SERVICE MANUAL

VK and TR GAS FRYERS W/Wo

KleenScreen PLUS

VK Series TR Series

VFRY18 (after SN 481819109)

– NOTICE –

This Manual is prepared for the use of trained Hobart 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 Hobart 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 Hobart Service Technician.

The reproduction, transfer, sale or other use of this manual, without the express written consent of Hobart, 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.

October 2020

• Updated gas supply pressure in SPECIFICATIONS.
• Added GAS INLET PRESSURE ADJUSTMENT.

Service Updates

November 2018

SERVICE UPDATES

• • Added TIS Document List.

November 2017

• • Updated SPECIFICATIONS.

September 2017

• • Added INTERFACE CONTROL BOARD PIN- OUTS.

TIS DOCUMENT LIST – VK & TR GAS FRYERS

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

MODELS, FEATURES AND OPTIONS

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

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 microfiltration 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.

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. 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.

Fig. 2

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

ANALOG CONTROL

SOLID STATE CONTROL

COMPUTER CONTROL

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
• VOM with minimum of NFPA-70E CATIII 600V, UL/CSA/TUV Sensitivity of at least 20,000 ohms per volt. Meter leads must also be rated at CAT III 600V.

SPECIAL

• Temperature tester (thermocouple type).
• Manometer.
• Combustion analyzer.
• Set of metric hex wrenches (must include a 2 mm wrench).
• Set of jeweler’s screwdrivers.
• Grounding kit.
• Burndy pin extraction tool RX2025 GE1; Newark Electronics Catalog Number 16F6666. Used for removing pin terminals on Burndy connectors.
• Thumb drive (part number 443444).

NOTE: Customer to supply program for uploading menu items.

SPECIFICATIONS

ELECTRICAL:

• 120VAC supply.
  • Filter motor/pump
  • Basket lift motors
  • Transformer
• 24VAC transformer
  • Fryer controls
  • Basket lift relays
  • Filter relay

MANIFOLD GAS PRESSURES (per fryer section)

• Natural 0.08″ W.C.
• Propane 0.08″ W.C.

BUILDING SUPPLY PRESSURE (MAXIMUM)

• Natural 7-9″ W.C.
• Propane 11″ W.C.

Building supply pressure max ½ psi. (14″ W.C.)

A separate high pressure step-down gas regulator (not supplied with unit) must be used for pressures exceeding maximum. On fryers built between 12/1/12 thru 4/7/16 an incoming gas pressure regulator is installed on the fryer that has a max supply pressure rating of ½ PSI (14″ W.C.).

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 and follow lockout / tagout procedures.

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 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.

NOTE: This procedure applies to fryers with automatic basket lift option only.

1. Remove basket assembly lift arms from support rods.
2. Remove screws securing upper cover to flue wrap.

Fig. 8

• 1. 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.

ANALOG CONTROL

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit and follow lockout / tagout procedures.

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. 10

5. Remove control box cover.

Fig. 11

6. Disconnect lead wires as necessary to remove control.

Fig. 12

7. Remove screws from front of control panel and remove control.

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 and follow lockout / tagout procedures.

1. Remove CONTROL PANEL.
2. Note lead wire locations and remove wiring.
3. Remove screws securing control to fryer and remove.

Fig. 13

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

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. 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 and follow lockout / tagout procedures.

1. Drain shortening from fryer tank.
2. Unplug temperature probe lead wire connector.

Fig. 15

NOTE: This picture shows the probes with the burner removed.

3. Loosen compression nut and remove probe from fryer.

Fig. 16

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 and follow lockout / tagout procedures.

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. 17

4. Remove the capillary tube retaining and packing nuts.

Fig. 18

NOTE: This picture shows the probes with the burner removed.

5. Slide high limit probe out of fry tank.

Fig. 19

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

POWER SUPPLY BOX

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

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.

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 lower to clear bracket.

Fig. 20

2. Access front of fryer to slide power supply box toward rear of fryer to disconnect from front support bracket.

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.

Fig. 22

Fig. 23

5. Reverse procedure to install.

POWER SUPPLY BOX COMPONENTS BEFORE 12/1/12

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. 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.

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. 27

3. Remove screws and remove from box.

4. Reverse the procedure to install new relay control board.

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. 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 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 gas line from gas valve.
2. Remove electric plug connector from gas valve.
3. Unbolt high limit thermostat clamp from transfer tube.

Fig. 29

4. Remove bolts and remove burner from fryer.

Fig. 30

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 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.

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 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 BASKET LIFT COVERS.
2. Remove nut securing lift bar to lift tube.
3. Remove screws securing lift tube bracket to fryer then remove bracket and lift tube.

Fig. 31

4. Reverse procedure to install.

BASKET LIFT MOTOR

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

1. Remove BASKET LIFT TUBE.
2. Disconnect lead wires from cam switch and basket lift motor.
3. Loosen set screws securing crank arm assembly to basket lift motor shaft.

Fig. 32

4. Remove screws securing basket lift motor to cam bracket, then remove motor from bracket.

Fig. 33

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

NOTE: After reinstalling motor keep all wire leads clear from moving parts.

BASKET LIFT CAM SWITCH

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

1. Remove BASKET LIFT TUBE.
2. Disconnect lead wires from cam switch.
3. Remove screws securing cam switch to cam bracket.

Fig. 34

4. Reverse procedure to install.

BASKET LIFT CAM

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

1. Remove BASKET LIFT COVERS.
2. Remove nut securing lift bar to cam assembly.
3. Loosen cam set screw.
4. Remove screws securing cam to the crank arm assembly.

Fig. 35

5. Reverse procedure to install.

FILL SOLENOID VALVE (KSP)

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit and follow lockout / tagout procedures.

1. Remove filter tank from fryer.
2. Access fill solenoid valve.
3. Loosen union at rear of valve,
4. Remove bolts securing valve and remove valve from the fryer.

Fig. 36

5. Reverse procedure to reinstall valve.

FILTER HOSE SWITCH (KSP)

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

1. Open fryer door to access filter hose switch.
2. Unplug lead wire connections.

Fig. 37

3. Press tabs on rear of switch and push out front of fry cabinet.

4. Reverse procedure to install new switch.

FILTER PUMP AND MOTOR (KLEENSCREEN FRYERS ONLY)

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

1. Access rear of fryer.
2. Remove four bolts holding serial plate bracket, and carefully lower bracket.
3. Disconnect both hoses from filter pump.

Fig. 38

4.  Disconnect electric connections to filter pump motor.

5. Unbolt filter pump motor from fryer frame.

6. Carefully remove filter pump assembly through rear of fryer.

7. Reverse procedure to reinstall filter pump assembly.

DRAIN VALVE INTERLOCK SWITCH (DVI)

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit and follow lockout / tagout procedures.

1. Open fryer section door.
2. Locate drain valve switch
3. Remove nut holding drain valve handle and remove handle.

Fig. 39

NOTE: Make sure drain handle is in closed position. If fry tank is full of shortening, carefully remove drain handle. Make sure you do not turn handle to open position. Doing so will allow shortening to drain on floor or you.

4. Remove drain valve interlock switch bracket from valve.

5. Remove screws holding the drain valve interlock switch on bracket and take switch from bracket.

Fig. 40

6. Unplug drain valve interlock switch from wiring harness and remove switch from fryer.
7. Reverse procedure to install and check for proper operation.

FRY TANK

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

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 BURNER ASSEMBLY.
2. Remove both HIGH LIMIT THERMOSTAT and TEMPERATURE [ROBE.
3. Remove DRAIN VALVE INTERLOCK SWITCH.
4. Remove drain assembly from drain valve.
   1. Remove hose clamp from rubber boot.
   2. Remove drain piping from drain valve.

Fig. 41

5. Remove drain valve from fry tank.

Fig. 42

6. Loosen and disconnect the oil return line, if equipped with filter system.

Fig. 43

7. Remove fry tank bolt down bracket.

Fig. 44

8. Remove fry tank cover plate.

Fig. 45

• 1. Cover plate is glued to tank and will have to be pried off.
  2. Order a replacement plate prior to replacing fry tank.

9. If basket lifts are installed, they will have to be removed from rear of tank.

10. Remove tank from fryer.

Fig. 46

11. Reverse order of this procedure to install new fry tank.

SERVICE PROCEDURES AND ADJUSTMENTS

Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times and follow Arc Flash procedures. If test points are not easily accessible, disconnect power and follow Lockout/Tagout procedures, attach test equipment and reapply power to test.

ELECTRIC CONNECTIONS

The VK series fryers are supplied with a 120Volt cord and three prong plug. If local electrical codes require that these fryers be plugged into a Ground Fault Interrupter or GFI. You must use GFI part number 913053. Other GFI outlets may not have the correct tolerance for the spark to ground ignition system employed with the VK series fryers.

HARMONIC TONE

Harmonic Tone (hum) at First Start

At first start, fryer will begin heating in low fire. There will be a harmonic tone that is NORMAL to hear. As fryer continues to heat, harmonic tone will dissipate and become less noticeable. When fryer reaches 135°F (end of melt cycle), fryer will heat on high fire and blower speed will increase.

TEMPERATURE PROBE FAULT CODES

The temperature probe is used for both the solid state control and the computer control. The probe is an RTD (resistance temperature detector) of the thermistor type. As temperature increases the resistance value decreases.

Probe Fault

If a temperature probe fault or high temperature condition occurs, a fault message will be displayed and the electronic alarm will sound continuously. The heat demand and basket lift outputs are de-activated. If a cooking cycle is in process (timer active), it will be cancelled and the key pad disabled.

This will continue until the fault clears, power is cycled or problem resolved.

TEMPERATURE PROBE TEST

To Check:

1. Turn power switch off.
2. Disconnect the temperature probe plug.

Fig. 47

3. Test the probe using a VOM to measure resistance. Connect the meter leads to the wires removed in step 2.

1. 1. If the measured resistance values are within the allowable range, the probe is functioning properly. Reverse procedure to install.
   2. If the measured resistance values are outside the allowable range, install a replacement probe and check for proper operation.

COOKING CONTROL CALIBRATION

NOTE: Verify condition of temperature probe as outlined under TEMPERATURE PROBE TEST before proceeding.

1. Check the level of shortening in fry tank. The level must be between the MIN & MAX fill lines before proceeding.
2. Allow shortening to cool below 300°F.
3. Place a thermocouple in the geometric center of the fry tank one inch below the shortening surface.
4. Set the cooking control to 350°F and turn the fryer on.
5. Monitor the heat indicator lamp. When cooking control is calling for heat, lamp will be on. If cooking control is satisfied, lamp will be off.

       Analog Control – Heat light is to right of zero on temperature scale.

      Solid State Control – Decimal point of first character indicates heat on when lit.

      Computer Control – Two LED lamps on the Oil Temp key that indicate heat on.

NOTE: Agitate the shortening, to eliminate any cold zones.

• 1. Allow cooking control to cycle three times to stabilize shortening temperature.
  2. Record meter reading from thermocouple when the cooking control cycles off and on for at least two complete heating cycles.

6. Calculate the average temperature by adding the temperature reading when the heat lamp goes out to the temperature reading when the heat lamp comes on & divide this        answer by 2.

[ Temp. (Lamp off) + Temp. (lamp on) ] ÷ 2 = Average Temp. Example: 360° + 340° ÷ 2 = 350°F.

The average temperature should be 350°F (± 5°F).

• 1. If the average temperature reading is within tolerance, cooking control is properly calibrated.
  2. If the average temperature reading is out of tolerance, perform the following:
     1. Analog Control – Remove knob and turn adjustment screw counterclockwise to increase temperature and clockwise to decrease temperature.
     2. Solid State Control – Adjust OFFSET TEMPERATURE.
     3. Computer Control – Adjust OFFSET TEMPERATURE.

7. Repeat the average temperature calculation for up to three attempts. Allow the cooking control to cycle at least two times between adjustments before performing the               calculation.

8. If calibration is unsuccessful, the cooking control may be malfunctioning and cannot be adjusted properly. Install a replacement cooking control and check calibration.

FLAME SENSE CURRENT CHECK PRIOR TO 12/1/12

Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power and follow lockout / tagout procedures, attach test equipment and reapply power to the test.

1. Remove cover of power supply box.
2. Locate red flame sense wire.

Fig. 48

3. Remove the red flame sense wire.

4. Place one Microamp meter lead on the red wire.

5. Place the other meter lead on the terminal you removed the red flame sense wire from.

6. Power up the fryer and have it call for heat.

7. You should receive a minimum Microamp reading of at least 1.0 microamp.

8. If the reading is greater or equal to the value given, then the flame sense current is within tolerance.

9. If the reading is lower than the value given, then troubleshoot the flame sense circuit.

NOTE: If the reading is below 0.0 microamps, reverse the meter leads and take another reading.

FLAME SENSE CURRENT CHECK AFTER 12/1/12

Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power and follow lockout / tagout procedures, attach test equipment and reapply power to the test.

1. Remove cover from power supply box.
2. Locate two pins (FC- and FC+) on side of the ignition/ blower control board.

Fig. 49

3. Set your multi meter for Microamps and place meter leads on two pins.

4. Restart the fryer and read the microamps as the fryer is sparking.

NOTE: The only time you will be able to read the microamps is when the fryer is sparking. When the spark quits the reading will go away. You may only have several seconds to obtain this reading.

5. The flame sense current must be at least 2.0 to 3.0 microamps, and the reading must be steady.

6. If reading is below 1.3 microamp or unsteady, check pilot flame and electrical connections.

ELECTRONIC IGNITION CONTROL

NOTE: This procedure applies to all fryers.

Ignition Module Lockout

This happens when fryer is unable to detect flame sense. The electrode will try to ignite one time. When flame has not been detected within 5 seconds red light on ignition module will blink.

Fig. 50

“A” style controller: Red light will blink and blower will continue to run until power has been turned off.

“C” and “D” style controllers: Red light will continue to blink, but blower will shut down after a number of seconds and a loud “beep” will continue to sound until fryer is powered down.

Electronic Ignition System

Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times and follow Arc Flash procedures. If test points are not easily accessible, disconnect power and follow Lockout/Tagout procedures, attach test equipment and                                         reapply power to test.

1. Access burner electrode.
2. Remove ignition wire from burner electrode.
3. Fasten metal end of ignition wire about ¼ away from a grounded metal surface on fryer.
4. Try to light the burner.
5. You should be able to see a spark. If no spark, check ignition module in power supply box.

MODULATING GAS VALVE ADJUSTMENTS

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

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.

The modulating gas valve is adjusted at the factory and requires no adjustments. If the modulating gas valve needs to be replaced, the new gas valve from the parts depot will be adjusted property and will only need to have the gas pressure verified coming into the gas valve.

All fryers built after 12/1/12 will have gas regulators installed on the incoming gas line. The gas pressure on the new gas vales will not have to be checked.

BASKET LIFT ARM ADJUSTMENT

1. With shortening at room temperature, verify the shortening level is between MIN & MAX lines in fry tank. Add shortening as needed.

NOTE: Shortening will expand when heated. Do not fill the fry tank past the MAX line.

2. Turn power switch on and set temperature to 350°F. Allow the shortening to reach set temperature.

3. Check basket lift operation.

1. 1. If necessary, adjust as outlined below.

4. When basket is in the up position, the bottom of the basket should be out of the shortening. When basket is in the down position, the bottom of the basket should clear the          crumb screen and the product should be submerged.

1. 1. To adjust, remove basket arm from lift shaft, loosen stop nut and turn height adjustment bolt to raise or lower basket arm as required. Both baskets should be same height.
   2. Tighten stop nut when complete.

NOTE: If adjustment is to low, when the basket is lowered, it will disengage from basket arm

Fig. 51

SOLID STATE CONTROL

Operation

Use service information in this section when servicing a fryer with a solid state control. Refer to instruction manual for specific operating instructions.

NOTE: In operator programming mode, control can be reset to its default values by pressing the TEMP key for 2 seconds.

Service Programming

Solid state control Service Mode is used to perform system diagnostic tests or edit programs that affect the fryers operation.

Error Messages

Refer to ALARM MESSAGES at end of section.

Enter Service Mode

NOTE: Control heat demand output signal is off and heat/ignition status input signal is ignored.

1. Cycle power switch. When the program version number is displayed, press PROGRAM key to enter Service Mode.
   1. Beeper chirps on each successful keypress.
2. To scroll through each of the program items, press PROGRAM key and release.
   1. To reset all service mode program items to factory default, press and hold TEMP key for 2 seconds.
3. To exit Service Mode and save selections, press PROGRAM key and hold for 1 second. Fryer returns to normal operation and display shows the current heating mode based on shortening temperature:

• MELT L (liquid; default) or Melt S (solid) if shortening temperature is below 135°F.
• HEATING if no melt is selected and shortening temperature is below set point.
• Fryer set point temperature if actual shortening temperature is within set point range.

Display Test

1. Cycle power switch. When FRYERS is displayed, press PROGRAM key.
   1. Display shows DSP TEST.
   2. Press PROGRAM key again to light all the display segments in the first character.
   3. Continue pressing PROGRAM key until the display segments for all eight characters are tested.
2. To exit test, press and hold the PROGRAM key for one second.

Alarm Messages

Alarms take precedence over any other controller mode or function (except drain valve function).

COMPUTER CONTROL

Operation

For operating instructions and programming, refer to OPERATOR MANUAL and computer controls programing start guide.

Fig. 52

Service Programming

The computer controls service settings mode is used to select the settings that affect fryer operation and to perform fryer diagnostic tests.

Enter Service Setting Mode

Fig. 54

NOTE: The controls heat demand output signal is off and the heat/ignition status input signal is ignored if the fryer is in cook mode or idling.

1. Turn power switch on and when the program revision is displayed, press PROGRAM to enter Service Setting Mode.
   1. The SERVICE SETTINGS are shown on the left and right display screens.
2. Verify the settings shown on the display screen are correct for the fryer being serviced.
3. To change a service setting.
   1. Press the desired product number key (1 thru 6) on the control panel that corresponds to the service setting number on the display screen.
      1. Beeper chirps on each successful key press and all LED’s are off. When a service item is selected, only the keys required to change the setting are active.
   2. Press toggle key to alternate between available selections, or use product number keys where indicated to enter a value. The current selection will be “blinking”.
   3. Press PROGRAM key to save the selection  – “Blinking” stops.
   4. Access the other service settings as necessary.

4. To enter DIAGNOSTICS mode, press product number key 7 on the control panel.

Fig. 55

Fig. 56

• 1. Press the desired product number key (1, 2, 3, 4, & 6) on the control panel that corresponds to the diagnostic test number on the display screen to check the output signal to the component.
     1. Press the same product number key again to turn the output off.

NOTE: Item 5 (drain) displays the real time status and does not require pressing the corresponding product number key. Item 3 (heater) – The output signal will be active for 3 seconds (heat on) then turn off.

2. For item 6 DISPLAY: – change the setting as desired.

1. 1. 1. Press product number key 6 to access the display screen adjustment settings.
      2. Press the left or right arrow key on the PROGRAMMING MENU SELECTION screen to select the screen to adjust. Display shows “THIS LCD SELECTED”.

Fig. 57

3. To adjust the selected screen:

1. 1. 1. 1. BACKLIGHT – Press toggle key to turn display backlight ON or OFF.
         2. PIXEL MODE – Press product key number 1 two times to change display from white background with black letters to black background with white letters. Press the key again to change it back to original setting.
         3. CONTRAST – Press the L key on the keypad to lower the contrast or press the R key on the keypad to raise the contrast.

4. Press PROGRAM key to return to DIAGNOSTICS MODE.

5. To exit SERVICE SETTINGS MODE and return to normal operation, keypress PROGRAM key.

1. 1. Display reverts to product menu items.

Alarm Messages

The alarms take precedence over any other controller mode or function (outputs off, active timers canceled).

DISPLAY, LED AND KEYPAD TEST – COMPUTER CONTROL

1. Press and hold the 5 key while turning power on to Initiate test. Release the 5 key during display of software revision level and all LED<s and display segments should light.
2. For each number key (1-9, & 0) pressed, the corresponding value is displayed in each character position on the left and right display. (i.e.5 key shows 55555555 55555555).

NOTE: Beeper chirp’s for as long as key is held.

3. For each function key pressed, the following values are displayed in each character position on the left and right display:

4. Turn power off to exit test.

BLOWER CONTROL BOARD SETTINGS

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

NOTE: This procedure for fryers built before 12/1/2012.

Whenever you have problems with the blower motor make sure the following adjustments are correct.

1. SW2: Set the SW2 potentiometer to the number 2 setting.
2. SW4: Set the SW4 potentiometer to the number 4 setting.
3. Dip switches: Set the fourth switch (the one closest to the potentiometers) to the up position.

Fig. 58

NOTE: For fryers built after 12/1/2012, there are no adjustments for blower settings, The Ignition/Blower control board is preprogrammed. If a fryer built before 12/1/12 has been converted to the new Ignition/ Blower control board, there will be no adjustments.

HIGH/LOW FIRE TIMER SETTING

Disconnect the electrical power to the machine and follow lockout / tagout procedures.

NOTE: This procedure is for fryers built before 12/1/2012

Whenever you have problems with high or low firing of the burner make sure the following adjustments are correct.

NOTE: To set the fire timers use a jeweler’s flathead screwdriver.

NOTE: The timer closest to the ignition module is the low fire timer, and the one closest to the bottom is the high fire timer.

1. Low fire timer: Set the low fire timer for 2 seconds.
2. High fire timer: Set the high fire timer for 8 seconds.

Fig. 59

NOTE: For fryers built after 12/1/12, the fire timers are replaced by a Ignition/Blower control board. The high and low fire time settings are programmed into the control board. If a fryer built before 12/1/12 has been converted to the new Ignition/Blower control board, there will be no adjustments.

AIR FILTER

A dirty air filter will prevent the correct amount of air intake for the blower. The results are poor combustion resulting in the fryer “puffing” severely.

To clean the air filter, remove the filter by pulling it off. The clamp is only hand tightened. Clean air filter in dishwasher or in sink with hot soapy water. Make sure air filter is completely dry prior to reinstalling, making sure that the filter is snug onto the blower intake. Make sure NOT to tighten the clamp more than hand tight.

Fig. 60

SPARK GAP SETTING BEFORE 12/1/12

Fig. 61

The spark igniter rod should be set between 1/8″ and 3/16″ away from the mesh burner. This gap will allow the igniter to produce the optimal spark required to ignite the burner.

Fig. 62

If the spark igniter rod is not adjusted correctly the gas could build up in the burner assembly and cause a delayed ignition of the burner. The resulting “puffing” could result in damage to the fryer.

NOTE: If the power supply box has been converted to the new controls, the spark igniter rod should be replaced with the new style spark rod.

SPARK GAP SETTING AFTER 12/1/12

1. Insure the spark igniter is installed properly on the burner.
2. The ground rod should be set touching mesh or with a maximum gap between rod and burner mesh of 1/16 of an inch.

Fig. 63

3. There should be a gap of 1/8 to 3/16 of an inch between igniter rod and ground rod.

Fig. 64

4. This igniter sparks to the ground rod. To insure we have a proper ground, we put a wire on the ground rod terminal and secure it to burner.

Fig. 65

GAS INLET PRESSURE ADJUSTMENT

1. Turn gas supply off.
2. Access blower in fryer.
3. Loosen screw inside brass port several rotations.

NOTE: Screw will not fall out of port.

Fig. 66

4. Install manometer tube over brass port.

5. Turn gas supply on.

6. Check gas inlet pressure.

   BUILDING SUPPLY PRESSURE (MAXIMUM)

• • Natural Gas 7 – 9″ W.C.
  • Propane Gas 11 – 12″ W.C.

Building supply pressure max ½ psi. (14″ W.C.)

If incoming pressure exceeds 14″ W.C. (1⁄2 psig -3.45 kPa), a step-down pressure regulator must be installed.

If building supply pressure is too high or low, contact facility manager to have corrected.

7. Turn gas supply off.

8. Remove manometer.

9. Tighten brass port screw.

ELECTRICAL OPERATION

COMPONENT FUNCTION – FRYER CONTROLS

COMPONENT FUNCTION – KLEENSCREEN FILTER CONTROLS

COMPONENT LOCATION

Fig. 67

Fig. 68

Fig. 69

Fig. 70

Fig. 71

SEQUENCE OF OPERATION – A SERIES – AFTER 12/1/12

Refer to the schematic diagrams for Analog Control operation.

NOTE: If the Solid/ Liquid switch is set to Solid, the control will cycle the heat on and off in short intervals until the shortening is heated to 135°F.

1. Conditions:
   1. Fryer connected to correct supply voltage and properly grounded.
   2. Incoming gas supply is on and manual gas valve turned on.
   3. Power switch to the fryer section in the off position.
   4. Solid/Liquid switch set to correct position.
   5. Shortening at proper level in fry tank and below last set point temperature used.
   6. Manual drain valve closed (drain valve interlock switch N.O. is closed).
   7. High limit thermostat closed.
2. Turn power switch on.
   1. 24VAC transformer energized.
3. Analog control is powered 24VAC.
4. Start switch is closed (momentary).
5. If shortening temp is below 135°F then melt cycle will operate.
6. Temperature goes above 135°F and control calls for heat.
   1. 3 sec prepurge.
   2. Spark sent to igniter.
      • 7 sec trial for ignition. If flame not detected after 8 sec, Lockout.

NOTE: System remains locked out until the power switch is cycled to reset system and restart trial for ignition cycle. (Wait 5 minutes for gas to dissipate)

• • • 2 sec after flame detected, burner blower motor in low speed and low fire initiated.

3. Cooking control evaluates input signals from: Ignition status, drain valve interlock, and temperature probe.

4. Ignited burner heats shortening in fry tank.

NOTE: As long as the ignition module senses a flame, the internal main voltage (MV) contacts (N.O.) on the ignition module remain closed, and the gas valve stays on.

8. Shortening reaches set temperature.

1. 1. Cooking control de-activates heat output (24VAC).

1. Gas valve coil de-energized and valve closes.

2. Gas flow stops and burner goes out.

9. When fryer calls for heat again, ignition sequence will begin at step 6A.

SEQUENCE OF OPERATION D AND C SERIES

Refer to SCHEMATIC AI3495 for Cooking Control operation.

NOTE: If using solid shortening, the control should be programmed to use the melt cycle. In the melt cycle, the control will cycle the heat on/off in short intervals. This will gradually heat and liquify the shortening until it reaches 135°F. Melt cycle default times in seconds are:

On solid state controls only, CY (cycle) is displayed before the shortening letter designation and zero represents no melt.

The control then resumes normal operation as described in this sequence.

1. Conditions.
   1. Fryer connected to correct supply voltage and properly grounded.
   2. Gas supply and gas combination valves are on.
   3. Power switch to the fryer section in the off position.
   4. Shortening at proper level in fry tank and below last set point temperature.
   5. Desired shortening selected. (Solid/Liquid)
   6. Cooking control is setup properly and ready to use.
   7. Manual drain valve closed (drain valve interlock switch N.O. is closed).
   8. High limit thermostat closed.
2. Turn power switch on.
   1. Power to terminal 5 (COM) on left and right basket relays.
   2. 24VAC transformer energized.
3. Cooking control powers on, initializes and performs a diagnostic self check.

NOTE: If cooking control passes diagnostic self check, the output signals are turned on and operation sequence continues. If cooking control does not pass diagnostic self check, the control displays an error message for the problem, disables keypad and sounds the electronic alarm continuously. Refer to SOLID STATE CONTROL ALARMS OR COMPUTER CONTROL ALARMS.

4. 24VAC to P5 of interface board.

5. Control calls for heat.

1. 1. 25 VDC to P3 on interface board.
   2. Triac on interface board supplies 24VAC to ignition module to P6 on interface board.

6. If shortening temp is below 135°F then melt cycle will operate.

7. Temperature goes above 135°F and control calls for heat.

1. 1. 3 sec prepurge.
   2. Spark sent to igniters.
      • 7 sec trial for ignition. If flame not detected after 8 sec, Lockout.

NOTE: System remains locked out until the power switch is cycled to reset system and restart trial for ignition cycle. (Wait 5 minutes for gas to dissipate)

• • • 2 sec after flame detected, burner blower motor in low speed and low fire initiated.

3. Once burner flame is present, burner blower motor goes from low speed to high speed.

4. Ignition module provides ignition status input signal to control

8. Cooking control evaluates input signals from: Ignition status, drain valve interlock, and temperature probe.

1. Ignited burner heats shortening in fry

NOTE: As long as the ignition module senses a flame, the internal main voltage (MV) contacts (N.O.) on the ignition module remain closed, and the gas valve stays on.

9. Shortening reaches set temperature.

1. 1. Triac on Interface Board de-energized.

1. Gas valve coil de-energized and valve

2. Gas flow stops and burner goes

10. When fryer calls for heat again, ignition sequence will begin at step 5A.

11. If fryer is left idle, the ignition sequence changes.

12. If shortening is allowed to cool over a long period of time, burner will operate on low heat to maintain shortening temperature near operating temperature.

NOTE: When the fryer shortening is cooling, the controller observes how fast or slow the temperature drops. If the temperature drops slowly the controller will operate the burner with the blower motor in low speed allowing the burner to operate at a lower BTU output to save our customers money by using less gas. The fryer will still reach set temperature, just at a slower pace. If the temperature drops rapidly, the controller will operate the burner blower motor in low speed until the flame is rectified, then it will change to the high speed for the rest of the call for heat

Drawer Filter System

Refer to SCHEMATIC AI3496 for Drawer Filter System operation. Refer to VK OPERATOR MANUAL and DRAWER FILTRATION SYSTEM

SUPPLEMENT for specific instructions on filtering.

NOTE: The discard valve handle is connected to a mechanical valve and magnetic reed switch assembly to route the flow of shortening in the filtering system and supply power to the pump motor.

1. Conditions.
   1. Fryer connected to correct supply voltage and is properly grounded .
   2. Power switch to fryer section to filter turned on.
   3. The cooking control should be setup properly and ready to use.
   4. Cooking control temperature setting between 300°F (minimum) and 350°F (maximum).

NOTE: Shortening should not be filtered outside of this temperature range. At lower temperatures the shortening is thicker which may increase filtering time and place a greater load on the pump. At higher shortening temperatures, oil seal life is decreased.

5. Filter drawer assembly installed properly.

6. Drain valve handle (white) retracted.

1. 1. 1. Drain valve interlock switch N.O. contacts open. Mechanical drain valve closed.

2. Allow shortening to cycle between 300°F and 350°F for approximately 10 minutes.

NOTE: If using solid shortening, once it has melted, stir the shortening to eliminate any sold shortening in cold zone of the fry tank.

3. Open drain valve to fryer section in need of filtering and drain shortening into filter tank.

1. 1. Display indicates draining.
   2. Drain valve interlock switch contacts open and position of drain valve is indicated to cooking control.

NOTE: If using solid shortening, allow hot shortening to stand in filter tank for approximately 6 minutes prior to filtering.

4. Press filter key on the control panel and hold for 3 seconds. The filter output signal (24VAC) at pin E1-9 is turned on and the interface board K3 relay coil is energized at               pins 11 & 4.

1. 1. K3 N.O. contacts close and 24VAC is output from the interface board at pin 12.
   2. R1 pump motor relay coil (24VAC) is energized and both sets of N.O. contacts close.

NOTE: Jumper wire number 24 connects one set of R1 N.O. contacts to R2 COM.

• • 1. Fill solenoid valve is energized (120VAC) thru R2 fill relay N.C. contacts and valve opens.
    2. Pump motor is energized (120VAC) and pump circulates shortening through filtering system.

5. When filtering is completed, close the drain valve and allow the fry tank to refill.

1. 1. Display indicates fill tank.
   2. Drain valve interlock contacts close and the position of the drain valve is indicated to the cooking control.

6. When all filtered shortening is returned to the fry tank, press filter key on the control panel.

1. 1. Power is removed from fill solenoid valve and pump motor.
   2. Display indicates tank full hit temp. If shortening is at proper level in fry tank, press and hold temp key until shortening temperature is displayed. Filtering cycle is complete and fryer resumes normal operation.

NOTE: If using solid shortening, when all filtered shortening is returned to fry tank and pump motor is off, open filter drawer approximately one inch. Allow remaining shortening in line to drain into filter tank to prevent possible clogging after shortening cools and solidifies. Close filter drawer when complete.

SCHEMATIC DIAGRAMS

Analog Controls – No Options

Analog Controls – Kleenscreen

Solid State or Computer Control – No Options

Solid State of Computer Control – Kleenscreen

WIRING DIAGRAMS

VK Fryer (C and D Models)

Power Supply Box (Before 12/1/12) – VK Fryer with basket lifts and Kleenscreen

Power Supply Box (Before 12/1/12) – VK Fryer without basket lifts and Kleenscreen

VK Fryers with Electronic Ignition and Analog Control and Kleenscreen

VK Fryers with Electronic Ignition and Analog Control

Diagram LINKS below for Power Box Wiring for Units Built after December 2012

VK/TR D & C Fryer Wiring Diagram

VK/TR Analog Control W/ Kleenscreen Fryer Wiring Diagram

VK/TR Analog Control W/E.I. Stand Alone Fryer Wiring Diagram

TROUBLESHOOTING

TROUBLESHOOTING

INTERFACE CONTROL BOARD PIN-OUTS