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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