1GR45A 136647 3GR85AF 136655

1GR65A 136648 4GR45AF 136656

1GR85A 136649 4GR65AF 136657

2GR45AF 136650 4GR85AF 136681

2GR65AF 136651 2XGR45AF 136658

2GR85AF 136652 2XGR65AF 136659

3GR45AF 136653 2XGR85AF 136660

2GR45AF KLEENSCREEN

FRYER BATTERY

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.

3GR65AF 136654

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

F25377 (March 2010)

GRA SERIES GAS FRYERS

TABLE OF CONTENTS

GENERAL ................................................................................3

Introduction ............................................................................ 3

Single Floor Model Fryers ................................................................ 3

Kleenscreen Filtration System ............................................................. 4

Specifications .......................................................................... 4

Electrical ..........................................................................4

Gas Pressures ..................................................................... 4

Tools................................................................................. 4

REMOVAL AND REPLACEMENT OF PARTS .................................................... 5

Splash Guard (Kleenscreen Fryers Only) ..................................................... 5

Cooking Controls ....................................................................... 5

Discard Valve Switch (Kleenscreen Fryers Only) ............................................... 5

Gas Burners ........................................................................... 6

Gas Orifice ............................................................................ 7

Gas Combination Valve .................................................................. 7

Gas Pilot .............................................................................. 8

Temperature Probe ..................................................................... 9

High Limit Thermostat ................................................................... 9

Power Supply Box Components ........................................................... 10

Fill Solenoid Valve (Kleenscreen Fryers Only) ................................................ 11

Pump and Motor (Kleenscreen Fryers Only) ................................................. 11

Fry Tank Assembly..................................................................... 12

SERVICE PROCEDURES AND ADJUSTMENTS................................................. 14

Temperature Probe Test ................................................................ 14

Cooking Control Calibration .............................................................. 15

Electronic Ignition System ............................................................... 15

Flame Sense Current Check ............................................................. 16

Electronic Ignition Control Test............................................................ 16

Gas Manifold Pressure Adjustment ........................................................ 18

ELECTRICAL OPERATION .................................................................. 19

Component Function ...................................................................19

Power Supply Box Components ........................................................... 21

Sequence of Operation .................................................................22

Kleenscreen Filtering System ......................................................... 23

Schematic Diagrams ................................................................... 24

Fryers Without Kleenscreen Filtration System ............................................24

Fryers with Kleenscreen Filtration System ............................................... 25

Wiring Diagrams ....................................................................... 26

Frymate (Dump Station) ............................................................. 30

TROUBLESHOOTING ...................................................................... 31

All Models ............................................................................ 31

Ignition Module ........................................................................ 32

Frymate (Dump Station) with Optional Heater ................................................ 35

Kleenscreen Filtering System ............................................................. 36

F25377 (March 2010)

Page 2 of 36

GRA SERIES GAS FRYERS - GENERAL

GENERAL

INTRODUCTION

This Service Manual covers specific service information related to the models listed on the front cover. GRA series gas fryers come equipped with behind-the-door solid state controls. The features and operation of the cooking controls are the same for both single floor model fryers and kleenscreen battery fryers.

Model

1GR45A

1GR65A

1GR85A

2GR45AF

NO. OF HEAT TUBES

EACH FRY TANK

4 120,000 15.5 45-50

5 150,000 21.0 65-70

5 150,000 21.0 85-90

4 120,000 31.0 45-50

EACH FRY TANK

Fryers with the Filter-Ready option installed, use the Mobile Filter. For service information related to the Mobile filter refer to F24599 MOBILE FILTERS.

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

BTU/HOUR

SINGLE FLOOR MODEL FRYERS

FRYER WIDTH

(INCHES)

SHORTENING CAPACITY (LBS) EACH FRY TANK

3GR45AF

4GR45AF

2GR65AF

3GR65AF

4GR65AF

2GR85AF

3GR85AF

4GR85AF

2XGR45AF

2XGR65AF

2XGR85AF

4 120,000 46.5 45-50

4 120,000 62.0 45-50

5 150,000 42.0 65-70

5 150,000 63.0 65-70

5 150,000 84.0 65-70

5 150,000 42.0 85-90

5 150,000 63.0 85-90

5 150,000 84.0 85-90

4 120,000 31.0 45-50

5 150,000 42.0 65-70

5 150,000 42.0 85-90

Page 3 of 36

F25377 (March 2010)

GRA SERIES GAS FRYERS - GENERAL

KLEENSCREEN FILTRATION

SYSTEM

The Kleenscreen filtration system is integrated into the GRA 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 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.

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.

TOOLS

Standard

• Standard set of hand tools.

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

• Temperature tester (thermocouple type).

• U-Tube Manometer.

Special

• Field service grounding kit (available locally)

• OnWatch QuickLook™ 72, checks flame sense and input voltage to the Honeywell S8600 series ignition control module with an EnviraCOM™ port.

A GRO Frymate (dump station) can also be included as one or more of the sections.

SPECIFICATIONS

Electrical

• 120VAC supply. A 24VAC transformer provides power for the fryer controls and the filtering controls on Kleenscreen battery fryers.

Gas Pressures

Manifold (per fryer section):

• Natural - 4" W.C.

• Propane - 10" W.C.

Building supply pressure (Min):

• Natural - 5" W.C. (7" W.C. battery units)

• Propane - 11" W.C. (12" W.C. battery units)

NOTE: Propane or Natural gases -14" W.C. (Max)

You can order the QuickLook™ 72 on line at www.onwatchinc.com. The OnWatch Combo Item #721014 includes both the QuickLook™ 72 and a 3 ft. data port extension cable.

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

F25377 (March 2010) Page 4 of 36

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

SPLASH GUARD

(KLEENSCREEN FRYERS ONLY)

1. Open fryer section doors.

2. Remove screws securing splash guard.

3. Remove screws securing controls.

4. Remove cooking controls.

5. Disconnect lead wires from the component being replaced then remove from control box.

3. Remove splash guard.

4. Reverse procedure to install.

COOKING CONTROLS

1. Open fryer section door(s).

2. Remove connections to cooking controls.

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

DISCARD VALVE SWITCH

(KLEENSCREEN FRYERS ONLY)

1. Open the fryer section doors above filter pan.

F25377 (March 2010)Page 5 of 36

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

2. Pull filter drawer out, remove filter tank assembly and push the tank support arms back into place under the fryer.

3. Remove splash guard from base frame.

4. From underneath the fryer: A. Disconnect the discard valve switch lead

wire connector from power supply box.

2. Remove cooking controls to access burner(s) if necessary.

3. Remove drain pipe to access burner(s) if necessary.

B. Remove switch mounting screws.

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

GAS BURNERS

4. Remove gas burner shipping ties (if installed).

5. Lift gas burner up and tilt the top of burner

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

F25377 (March 2010) Page 6 of 36

NOTE: The burners mount to the burner mounting bracket by shoulder bolts that rest in the keyway slot.

toward fryer tank until it clears the gas orifice at the bottom.

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

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

GAS COMBINATION VALVE

6. Remove burner.

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

GAS ORIFICE

1. Remove gas orifice spud from orifice extension.

The spud screws into orifice extension. When installing, do not over tighten the spud or damage to the threads may occur.

NOTE: If a gas combination valve is malfunctioning, do not attempt to disassemble the valve for repair. Install a replacement gas combination valve.

1. Remove GAS BURNERS.

2. Disconnect lead wires from gas combination valve.

F25377 (March 2010)Page 7 of 36

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

3. Disconnect pilot tube from gas combination valve.

4. Disconnect gas line fittings then remove gas combination valve.

A. Remove gas line fittings from gas

combination valve and install (in same orientation) on the replacement valve.

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

A. Clean the pipe threads and apply pipe joint

compound to threads. Any pipe joint compound used must be resistant to the action of propane gases.

GAS PILOT

4. Disconnect pilot tube from gas pilot.

5. Remove screws (2) securing gas pilot to mounting bracket.

A. To remove gas orifice from pilot for

inspection or cleaning, disconnect the gas orifice fitting from pilot body.

1. Remove GAS BURNERS as necessary.

2. Remove pilot burner assembly and bracket from pilot bracket stand-off on the fry tank.

B. If orifice is clogged with debris, clean with

air or liquid only.

GAS PILOT FOR ELECTRONIC IGNITION SHOWN

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

3. Remove wire tie and disconnect ignitor cable from ignitor/flame sense electrode on the gas pilot.

F25377 (March 2010) Page 8 of 36

A. Secure ignitor to pilot tube with wire tie.

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

TEMPERATURE PROBE

Do not sharply bend and kink, or clamp

down on the capillary tube or damage may occur.

1. Drain shortening from fryer tank.

2. Disconnect smaller, 6-pin male connector. (Temperature probe and drain valve interlock (DVI) connector)

and probe to the fryer heat tube (inside tank) then remove probe.

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

8. Check COOKING CONTROL CALIBRATION under SERVICE PROCEDURES AND ADJUSTMENTS.

3. Remove the temperature probe lead wires from pins 1 and 3 of the 6-pin male connector.

4. Remove GAS BURNERS as necessary.

5. Remove the probe retaining and packing nuts.

HIGH LIMIT THERMOSTAT

Do not sharply bend and kink, or clamp

down on the capillary tube or damage may occur.

1. Drain shortening from fryer tank.

2. Remove GAS BURNERS as necessary.

3. Disconnect lead wires from high limit thermostat.

6. Remove screws securing probe mounting clips

F25377 (March 2010)Page 9 of 36

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

4. Remove screws securing the high limit to mounting bracket.

5. Remove the capillary tube retaining and packing nuts.

POWER SUPPLY BOX

COMPONENTS

NOTE: The power supply box must be removed to

access the following components: Ignition control module, transformer, R1 pump motor relay, R2 fill relay.

6. Remove screws securing mounting clips and capillary tube to the fryer heat tube (inside tank) then remove capillary tube.

1. Disconnect all wiring harness connectors and power cords from power supply box.

2. From rear, remove screw securing power supply box to mounting bracket.

NOTE: Power supply box is slotted at the front and secured by a hanging bracket (loose fit).

3. Remove cover from power supply box.

4. Disconnect lead wires from the component

7. Reverse procedure to install.

F25377 (March 2010) Page 10 of 36

being replaced then remove from power supply box.

GRA SERIES GAS FRYERS - REMOVAL AND REPLACEMENT OF PARTS

4. Disconnect swivel pipe fitting at rear of fry tank.

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

FILL SOLENOID VALVE

(KLEENSCREEN FRYERS ONLY)

1. Open the fryer section doors above filter pan.

2. Pull filter drawer out, remove filter tank assembly and push the tank support arms back into place under the fryer.

3. Remove splash guard.

REAR VIEW SHOWN

5. Disconnect fill solenoid valve lead wire connector (4 pin) from power supply box.

6. Remove screws (2) securing the solenoid valve body flange to pipe tee then remove the assembly from fryer.

A. Remove pipe fittings from solenoid valve

and install on replacement valve.

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

PUMP AND MOTOR

(KLEENSCREEN FRYERS ONLY)

1. Drain filter tank of shortening.

F25377 (March 2010)Page 11 of 36

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