SERVICE MANUAL McDonald`s SinBaD Series SINGLE
Contents
1. opening in the cabinet Remove the setscrew securing the dispense door arm to the motor shaft and slip the arm from the shaft being careful 2 3 motor throu not to lose the square key Remove the four Keps nuts from this a the screws securing the motor assembly to the dispense motor bracket Dispense Door Arm Inner Motor Stop Ground Wire Outer Motor Stop Detail of Hall Effect Sensor Assembly and Brackets sensor wiring omitted for clarity Bracket with offset goes on last Leave a 1 4 inch 6 25mm gap between edge of Dispense Arm and Inner Motor Stop Loosen the setscrew securing the sensor flag to the motor shaft and slide the flag and shim spacer from the shaft Slip the Hall effect sensor brackets off the mounting screws and separate the motor and mounting bracket Assemble the replacement motor to the bracket then replace the Hall effect sensor brackets installing the bracket with offset last see illustration in step 5 Replace and tighten the four Keps nuts torquing to 5 10 inches pound NOTE Ensure the ground wire is reattached to the upper right hand mounting screw Insert the square key into the groove in the long motor shaft align the slot in the dispense arm hub with the square key and slip the arm onto the shaft with the hub on the outside see illustration in step 5 NOTE The door must be positioned between the motor stops rotate the shaft if necessary and t2. DISPENSE CHUTE P Failed proximity sensor Replace the proximity sensor DOOR DOES NOT Test Place a basket into the dis OPEN pensing well and check for illumina tion of the proximity sensor If the sensor is not illuminated the sensor has failed Failed misaligned upper Hall effect Realign or replace the upper Hall sensor effect sensor as necessary Test Ifthe unit zeroes and loads the dispense chute normally remove the hopper and basket from the unit and empty the dispense chute Replace the basket If the drum motor does not start the upper Hall effect sensor is out of alignment or has failed Failed controller F Replace the controller Test Disconnect the cables from the suspect controller and connect them to a controller known to be good Turn the unit off then back on using the ON OFF switch the press the RUN switch If the unit operates cor rectly the controller has failed 1 8 Probable Causes Corrective Action A Failed dispense motor A Replace the dispense motor Test Turn the unit offthen back on using the ON OFF switch then press the RUN switch After the unit ze roes check for 24 35 VDC on the motor end of the dispense motor ca ble If voltage is present the dispense motor has failed Failed motor interface board or Replace the motor interface board dispense motor cable or dispense motor cable as re quired Test Turn the unit off then back on using the ON OFF switch
3. Lid Hopper 816 0568 Glass Sight 823 3683 Arm Basket Rack 823 3685 Rack Basket 824 0893 Pan Crumb 824 1022 Receiver SinBaD Bracket 824 1023 Tray Basket Rack 910 7920 Handle Hopper Lid 910 8688 Deflector 1 2 3 4 5 6 7 8 CABINETRY 3 2 ITEM PART COMPONENT 106 0643 Cover Assembly SinBaD Drum Motor 106 0777 Side Left Cabinet 106 1438 Side Right Cabinet 806 9228 Cover Right Cabinet Top 806 9235 Cover Left Cabinet Top 806 9782 Base Assembly 807 1083 Bushing Nylon fits 2 inch hole 826 1680 Clamp Plastic Wire Pkg of 8 826 1389 Screw 4 20 x inch Hex Head Pkg of 10 809 0189 Washer 4 inch SAE Flat 809 0191 Washer V4 inch Lock 809 0194 Washer SAE Flat 809 0250 Nut 6 32 Keps Hex 809 0434 Screw 10 x inch Hex Washer Head 809 0783 Nut 18 Hex Nylon Lock 810 0356 Caster w o Brake 5 inch for 3 inch caster use 810 2508 810 0357 Caster w Brake 5 inch for 3 inch caster use 810 2509 810 1644 Guide Basket 823 2761 Panel Cabinet Front 823 3191 Liner Cabinet Bottom 823 3383 Liner Cabinet Inner 824 0752 Cover Dispense Motor 824 0771 Cover SinBaD Load Cell 900 8208 Cover Back 900 8211 Brace Upper Back 900 8223 Brace Lower Back Right 900 8224 Brace Load Cell Vertical 900 8324 Panel Motor Access 900 8352 Brace
4. Lower Back Left 900 9440 Support Base gt KH 3 3 DISPENSE SYSTEM COMPONENTS 3 4 210 0810 Stop Door Open Position 806 8969SP Switch Assembly Position Hall Effect Sensor 806 9258 Load Cell Assembly 806 9271 Load Cell Arm Assembly 807 3004 Motor 24VDC Dispense 826 1389 Screw 4 20 x 34 inch Hex Head Pkg of 10 809 0171 Thumbscrew 4 20 x 1 inch 809 0191 Washer 4 inch Lock 809 0193 Washer 14 inch Nylon Flat 826 1366 Nut 4 40 Keps Hex Pkg of 25 809 0247 Nut 8 32 Keps Hex 809 0434 Screw 10 x inch Hex Washer Head 809 0480 Setscrew 28 x inch 809 0613 Screw 8 32 x 2 inch Fillister Head 809 0649 Bolt 4 20 x 14 inch 809 0674 Setscrew 8 32 x inch Cup Point Square Head 809 0675 Screw 4 40 x inch Slotted Pan Head 809 0737 Screw 4 20 x 4 inch Slotted Round Head 810 1391 Key inch x inch 810 1770 Brace Load Cell 810 1771 Rod 4 inch x inch Aluminum 816 0400 Door Dispense Chute 823 2607 Flag Door Position Hall Effect Sensor Flag 823 2670 Arm Dispense Door 823 2717 Chute Dispense 823 3412 Top Dispense Chute 900 8169 Shim Motor Shaft 900 8211 Brace Upper Back 900 8233 Saddle Load Cell 910 5855 Bracket Dispense Motor 910 7950 Stop Door Closed Position 910 8164 Bracket Lower Position Switch Lower Hall Effect Sensor Bracket 910 8165 Bracket Upper Position
5. Switch Upper Hall Effect Sensor Bracket 826 1746 Tester Load Cell Not illustrated 3 5 DRUM MOTOR COMPONENTS ITEM PART COMPONENT 200 0953 Bracket Drum Motor Mounting 807 3436 Motor 24VDC Drum 809 0247 Nut 8 32 Keps Hex 809 0613 Screw 8 32 x 2 inch Fillister Head 810 1571 Arm Drum Rotator Bullet 3 6 ELECTRONICS ITEM PART COMPONENT 106 0242 Interface Board 106 0503 Cable Assembly Proximity Sensor 806 8889 Cord Power 806 8956 Cable Transformer to Interface Board 806 8957 Cable Computer Interface Board 12VDC Power 106 1480 Computer Assembly 807 1083 Bushing Nylon fits 2 inch hole 807 2734 Switch ON OFF 120V Rocker 807 2818 Filter 120 250V AC Line 807 2912 Cable Dispense Motor to Computer Terminal J5 807 2915 Cable Drum Motor to Computer Terminal J4 807 2943 Transformer 115 230 24 807 3056 Cable Position Switch to Interface Board Terminal J8 807 3058 Cable Computer Interface Board Signal 807 3240 Strain Relief Power Cord 809 0097 Screw 6 32 x 1 inch Slotted Truss Head 809 0250 Nut 6 32 Keps Hex 826 1371 Screw 8 x inch Hex Head Drill Point Pkg of 25 810 0383 Spacer Nylon 816 0566 Block Proximity Sensor 900 8938 Bracket Electronic Components Mounting gt 3 7 McDonald
6. area where itis Relocate unit to an area where it is being bumped or jarred during opera less likely to be bumped or jarred tion during operation Ensure unit is not in contact with adjacent walls B Unit is in an area subject to unusual B The effect of environmental vibra environmental vibration such as ad tions may be lessened by placing jacent to a railroad track or near a the unit on a thick mat major highway programmed dance with Appendix A A 12VDC is not getting to the D Failed Test 1 Replace the motor controller interface board BATCH WEIGHTS ARE INCONSISTENT OR INACCURATE Test 1 Check for 12VDC at motor Failed Test 2 Replace the 12VDC interface board connector J3 If power cable voltage is not present probable cause is failure of the motor interface board If voltage is present perform Test 2 DRUM MOTOR RUNS Test 2 Check for 12VDC at the CONTINUOUSLY AS controller end of the 12VDC cable If SOON AS THE ON OFF voltage is present on connector J3 but SWITCH IS PLACED not at controller end of the cable the IN THE ON POSITION cable has failed If voltage is present at the controller end of the cable the controller is suspect Go to B B Failed controller E Replace the controller Test Substitute new controller for suspect controller Turn unit off and back on using the ON OFF switch Press RUN switch If unit functions correctly the controller has failed A Failed drum motor A Rep
7. press a BATCH WEIGHT selector other than 1 the unit will return to the STANDBY mode immediately after the selector is pressed Press the CLEAN Switch once The dispensing chute door will open and the lights above the numbered selectors will blink indicating that the system is zeroing itself and performing its self calibration routine This process takes about 20 seconds When the process is complete the dispensing chute door will close and the indicator lights will go out Carefully place an object weighing 4 pound 11 kg less than the desired batch weight on the dispensing chute door and wait at least 5 seconds for the load cell to stabilize For example to program a batch weight of 1 Ib 45 kg use an object weighing Ib 34 kg Press one of the numbered switches to program the weight associated with that switch The switch s indicator will light momentarily then go out showing that the weight for that switch has been successfully recorded Repeat steps 4 and 5 for each of the remaining numbered switches Press the PROGRAM Switch once to exit the PROGRAMMING mode Press the RUN Switch lH once to return to the RUN mode The light in the switch will illuminate and the dispensing chute door will open and remain open for about 20 seconds as the unit re zeros itself Additionally the lights in the batch weight selectors will sequentially flash during the self zeroing routine When the door closes replace and reload the hopper to
8. s Sin aD SINGLE BASKET DISPENSER Appendix A Batch Weight Programming The Batch Weight Selectors in McDonald s Sin aD are factory programmed with three standard batch weights 0 5 1b 23 kg 1 0 Ib 45 kg and 1 5 1b 68 kg If necessary they can be reprogrammed in the field using the following procedure NOTE ONLY the previously listed weights should be programmed Programming other weights contravenes McDonald s policy A CAUTION Programming the unit for weights less than 38 Ib 17 kg will result in erratic batch weights The PROGRAMMING mode can only be entered when the unit is in STANDBY mode To enter the STANDBY mode press the RUN Switch l l once Verify that the indicator light in the Switch is out If not press the RUN Switch again 1 Remove the hopper assembly from the unit NOTE If the hopper is not empty refer to Section 3 1 of the Operator s Manual for instructions on emptying the hopper Press the PROGRAM Switch once to enter the PROGRAMMING mode The indicator light in the switch will blink Press BATCH WEIGHT Selector 1 four times The indicator lights in each of the selectors will light in sequence until all are lit at which time the indicator in the PROGRAM Switch will stop blinking and the indicator in the CLEAN Switch will blink NOTE If you do not begin pressing Selector 1 within 5 seconds after entering the PROGRAMMING mode the unit will automatically return to the STANDBY mode If you
9. then press the RUN switch After the unit ze roes check for 24 35VDC on J5 of the motor interface board If voltage is not present the motor interface board has failed If voltage is present the dispense motor cable has failed DISPENSE CHUTE DOOR DOES NOT CLOSE Failed misaligned lower Hall effect Realign or replace the lower Hall sensor effect sensor as necessary Test Ifthe unit zeroes and the door partially closes the lower Hall effect sensor is out of alignment or has failed Failed controller Replace the controller Test Disconnect the cables from the suspect controller and connect them to a controller known to be good Turn the unit off then back on using the ON OFF switch the press the RUN switch If the unit operates cor rectly the controller has failed iagrams D iring 1 4 SHIELDED pac U ITION NTERFACE CABLE EXTENDER t t EPA 1 10 INVHOVIC ODNIJIM CIa3lallalNIS YALNdNOS SONIOVAL ANY SLINDYID ONISSIDOYA HOSN3S ALINIXOUd YOSNIS YOSNAS 193333 193433 TIVH Q3
10. transformer brown and blue wires and 24VAC on the black and orange wires and 12VAC on the black and yellow wires If line voltage is pres ent on the transformer brown and blue wires and either of the other two voltages is incorrect the transformer has failed Failed motor interface board E Replace the motor interface board Test Check for 12VDC on connector J3 of the board If voltage is incor rect the board has failed Failed 12VDC power cable F Replace the 12VDC power cable Test Check for 12VDC on connector J3 of the motor interface board If voltage is correct the 12VDC power cable has failed Probable Causes Corrective Action UNIT WILL NOT ZERO A Failed controller Test 1 fa load cell simulator is available disconnect the load cell from the controller and connect the simulator Turn unit offthen back on using the ON OFF switch Press the RUN switch Ifthe unit does not zero the controller has failed Test 2 fa load cell simulator is not available turn unit offthem back on using the ON OFF switch Press the RUN switch and look for the follow ing conditions 1 Drum motor activates briefly then stops 2 Indicators in RUN switch and PROGRAM switch do not flash If both conditions are true the con troller is suspect Failed load cell Test 1 fa load cell simulator is available disconnect the load cell from the controller and connect the simulator Turn unit offthen back
11. trying to insert a piece of paper between the two If it can be inserted without drag it s okay b No part of the dispense chute is touching the cabinet 1 2 2 Erratic or Inaccurate Batch Weights The probable cause of erratic or inaccurate batch weights is bumping or jarring of the unit while the drum motor is running The unit should be positioned in an area where it is not likely to be bumped or jarred during operation If erratic or inaccurate batch weights occur at random intervals it is likely that the unit is being bumped or jarred by workers The only solutions in this case are to move the unit or better educate employees about the effects of bumping the unit during operation If the erratic or inaccurate batch weights occur at specific times or if the problem comes and goes there may be a source of unusual vibration Two things to consider are facility location e g is the store close to a railroad track or a highway where trains or heavy trucks pass on a regular schedule and unit location e g is it next to a heavy door that slams shut etc In the case of facility location not much can be done although it may be possible to dampen the vibrations by placing the unit on a rubber pad In the case of unit location consider an alternate location for the unit Avoid moving the unit long distances without the load cell shim in place Excessive jarring of the unit in movement may damage the load cell If erratic or inaccurate ba
12. two bolts securing the load cell arms to the load cell see illustration at right Carefully lower the load cell arms dispense motor assembly to the bottom of the dispense chamber 5 Remove the two bolts securing the load cell load cell brace assembly to the load cell saddle see illustra tion below and remove the load cell and load cell brace Remove these bolts Load cell saddle IS 18 Remove gi these n bolts 6 Reattach the replacement load cell and the load cell brace to the load cell saddle and securely tighten the bolts Verify that the gap between the load cell and stop screw in the load cell brace is approximately 015 inch 005 inch 4mm 13mm 7 Reverse steps 1 through 4 to complete the procedure 2 2 3 Replacing the Dispense Motor 1 Disconnect the unit from the electrical power source and remove the back panel to access wiring 2 Disconnect the dispense motor wiring harness and Hall effect sensor cable see photo below Remove the basket alignment rack from the dispensing Remove well Remove the two bolts securing the dispense motor to these the load cell arms see illustration at right Be ready to bolts support the approximate 6 pound 3 kilogram weight of the dispense motor assembly when the bolts are removed Carefully pull the dispense motor assembly out through the j
13. SERVICE MANUAL McDonald s Sin Ra Series SINGLE BASKET DISPENSER le Pg FOR YOUR SAFETY Do not store or use gasoline or other flammable liquids and vapors in the vicinity of this or any other appliance This document is to be inserted into the Non Fryer Section of the Equipment Manual MANUFACTURED FOR McDONALD S BY FRYMASTER L L C P O BOX 51000 SHREVEPORT LOUISIANA 71135 1000 1 318 865 1711 NOM 1 800 24 FRYER N WARRANTY STATEMENT TROUBLESHOOTING mie ronca COMPONENT REPLACEMENT NA A T aD o APPENDIX A Frymaster L L C 8700 Line Avenue 71106 5489 Campus Drive 71129 P O Box 51000 Shreveport Louisiana 71135 1000 TEL 318 865 1711 FAX Parts 318 219 7140 Tech Support 318 219 7135 Printed in the United States Service Hotline AUGUST 2004 1 800 24 FRYER 8 1 9 5 862 A DANGER IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE INJURY OR DEATH READ THE INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT A DANGER DO NOT ATTEMPT TO REPAIR OR REPLACE ANY COMPONENT OF THIS EQUIPMENT UNLESS ALL POWER TO THE EQUIPMENT HAS BEEN DISCONNECTED A DANGER FOR YOUR SAFETY DO NOT S
14. SO I0 N3dO YOOU 1 OS NOSV3 AWVS AFLVALSNTI LON AYLINDAIO 1139 QVO ALIOMIdINIS S3HOLIMS TWNOILONNA SV NMOHS SHOSN3S 193333 TIVH ANY HOSN3S ALINIXO4d 3 LON a Ba S 4 v oj S a 1139 avol STICON aSN4 3ounos OQA vc Aw YOLOW SONIOVAL ayog YOLOW 3SN3dASI0O HOLOIN LINE FILTER SOVLIOA 1 11 805 1020A ZHO9 09 082 0 2 062 202 ZHO9 0S OWAS0Z 007 ZHO9 09 ZHO9 0S 042 0 2 062 802 002 204 202 VO 7819 vC VO ZOLOAVE VO ZOLIAPZ 2 09 09 OVASI ZHO9 0S vo zaLaArz ZHO9 09 OWASLIL ZHO9 09 2VAOOL 2012 2 100 91862 38 2149319 15 YANYOASVYL IVNOILdO vo ZOLOAVG 84 dMOO M3AMOJSNVML AR A YANYOASNVYL 1 12 McDonald s Sin aD SINGLE BASKET DISPENSER CHAPTER 2 COMPONENT REPLACEMENT 2 1 Accessing Components The unit s back panel must be removed to access all electronic components except the drum motor The panel is held in place by two hex head screws located along the bottom edge A separate access panel must be removed to gain access to the drum motor It is held in place with two hex head screws In order to ac cess the ON OFF s
15. TORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE DANGER FRYMASTER EQUIPMENT IS MANUFACTURED FOR USE WITH THE TYPE VOLTAGE SPECIFIED ON THE EQUIPMENT RATING PLATE FOR PROPER ELECTRICAL INSTALLATION PROCEDURES IN THE UNITED STATES REFER TO THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE ANSI N F P A NO 70 INCANADA REFER TO THE CANADIAN ELECTRICAL CODE PART 1 CSA 22 1 FOR INSTALLATION IN COUNTRIES OTHER THAN THE UNITED STATES AND CANADA REFER TO THE NATIONAL CODE APPROPRIATE FOR THE COUNTRY IN WHICH THE EQUIPMENT IS BEING INSTALLED WARNING DO NOT OPERATE THIS EQUIPMENT UNLESS ALL SERVICE AND ACCESS PANELS ARE IN PLACE AND PROPERLY SECURED A WARNING COMPUTERS FCC This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation While this device is a verified Class A device it has been shown to meet the Class B limits CANADA This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES 003 standard of the Canadian Department of Communications Cet appareil numerique n emet pas de bruits radioelectriques depassany les limites de classe a et b prescrites dans la norme NMB 003 edictee par le ministre des
16. arefully screw the replacement sen sor into the Teflon block until it is finger tight Tighten the stop nut against cabinet Plug the sensor cable into jack J5 on the controller and reconnect the unit to the electrical power source 2 2 7 Replacing the Motor Interface Board 1 2 Disconnect the unit from the electrical power source Holding the new interface board next to the one being replaced disconnect each cable from the failed interface board and connect it to the new board one at a time Remove the four Keps nuts securing the old board to its mounting and slip it off the mounting studs be ing careful not to dislodge the spacers behind the board Slip the new board onto the mounting studs and replace the Keps nuts Reconnect the unit to the electrical power source 2 5 McDonald s Sin BaD SINGLE BASKET DISPENSERS CHAPTER 3 PARTS LIST ACCESSORIES NOTES Item 13 may be attached to either side of Item 14 Item 16 may be mounted on either side of cabinet to correspond to location of Item 13 COMPONENT 900 2949 Shim Caster 803 0276 Rack Wire Basket Positioning 810 2220 Leg 809 0132 Screw 14 20 x inch Slotted Pan Head 826 1368 Nut 4 20 Serrated Flange Pkg of 10 809 0747 Thumbscrew Y4 30 x inch 810 0378 Caster 5 inch Wheel Rigid 810 2231 Block Threaded 812 1496SP Hopper 816 0378 Drum 816 0491
17. communications du Canada HAZARD COMMUNICATION STANDARD HCS WHEN THE PROCEDURES IN THIS MANUAL INCLUDE THE USE OF CHEMICAL PRODUCTS THE PRODUCTS WILL BE PRINTED IN BOLD FACE FOLLOWED BY THE ABBREVIATION HCS IN THE TEXT PORTION OF THE PROCEDURE SEE THE HAZARD COMMUNICATION STANDARD HCS MANUAL FOR THE APPROPRIATE MATERIAL SAFETY DATA SHEET MSDS McDonald s SinBa SINGLE BASKET DISPENSER WARRANTY STATEMENT Frymaster L L C makes the following limited warranties to the original purchaser only for this equipment and replacement parts Warranty Provisions Frymaster L L C warrants all components against defects in material and workmanship for a period of one year All parts with the exception of fuses are warranted for one year after installation date of cabinet If any parts except fuses become defective during the first year after installation date Frymaster will also pay straight time labor costs to replace the part plus up to 100 miles 160 km of travel 50 miles 80 km each way Parts Return All defective in warranty parts must be returned to a Frymaster Factory Authorized Service Center within 60 days for credit After 60 days no credit will be allowed Warranty Exclusions This warranty does not cover equipment that has been damaged due to misuse abuse alteration or accident such as e Improper or unauthorized repair Failure to follow proper installation instructions and or scheduled maintenance proc
18. d A built in 1 4 second delay allows the load cell to stabilize before the controller reactivates the 1 1 drum motor to reload the dispensing chute If a basket has been pre positioned beneath the dispensing chute the unit will dispense the batch as soon as the load cell is satisfied and begin loading another batch The second batch will be held until the first batch is removed and a new basket is inserted The process continues until the unit is placed in the STANDBY mode or the ON OFF switch is placed in the OFF position 1 2 Troubleshooting and Problem Isolation This section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment and the probable causes of each Problems you are likely to encounter can be grouped into three categories a Failures to zero b Erratic or inaccurate batch weights c Failures to function correctly A series of troubleshooting guides is also included at the end of the chapter to assist in identifying some of the more common problems 1 2 1 Failures to Zero As discussed in Section 1 1 the unit determines batch weights by comparing the load cell resistance to a pre recorded resistance value equal to the empty or zero resistance value plus a resistance differential value corresponding to a particular batch weight When the load cell resistance is equal to the zero resistance plus the resistance differential the loa
19. d cell is satisfied and the drum motor is stopped Although each load cell is theoretically identical in actuality any given cell may have a slightly different resistance from any other cell Consequently the cell must be zeroed to determine and record its actual resistance in order to ensure accurate batch weights The unit must be zeroed with the dispense chute in place and no part of the dispense chute may be in contact with the cabinet The load cell itself is basically an aluminum bar When not under stress it has a particular resistance When the The Load Cell Assembly bar is vertically distorted by applying weight to one end sa the resistance changes Also if the bar contacts any other component such as the end of the dispense motor shaft its resistance will be changed forcing it outside the acceptable range Circuitry within the controller measures the load cell resistance and compares this to a factory programmed and very narrow range As long as the load cell resistance falls within this range the unit Load Cell Brace will zero Other than the load cell or an associated component being in contact with something it shouldn t there are only three probable causes for failing to zero The first is a malfunctioning controller If the controller cannot measure load cell resistance or loses the programmed resistance range it cannot zero The recommended method of checking the controller
20. edures as pre scribed in the manual shipped with the unit Improper maintenance Damage in shipment Abnormal use Removal alteration or obliteration of the rating plate This warranty also does not cover e Transportation or travel over 100 miles 160 km 50 miles 80 km each way or travel time over two hours e Overtime or holiday charges e Consequential damages the cost of repairing or replacing other property that is damaged loss of time profits use or any other incidental damages of any kind There are no implied warranties of merchantability or fitness for any particular use or purpose For international warranty the above paragraphs apply except that the customer is responsible for freight and duty charges McDonald s Sin aD SINGLE BASKET DISPENSER CHAPTER 1 TROUBLESHOOTING 1 1 Functional Description When the unit is plugged into an electrical outlet line voltage is supplied to the transformer Placing the ON OFF switch in the ON position supplies 24V to the motor interface board The motor interface board supplies 12VDC to the controller and 24VDC to the dispense motor and drum motor The drum motor will activate briefly as the computer in the controller wakes up then motor logic circuits in the controller will turn it back off If closed the dispensing chute door will open and remain open When the ON OFF switch is placed in the ON position the controller automatically enters the STANDBY mode Whe
21. here must be at least 4c inch 8 mm clearance between the door and the motor Torque the setscrew to 20 25 inches pound 10 Slip the shim spacer onto the short motor shaft followed by the sensor flag with the hub facing the 11 shim Rotate the dispense arm so that the tang is pointed up see illustration in step 5 and there is a gap of approximately 4 inch 6 25 mm between the edge and the inner motor stop Remove any slack in the motor shaft by placing the arm end on a work surface and gently pressing down on the motor At the same time rotate the sensor flag so that it is positioned between the faces of the up per left Hall effect sensor Verify that there is a gap of approximately inch 6 25 mm between the arm and the inner motor stop then tighten the setscrew torquing to 12 inches pound 12 Reinstall the dispense motor assembly by reversing steps 1 through 4 2 2 4 Replacing the Drum Motor l 2 6 Disconnect the unit from the electrical power source Disconnect the drum motor wiring from the drum motor cable see illustration at right NOTE The drum motor cable plugs into the motor interface board and the motor wiring plugs into it It is not necessary to disconnect the drum motor cable from the motor interface board CW RN T nuts Remove the four Keps nuts see illustration at right that secure the dr
22. is to use a load cell simulator P N 826 5658 If the unit fails to zero with the simulator substituted for the load cell the controller has probably failed An alternate method is to substitute a controller known to be good for the suspect controller It is not necessary to install a controller to test it Simply plug the cabling into the new controller If the unit zeroes the controller in the unit has failed and should be replaced with the new one The next probable cause is a failed load cell Failure may be caused by bending of the cell or by damage to the cabling Because the resistance range is narrow it is usually impossible to see the damage so the appearance of the load cell is not a good indicator 1 2 of load cell failure although an obviously damaged cell is immediately suspect The recommended method for diagnosing a failed load cell is to use the simulator mentioned earlier If the unit zeroes with a simulator substituted for the load cell the load cell has probably failed If the controller and load cell test OK the third and least likely probable cause is a failure of the cable between the load cell and the computer NOTE If the unit zeroes sometimes but fails at others check for a loose connection at the controller In any of the situations the only solution is to replace the failed component but before doing that verify that a The load cell brace is not touching the end of the dispense motor shaft Do this by
23. lace the drum motor Test With loading chute empty turn the unit off then back on using the ON OFF switch Press the RUN switch Check for 24VDC at motor end of drum motor cable If voltage is DRUM MOTOR DORs present the drum motor has failed NOT ACTIVATE AT ALL B Failed motor interface board B Replace the motor interface board Test Check for 24V AC at connector NOTE Before replacing the J1 of the motor interface board If motor interface board check the voltage is present and a motor known continuity of the drum motor cable to be good does not activate when to be sure it is not the problem RUN switch is pressed the motor in terface board may have failed Probable Causes Corrective Action A Failed dispense motor A Replace the dispense motor Test Turn the unit offthen back on using the ON OFF switch then press the RUN switch Check the DOOR LED for a bright red glow and for 24 35VDC at the motor end of the dispense motor cable If both condi tions are true the dispense motor has failed Failed dispense motor cable Replace the dispense motor cable Test Check for 24 35VDC on con nector J5 of the motor interface board If voltage is not present the dispense motor cable has failed Failed motor interface board Replace the motor interface board Test Check for 24 35VDC on con nector J5 of the motor interface board If voltage is present the motor interface board has failed
24. n in the STANDBY mode the batch weight selector switch circuits are disabled and the CLEAN and PROGRAM circuits are enabled No indicator LEDs are illuminated when the unit is in the STANDBY mode Pressing the RUN switch places the controller in the RUN mode and causes the RUN mode indicator above the switch to illuminate Every time the unit is placed in the RUN mode the controller will perform an initialization process to zero the load cell The dispensing chute door will open and remain open throughout the process to ensure accuracy When in the RUN mode the batch weight selector switch circuits are enabled and the CLEAN and PROGRAM circuits are disabled The load cell is an aluminum bar that acts as a bridge resistor One end of the load cell is fixed The load cell arms dispensing chute and dispense motor are attached to the opposite end Their weight causes a slight distortion of the bar which changes the bar s resistance During the zeroing process circuitry in the controller measures the resistance associated with the weight of the empty dispensing chute the dispense motor and the load cell arms It compares this to a factory programmed resistance range and if within the range records this as the zero value If the resistance is outside of tolerance the unit goes into a zero failure mode signified by blinking of the RUN mode indicator and the PROGRAM mode indicator During programming of the batch selector switches
25. on using the ON OFF switch Press the RUN switch If the unit zeroes the load cell is suspect Test 2 fa load cell simulator is not available turn unit offthen back on using the ON OFF switch Press the RUN switch and look for the follow ing conditions 1 Drum motor activates briefly then stops 2 Indicators in RUN switch and PROGRAM switch flash If both conditions are true and a piece of paper can be inserted be tween the dispense motor shaft and the load cell brace the load cell has failed Loose or broken load cell cable Test Check connection to verify that the cable is securely plugged into connector J3 on the controller 1 6 A Replace the controller NOTE Before installing a new controller plug the cabling into the new controller turn the unit off then back on using the ON OFF switch and press the RUN switch If the unit zeroes the diagnosis is confirmed and the replacement computer can then be installed If the unit still does not zero the problem is not with the controller Replace the load cell NOTE Before replacing a load cell verify that a piece of paper can be inserted between the dispense motor shaft and the load cell brace If not the load cell is out of align ment Refer to Section 2 2 2 for corrective action C Ifthe cable is loose reconnect it I the cable is broken replace the load cell Probable Causes Corrective Action A Unit is located in an
26. ontroller has failed The third is that controller signals are not reaching the motor drive circuits If the drum motor does not activate at all the probable cause is failure of a component in the input power eircuit Failures of the dispense chute door to open or close are caused by problems with the Hall effect sensors the proximity sensor the dispense motor the motor interface board or the controller The primary indication of a problem involving the closed Hall effect sensor J8 on the controller is the partial closing of the door following the zero routine or the removal and replacement of a basket during normal operation A failed open Hall effect sensor J8 on the controller is indicated by the normal zeroing of the unit and loading of the dispense chute but failure of the door to open to dispense the fries A failed proximity sensor will give the same indication so care must be taken to differentiate between the two If the Hall effect sensors have been ruled out as the cause of the failure to function the most likely cause is a motor related problem Failures of the drum motor to start or stop are caused by problems in the controller load cell motor inter face board or drum motor and the associated wiring If the motor fails to stop the problem is not with the motor It may be with the controller the load cell or the motor interface board 1 3 Troubleshooting Guides The Troubleshooting Guides in
27. return the unit to operation 1
28. tch weights occur consistently it is likely that one or more of the batch weight selectors may have been improperly programmed Verify that the selectors have been properly programmed in accordance with the instructions in Appendix A 1 2 3 Failures to Function and Improper Functioning The probable causes of this category of problem are improper connections and failed components If you have not already done so you should read Section 1 1 the system theory of operation before continuing with this section The paragraphs that follow identify the general types of failures that may be encountered and the possible causes of each Troubleshooting Guides at the end of the chapter provide step by step problem isolation procedures Failure of the unit to initialize when ON OFF switch is placed in ON position can be caused by failure of a component in the input power circuit or failure of the controller When the ON OFF switch is placed in the ON position the two error conditions that may be encountered are that the drum motor does not activate at all or it runs continuously Normally when the ON OFF switch is placed in the ON position the drum motor briefly activates approx imately 2 seconds then stops If the drum motor runs continuously as soon as the ON OFF switch is placed in the ON position there are three probable causes The first is that 12VDC is not getting to the controller 1 3 from the motor interface board The second is that the c
29. the controller measures the difference between the previously determined zero resistance and the resistance associated with the new weight It records the differential so that a batch weight always corresponds to the zero resistance plus the differential resistance not a specific resistance value This avoids erratic batches caused by fluctuations in the zero weight When a batch weight selector is pressed the controller activates the drum motor to transfer fries to the dispensing chute When the fries enter the chute their weight further distorts the load cell causing a change in resistance When the resistance is equal to the zero resistance plus the resistance differential associated with the batch weight selector pressed the controller signals the drum motor to stop A proximity sensor at the rear of the dispensing well senses when a basket has been inserted into the well It signals the controller which in turn activates the dispense motor to dump the fries When the door reaches the full open position a flag on the dispense motor shaft is detected by a Hall effect sensor that signals the controller The controller in turn reverses the current to the motor closing the door When the door reaches the closed position another Hall effect sensor detects the flag on the motor shaft and signals the controller The controller reduces power to the dispense motor to approximately causing the motor to hold the door close
30. the following pages provide a systematic method for isolating specific prob lems and the action s to take to correct them When using the guides to isolate the cause of a particular problem begin with the first probable cause and work down Also don t forget the Operator Troubleshoot ing Guides found in the Operator s Manual Most problems likely to be encountered are covered in these two sets However don t hesitate to call the Frymaster Technical Services Department at 1 800 24 FRYER 1 800 243 7937 if you need assistance in solving a particular problem Probable Causes Corrective Action A Failed power cord A Replace the power cord Test Check for line voltage on the line side of the line filter If not pres ent the power cord has failed Failed line filter B Replace the line filter Test Check for line voltage on the line side of the filter and on the load side If line voltage is present on the line side but not the load side the fil ter has failed Failed ON OFF switch C Replace the ON OFF switch Test Check for line voltage on the load side of the line filter and on the transformer brown and blue wires If line voltage is present on the load side of the filter but not on the transformer NO POWER WITH brown and blue wires the switch has UNIT VERIFIED TO BE failed PLUGGED IN ANDID Failed transformer D Replace the transformer CIRCUIT BREAKER VERIFIED TO BE ON Test Check for line voltage on the
31. um motor to the drum motor bracket and pull o the motor straight back off the mounting Screws Grasp the motor shaft with a pair of locking pliers and unscrew the rotator arm 5 08 bullet from the motor shaft and 77 transfer it to the new motor Disconnect E motor wiring Slip the new motor over the four AD here mounting screws being careful not to dislodge the screws Replace and tighten the Keps nuts ne yH Reverse steps 1 and 2 to complete the procedure 2 2 5 Replacing the Transformer or Line Filter 1 2 Disconnect the unit from the electrical power source Holding the new component next to the component being replaced disconnect each wire from the old component and connect it to the new component one at a time Remove the screws securing the old component to the mounting bracket remove the old component and install the new component Reconnect the unit to the electrical power source 2 4 2 2 6 Replacing the Proximity Sensor 1 2 4 Disconnect the unit from the electrical power source Unplug the proximity sensor from the controller Unscrew the failed sensor from the block Thread the stop nut on the replacement sensor back toward the cord end until approximately Y inch 12 5mm of threads remain C
32. witch and controller the right cabinet top must also be removed It is secured by two pan head machine screws and Keps nuts at the left rear corner as viewed from the rear of the unit and one hex head screw at the right rear corner The front of the panel is held in place by a pair of tabs that fit into slots cut into the front of the cabinet When the retaining screws have been removed lift up on the rear and move the cabinet top toward the front to disengage the tabs 2 2 Replacing Components 2 2 1 Replacing the Controller 1 Disconnect the unit from the electrical power source 2 Disconnect all cables from the jacks on the back of the controller If cables are not marked indicating their jacks mark the cables before disconnecting them 3 The controller is held in place by four Keps nuts Remove the nuts and pull the controller straight rear ward off the mounting studs 4 Reverse steps 1 3 to install new controller 2 2 2 Replacing the Load Cell and Associated Components 1 Disconnect the unit from the electrical power source 2 Disconnect the load cell cable from the back of the controller see photo below These components shown separated from cabinet to reveal load cell arms Load Cell Arms Dispense Chute 3 Remove the dispensing chute by lifting it up from the BN load cell arms and carefully sliding it toward you see illustration at right 2 1 4 Remove the
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