Vulcan Hart Fryer ML 135503 User Manual

SERVICE MANUAL  
GHF SERIES HEAVY DUTY  
RANGE MATCHING GAS  
FRYERS & FRYMATES  
MODELS  
GHF91G  
GHF90G  
ML-135503  
ML-135504  
- NOTICE -  
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 it's entirety, the repair procedure you wish to  
performtodetermineifyouhavethenecessarytools,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.  
Reproduction or other use of this Manual, without the express  
written consent of Vulcan, is prohibited.  
For additional information on Vulcan-Hart or to locate an authorized parts  
VULCAN-HART  
DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC  
P.O. BOX 696, LOUISVILLE, KY 40201-0696  
TEL. (502) 778-2791  
WWW.VULCANHART.COM  
FORM 35618 (11-04)  
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GENERAL  
NOTE: If pilot does not remain lit, repeat steps 2  
INTRODUCTION  
through 5, but allow a longer period of time before  
releasing the combination valve knob. Adjust pilot  
flame,ifnecessary,asoutlinedunderPilotAdjustment  
in Service Procedures and Adjustments.  
Models  
This service manual was written for:  
6. Turn combination valve knob to ON.  
GHF91G Gas Fryers and GHF90G Gas Frymates.  
SPECIFICATIONS  
INSTALLATION  
GasData  
Generally, installations are made by the dealer or  
contractedbythedealerorowner.Detailedinstallation  
instructions are included in the Installation and  
Operation Manual, which is sent with each fryer.  
MODEL  
GHF91G  
GHF90G  
No. Tubes  
BTU/HR  
120,000  
0
4
0
OIL FILTERING  
Filtering instructions are included in the Installation  
and Operation Manual.  
TOOLS  
OPERATION  
Standard  
• Hand tools (standard set)  
Detailedoperationinstructionsareincludedwitheach  
fryer in the Installation and Operation Manual.  
• VOM with AC current tester (any quality VOM  
with a sensitivity of at least 20,000 ohms per  
volt can be used)  
CLEANING  
• Gas test kit  
Detailed cleaning procedures are included in the  
Installation and Operation Manual.  
• Temperature tester (thermocouple type)  
• Manometer  
LIGHTING PILOT  
1. Turn thermostat OFF.  
2. Push combination valve knob in and turn to  
OFF.  
3. Wait 5 minutes for unburned gas to vent.  
4. Push combination valve knob in and turn to  
PILOT.  
5. While holding the combination valve knob in,  
light the pilot with a lit taper. Hold the  
combination valve knob in for approximately  
30 seconds before releasing.  
– 3 –  
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REMOVAL AND REPLACEMENT OF PARTS  
COVERS AND PANELS  
BURNERS  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
1. Open door panel.  
Door  
2. Loosen (Do not remove) the two mounting  
bolts at the top of each burner.  
1. Open door and using a5/16" wrench or ratchet,  
remove (2) screws securing the top door  
mountingbrackettotheleftbodysidechannel.  
3. Pushburnerupwhilepullingthebottomofthe  
burner forward to clear the burner nozzle.  
2. Hold door in one hand and lift the door panel  
assembly off of the bottom hinge.  
3. Reverse this procedure to reinstall the door  
panel.  
Front Panel  
1. Using a flat head screwdriver, remove (2)  
screws holding the front panel in place.  
2. Remove the panel from the unit.  
4. Reverse the procedure to install.  
3. Remove heat shield.  
– 4 –  
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6. Loosen the packing nut and holding nut.  
THERMOSTAT  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
1. Drain shortening from fry tank.  
2. RemoveleftburnerasoutlinedunderBurners.  
3. Remove thermostat knob by pulling knob off  
thermostat shaft.  
4. Remove thermostat mounting screws and  
remove thermostat from mounting bracket.  
7. Remove the thermostat bulb from the clamp.  
5. Remove wire leads from the rear of the  
thermostat, noting all connections for  
reassembly.  
8. Pullthethermostatbulbthroughtheunderside  
of the fry tank and remove the thermostat  
assembly.  
9. Reverse the procedure to install. When  
installing the new thermostat assembly, do  
notkinkthethermostatcapillary.Wrapthreads  
of packing nut with Teflon tape to prevent  
leakage.  
– 5 –  
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7. Pull the high limit bulb through the underside  
of the fry tank and remove the high limit  
assembly.  
HIGH LIMIT  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
1. Drain shortening from fry tank.  
2. Remove wire leads from high limit, noting all  
connections for reassembly.  
8. Reverse the procedure to install. When  
installing the new high limit assembly, do not  
kink the high limit capillary. Wrap threads of  
packing nut with Teflon tape to prevent  
leakage.  
THERMOPILE  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
WARNING:ALLGASJOINTSDISTURBEDDURING  
SERVICING MUST BE CHECKED FOR LEAKS.  
CHECK WITH SOAP AND WATER SOLUTION  
(BUBBLES). DO NOT USE AN OPEN FLAME.  
3. Remove high limit from mounting bracket.  
4. RemoveleftburnerasoutlinedunderBurners.  
5. Loosen the packing nut and the holding nut.  
1. Disconnectthermopileleadwiresasoutlined  
under High Limit.  
2. Remove (1) 10-24 screw and pull the pilot  
assembly away from the tank body.  
3. Remove (2) side screws to detach the pilot  
from the holding bracket.  
6. Remove the high limit bulb from the clamp.  
4. Remove pilot tubing from pilot.  
5. Remove screws holding pilot bracket.  
– 6 –  
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6. Remove thermopile from pilot bracket.  
2. Remove the right hand burners as outlined  
under Burners (optional).  
3. Disconnectleadwiresfromcombinationvalve  
and mark for reconnecting.  
4. Disconnect pilot tubing from combination  
valve.  
7. Reverse procedure to install.  
PILOT ORIFICE  
5. Disconnect combination valve union (Fig.1)  
and pressure fitting (Fig. 2).  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
WARNING:ALLGASJOINTSDISTURBEDDURING  
SERVICING MUST BE CHECKED FOR LEAKS.  
CHECK WITH SOAP AND WATER SOLUTION  
(BUBBLES). DO NOT USE AN OPEN FLAME.  
1. Remove pilot assembly from fryer as outlined  
under thermopile.  
2. Remove hex nut on the bottom of the pilot to  
expose the orifice.  
3. Replace orifice and reverse procedure to  
assemble.  
Fig.1  
Fig. 2  
COMBINATION VALVE  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
6. Removethecombinationvalvefromthefryer.  
7. Reverse procedure to install.  
WARNING: ALL GAS JOINTS DISTURBED  
DURING SERVICING MUST BE CHECKED FOR  
LEAKS. CHECK WITH SOAP AND WATER  
SOLUTION (BUBBLES). DO NOT USE AN OPEN  
FLAME.  
1. Disconnect fryer from main gas supply.  
– 7 –  
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8. Remove screws holding pilot assembly to  
bracket and remove pilot assembly.  
FRY TANK  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
WARNING:ALLGASJOINTSDISTURBEDDURING  
SERVICING MUST BE CHECKED FOR LEAKS.  
CHECK WITH SOAP AND WATER SOLUTION  
(BUBBLES). DO NOT USE AN OPEN FLAME.  
1. Disconnect fryer from main gas supply.  
2. Drain oil from tank.  
3. Remove baskets, fryer basket hanger and  
crumb screen.  
9. Liftthefrytankupandoutofcabinet.Carefully  
place the tank assembly on the floor (this  
procedure requires two people).  
10. Remove the tank ball drain valve.  
11. Reverse the procedure to install new tank.  
4. Remove screws holding fry tank.  
5. Remove burners as outlined under Burners.  
6. Remove the manifold bracket from the tank  
assembly.  
7. Remove thermostat and high limit as outlined  
under Thermostat and High Limit.  
– 8 –  
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SERVICE PROCEDURES AND ADJUSTMENTS  
7. Turn combination valve to ON. Turn  
MILLIVOLT CONTROLS TEST  
thermostat to a setting higher than the  
shorteningtemperature.  
1. Verify proper gas (natural or propane) is  
present.  
A. If the voltage measures 150 millivolts or  
morebuttheburnersdonotignite,replace  
the combination valve.  
connections.  
2. Check for correct wiring and secure  
B. If the voltage is less than 150 millivolts,  
3. Verify the pilot flame is adjusted properly as  
measure the voltage between terminals  
outlined in Pilot Adjustment.  
NO of the high limit and TP of the  
4. If the pilot is not lit, light pilot as outlined  
under Lighting Pilot. Allow the pilot to burn for  
3 to 4 minutes to stabilize.  
combination valve.  
1) If the voltage is 200 millivolts or  
greater, replace the thermostat.  
A. If the pilot remains lit, proceed to step 6.  
2) If the voltage is less than 200  
millivolts, replace the combination  
valve.  
B. If the pilot will not remain lit, proceed to  
step 5.  
5. Connect DC voltmeter to terminals TH TP  
and TP of combination valve. Relight the  
pilot, hold the combination valve knob in and  
allow the pilot to burn for 3 to 4 minutes to  
stabilize.  
THERMOSTAT CALIBRATION  
1. Place temperature tester in the fry tank near  
the thermostat bulb.  
A. If the voltage measures 450 millivolts or  
greater and the pilot will not stay lit,  
replace the combination valve.  
2. Set the thermostat to 300°F and allow the  
temperature to stabilize.  
3. Checkthetemperaturetesterreadingagainst  
the thermostat dial reading. If there is  
a variance of more than 20°F (280°F to  
320°F), calibration is required.  
B. If the voltage is less than 450 millivolts,  
measure the voltage at terminals NO and  
C of high limit.  
1) If the voltage is 500 millivolts or  
more, replace the high limit.  
Calibration Steps  
2) If the voltage is less than  
500 millivolts, disconnect the lead  
wire from terminal TH TP of the  
combination valve and remeasure  
voltage at the high limit.  
1. Remove thermostat knob from shaft.  
2. Usingasmallscrewdriver,rotatethesetscrew  
inside the hollow shaft counterclockwise to  
increase the temperature or clockwise to  
decrease the temperature (1/4 turn equals  
approximately 18°F).  
a. If the voltage is less than  
500 millivolts, replace the  
thermopile.  
3. Allow temperature to stabilize and recheck  
temperature. Repeat until the temperature  
falls within the limits as stated in step 3 under  
Thermostat Calibration.  
b. If the voltage is 500 millivolts or  
more, replace the combination  
valve.  
4. Install thermostat knob and set dial to 350°F.  
6. Connect DC voltmeter to terminals TP and  
TH of combination valve.  
– 9 –  
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5. Allow temperature to stabilize at new setting  
andcomparetemperaturetestertodialsetting.  
Recalibrate if the temperature does not fall  
within the range of 330°F to 370°F.  
BURNERS, NOZZLES AND ORIFICES  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
6. If the temperature does not fall within the  
limitsatbothsettings, replacethethermostat.  
Burners  
If the burner ports become clogged, the fryer will not  
operate properly. If the burner is cracked, it must be  
replaced.  
PILOT ADJUSTMENT  
1. Light pilot as outlined under Lighting Pilot on  
page 3.  
1. Removeburner(s)asoutlinedunderBurners.  
2. Checkburner(s)forcracksandcloggedports.  
2. If the flame does not extend beyond the outer  
edges of the pilot shield 1/2", or extends more  
than 1/2", an adjustment is necessary.  
3. If the ports are clogged, wash burner(s) in  
warm, soapy water. If this does not remove  
obstructions, a #37 drill bit can be used (do  
not use in an electric drill; hand-turn only).  
Nozzles and Orifices  
1. Remove the burners as outlined under  
Burners.  
2. Hold the burner nozzle with channel locks  
and remove the orifice. Check the orifice for  
obstructions or damage.  
3. If the orifice is clogged, wash the orifice in  
warm, soapy water. If this does not remove  
obstructions, a #37 drill bit can be used (do  
not use in an electric drill; hand-turn only).  
3. Remove the cap covering pilot adjustment  
screw. Turn the recessed pilot adjustment  
screw counterclockwise to increase the size  
of the flame or clockwise to decrease the  
size of the flame.  
4. Withchannellocks,removetheburnernozzle.  
5. Reverse procedure to install new burner  
nozzle and orifice.  
– 10 –  
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3. Turn on the gas and light the pilot as outlined  
under Lighting Pilot in General.  
COMBINATION VALVE REGULATOR  
ADJUSTMENT  
4. Turn the combination valve to ON.  
WARNING: SHUT OFF THE GAS BEFORE  
SERVICING.  
5. Set the thermostat so the burners will come  
on.  
Accurate gas pressure adjustments can only be  
made with the gas on and the burner lit. If the  
incoming line pressure to the valve is less than the  
minimum stated, then the pressure cannot be set  
correctly.  
6. Read the pressure gauge. The manifold  
pressure reading should match the pressure  
rating on the data plate.  
A. To adjust, remove the cap covering the  
manifoldpressureadjustmentscrew.Turn  
the recessed manifold pressure  
adjustment screw counterclockwise to  
decrease pressure or clockwise to  
increase pressure.  
The combination valve is preadjusted for natural or  
propane gas as specified on the rating plate. The  
natural gas rating is 4" W.C., and the propane rating  
is 10" W.C.  
1. Turn the combination valve knob to OFF.  
7. Installthecapandcheckforproperoperation.  
2. Remove the plug from the submanifold and  
install pressure gauge at this point.  
– 11 –  
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ELECTRICAL OPERATION  
3. Total Shutdown.  
CONTROL SYSTEM DESCRIPTION  
A. When the high limit trips, 0.0 millivolts  
will read across both coils of the  
combination valve, causing both valves  
to close.  
1. Thethermopile(TP)providesthetotalcontrol  
voltage for this system.  
A. One side of the thermopile is connected  
to the common (C) of the high limit (HL).  
B. Pilotrelightcannotbeaccomplisheduntil  
oil cools sufficiently to allow high limit to  
close.  
B. The other side of the thermopile is  
connected to the normally open (NO)  
contacts of the high limit.  
C. If any wire in the system is cut or broken,  
the system will shut down.  
C. The common of the high limit (below the  
highlimittriptemp.)isconnectedthrough  
the normally closed (NC) contacts of the  
high limit, through wire 3 to the  
combination valve pilot connection  
common.  
SYSTEM CONDITION QUICK CHECK  
PROCEDURES  
1. Use the Pilot Lighting procedure and check  
millivolts (mV) at wires 3 and 4.  
D. The other side of the pilot valve is  
connected through wire 4 to wire 1 to the  
high limit normally open contacts which  
hold the pilot valve open.  
A. If the pilot lights, then pilot combination  
and high limit are good.  
1) If the high limit trips, connection is  
made from the common to the  
normally open contacts, turning off  
pilot valve voltage. The gas valve  
closes.  
B. If the pilot will not stay lit, check high  
limit and open the thermopile circuit. It  
should read 300 mV; if there are Ø volts,  
check high limit. If the high limit is good,  
replace combination valve.  
2. Thermostat Control.  
C. Check for voltage at disconnected  
thermopile. It should read 300 mV; if  
there are Ø volts, replace thermopile.  
Check high limit. If the high limit is good,  
replace combination valve.  
A. One side of the millivolt supply is  
connected through the high limit system,  
as described above, to the thermostat  
common(wire3)ofthecombinationvalve.  
2. Turn on thermostat; burners should light.  
B. The other side of the thermopile is  
connected from the normally open  
contactsofthehighlimit tothethermostat  
through wire 1.  
A. If the burner does not light, check the  
following:  
1) Voltage at combination valve at  
wires 2 and 4.  
C. Whenthethermostatcallsforheat(closed  
circuit) power from the thermopile is then  
connectedtotheothercombinationvalve  
thermostat connection through wire 2.  
2) If correct voltage is present, then  
check combination valve.  
3) IfthereareØvolts, checkvoltage  
between wire 3 of combination  
valve and wire 1 of thermostat. If  
correct voltage is present, then  
check resistance of thermostat  
andwire32. Ifthereisnovoltage,  
check resistance of wire 1 to  
normally open contacts of high  
limit.  
D. If the high limit trips, the thermopile is  
connected across zero ohms, the output  
voltage of the thermopile drops to 0.0  
millivolts, and the thermostat coil of the  
combination valve drops out, shutting  
the thermostat valve.  
– 12 –  
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SCHEMATIC  
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.  
Hi-Limit - Prevents overheating of fryer in the event of thermostat failure. Opens at 450°F and automatically resets  
at 415°F.  
– 13 –  
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TROUBLESHOOTING  
POSSIBLE CAUSE  
SYMPTOM  
A. Insufficient gas supply to unit.  
1. The temperature of the shortening drops,  
or excessive recovery time is required.  
B. Ventilating system pulling heat out of  
heat exchanger and flue box.  
C. Overloading fryer capacity.  
2. Pilot won't stay lit. Fryer shut off.  
A. Malfunctioning thermopile or loose/dirty  
connection in thermopile.  
B. Malfunctioning shutoff valve.  
C. Pilot burner orifice and air openings need  
cleaning.  
A. Excessive temperature settings (over  
375°F).  
3. Rapid shortening breakdown, crumbs and  
specks in frying compound.  
B. Shortening not being filtered regularly.  
C. Incorrect preparation of breaded food.  
Do not use salt.  
Allow breading time to adhere to  
food.  
Do not allow loose flour to fall into  
shortening from hands.  
D. Do not add strainings or drippings from  
meat fats to shortening.  
E. Use correct shortening and follow  
temperature recommendations.  
F. Take out 10% to 15% of the shortening.  
G. Check thermostat settings with  
thermometer periodically.  
– 14 –  
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TROUBLESHOOTING  
SYMPTOM  
POSSIBLE CAUSE  
4. Leaking tank.  
A. Foam-over by depleted shortening permits  
oil to drip from the tank surface, giving the  
appearance of leaking.  
B. Careless draining procedures. Gas valve  
should be in the PILOT or OFF position  
before draining oil. Burners heating an empty  
tank will damage tank joints.  
C. Carbon buildup causes rapid attack on tank  
by promoting acid formulation.  
5. Pilot burner flames adjusted properly, but  
fluctuate to very low and blow out easily.  
A. Check gas pressure at submanifold fitting on  
fryer when fryer is in operation. Check all  
other equipment on the same gas line in  
operation.  
B. Pressure at submanifold (pipe on which  
burnersaremounted)shouldnotbelessthan  
4.0" W.C. (natural and mixed gas) or 10"  
W.C. for propane gas.  
– 15 –  
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NOTES  
FORM 35618 (11-04)  
– 16 –  
PRINTED IN U.S.A.  
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