Home

Frymaster 8196345 Fryer User Manual

1. 1 42 ura i 5 LL E H TT LHM 26 f eo T iA D L EE 5 n mai 2 ER 5 5 am 2 TE Ei Es cre ma Hu Hu a LC ad ama 5 DH Y zm Tz EHE eer zi eer zi eer zi 10 d 10 d 10 i gej bi KT 44 e ri L ne 9 Ra R m E a m mm gt Ou 1 50 o e MER pe wa U T m S 1 17 3 Modular Basket Lift 100 120V LEFT SIDE RIGHT SIDE 930 101C ew PAY w FE d Na 130 BRN 1 RED 1 RESISTOR Ben 2 RED 2 125 12 5 uF pom 98 96 95C 97C No 8 UPPER SWITCH 4C 29C 610 A A A 12 1 10 9 5 4 3 2 REFERENCES TO LEFT amp RIGHT ARE FROM THE REAR OF THE FRYER 8050518E 1 43 1 17 4 Modular Basket Lift 208 250V LEFT SIDE 15C 8C RIGHT SIDE NOT M BLK USED ON BLK M 208 220V 9934 D p 25dhm BRN 1 RED 1 BRN 2 RED 2 C
2. FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD 106 6706 Meter Test Setting Pins Results 12VAC Power to Controller 50VAC Scale 1 and 3 on J3 or J2 12 18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GROUND 22 28 120 VAC Power 250VAC Scale 11 on J3 and GROUND 110 125 120 VAC Power to Blowers 250VAC Scale 12 J3 and GROUND 110 125 24VAC Power to Full Vat High Limit 50VAC Scale 9 on J3 and GROUND 22 28 Probe Resistance Full Vat R x 1000 OHMS 2 and 6 J3 13 and 14 on J2 d Probe Isolation R x 1000 OHMS 6 on J1 or J3 and GROUND High Limit Continuity Full Vat Rx 1 OHM 9 on J3 and Wire 13 Gas Valve 0 Disconnect 20 harness from controller before testing probe circuit See Probe Resistance Chart at end of chapter 5 mega Ohms or greater 14 Thermostats Protector series gas fryers have temperature probes located on the front centerline of each frypot In this type of thermostat the probe resistance varies directly with the temperature That is as the temperature rises so does resistance at a rate of approximately 2 ohms for every 1 F Circuitry in the computer monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures setpoints Protector series gas fryers are also equipped with a high limit thermostat In the event that the fryer fails to properly control the oil temperature
3. PART COMPONENT 211 6510 212 6510 810 1105 106 4397 230 4960 106 4067 810 0275 809 0970 230 4685 810 1494 810 2970 CON HM 823 6325 106 7977 106 8955 824 1846 823 6289 823 6591 Side Standard Cabinet Left SS use 221 0323 for Enameled Steel Side Standard Cabinet Right SS use 222 0323 for Enameled Steel Magnet Door vertical use 810 2346 for horizontal over filter pan Door Left or Right Left shown move handle to bottom for right Handle Eurolook Door Pin Assembly Door Spring Door Pin Retaining Ring Hinge Door Lower Caster without Brake Caster with Brake Flue Cap Stainless Steel Two Station Fryer Three Station Fryer Four Station Fryer Top Cap Two Station Fryer Three Station Fryer Four Station Fryer Not illustrated 2 4 2 4 Drain System Components 2 4 1 Drain Valves and Associated Parts Full Vat or Dual Vat Right Drain Valve Assembly 106 9025SP ITEM PART COMPONENT 1 809 0540 Nut 2 13 2 Way Hex Lock 2 900 2936 Retainer Nut Drain Valve 3 810 3350 Handle Drain Valve FV 4 810 0677 Grip Drain Handle 5 901 2348 Cover Safety Switch 6 807 2103 Switch Micro 7 816 0220 Insulation RF Switch 8 806 8137 Bracket Switch Drain Assy 9 200 6496 Support Drain 3 Tube 10 810 1018 Valve 1 4 inch Drain 11 816 0135 O Ring Round Drain Seal 12 810 1165 Washer Teflon Drain Valve 2 5 2 4 2
4. Upd 104 626901 25 TR W e RR I 00 G 2 25 22 88 BB 86 a 335 MUNDO XDE OV 69908 XU amp 440 15813 1 47 1 18 4 FPGL30 Series Data Network Flowchart J Left CM7 1200 Pins 2 amp 3 J6 3 wire harness J7 NOTE Pins 2 4 3 Middle Harness be tested on any plug CM7 throughout the system J6 and should read 1200 3 wireihamass 3 wire harness The data network plugs J7 NOT USED on the boards can be swapped ie J6 and Right CM7 J7 on the CM7 3 wire harness J9 1200 283 J10 1 48 PROTECTOR SERIES GAS FRYERS CHAPTER 2 PARTS LIST 2 1 Accessories ITEM PART COMPONENT 1 803 0209 Brush Frypot 2 803 0197 Cleanout Rod 27 inch 2 810 2793 Hanger Basket 4 809 0171 Thumbscrew 14 20 X 1 inch Universal Hood use 809 0921 for Spacer 5 106 8930 Cover Frypot Full Vat 826 0993SP Handle Kit Frypot Cover includes handle and screws 6 803 0375 Basket Support Rack Full Vat m 803 0136 Basket Support Screen Full Vat screen w handle used in place of Item 6 7 803 0099 Basket Full Vat 8 803 0271 Basket Dual Vat Twin 9 230 2975 Connecting Strip Frypot 10 810 0478 Gas Line 1 Inch Dormont Flexible 80
5. Pump Motor Switch FootPrint PRO Schematic 1 23 1 10 6 Leakage Leakage of the frypot will usually be due to improperly sealed high limit thermostats RTD s temperature probes and drain fittings When installed or replaced each of these components must be sealed with Loctite PST56765 sealant or equivalent to prevent leakage In very rare cases a leak may develop along one of the welded edges of the frypot When this occurs the frypot must be replaced If the sides or ends of the frypot are coated with oil the most likely cause is spillage over the top of the frypot n n rather than leakage The clamps on the rubber boots that hold the drain tube sections together may loosen over time as the tubes expand and contract with heating and cooling during use o Also the boot itself may be damaged If the section of pote drain tube connected to the drain valve is removed for T sA reason ensure that its rubber clamps in good p condition and properly fitted around the drain tube when 18 itis reinstalled Also check to ensure that the drain tube runs downward from the drain along its whole length and has no low points where oil may accumulate 1 10 7 Basket Lift Malfunctions Protector series gas fryers may be optionally equipped s lt 100 120 Modular Basket Lift Assembly with automatic basket lifts to ensure uniform cooking P N 1061807SP T
6. A DANGER Instructions to be followed in the event the operator smells gas or otherwise detects a gas leak must be posted in a prominent location This information can be obtained from the local gas company or gas supplier A DANGER This product contains chemicals known to the state of California to cause cancer and or birth defects or other reproductive harm Operation installation and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers crystalline silica and or carbon monoxide Inhalation of airborne particles of glasswool or ceramic fibers is known to the State of California to cause cancer Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm A DANGER crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day Some food particles can spontaneously combust if left soaking in certain shortening material ZA WARNING Do not bang fry baskets or other utensils on the fryer s joiner strip The strip is present to seal the joint between the fry vessels Banging fry baskets on the strip to dislodge shortening will distort the strip adversely affecting its fit It is designed for a tight fit and should only be removed for cleaning NOTICE The Commonwealth of Massachusetts requires any and
7. 810 3368 Four Station Fryer 2 23 2 12 ATO Auto Components 2 121 JIB Jug In Box Low Indicator Light Assembly J 9 2 Qu 106 9033 Protector JIB Light Assembly ITEM PART COMPONENT 1 106 8105SP Light Yellow 24VDC LED Flush 2 230 4142 Bracket Protector Light 2 12 2 ATO Automatic Top Off Board 106 9613 120V Assy or 106 9614 208 240V Assy ITEM PART COMPONENT 1 106 9258 Box Assembly Auto Top Off 2 Board RTD 2 816 0771 Seal Top Off Board 3 106 9611 PCB Board Automatic Top Off 2 RTD 4 807 1999 Transformer Dual Voltage 208 240V 807 2176 Transformer Dual Voltage 120V 5 220 4352 Cover Top Off Board 3 4 or 5 Vat 220 3987 Cover Top Off Board 2 Vat 807 3575 Plug Carling Switch Hole Not illustrated 2 24 2 12 3 Automatic Solenoid and Pump Assemblies ITEM PART COMPONENT 1 106 96805 Pump 1 4 FNPT 12VDC 19PSI 15 1GPH 2 106 8477 Solenoid Manifold Assembly GL30 3 includes three solenoid assemblies 3 106 8014 Solenoid Manifold Assembly GL30 6 includes six solenoid assemblies 4 807 4590 Solenoid 5 813 0940 Elbow NPT x Flare 6 816 0708 Fitting NPT x Male Barb 7 816 0710 Fitting 4 x Barb 90 8 813 0640 Plug SQ HD BM 9 807 4493 Switch Momentary Flush 811 1139 Tubing Braided Silicone 20 inch s 810 3375 Flexline gt OD x 17 inch use
8. Perform steps 1 through 4 from section 1 9 1 Disconnect the wires attached to the interface board marking or making a note of the wires and terminals to facilitate reconnection Remove the nuts at each corner of the interface board and carefully pull it from the studs far enough to allow the connector on the back of the board to be disconnected then remove the board from the box When removing the board be careful not to lose the spacers that fit over the studs behind the board Recover the relay s from the failed interface board and install on the replacement board Reverse the procedure to install the replacement board being sure that the spacers behind the board are in place Reverse the steps to reinstall the computer 1 8 1 9 4 Replacing an Ignition Module Disconnect the fryer from the electrical supply Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame Remove the top two screws in the upper corners of the computer Swing the computer out from the top and allow it to rest on its hinge tabs Disconnect the wires from the ignition module marking or making a note of the wires and terminals to facilitate reconnection Remove the four ignition module screws and pull the module from the component box Move the spacers to the new module 8 Reverse the procedure to install the replacement module ka M A A no 1 9 5 Replacing an Ignitor Assembly A DANGER Drain the
9. Wired incorrectly Hlexlines connected to wrong vat Check wiring Switch flexlines to correct vat 1 30 1 13 2 Automatic Board Pin Positions and Harnesses Connector From To Harness Pin Function Voltage Wire Color 1 Output DV Vat 1 Green 2 Output FV Vat 1 Red 1 8074718 FV 3 Output DV Vat 2 Green Solenoids Ground 8074717 DV 4 Output FV Vat 2 Red 5 Output DV Vat 3 Green 6 Output FV Vat 3 Red Top Off Pump 8074719 r Top Off Pump 16VDC Red J8 JIB Reset Switch 8 JIB Low Reset Black 9 24VAC DV Vat 1 White 10 24VAC FV Vat 1 Black 8074718 FV 11 24VAC DV Vat 2 White Solenoids 24 8074717 DV 12 24VAC FV Vat 2 Black 13 24VAC DV Vat 3 White 14 24VAC FV Vat 3 Black Top Off Pump amp JIB 15 Reset Switch 8074719 16 Ground 16VDC Rad 1 24VAC Ret 24VAC Orange 2 24VAC Blue 3 y pim Transformer 8074553 4 5 12 Ret 12VAC Red 6 12VAC Brown 7 8 1 DV Probe Ground White J1 Vat 1 8074655 Vat 1 2 DV Prob Red J2 Vat 2 ATO RTD 8074654 Vat 2 J3 Vat 3 8074654 Vat 3 3 EV Probe Ground White 4 FV Probe Red J6 Orange LED 8074555 1 H6vDC 16vDc Black 2 16VDC Ret Red 1 2 J7 3 Ground 4 RB7 DAT
10. 809 0953 Bolt 20 x inch Hex Head gt 807 1926 Bushing 875 inch Split 809 0514 Capscrew 5 16 inch 18 NC Hex 809 0448 Clip Tinnerman 826 1351 Nut Retainer 4 20 Pkg of 10 for basket hanger thumbscrew Std Fluecap 809 0171 Thumbscrew 20 x 1 inch for use on Standard Fluecap 826 1366 Nut 4 40 Keps Hex Pkg of 25 809 0237 826 1358 Nut 6 32 Keps Hex Pkg of 25 809 0049 809 0247 Nut 8 32 Keps Hex 809 0052 Nut 10 24 Hex 826 1376 Nut 10 32 Keps Hex Pkg of 10 809 0256 809 0766 Nut 10 32 Keps Hex SS 809 0581 Nut NPT Locking 809 0020 Nut Cap 10 24 NP 826 1372 Nut Grip 4 20 Hex NP Pkg of 10 809 0059 809 0417 Nut Flange 4 inch 4 20 Serr 809 0535 Nut T inch 20 7 16 SS 809 0495 Nut inch 20 Press 809 0804 Nut inch 20 Keps Hex 826 1362 Nut 74 20 Hex Pkg of 10 809 0071 809 0540 Nut Lock 13 Hex 2 Way ZP 809 0656 Screw 4 40 X 3 8 inch Slotted Round Head 826 1359 Screw 4 40 inch Slotted Round Head Pkg of 25 809 0354 826 1365 Screw 6 32 x inch Slot Head Pkg of 25 809 0095 809 0098 Screw 6 32 x 1 inch Slotted Round Head 809 0357 Screw 6 x inch Phillips Head NP 809 0359 Screw 8 x 4 inch Hex Washer Head 809 0360 Screw 8 x inch Hex Washer Slot Head 826 1371 Screw 8 x Hex Head ZP Pkg of 25 809 0361 809 0364 Screw 8 x inch Hex Washer Head ZP 809 0441 Screw 8 x 1 i
11. AD on the left numbers count up on the right The computer displays OB F C RC If updating ATO software the computer will display EU U on the left and will count down from 2500 on the right When the update is complete the CM7 displays D NE on the left and RM SDCRDon the right Remove the SD card using the fingernail slot on the top of the SD card Repeat steps 1 8 for all computers 10 Remove ALL power from the fryer on the rear of the unit 11 Restore power to the fryer There is short delay prior to the computer powering up and displaying OFF 12 With the computer displaying F F verify software update by pressing the TEMP button to check updated CM7 ATO version Figure 4 Figure 5 1 38 1 16 Principal Wiri ng Connections LINE VOLTAGE L1 GROUND LINE VOLTAGE COM AIR PRESSURE SWITCH CE AND SOME EXPORT UNIT BLACK GREEN WHITE 5 TO Tt amp J3PIN 1 TO GROUND TO T2 amp PIN 1 2AVAC RED TO J1 PINS amp J3PIN8 FROM TRANSFORMER BOX ANAC ANAC HOOD RELAY ORANGE TO J3 PINS BLUE TO PIN1 WHITE BLACK TO J3 PINS 12VDC LINE VOLTAGE L1 LINE VOLTAGE COM FROM TRANSFORMER BOX HEAT STRIP FILTER PUMP FILTER PUMP SOLENOID C1PIN1 C1PIN3 Tz C2PIN1 C2PIN 3 C2PIN 12 IN COMPONENT BOX FULL VA
12. COMPUTER LT HT RELAY gt s gt COMPUTER RT BL RELAY gt NOT USED NOT USED 8 Dual Vat configurations computer S LTBLREWY _ gt Full Vat configurations ALR RIGH RT ALARM OUT COMPUTER SOUND DEVICE gt LT ALARM OUT AD LEFT 12 COMPUTER 48 PING gt du COMPUTER J1 PINZ amp J3PIN2 1 lt COMPUTER gt NOT USED NOT USED 12VAC XFMR 1 WI TEMP PROBE J2PIN14 JZPIN14 TEMP PROBE gt 2 gt z NOT USED NOT USED J2PIN3 12VAC XFMR 3 gt gt NOT USED NOT USED NOT USED NOT USED 4 4 NOT USED NOT USED NOT USED NOT USED TEMP PROBE ELE J2PIN13 TEMP PROBE gt s gt _ PASKET LIFTON lt TBLREAY RTBLREAY gt BASKET LIFT DN p NOT USED PWR via RT HT RELAY 24VAC IN NOTUSED__ 3 SH 9 VIS OR VID MAIN GAS VALVE mgpa lt eee BASKET LIFT LT BL RELAY RTBLRELAY BASKET em 10 lt gt NOT USED NOT USED BLOWER via old 120VAC IN a lt KO nen sh 426 NOT USED NOT USED BLOWER n XEMR BOX 12 gt 2 MODZ6V GROUND GROUND GROUND p 25 GROUND Aa res ELS BERR al MOD25V TERM A PIN 8via LT HT RELAY J3PIN8 via RT HT RELAY MOD25V TERM lt gt pwr DRAIN SWITCH OP corn emia lt mio 4 DRAN SWITCH oem NOT USED NOT USED SPINS MOD ve AS lt vs lt NOT USED NOT USED CURRENT FLOW THROUGH INTERFACE BOARD 106 6706 SMT HE SERIES APPLICATION 1 3
13. Drain Tube Sections and Associated Parts See Section 2 4 1 for Drain Valves oc ITEM PART COMPONENT 1 823 6610 4625 Drain Tube Full Vat Left Closed Right End Open 823 6467 Drain Tube Dump 6130 823 6615 Drain Tube Dump GL230 823 6611 Drain Tube Full Vat Right Left Open Right End Open 823 6612 Drain Tube Full Vat Center Left Open Right End Open 6 823 6614 Drain Tube Full Vat GL230 Right Left Open Right Closed Short 7 823 6613 Drain Tube Full Vat Right Left Open Right Closed Long 8 816 0772 Sleeve 9 809 0969 Clamp 10 810 2493 Elbow 4 inch x 90 Tube Comptession 811 1071 Tube 14 inch OD Teflon Manifold Vent 816 0630 Vinyl Not illustrated 2 6 2 5 2 5 1 Electronics and Electrical Components Component Boxes Pan PS O C Hong Kong Units Left module is not present in full vat units See NOTE 1 on Page 2 8 2 5 1 Component Boxes cont ITEM PART COMPONENT 810 1164 Block One Piece Screwless Terminal 2 816 0217 Insulation Terminal Block Paper 3 807 3843 Fuse 3A 250V Domestic 807 3293 Fuse 5A 125V International Only 4 807 3483 Cable 21 inch Ignition For 807 3366 3365 Modules 826 2024 Cable Ignition 1 wire 1 Rajah 826 1721 Cable Ignition 2 wire 2 Rajah 807 1878 Cable Ignition 19 and Australia 807 1200 Cable Ignition 27 5 807 3484 Conn
14. Inadequate make up air Heat damaged computer or ignition module e Cracked ignitor or broken ignition wire Defective ignition module Cracked burner tile typically causes a very loud pop If popping occurs only during peak operating hours the problem may be incorrect or fluctuating gas pressure Verify that the incoming gas pressure pressure to the gas valve is in accordance with the appropriate CE or Non CE Standard found in Section 2 3 page 2 4 of the Protector Series Gas Fryer Installation and Operation Manual PN 819 6339 and that the pressure remains constant throughout all hours of usage Refer to Section 1 7 Checking the Burner Manifold Gas Pressure in this manual for the procedure for checking the pressure of gas supplied to the burner If popping is consistent during all hours of operation the most likely cause is an insufficient air supply Check for negative pressure conditions in the kitchen area If air is flowing into the kitchen area this indicates that more air is being exhausted than is being replenished and the burners may be starved for air If the fryer s gas and air supplies are correct the problem is most likely with one of the electrical components Examine the ignition module and computer for signs of melting distortion and or discoloration due to excessive heat build up in the fryer this condition usually indicates improper flue performance A melted or distorted ignition module is automatica
15. VAC to left ignition module dual vat only TET 24 VAC from transformer s 24 to right ignition module L a 24 VAC to gas valve right valve if dual vat ET ev 12 VAC from transformer kaz CE and Japanese units only air switch closed ADM 5 GND m mmGND IGNDm mPWRD2 HEAT HEAT IVS gh RELAY RELAY at PWR AND AND a D4 m 388 BLOWER BLOWER MOTOR MOTOR RELAY ko RELAY PWR SMT INTERFACE BOARD KIT 826 2264 106 6706 NOTE In full vat fryers the relay for the left side K2 may not be present The chart on the following page illustrates current flow through the board and the table at the top of page 1 4 identifies frequently used test points 1 2 INTERFACE BOARD 12 VACTOCPTR ELE 1 GROUND 5 GROUND COMPUTER 12 VAO gt 5 COMPUTER RTHT RELAY gt COMPUTER _ _12VDCTORELAYS
16. a defective sensing wire in the ignitor assembly a defective module a defective ignition wire and a defective ignitor 1 19 Occasionally an ignition failure situation occurs in which all components appear be serviceable and the microamp reading is within specification but the unit nevertheless goes into ignition failure during operation The probable cause in this case is an intermittent failure of an ignition module When the unit is opened up for troubleshooting the module cools down enough to operate correctly however when the unit is again closed up and placed back into service the module heats up and fails PROBLEMS RELATED TO THE GAS VALVE If the problem is not in the 24 VAC circuit it is most likely in the gas valve itself Before replacing the gas valve refer to Section 1 11 2 TROUBLESHOOTING THE GAS VALVE 1 10 2 Improper Burner Function With problems in this category the burner ignites but exhibits abnormal characteristics such as popping dark spots on the burner ceramics fluctuating flame intensity and flames shooting out of the flue Popping indicates delayed ignition In this condition the main gas valve is opening but the burner is not immediately lighting When ignition does take place the excess gas explodes into flame rather than smoothly igniting The primary causes of popping are e Incorrect or fluctuating gas pressure Defective or incorrectly adjusted combustion air blower
17. a mallet and short piece of wood tap the corner tabs of the combustion chamber over the insulation to ensure a solid seal of the burner Install the upper burner rails 2 with the heat deflectors slanting toward the rear of the frypot The rails will cover the L shaped pieces of combustion chamber insulation previously installed Place the upper inner combustion chamber insulation and insulation retainers 3 on the top two studs on each side of the front of the frypot and secure with 4 20 washer nuts It is normal for the retainers to slice off the overhanging insulation Place the lower rear combustion chamber insulation 4 on the lower four studs at the rear of the frypot Place one 1 625 inch tubular spacer 5 on each of the flue assembly upper studs at the rear of the frypot NOTE There are three different sizes of spacers Verify the size to ensure the correct spacers are installed Press the flue assembly 6 over the burner rails It may be necessary to use a rubber mallet or screwdriver to align the components Use four 4 20 washer nuts to secure the flue assembly Do not tighten the retainer nuts at this point They should be finger tight only NOTE The edge will cover one to two inches of the lower insulation Install the lower rear combustion chamber back s and retainer s 7 with the flanged edge s against the flue Secure with 20 washer nuts NOTE Full vat units have two piece b
18. all gas products to be installed by a licensed plumber or pipe fitter iii PROTECTOR SERIES GAS FRYERS TABLE OF CONTENTS CAUTIONARY STATEMENTS CHAPTER 1 Service Procedures 1 1 Functional Description 5 12 Electronic Ignition System 21 1 13 Interface Board 2 14 Thermostats 4 1 5 Accessing Fryers for Servicing 4 1 6 Cleaning the Gas Valve Vent Tube 5 1 7 Checking the Burner Manifold Gas Pressure 5 1 8 Measuring Flame Current 1 7 1 9 Replacing Fryer Component 1 7 9 1 Replacing the Controller or the Controller Wiring Harnes 7 92 Replacing the Temperature Probe or High Limit Thermostat 1 8 19 3 Replacing the Interface Board 21 8 9 4 Replacing an Ignition Module 1 9 9 5 Replacing Ignitor Assembly 9 9 6 Replacing or Cleaning a Combustion Air Blower 10 97 Adjusting the Air Gas Mixture 11 9 8 Replacing Gas Valve 12 9 9 Replacing a Burner Assembly 13 910 Replacing the Filter Motor Filter Pump or Filter Pump Solenoid Valve 14 94 Replacing the Frypot 14 9 12 Replacing Frypot Insulation and or Upper Burner Rails 16 1 10 Troubleshooting and Problem Isolation 19 10 Ignition Failure 19 10 2 Improper Burner Function 20 10 3 Improper Temperature Control 21 10 4 Computer Malfunction 22 10 5 Filtration Malfunctions 22 1 10 6 Lea
19. ignition by measuring the flow of microamps through the flame If the burner does not light or is extinguished current to the ignition module is cut the gas valve closes and the ignition module locks out until the power switch is turned off and then back on A probe monitors the temperature in the frypot When the programmed setpoint temperature is reached resistance in the probe causes the heat cycle circuitry in the computer to cut off current flow through the heat relay This in turn cuts off the 24 VAC to the ignition module causing the gas valve to close 1 3 Interface Board All fryers in this series have an interface board located in the component box behind the control panel The interface board provides a link between the computer and the fryer s individual components without requiring excessive wiring and allows the computer to execute commands from one central point K2 and K3 are double pole double throw DPDT relays that supply 24VAC to the ignition and gas valve circuits as well as 120VAC to the blower motor The relays on this board plug into sockets If a relay fails that relay can be replaced LEDs labeled D1 through D7 are arrayed around the board to assist in troubleshooting d t SAME D7 INTERFACE BOARD wk rasoo T Dira LED DIAGNOSTIC LIGHTS 5068 JA B UD 24 VAC to left gas valve dual vat only 2 0 08 24
20. is directly heated by a high efficiency infrared burner system requiring approximately 43 less energy than conventional burners to cook the same volume Self contained combustion chambers referred to as burners are fitted into rails attached to the sides of the frypot one on each side Each combustion chamber is fitted with special ceramic tiles that are heated by the burning of a forced air gas mixture The tiles transfer heat to the frypot by means of infrared radiation providing much more constant and uniform heat dispersion over the surface of the frypot than do conventional burners Because less heat is lost to the atmosphere in the process compared to open burner designs less fuel is required to achieve and maintain a given frypot temperature In full vat units gas flow to both of the burners is regulated by one electromechanical gas valve All fryers in this series are equipped with 24 VAC gas valve systems and all are configured with electronic ignition 12 The Electronic Ignition System An ignition module mounted in the component box Inside the Ignition Module located behind the control panel is connected to an ignitor assembly at the burner The ignition module eda performs four important functions it provides fuse protection for the 24 volt circuit provides an ignition spark supplies voltage to the gas valve and proofs the burner flame The module contains a four second time delay circuit and a coi
21. tested pins to ground 1 If resistance is not 5 mega Ohms or greater in each pin the probe has failed and must be replaced 2 If resistance is 5 mega Ohms or greater in each pin the probe is okay 1 11 4 Replacing the Transformer or Filter Relay Disconnect the fryer from the electrical power supply Remove the cover from the transformer box in the rear of the fryer to expose the interior of the transformer box Replace the transformer or filter 1 28 relay marking the wires to ease reassembly Once replaced reconnect the power When replacing a filter relay in the transformer ensure the 24VAC relay 8070012 is used Filter Pump Transformer Filter Relay 12V Computer 24V Ignition System Transformers 1 12 Probe Resistance Chart Probe Resistance Chart For use with Protector Series SETI manufactured with Minco NIE probes only F OHMS c OHMS c OHMS E OHMS F OHMS 60 1059 16 130 1204 54 200 1350 93 270 1493 1 340 1634 171 65 1070 18 135 1216 57 205 1361 96 275 1503 135 345 1644 174 70 1080 21 140 1226 60 210 1371 99 280 1514 138 350 1654 177 75 1091 24 145 1237 63 215 1381 102 285 1524 141 355 1664 179 80 1101 27 150 1247 66 220 1391 104 290 1534 143 360 1674 182 85 1112 29 155 1258 68 225 1402 107 295 1544 146 365 1684 185 90 1122 32 160 1268 71 230 1412 110 300 1554 149 370 1694 188 95 1133 35 165 1278 74 235 1422 113 305 1564 152 375 1704 191 100 1143 38 170 1289 77 240 1432 116 310 1574 154 380 1714 193 1
22. the frypot during the recovery process will also cause a slow recovery rate If these causes are ruled out the probable cause is a misadjusted gas valve regulator Refer to Section 1 7 Checking the Burner Manifold Gas Pressure for the gas valve adjustment procedure 1 10 3 Improper Temperature Control Temperature control including the melt cycle is a function of several interrelated components each of which must operate correctly The principle component is the temperature probe Other components include the interface board the computer itself and the ignition module 1 21 Improper temperature control problems be categorized into melt cycle problems failure to control at setpoint problems MELT CYCLE PROBLEMS Initiation of the melt cycle with CM7 computers is automatic Problems may originate from the computer itself the temperature probe or a malfunctioning heat relay on the interface board FAILURE TO CONTROL AT SETPOINT Problems in this category may be caused by the temperature probe the interface board or the computer 1 10 4 Computer Malfunctions RECOVERY TIME Recovery time is a method of measuring a fryer s performance Put simply it is the time required for the fryer to increase the oil temperature from 250 F to 300 F 121 C to 149 C This range is used as a standard since ambient kitchen temperatures can affect the test if lower ranges are used The CM7 computer performs the recover
23. 05 1154 41 175 1299 79 245 1442 118 315 1584 157 385 1724 196 110 1164 43 180 1309 82 250 1453 121 320 1594 160 390 1734 199 115 1174 46 185 1320 85 255 1463 124 325 1604 163 395 1744 202 120 1185 49 190 1330 88 260 1473 127 330 1614 166 400 1754 204 125 1195 52 195 1340 91 265 1483 129 335 1624 168 405 1764 207 1 13 ATO Automatic Top Off Service Procedures The automatic top off system is activated when the oil level falls below a sensor in the rear of the frypot The signal is sent to the ATO board to engage the solenoid to the frypot and turn on the ATO pump The pump draws oil from the JIB Jug In Box to a port in the rear of the frypot Once the oil level has satisfied the sensor the pump and solenoid turn off The ATO board is located inside the box behind the JIB see Figure 1 The power for the ATO board is supplied from the transformer box The power passes through the transformer inside the ATO box to the board Figure 1 1 29 1 13 1 ATO Automatic Top Off Troubleshooting Problem Probable Causes Corrective Action The yellow JIB low light won t illuminate w Power not present in the transformer box Failed transformer Loose wire connection Ensure power is present in the transformer box If power is present in transformer box check the transfor
24. 1025 Connector 14 inch Male NPT to inch Tube 23 810 1026 Tee inch Male NPT to Female NPT Street 24 813 0700 Nipple 14 inch NPT x 3 inch 25 810 0691 Tube inch Vent 2 20 2 10 Filtration System Components 2 21 2 10 Filtration System Components cont ITEM PART COMPONENT 1 823 6616 Lid Multi Vat Fryers Standard Size Filter Pan 823 6333 Lid Two Vat Fryer Half Size Filter Pan 2 810 2874 Crumb Tray Standard Size Filter Pan 3 4 and 5 Vat 810 3288 Crumb Tray Two Vat Fryer Half Size Filter Pan 3 810 2091 Hold Down Ring 13 65 x 21 41 Standard Size Pan 3 4 and 5 Vat 810 3289 Hold Down Ring 11 20 x 19 10 Two Vat Fryer Half Size Filter Pan 4 812 2024 SanaGrid Filter Screen Standard Size Filter Pan 812 2041 SanaGrid Filter Screen Two Vat Fryer Half Size Filter Pan 5 106 8677 Pan One Piece Filter Standard Size 106 8211SP Pan Two Vat Fryer Half Size 826 1392 O Ring Pkg of 5 used with Item 5 813 0568 Plug inch Socket Head Pipe used with Item 5 two required 6 823 3879 Suction Tube Standard 823 6458 Suction Tube Two Vat T Motor and Gasket Kit 826 1785 100V 50 60 Hz 826 1712 115V 50 60 Hz 826 1756 208V 50 60 Hz 826 1270 220 240V 50 60 Hz 826 1755 250V 50 60 Hz 8 826 1264 Pump and Gasket Kit 4 GPM 816 0093 Gasket Pump Motor 807 11973 Viking Pump Seal Kit 809 1020 Cap Screw 5 16 inch 18 5 50 NC Hex Connects pump to motor 9 811 1071 Tube 4 i
25. 6 1698SP 36 Inch for gas line only w o Items 11 and 12 use 810 0088 806 1699 48 Inch for gas line only w o Items 11 and 12 use 810 0085 11 810 0074 Quick Disconnect Fitting 1 Inch Male 12 810 0073 Quick Disconnect Fitting 1 Inch Female 13 826 0900 Kit Chain Restraint 14 826 1045 Bushing Flexible Gas Line 813 0032 15 810 0070 Coupling Gas Line Female Quick Disconnect inch 810 0073 Coupling Gas Line Female Quick Disconnect 1 803 0170 Filter Pack Paper 100 Sheets 803 0002 Powder Filter 80 1 Cup Application Packages 826 1157 Kit Fuse and Fuse Puller 2 Fuses Not illustrated 2 1 2 2 Basket Lift Assembly Associated Parts 10 ueeq sey r eq 1sntu L ZZ 901 9 J0jsis8 y A0SZ 90Z 104 peoejdai eq 450658 908 Alqwesse 2015152 y 10 paoejda sq 992 108 1olSISe SHUN 021 001 104 Z Ajeye1edes eq pZ G Jo jou 052 802 dS0181 901 Pue AOZ1 00L 57081 90 5 SALON r a gt lt ASS SS W ELS ERI 2 2 2 2 Basket Lift Assembly and Associated Parts cont ITEM PART COMPONENT 1 200 2942 Mount Mod
26. 7 18 4 FPGL30 Series Data Network Flowchart 1 48 CHAPTER 2 Parts List 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 ACCESSORIES wi Basket Lift Assemblies and Associated Parts Doors Sides Flue Caps Top Caps and Casters Drain System Components 2 4 Drain Valves and Associated Parts 2 4 2 Drain Tube Sections and Associated Parts Electronics and Electrical Components 2 5 Component Boxes 2 5 2 Transformer Boxes 2 5 3 Computers and Associated Components Wiring 2 6 Main Wiring Harnesse 2 6 2 CM7 and ATO Wiring Harnesses Frypots and Associated Components 22 Full Vat Frypot Components 2 7 2 Frypot Assemblies and Associated Parts Gas Supply and Combustion System Components Gas Valves and Associated Components Filtration System Components Return Valve Assembly and Associated Parts ATO Auto Top Off Components 2 12 1 JIB Jug In Box Low Indicator Light Assembly 2 12 2 ATO Automatic Top Off Board 212 3 ATO Automatic Top Off Solenoid and Pump Assemblie 2 124 JIB Cradle JIB BIB Cap and Pick Up Assembl Wiring Connectors Pin Terminals and Tools E IN THIS PAGE INTENTIONALLY LEFT BLANK PROTECTOR SERIES GAS FRYER CHAPTER 1 SERVICE PROCEDURES 11 Functional Description Protector series gas fryers contain a welded stainless steel frypot that
27. 795 Frypot Assembly Full Vat Protector LP 2 106 9025SP Valve Drain Assy FV 3 826 2569 Probe RTD and Fitting Kit 4 807 0678 Temperature Probe 210 0681 Probe Guard 5 826 1177 Thermostat High Limit 425 F 218 C Not illustrated 2 16 2 8 Gas Supply and Combustion System Components See pages 2 14 through 2 15 for burners and burner insulation part numbers FPGL30 Full Vat Gas Manifold Typical The example illustrated is typical of FPGL30 Protector Series Fryer Gas Manifolds Each manifold is assembled from standard 1 2 3 4 and 1 inch NPT black iron pipe nipples elbows tees plugs and unions which may be locally acquired See page 2 19 and 20 for details of gas valves and related components 2 17 2 8 Gas Supply and Combustion System Components cont ITEM PART COMPONENT 1 Ignitor includes gasket 816 0059 which may be ordered separately 826 0981 Natural Gas G20 G25 826 0982 Propane G30 G31 826 1002 Manufactured Gas 2 Blower Assembly Combustion Air includes harness and Items 4 and 5 106 2996SP 100 50 60 Hz Left 106 2999SP 100V 50 60 Hz Right 106 2994SP 115V 50 60 Hz Left 106 2997SP 115 50 60 Hz Right 106 2995SP 208 240 50 60 Hz Left 106 2998SP 208 240V 50 60 Hz Right 106 3000SP 230V 50 60 Hz CE Left 106 3001SP 230V 50 60 Hz CE Right 3 816 0554 Cover Blower Motor component of all blower
28. 8 FUSE m f e CEN NOTE Some units may LED 3 24V be wired in this manner Heat Relay K3 Replaceable Y IGNITION I LED 4 PWR MODULE PWR right side V1S b Left Flame High Voltage Sensor IGNITION to Left Ignitor PWR left side Right Flame MODULE High Voltage Sensor to Right Ignitor Jumper 25 V1D Ha LED 5 GV ED 5 GV NA J3PIN9 J3PIN9 HIGH LIMIT SWITCH DRAN SAFETY SWITCH 1 27 1 11 2 Troubleshooting the Gas Valve Prior to checking for problems associated with the gas valve ensure that the unit is calling for heat Also for non CE units verify that the gas valve is in the ON position The following processes will assist you in troubleshooting the gas valve and ruling it out as a probable cause If 24 VAC is not present across gas valve main coil the probable cause is the 24 VAC circuit Refer to the 24 VAC circuit troubleshooting guide If 24 VAC is present across gas valve main coil check the incoming gas pressure and compare to the tables on page 2 4 of the Installation and Operation manual 1 If incoming gas pressure is not correct the probable cause is a problem with the gas supply to fryer 2 If incoming gas pressure is correct check the burner manifold gas pressure and compare it to the tables on page 2 7 of the Installation and Operation manual a If burner manifold gas pressure is not correc
29. 9 11 e burner assemblies 1 nsulation retainers and blanket insulation 2 e upper oil zone insulation bracket and upper oil zone insulation 3 e plenum 4 Remove the front lower combustion chamber insulation retainer and insulation 5 and the front lower combustion chamber inner insulation retainer and insulation 6 NOTE Full vat units have two piece insulation retainer and insulation components Dual vat units have one piece components 7 Remove t Remove t 9 Remove 0 66 upper combustion chamber insulation retainer and insulation 7 inner upper combustion chamber insulation retainer and insulation 8 he rear lower combustion chamber retainers back and insulation 9 NOTE Full vat units have two piece backs and four retainers Dual vat units have one piece backs and two retainers 10 Remove t e flue assembly 10 Disassembling Frypot Full Vat Illustrated See page 1 18 for reassembly illustration 20 21 22 23 24 25 26 27 28 29 Remove the upper burner rails 11 NOTE For the following steps refer to frypot exploded view on page 1 16 for component identification Remove any residual insulation sealant and or oil from the exterior of the frypot Place the L shaped pieces of the combustion chamber insulation 1 in the front and rear corners of both upper rail retaining slots See page 1 16 Using
30. A 5 RB6 CLOCK 8074552 1 Ground Black Network Resistor Network Resistor 2 CAN Lo Red J10 pins 2 8 3 3 CAN Hi White or to next ATO Board 8074546 4 4 amp 5 vat units to next ATO board 5 6 1 Ground Black 2 CAN Lo Red J9 CM7 J6 J7 8074646 CAN Hi White 5 6 1 31 1 13 3 Replacing the ATO Board or Transformer Disconnect the fryer from the electrical power supply Locate the ATO box see Figure 1 page 1 29 behind the JIB Jug In Box Remove the cover to expose the transformer and ATO board see Figure 2 Mark and unplug any wires or harnesses Replace the defective component and reattach all wires or harnesses Replace the cover Once replaced reconnect the power Remove and restore power to ALL computers after power has been restored to the ATO board 1 13 4 Replacing the ATO Pump or Solenoid Disconnect the fryer from the electrical power supply Locate the ATO pump and solenoid tree see Figure 3 behind the ATO box Mark and unplug any wires or harnesses Replace the defective component and reattach all wires or harnesses Once replaced reconnect the power 1 14 CM7 Computer Service Procedures 1 14 1 CM7 Computer Troubleshooting Figure 3 Problem Probable Causes Corrective Action No Display on A Computer not turned on Press the ON OFF switch to Computer turn the computer on B No power to the fryer If the computer power cord is not plugged in the computer will
31. AT J 2 L m sen BLOWER INSET HONG KONG UNITS ONLY 8051315 8051526C Refer to PRINCIPAL WIRING CONNECTIONS on Page 1 39 for detail of connection points J1 J2 J3 1 40 TEMP PROBE U en GAS VALVE 1 17 2 Transformer Filter Boxes 1 17 2 1 FPGL230 and 430 Transformer Filter Box Domestic GRN YEL 80517228 STSTZTSTS TA T3T2 TL une STSTTSTS TA T3TZ HT p euue 120V CONFIGURATION SHOWN 180 BLUE RED 17C ORG GREEN S ST8T7TSTS 4T V2 iT 146 GRN YEL asc soc WHT I ST8T7TeTs 4 T3 2 T3 sc onc 40 RED 1 41 330 Transformer Filter Box Domestic 1 17 2 2 serere aoa EZ HIMOd NIOHS NOWWUNDLNOD d p
32. I sc LI 1010 125 4 L 125uF ER dh t 2 US d 1000hm 98C 96C L 95 97C 100C 22 2g z 8 8 UPPER UPPER SWITCH SWITCH 2 22 8 5 8 8 LOWER z LOWER SWITCH SWTCH 32C 4C 29C 10C ZN ZN ZN ZN 12 n 10 9 8 7 6 5 4 3 2 1 O x gt w x m REFERENCES LEFT amp RIGHT ARE 8050946B FROM THE REAR OF THE FRYER 1 44 Simplified Wiring Diagrams 1 18 FPGL30 Series Full Vat 1 18 1 Dap 351 3 dNAOS SOVITONSNIT pt lt E 2 1 Hai i NOILINDI 5 8 SLINN anos 39 NO NO ATNO HOLIAS HIV m 7300 m Am 0 19dd NO AINO HOLIMS 134 5 35V 110A INIT NOLLONNA 41MGOW MYVdS 1VNG 1 531935 0 19d4 1 45 1 18 2 FPGL30 Series Full Vat Australia and Pacific Rim aNnos 1 a zi SOVITOA w PI Sy yu Kasa sal gt 4 L HO HOLINDI eld gt lt 1 1 I 1 1 1 Sr l 4 anaon zB NOILIND H9 1H anaon 1431 SLINN LHOdX3 3NOS HOL
33. IMS HIV WIH OIHIOVd ANY VITVHLSNV LVA T1IN4 5 5 06 TOd4 1 46 1 18 3 FPGL30 Series Simplified Wiring azacisos anon air ika ET XX ar pn Dar 1 1 IM E L U aw arer er 9595208 er mu tvog Em 30VA831NI ua 01 er er 7105 SX n g NI 1060601 73 480801 Nid 9 JSNOILWIO7 019 OLY 384080 24 D 3 GBLSYWAUA 5870801 19 31891 330 401 HOLIAS EIF 6149108 5049501 5019201 5 011509 A4 815 08 v 214891 OEM Ww wa eG 9 9 app a nasa civ wm s S xoa 4a dni 00238 Dl 81 9 0389 gt L IH D NE E NIE xewsamz I T a Berg E THA 6 T X08 19 1 alan T 1 41043705 Sv 395 Tass 440 401 E ng 2 coJoo TAR 60 GP cerze 40 T Ee T 10d 104 er xog xawanasnva ZI SF UT we e srl 40 01 5 501334402 sa w
34. Pump or Filter Pump Solenoid Valve 10 11 12 13 14 15 Disconnect the unit from the electrical power supply Remove the filter pan from the unit Position a container beneath the oil return fitting at the front of the cabinet Disconnect the flexible oil line from the fitting allowing any residual oil to drain into the container At the rear of the fryer unplug the left connector as viewed from the rear of the fryer from the transformer box Remove the four nuts and bolts attaching the motor mount to the rear motor mount support At the front of the fryer remove the cover plate from the front of the motor and disconnect the motor wires Place a 1 foot 30 5 cm length of wood or similar support beneath the motor mount near the front of the unit and remove the two remaining nuts and bolts attaching the motor mount to the front cabinet cross brace Carefully remove the support and lower the motor mount to the floor allowing the rear of the mount to slide forward and off the rear motor mount support Disconnect the return flexline from the pump The motor and pump assembly can now be pulled from beneath the fryer and the failed component can be removed and replaced Position the replacement motor and pump assembly beneath the fryer and reconnect the oil return flexline to the pump Lift the rear of the motor mount up and onto the rear motor mount support Lift the front of the motor mount up and support it with a 1 fo
35. T FROM 22 FROM 3 COMPUTER 12VAC C1PIN 6 12VAC J2PIN1 GROUND GROUND PROBE O J2PIN14 33PIN3 coweureR C1PIN5 12VAC O 2 COMPUTER RELAY K2 COMPUTER G RELAYS 1200 amp J3 PINS Pns Q c1PIN7 COMPUTER O ks ks L Q 2 15 DOWN C1PIN4 24VAC RS RA ccm ALR RIGHT 69 RIGHT ALARM OUT FULL VAT Ks 69 2 14 81 UP computer TEL SOUND DEVICE BLOWER via Ka AD LEFT O LEFT ALARM OUT DUAL VAT 69 cspn2 JBPING gt COMPUTER stpN2ssspn2 6 computer GROUND GROUND 5 computer MODULE VALVE 1 DUAL VAT vi seis J3PIN8 VIA 2 MODULE 25v OPTIONAL DRAIN SWITCH ALR J2PIN10 MODULE VALVE 1 FULL VAT viS J3PIN9 1 39 1 17 Wiring Diagrams not present here on 1 17 1 Main The Heat Strip is 330 s TO TRANSFORMER BOX gt 955550047 IE COMPUTER um FILTER PULP SOLENOID PUMP S SZCZ SOUND DEVICE FULL VAT 5 gM L FNI MS CM Ell N FULL V
36. YPICAL times Basket lifts will always come in pairs although each operates independently of the other A modular basket lift consists of a toothed rod to which the basket lift arm is attached a reversible drive gear motor and a pair of roller activated microswitches A gear on the motor shaft engages teeth in the rod Depending upon the direction of motor rotation the gear drives the rod up or down Timing circuitry in the controller initiates and stops operation of the basket lift depending upon the variables programmed by the operator When a product button is pressed the timing circuitry activates a coil to supply power to the motor which lowers the basket into the frypot When the rod contacts and closes the lower microswitch power to the motor is cut and the direction of current flow is reversed this reverses the direction of motor rotation When the programmed cooking time has elapsed power is again supplied to the motor The motor raises the basket from the frypot until the rod loses contact with the upper microswitch cutting power to the motor and again reversing the direction of current flow Problems with the basket lift can be grouped into three categories e Binds and jams e Motors and gears e Electronics 1 24 208 250V Configuration BINDS AND JAMS Noisy jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and bushings Apply a light coat of Lubriplate o
37. acks and four retainers Dual vat units come with one piece backs and only two retainers Insert the burners 9 into the rails to ensure the rail spacing and alignments are correct The burner should slide freely into and out of the rails The upper rail can be bent slightly to increase or decrease tension on the burner and the edges of the slot can be closed or opened slightly to best it the burner frame Carefully wrap a strip of burner insulation 8 tightly around the rear and sides of the burner 9 with the glass tape side of the strip on the outside Do not use duct tape or adhesive to secure the strip to the burner frame Align the burner to the burner rails while maintaining tension on the insulation strip Insert the burner at a slight angle and begin pushing the burner slowly into the rails until it contacts the rear combustion chamber The fit should be snug but not excessively tight Verify that the burners are flush with the front edge of the burner rails Remove the excess burner insulation by cutting with a knife or diagonal pliers Do not try to tear the insulation Insert the upper front insulation 10 into its retainer 11 making sure that the holes in each piece are aligned with one another Install the assembly with the insulation side toward the frypot and secure with 47 20 washer nuts Do not over tighten Place a washer on each of the four lower studs on the front of the frypot Install the lower inner front insula
38. ance with the appropriate national and local codes of the country and or region in which the appliance is installed See NATIONAL CODE REQUIREMENTS in Chapter 2 of this manual for specifics NOTICE TO U S CUSTOMERS This equipment is to be installed in compliance with the basic plumbing code of the Building Officials and Code Administrators International Inc BOCA and the Food Service Sanitation Manual of the U S Food and Drug Administration NOTICE Drawings and photos used in this manual are intended to illustrate operational cleaning and technical procedures and may not conform to onsite management operational procedures NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS u s 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 Commun
39. cations du Canada A DANGER Improper installation adjustment maintenance or service and unauthorized alterations or modifications can cause property damage injury or death Read the installation operating and service instructions thoroughly before installing or servicing this equipment Only qualified service personnel may convert this appliance to use a gas other than that for which it was originally configured A DANGER No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood Questions Call the Frymaster Dean Service Hotline at 1 800 551 8633 A DANGER Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection Single fryers equipped with legs must be stabilized by installing anchor straps All fryers equipped with casters must be stabilized by installing restraining chains If a flexible gas line is used an additional restraining cable must be connected at all times when the fryer is in use A DANGER The front ledge of the fryer is not a step Do not stand on the fryer Serious injury can result from slips or contact with the hot oil A DANGER Do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any other appliance
40. cuit and indicates that the high limit has opened properly CM7 display shows LOU TEMP Frypot temperature is between 180 F 82 C and 315 F 157 C This display is normal when the fryer is first turned on while in the melt cycle mode To bypass the melt cycle press and hold a 2 product button under the LCD display until a chirp is heard The alarm will chirp and the computer displays EXIT MELT alternating with YES 0 Press the 1 YES button to exit melt It may appear for a short while if a large batch of frozen product is added to the frypot If the display never goes out the fryer is not heating CM7 display shows ERROR SDCRD Defective SD Card Replace card with another card 1 33 Problem Probable Causes Corrective Action CM7 display shows Problem with the temperature This indicates a problem within aaas the temperature measuring PROBE measuring circuitry including the circuitry Check resistance of FAILURE probe probe if faulty replace probe CM7 display shows Swap the computer wiring harness PROBE Damaged computer wiring harness with one known to be good If FAILURE with connector problem is corrected replace the alarm sounding harness CM7 display shows IGNITION FRILURE Open drain valve failed computer failed interface board open high limit thermostat Is displayed if the fryer loses its ability to h
41. d Enter 4 32 1 Tech Mode Press the UNLOCK Y button three times The computer displays TECH Press the button CODE is displayed Enter 13 18 1 35 1 14 3 CM7 Menu Summary Tree Reflected below are the major programming sections in the CM7 and the order in which submenu headings will be found under the sections in the Installation and Operation Manual Adding New Menu Items See section 4 10 2 Storing Menu Items in Product Buttons See section 4 10 3 Temperature Conversion from F to See section 4 10 4 CM7 Programming Menu Programming Program Mode et e ds 4 11 With the fryer OFF press the UNLOCK button once displays P R 0 6 R R Press the Enter 1650 t Setpoint Temperature 4 11 1 Product Selection 4 11 2 Name Cook Time Cook ID Shake Time Hold Time Filt After Sensitivity Assign Btn Boil Out t a CA 4 11 3 Manager With the fryer OFF press the UNLOCK button twice displays MA NAGER Press the v Enter 4321 I E Log Alert Tone Volume 1 9 Tone 1 3 Tech Mode With the fi Enter 7378 Setup L Fryer Setup 1 36 1 14 4 CM7 Board Pin Positions and Harnesses Pin Connector From To Harness PN Function Voltage Wire Color 1 12VAC In 12 2 Gro
42. d between solenoid and top off port 810 3265 Flexline gt OD x 24 inch used between solenoid and top off port gt 810 3263 Flexline gt OD x 36 inch used between solenoid and top off port Not illustrated 2 12 4 JIB Cradle JIB BIB Cap and Pick Up Assembies ITEM PART COMPONENT 1 220 3647 Cradle JIB Gas LOV 2 106 8512SP Cap JIB Assembly 3 106 9495 Cap BIB Assembly used internationally 4 230 3737 Cap JIB 5 823 6812 Cap w Clamp BIB Assembly used internationally 6 810 3242 Hose JIB 810 3300 Inlet Oil Reservoir Tube 8 810 3334 Bushing Heyco 2 25 2 13 Wiring Connectors Pin Terminals and Tools 2 175 7 PART COMPONENT 1 807 1068 2 Pin Female 2 807 0158 6 Pin Female 3 807 0156 9 Pin Female 5 807 0159 12 Female 5 807 0875 15 Pin Female 6 807 1067 2 Pin Male 7 807 0157 6 Pin Male 8 807 0155 9 Pin Male 9 807 0160 12 Pin Male 10 807 0804 15 Pin Male 11 826 1341 Terminal Female Split Pin Pkg of 25 12 826 1342 Terminal Male Split Pin Pkg of 25 13 807 2518 Plug Mate N Lock Dummy Pin 14 807 0928 Extract Tool Pin Pusher 15 806 4855 Pin Pusher Screwdriver Assembly 16 230 2345 SMT Pin Extractor Not illustrated 2 26 2 14 Fasteners PART COMPONENT 809 0429 Bolt 4 inch 20 x 2 00 inch Hex Head ZP Tap 809 0131 Bolt 14 inch 20 x 4 inch Hex gt
43. d from Transformer to ATO Board 807 4719 ATO Pump and JIB used from ATO Board to Top off Pump and JIB Reset 7 Switch 807 4718 FV ATO Solenoid Harness 807 4555 ATO Yellow LED used from Board to Yellow LED 807 4573 Computer Locator Wire used from Computer to Interface Board See wiring diagram 805 1734 for locator pin positions 807 4552 Communications Terminator used on Computer pin J and ATO board pin J10 to terminate network 807 4657 Jumper used on 4 and 5 battery ATO board plug J5 pin 7 and 8 106 9256SP Long Top off Power used between Component Box to ATO Box 807 4660PK SMT Pin Service Repair Kit gt 230 2345 SMT Pin Extractor Not illustrated See page 1 31 and 1 37 for Pin Positions 2 13 Associated Components 2 7 271 Full Vat Frypot Components Guloejdea ueuw pauinb sjexseb pue UONEJNSU suiejuoo 2662 928 6655 958 N d ejDuis e u eq pue uonejnsul 310N 2 14 2 7 1 Full Vat Frypot Components cont ITEM PART COMPONENT 106 8978SP Frypot Assembly Full Vat Protector HE NAT 106 8979 Frypot Assembly Full Vat Protector HE PRO 826 2595 Insulation Kit Complete Full Vat 826 2592 Insulation Kit Burner Full Vat 1 106 7524 Flue Assembly Full Vat 2 220 2222 Back Lower Full Vat Combustion Chamber 3 220 2226 Retainer Full Vat Uppe
44. d it so that the opening is pointing downward 1 7 Checking the Burner Manifold Gas Pressure On non CE fryers only ensure that the gas valve knob is in the OFF position u Honeywell 2 Remove the pressure tap plug from the gas valve assembly Pressure Tap Plug Typical Valve Assembly Typical CE Valve Assembly 3 Insert the fitting for a gas pressure measuring device into the pressure tap hole 4 fryers only place the gas valve in the ON position 5 Place the fryer power switch in the ON position When the burner has lit and burned steadily for at least one minute compare the gas pressure reading to the pressure for the corresponding gas in the appropriate table on the following page The tables list the burner manifold gas pressures for each of the gas types that can be used with this equipment 1 5 Standard Burner Manifold Gas Pressures Pressure mbar Gas Natural Gas Lacq G20 under 20 mbar Natural Gas Gronique G25 under 25 mbar Natural Gas Gronique G25 under 20 mbar Butane Propane G30 at 28 30 or 50 mbar Propane G31 under 37 or 50 mbar Belgian G25 7 0 mbar Non CE Standard Burner Manifold Gas Pressures Gas Pressure 3 W C 0 73 kPa 8 25 W C 2 5 kPa Natural Propane To adjust the burner gas pressure remove the cap from the gas valve regulator and adjust to the correct pressure CE Val
45. e Q 2 gt 8 a S m z G O aae kj Frymaster of the sa ommercial al Food Equipment Service Ass mends mber OCEESA i icing CFESA Ce rtified Techni 24 Hour Service Hotline 1 800 551 8633 FEBRUARY 2009 196345 SHIAHS GAOLOHLOAd www frymaster com E mail service frymaster com IF DURING THE WARRANTY PERIOD THE CUSTOMER USES PART FOR THIS MANITOWOC FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER DEAN OR ANY OF ITS AUTHORIZED SERVICE CENTERS AND OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION THIS WARRANTY WILL BE VOID FURTHER FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY IN WHOLE OR IN PART DUE TO THE INSTALLATION OF ANY MODIFIED PART AND OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only A Frymaster DEAN Factory Authorized Service Center FASC or other qualified professional should perform installation maintenance and repairs Installation maintenance or repairs by unqualified personnel may void the manufacturer s warranty See Chapter 1 of this manual for definitions of qualified personnel NOTICE This equipment must be installed in accord
46. e found Reconnect the fryer to the electrical power supply and check for proper operation 1 9 9 Replacing a Burner Assembly Disconnect the unit from the electrical and gas supplies Remove the combustion air blower per the procedure found in Section 1 6 6 Remove the four nuts from the air plenum assembly and pull the assembly straight out toward you until it clears the burner tubes NOTE On a dual vat fryer it may be necessary to remove the drain valve handles before the plenum can be removed NOTE If the flexible oil return lines are blocking the plenum carefully bend them upward enough to clear the plenum Disconnect the ignition cable from the ignitor by grasping its boot and pulling gently toward you Disconnect the flame sensor wire from the ignitor by gently pulling its push on terminal from the terminal strip on the ignitor Disconnect the flexible gas lines from the burner orifice and the enrichment tube from the ignitor assembly Remove the four 4 inch nuts securing the outer front covers to the frypot assembly Remove the sheet metal screws at the top of the outer front covers and pull the covers straight out toward you until clear of the mounting studs Remove the washers and tubular spacers from the mounting studs then pull the inner covers straight out toward you until clear of the mounting studs Grasp the burner firmly and pull it toward you until it clears the burner channels taking care not to damag
47. e frypot hold down bracket Remove the screws in the back panel and inside the flue cap at each end that secure the flue cap to the fryer and lift it clear of the fryer ignitor assemblies Inspect each of these components carefully and install them in the replacement frypot if they are in serviceable condition Use Loctite PST56765 sealant or equivalent on component threads NOTE Some servicers based upon their experience recommend that probes and thermostats be replaced whenever a frypot is replaced however this remains the customer s decision Reverse steps 1 19 to reassemble fryer NOTE Care should be taken not to over torque nuts on frypots made of 400 series stainless steel as this could tear the material One turn past hand tight is sufficient torque Perform steps 14 through 18 of Section 1 9 9 to ensure that there are no leaks in the burner insulation A CAUTION Before installing temperature probe high limit thermostat RTD probe and drain valve on replacement frypot clean the threads and apply Loctite PST56765 thread sealant or equivalent 1 9 12 Repl acing Frypot Insulation and or Upper Burner Rails NOTE Replacing the burner rails requires completely tearing down the frypot and installing new frypot insulat Remove t Remove t Remove Remove Remove t p p p ion Refer to the frypot exploded view below for component identification e frypot per Section 1
48. e the ceramic tiles in the process 0 Clean all debris from the burner channels and combustion area QN u Inspect the upper and lower burner rails for cracked or burned out welds a If the welds in the lower rail are cracked or burned out the frypot must be replaced Refer to Section 1 6 11 for procedure b Ifthe welds in the upper rail are cracked or burned out the upper rail must be replaced Refer to Section 1 6 12 for procedure Place a new insulating strip along the top rear and bottom edge of the burner and carefully slide it straight into the rails NOTE Use P N 826 0931 for full vat frypots and P N 826 0932 for dual vat frypots Reverse steps 1 through 9 to reassemble the components Fill the frypot with oil Turn the fryer on turn off or bypass the melt cycle and operate the unit for at least 10 minutes Visually examine the burner flame The color and intensity on both sides should be the same Use an inspection mirror to check for leaks in areas that cannot be directly observed If a leak is detected tighten all the lower insulation retainer nuts allow the frypot to run for five additional minutes and repeat steps 15 and 16 18 If the leak persists use a rubber hammer and a small block of wood to tap the corners of the lower combustion chamber insulation retainers Repeat steps 15 through 17 Repeat this step until no leakage is detected 1 9 10 Replacing the Filter Motor Filter
49. eat oil It is also displayed when the oil temperature is above 450 F 232 C high limit thermostat has opened halting the heating of the oil Computer will not go into program mode or some buttons do not actuate Failed computer Replace computer CM7 display shows LOU TEMP heating indicator cycles on and off normally but fryer does not heat A Failed computer B Damaged computer wiring harness Replace computer Replace computer wiring harness CM7 display shows IGNITION FAILURE with alarm sounding Heating indicator is on but fryer is not heating Drain valve not fully closed Press the reset switch on the MIB board All drain valves should close Using the ON OFF switch turn the computer OFF and then ON again CM7 display shows IGNITION FRILURE and alarm sounds but fryer operates normally false Failed computer Replace computer alarm This is displayed only during a CM7 display shows EORR test of the high limit circuit and BAD Computer in high limittestmode that the high limit has failed 1 34 Problem Probable Causes Corrective Action Check that all harnesses between CM7 s and ATO secure CM7 display shows Check for loose pins If the software for only Loose or damaged harness ee CMT problem persists swap computer from one bank to another and reinitiali
50. ector Rajah 6 106 0531SP Fuse Assembly Inline 826 1157 Kit Fuse and Fuse Puller 2 Fuses 7 200 5996 Box One Piece Component 8 807 2971 Ignition Module Australia 9 807 1006 Ignition Module CE and Non CE export except Australia Canada HK Mexico 10 807 33667 Ignition Module Dual Spark Full Vat U S Canadian HK and Mexico units 11 826 2264 Interface Board Kit SMT 807 4330 Speaker Adapter Harness SMT 807 4343 Wire Harness SMT Interface Board to Ignition Module 12 807 0833 Relay DPDT 5 12VDC Latch See NOTE 1 13 810 2243 Spring Relay Retaining 14 807 4199 Cable 20 pin Computer to 15 pin Interface Board SMT 15 806 6085SP Wire Assembly Ignitor 807 4403 Speaker SMT Not illustrated NOTE 1 Full Vat units use one 807 3366 Dual Spark Ignition Module and one latch relay Item 12 located in the lower right socket 2 8 2 5 2 Transformer Boxes 2 9 2 5 2 Transformer Boxes cont ITEM PART COMPONENT Box Assembly Transformer A 106 9021SP FPGL230 B 106 9022 FPGL330 C 106 9734 GL230 CE Export D 106 9710 GL330 CE Export E 106 5801 GL430 252 1 106 8133 Cable Assembly Transformer Box Line GL230 330 330 CE Export 2 106 8168 Cable Assembly Transformer Box Line GL230 CE Export 3 106 8170 Cable Assembly Transformer Box Filter Pump GL230 and 330 4 106 9742 Cable Assembly Transformer Box Filter Pump GL230 CE Xprt and 330 CE Export 5 106 8162 Cable Assembly Tra
51. ed glow is obtained Carefully hold the shutter in position and tighten the locking nut see illustration on the following page Loosen this nut and rotate shutter to open or close air intake 1 9 8 Replacing a Gas Valve Disconnect fryer from electrical and gas supplies Disconnect the drain safety and high limit thermostat wires from the gas valve Mark each wire to facilitate reconnection Remove the vent tube on non CE fryers and the enrichment tube fitting from the valve Disconnect the flexible gas line s If replacing the left most valve on any configuration or the right valve on a two fryer battery follow the instructions below If replacing valves in other positions skip to ALL_OTHER VALVES A Remove the filter pan from the unit Remove the door adjacent to the valve being replaced B Uncouple the pipe union and remove the gas valve and associated piping from the unit C Remove the fittings and associated piping from the failed valve and install them on the replacement valve using Loctite PST56765 or equivalent pipe thread sealant D Reconnect the gas valve assembly to the fryer using Loctite PST56765 or equivalent pipe thread sealant and reattach the flexible gas line s enrichment tube s and the vent tube on non CE units Reconnect the high limit thermostat wires and drain safety wires to the valve E Reconnect the fryer to the gas supply and open the cut off valve Apply a solution of soap
52. em Not illustrated 2 10 2 5 3 Computers and Associated Components NOTE See Page 2 7 for Interface Board to Computer Wiring Harness E et PART COMPONENT Replacement CM7 Computer 108 0231 Non CE 7 For use in US Canada Mexico and all other coun tries 810 3141 Sound Device Universal SMT Not illustrated 2 6 Wiring 2 6 1 Main Wiring Harnesses 12 PIN MALE CONNECTOR Zn ea 2 PIN FEMALE CONNECTOR LT 12 PIN MALE CONNECTOR LH PIN 1 na 2 PIN FEMALE CONNECTOR 12 PIN MALE CONNECTOR rt TE TE TE 7 CONNECTOR 807 1978 PIN 1 LL PN 3 PIN 4 Pu r d PN mid PN 6 6 PIN MALE CONNECTOR 5 807 4014 12 PINMALE CONNECTOR ITEM PART COMPONENT 807 1978 U S and Non CE Export Main Wiring Harness 50 52 807 4014 U S and Non CE Export Main Wiring Harness 350 52 807 2168 CE Main Wiring Harness not shown 2 12 2 6 2 CM7 and Wiring Harnesses Refer to wiring diagram on page 1 49 ITEM PART COMPONENT 807 4546 Computer Communication used from Computer to Computer 807 4655 FV Harness RTD Medium used from RTD to ATO Board 807 4654 FV ATO RTD Probe 807 4553 Power use
53. er corners of the computer The computer is hinged at the bottom and will swing open from the top 4 Unplug the wiring harnesses from the connectors on the back of the computer see following page marking their position for reassembly and disconnect the grounding wires from the terminals Remove the computer by lifting it from the hinged slots in the control panel frame Ground Wire Terminal Ground Wire Terminal 20 Pin Connector Communication Wires Locator Wire 5 Install the replacement computer Reinstall the control panel assembly by reversing steps 1 thru 4 6 Readdress the new CM7 computer readdress procedure can be performed from any one CM7 computer in the bank 1 7 1 9 2 Replacing the Temperature Probe or High Limit Thermostat Qt Disconnect the fryer from the electrical supply Drain cooking oil below the level of the probe or thermostat Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame Remove the top two screws in the upper corners of the computer Swing the computer out from the top and allow it to rest on its hinge tabs Disconnect the computer wiring harness and ground wire from the back of the computer and remove the computer by lifting it from the hinge slots in the control panel frame Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you Disconnect the flame sensor wires from the flame senso
54. frypot or remove the handle from the drain valve before proceeding further 1 Disconnect the fryer from the electrical supply 2 Disconnect the flame sensor wire by carefully pulling its push on terminal from the terminal strip on the ignitor Disconnect the gas enrichment tube at the ignitor end compression fitting Disconnect the ignition cable from the ignitor by grasping its boot and gently pulling toward you See photo below lame Sensor Wire Enrichment Tube Ignition Cable 3 Remove the sheet metal screws securing the ignitor to the mounting plate and pull the ignitor from the fryer 4 Reverse the procedure to install the replacement ignitor 1 9 1 9 6 Replacing Cleaning a Combustion Air Blower 1 Disconnect the blower wiring harness remove the blower assembly mounting nuts and remove the blower assembly from the fryer If cleaning the motor continue with Step 2 otherwise install the replacement blower reconnect the wiring harness and then go to Step 6 Wiring connection Blower assembly mounting nuts 2 Remove the blower motor shield and separate the blower motor from the housing as shown in the illustration below Remove these screws to remove the shield from the blower assembly Remove these nuts to separate the blower motor from the housing 3 Wrap the motor with plastic wrap to prevent water from entering it Spray degreaser or detergent on the blower wheel and
55. g gt 807 1948 Ty Wrap 2 807 1359 Mount Ty Wrap 826 1383 Washer inch O D x 4 inch LD ZP Pkg of 5 809 0435 809 0582 Washer NPT Locking 809 0184 Washer 10 LK ZP 809 0190 Washer 625 X 275 X 40 Flat SS 5 809 0191 Washer Lock Spring ZP 809 0193 Washer Flat Nylon 809 0194 Washer Flat 5 16 ZP 809 0196 Washer inch Flat 810 1165 Washer inch Teflon 2 28 THIS PAGE INTENTIONALLY LEFT BLANK Frymaster Q anitowoc Frymaster L L C 8700 Line Avenue Shreveport Louisiana 71106 TEL 1 318 865 1711 FAX Parts 1 318 219 7140 FAX Tech Support 1 318 219 7135 SERVICE HOTLINE 819 6345 PRINTED IN THE UNITED STATES 1 800 551 8633 FEBRUARY 2009
56. iated frypot is full or dual vat pot CE Gas Valve Assembly Typical 2 19 2 9 Gas Valves and Associated Components cont ITEM PART COMPONENT 1 Valve Non CE Gas 826 1122 Natural Gas G20 G25 826 1120 Kit Natural Gas w flexlines and hardware 826 1123 Propane Gas G30 G31 826 1121 Kit Propane Gas w flexlines and hardware 2 810 1715 Valve CE Gas G20 G25 G30 G31 3 810 1041 Accessory Kit contains parts to adapt Item 2 to specific fryer configuration 4 806 9678SP Plug Assembly CE Gas Valve 5 810 0494 Ferrule Nut Orifice 6 810 1355 Gas Line inch OD X 15 inch SS Flexible 7 810 1354 Gas Line inch OD X 12 inch SS Flexible 810 1353 Gas Line inch OD X 9 inch SS Flexible Used on some split pots 8 811 0800 Tube OD X 12 5 inch Enrichment cut and form to fit 9 813 0301 Tee inch Male NPT to inch Tube 10 813 0302 Elbow 14 inch Male NPT to inch Tube 90 used on DV valve 11 813 0304 Bushing 12 inch NPT to 4 inch NPT Flush Reducing 12 813 0405 Nipple inch NPT X 2 inch 13 813 0378 Fitting inch NPT Cross 14 813 0340 Adapter inch NPT to inch Tube 15 813 0154 Plug inch NPT Hex Head Pipe 16 810 1176 Tap inch NPT Pressure 17 813 0377 Tee 14 inch NPT Female 18 813 0354 Elbow inch NPT X inch Tube Compression 19 813 0016 Nipple inch NPT X Close 20 810 1006 Bushing NPT to 14 inch NPT Reducing 21 813 0495 Tee inch Male NPT to Female NPT 22 810
57. kage 24 107 Basket Lift Malfunctions 1 24 11 Troubleshooting Guides 26 11 Troubleshooting the 24 VAC Circuit 26 41 22 Troubleshooting the Gas Valve 28 11 3 Troubleshooting the Temperature Probe 28 12 Probe Resistance Chari 29 13 ATO Automatic Top Off Service Procedures 29 13 ATO Automatic Top Off Troubleshooting 30 13 2 ATO Automatic Top Off Board Positions and Harnesse 31 13 3 Replacing the ATO Board or Transformer 32 13 4 Replacing the ATO Pump or Solenoid 32 14 CM7 Computer Service Procedures 32 14 CM7 Computer Troubleshooting 32 114 22 CM7 Useful Codes and Password 35 14 3 7 Menu Summary 36 14 4 CM7 Board Pin Positions and Harnesses 1 37 PROTECTOR SERIES GAS FRYERS 1 18 TABLE OF CONTENTS cont Loading and Updating Software Procedure f Principal Wiring Connections 39 Wiring Diagrams 40 117 Main Wiring 40 1172 Transformer Filter Boxes 41 1 17 2 1 FPGL230 430 Transformer Filter Box Domestic 41 1 17 2 2 FPGL330 Transformer Filter Box Domestic 42 17 3 Modular Basket Lift 100 120V 43 1174 Modular Basket Lift 208 250V 44 Simplified Wiring Diagrams 45 18 FPGL30 Full Vat Dual Spark Module 45 118 22 FPGL30 Full Vat Single Spark Module Australia amp Pacific Rim 46 18 3 FPGL30 Series Simplified Wiring 4
58. l that activates the gas valve Three Gi types are in use A closed box design is used in most fryers but in some fryers built for export the module 4 ToAlarm 25V gt e e jJ resembles an interface board A single dual spark module Y n GND is used on current production full vat fryers The ignitor assembly consists of a spark plug an Ignition Wire Flame Sensor enrichment tube and a flame sensor At start up the power switch is placed in the ON position supplying approximately 12 volts DC to the heat control circuitry in the computer and to one side of the heat relay coils on the interface board If resistance in the temperature probe indicates the temperature in the frypot is below 180 F 82 C the current flows through a melt cycle circuit where a timer switch alternately closes for six seconds and opens for 24 seconds If the temperature is 180 F 82 C or above the current flows through a heat circuit bypassing the timer switch In either case ground is supplied to the other leg of the heat relay coils which closes electronic switches in the 24 VAC circuit to provide current to the ignition module Circuitry in the ignition module sends 24 VAC to the gas valve via a normally closed high limit switch and a normally closed drain safety switch Simultaneously the module causes the ignitor to spark for four seconds to light the burner A flame sensor verifies the burner 1 1
59. lly suspect and should be replaced however unless the condition causing excessive heat is corrected the problem is likely to recur 1 20 Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage Again if damage is due to excessive heat in the fryer that problem must also be corrected Check for proper operation by disconnecting the wire from the ignitor spark plug inserting the tip of a screw driver into the terminal With the insulated handle of the screwdriver hold the shaft near the frame of the fryer as the power switch is placed in the ON position A strong blue spark should be generated for at least four seconds A DANGER Make sure you are holding the insulated handle of the screwdriver and not the blade The sparking charge is approximately 25 000 volts Examine the ignitor spark plug for any signs of cracking A cracked ignitor must be replaced Tf all other causes have been ruled out examine the burner tiles for any signs of cracking If cracking is found the burner must be replaced Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure but may also be the result of variations in the kitchen atmosphere Verify incoming gas pressure in the same way as for popping discussed in the preceding paragraphs Variations in the kitchen atmosphere are usually caused by air conditioning and or ventilati
60. mer for correct voltage Ensure the yellow LED is securely attached to plug J6 on the ATO board Frypots won t top off m oA s Probe temperature lower than setpoint Oil is too cold ATO board power loss Failed solenoid ATO pump failed or over tightened Failed transformer harness Failed ATO board Check to see that fryer is heating Check probe resistance If probe is bad replace the probe Ensure that the oil in the JIB is above 70 F 21 C Power to the ATO board has been cut off Ensure the board has power and cycle ALL computers off and on to readdress system Check solenoid to see if functioning properly If the solenoid is working ensure that the screws on the bottom of the pump are not too tight Loosen the screws If loosening the screws doesn t fix the problem replace the pump Ensure transformer in ATO box is functioning properly Check power from transformer to ATO board Ensure all harnesses are plugged securely into place Check for proper voltages using the pin position chart found on page 1 31 If ATO found defective replace ATO board One vat tops off but other vats fail to top off A Failed solenoid Loose wire connection Check power to the pump A hot pump suggests a failed solenoid Ensure all wiring harnesses are securely connected to ATO board and solenoids Incorrect vat tops off
61. n this case More often the pump overheated for one of the following reasons Shortening that remained in the pan after previous filtering solidified in the suction tube recess in the bottom of the pan or the suction tube itself Adding hot oil to the pan and waiting a few minutes will usually correct this problem A flexible wire can be used to clean out the suction tube and the recess in the bottom of the pan NEVER use compressed air to blow solidified shortening out of the suction tube 1 22 The operator attempted to filter oil that was not heated Cold oil is thicker and causes the pump motor to work harder and overheat If the motor hums but the pump does not rotate there is a blockage in the pump Incorrectly sized or installed paper will allow food particles and sediment to pass through the filter pan and into the pump When sediment enters the pump the gears can bind up and cause the motor to overload tripping the thermal overload Solidified shortening in the pump will also cause it to seize with similar results A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a screwdriver or other instrument as illustrated on the following page Make sure power to the pump motor is off before trying this PUMP 1 Disconnect power to the filter system Sediment Particle 2 Remove the input plumbing from the pump 3 Use a screwdriver to manually turn the gears e Turning the pum
62. nch Hex Washer Head 809 0362 Screw 8 x 1 4 inch Hex Washer Head Drill Point 809 0518 Screw 8 32 x inch Hex Washer Slotted Head SS 809 0104 Screw 8 32 x Slotted Head ZP 826 1363 Screw 8 32 x NP Pkg of 25 809 0103 826 1360 Screw 10 24 x 5 16 inch Round Slot Head ZP Pkg of 25 809 0024 809 0123 Screw 10 24 x 3 4 inch Slotted Truss Head k 826 1330 Screw 10 32 x inch Slot Head SS Pkg of 25 809 0117 809 1003 Screw 10 32 x inch Hex Trim Head SS 809 0938 Screw 10 32 x inch Philips Truss Head 826 1375 Screw 10 32 x inch Hex Trim Head SS Pkg of 5 809 0401 809 1000 Screw 10 32 x 1 4 inch Hex Sck C S 826 1374 Screw 10 x Hex Head Pkg of 25 809 0412 809 0266 Screw 10 x Phillips Head ZP continued on the following page 2 27 2 14 Fasteners cont ITEM PART COMPONENT ki 809 0500 Screw 10 x inch Hex Washer Head 410 SS 809 0434 Screw 10 x inch Hex Washer Head 809 0123 Screw 10 x inch Slot Head 826 1389 Screw 4 20 x inch Hex Head ZP Pkg of 10 809 0131 826 1346 Spacer Ignition Module Pkg of 10 810 2763 Spacer Interface Board 826 1340 Spacer 25 inch x 1 187 inch Pkg of 10 810 0500 Spacer 25 inch x 9375 inch 810 2023 Spacer 25 inch x 110 inch Used on drain valves 200 6721 Plate Strain Relief 826 1337 Tab 4 Terminal Pkg of 5 807 0070 Terminal Ground Lu
63. nch OD Teflon Manifold Vent 10 810 1055 Flexline 11 5 inch Oil Return 11 810 1680 Flexline 6 5 inch Oil Return 12 810 1668 Adapter inch to 2 inch NPT Male 13 813 0530 Tee inch x 4 inch x 4 inch Reducing 14 813 0838 Nipple inch NPT Close 15 106 3470 Valve inch NPT Solenoid 16 810 2773 Adaptor 14 inch NPT to 44 inch NPT 17 813 0298 Nipple NPT x 2 00 inch 18 813 0342 Elbow Street 45 NPT 19 813 0700 Nipple 4 inch NPT x 3 00 inch 20 810 2493 Elbow 90 inch NPT x inch Quick Connect 106 5911 Heater Strip Assembly 100 120V 25W 18 106 5912 Heater Strip Assembly 208 250V 25W 18 Not illustrated 2 22 2 11 Return Valve Assembly and Associated Parts ITEM PART COMPONENT 106 8018 Valve Return Assy FV 1 810 2201 Valve Return gt Ball 2 902 2772 Handle Right Valve 3 813 0165 Elbow Street 2 x gt 90 BM 4 813 0087 Nipple 4 x 1 50 NPT 5 813 0062 Elbow 90 2 BM 6 813 0265 Nipple gt x 2 50 NPT BM 7 824 1601 Cover Microswitch RR Flush 8 807 4101 Switch Micro 9 816 0220 Insulation RF Switch 10 810 0045 Bushing 875 Diameter Hole 11 16 11 212 6701 Rod Handle Right RF 12 816 0643 Grip Oil Return Valve Handle 13 809 0601 Clip Clevis 14 810 1668 Adaptor Male OD x 15 810 1067 Flexline OD x 8 50 Long 16 Manifold Rear Oil Return 810 3275 Two Station Fryer 810 3245 Three Station Fryer
64. ng a multimeter set to the 250 VAC range check the connections on both sides of the component for the presence of the applied line voltage 1 25 wiring diagram on the Pages 1 45 and 46 identifies the components and wiring connection points 1 11 Troubleshooting Guides The troubleshooting guides on the following pages are intended to assist service technicians in quickly isolating the probable causes of equipment malfunctions by following a logical systematic process An additional set of operator troubleshooting guides are contained in Chapter 7 of the BIGLA30 Series Installation and Operation Manual It is suggested that service technicians thoroughly familiarize themselves with both sets 1 11 1 Troubleshooting the 24 VAC Circuit Prior to checking for problems associated with the 24 VAC circuit ensure that the unit is connected to a power supply the drain valve is fully closed and the computer is on and is calling for heat green dot appears under heat indicator and display toggles between L and TEMP NOTE All voltage measurements must be made within 4 seconds of the unit calling for heat If unit does not fire within 4 seconds ignition modules will lock out and computer must be turned off then on to reset The following processes will assist you in troubleshooting the 24 VAC circuit and ruling it out as a probable cause 24 VAC is not present on the interface board J3 pin 9 LED 5 GV 1 If LED 3 is not c
65. nition module fails to sense a flame within the 4 second time delay period and locks out When this happens the module sends 24 VAC through the interface board alarm circuit to the computer CM7 computers display IGNITION FAILURE The three primary reasons for ignition failure listed in order of probability are problems related to 1 Gas and or electrical power supplies 2 Electronic circuits 3 Gas valve PROBLEMS RELATED TO THE GAS AND OR ELECTRICAL POWER SUPPLIES The main indicators of this are that an entire battery of fryers fails to light and or there are no indicator lights illuminated on the fryer experiencing ignition failure Verify that the quick disconnect fitting is properly connected the fryer is plugged in with connector twisted and locked the main gas supply valve is open and the circuit breaker for the fryer electrical supply is not tripped PROBLEMS RELATED TO THE ELECTRONIC CIRCUITS If gas and electrical power are being supplied to the fryer the next most likely cause of ignition failure is a problem in the 24 VAC circuit Verify that the drain valve is fully closed The valve is attached to a microswitch that must be closed for power to reach the gas valve often although the valve handle appears to be in the closed position the microswitch is still open If the valve is fully closed refer to Section 1 11 1 TROUBLESHOOTING THE 24 VAC CIRCUIT Some typical causes of ignition failure in this category include
66. not activate Verify computer power cord is plugged in and that circuit breaker is not tripped Computer has failed Swap the computer with a computer known to be good If computer functions replace the computer harness D Damaged computer wiring D Swap with a harness known to be good If computer functions replace the harness 1 32 Problem Probable Causes Corrective Action E Power supply component or interface board has failed E If any component in the power supply system including the transformer interface board fail power will not be supplied to the computer and it will not function Computer locks up Computer error Remove and restore power to the computer Heat indicator off upon initial startup Display shows H or HOT with alarm sounding Failed computer Replace computer CM7 display is in wrong temperature scale Fahrenheit or Celsius Incorrect display option programmed See section 1 14 2 on page 1 35 to change temperature scale CM7 display shows HOT HI 1 Frypot temperature is more than 410 F 210 C or in CE countries 395 F 202 C This in an indication of a malfunction in the temperature control circuitry including a failure of high limit thermostat CM7 display shows HI LIRIT Computer in high limit test mode This is displayed only during a test of the high limit cir
67. nsformer Box 1 GL230 6 106 3827 Cable Assembly Transformer Box 1 GL330 7 106 9739 Cable Assembly Transformer Box 1 GL230 CE Export 8 106 9746 Cable Assembly Transformer Box 1 GL330 CE Export 9 106 3821 Cable Assembly Transformer Box 2 GL230 and 330 10 106 9740 Cable Assembly Transformer Box 2 GL230 CE Export 11 106 9747 Cable Assembly Transformer Box 2 GL330 CE Export 12 106 3825 Cable Assembly Transformer Box 3 GL330 13 106 9748 Cable Assembly Transformer Box 3 GL330 CE Export 14 106 6996 Cable Assembly Cordset Female 15 806 8706 Plug Assembly Lt 252 16 806 8707 Plug Assembly Rt 252 17 220 3191 Cover Transformer Box GL 18 220 0772 Cover Transformer Box 50 52 55 19 807 4482 Relay Filter 30A 24VDC DPDT 20 816 0219 Paper CE Triple Terminal Block Insulating 21 807 0070 Terminal Ground Lug 22 807 1973 Terminal Post 23 810 1164 Block One Piece Screwless Terminal 24 816 0217 Insulation Terminal Block Paper 25 810 1163 Block 3 Places Screwless Terminal 26 807 0800 Transformer 100 120V 24VAC 50 60Hz 50VA 27 807 1999 Transformer 208 222 230 240V V F Dual Voltage 28 807 2176 Transformer 100 120V V F Dual Voltage WIR 0798 Wire Assembly GL330 Transformer Filter Box used Item WIR 0799 Wire Assembly GL230 Transformer Filter Box used in Item A WIR 0852 Wire Assembly GL230 CE Transformer Filter Box used in Item C WIR 0854 Wire Assembly GL330 Transformer Filter Box used It
68. on units starting and stopping during the day As they start and stop the pressure in the kitchen may change from positive or neutral to negative or vice versa They may also cause changes in airflow patterns that may affect flame intensity Dark spots on the burner tiles are the result of an improper air gas mixture Adjust the combustion air blower to reduce the amount of air in the mixture to correct this problem Flames shooting out of the flue are usually an indication of negative pressure in the kitchen Air is being sucked out of the burner enclosure and the flames are literally following the air If negative pressure is not the cause check for high burner manifold gas pressure in accordance with the procedures in Section 1 7 An excessively noisy burner especially with flames visible above the flue opening may indicate that the gas pressure is too high or it may simply be that the gas valve vent tube is blocked If the incoming gas pressure is correct and the vent tube is unobstructed the gas valve regulator is probably defective Occasionally a burner may apparently be operating correctly but nevertheless the fryer has a slow recovery rate the length of time required for the fryer to increase the oil temperature from 250 F to 300 F 121 C to 149 C The primary causes of this include an over filled frypot a dirty or out of adjustment combustion air blower low burner manifold pressure and or damaged burner tiles Adding oil to
69. ontinually lit the probable causes are a failed 24 VAC transformer or failed wiring between the transformer and interface board 2 If LED 3 is continually lit check the right PWR terminal LED 4 for 24 VAC Verify that the F2 fuse is not blown a If 24 VAC is not present the probable cause is a failed interface board blown fuse or a defective heat relay b If24 VAC is present check for 24 VAC on VIS i If 24 VAC is not present check the fuses If they are good the probable causes are failed ignition module s or a failed interface board Replace the questionable ignition module with one known to be good to isolate the cause ii If 24 VAC is present the probable cause is a failed interface board 24 VAC is present on interface board J3 9 LED 5 GV If 24 VAC is not present across the gas valve main coil MV terminals probable causes an open high limit thermostat or a failed wire between the interface board and gas valve It may also be caused by a failed drain safety switch a Check continuity of high limit thermostat and drain safety switch If both are zero problem is in wiring 2 If24 VAC is present across the gas valve main coil MV terminals the 24 VAC circuit is working and the problem may be with the gas valve 1 26 24 VOLT CIRCUIT With Interface Board 106 6706 and One 807 3366 FV Ignition Module 24V TRANSFORMER J3 PIN
70. ot 30 5 cm piece of wood or a similar support Install but do not tighten the two nuts and bolts that attach the motor mount to the front cabinet cross brace Install and tighten the four nuts and bolts that secure the motor mount to the rear motor mount support At the front of the fryer tighten the two nuts and bolts at the front of the motor mount Reconnect the motor power wires and reinstall the wiring cover plate Reconnect the oil return flexline and reinstall the filter pan Reconnect the unit to the electrical power supply fill the frypots with oil and check for proper operation 1 9 11 Replacing the Frypot 1 2 Disconnect the fryer from the electrical and gas supplies Remove the filter pan from the unit and drain one frypot at a time into a Shortening Disposal Unit SDU or other appropriate metal container A DANGER DO NOT attempt to drain more than one full frypot into the SDU at one time Dismount the topcap by removing the screws on the bottom of each front corner and lifting the topcap straight up Remove the bezels by lifting them up to disengage the tabs along the lower edges from the slots in the control panel frame Remove the top screws in the upper corners of the computer QN tA on 20 21 Disconnect the oil return line s from the frypot to be removed Carefully lift the frypot from the fryer cabinet Remove the drain valve s
71. p gears backwards will release a hard particle and allow its removal e Turning the pump gears forward will push softer objects and solid shortening through the pump and allow free movement of the gears Filter paper pads that are installed incorrectly will also allow food particles and sediment to pass through and clog the suction tube recess on the bottom of the filter pan or the suction tube itself Particles large enough to block the suction tube recess or the suction tube may indicate that the crumb tray is not being used The electronics of the FootPrint PRO system illustrated in the schematic on the following page are simple and straightforward Microswitches which are attached to handles for each vat and wired in parallel provide the 24 VAC required activating the pump relay coil when the handles are moved to the ON position The Pom activated pump relay coil pulls in the pump motor m switch supplying power to the pump motor Verifying Solenoid Operation Proper operation of the 24 VAC manifold and pump solenoids be verified by removing the pump motor lead from terminal 4 of the pump motor relay in the filter wiring box and then activating the oil return lever Proper solenoid operation will be evidenced by an Ly audible click or vibration of both the pump solenoid and the manifold solenoid Solenoids Micro svitches Pump Relay Coll Pump Motor
72. r Insulation 4 220 2231 Retainer Outer Frypot 5 222 2694 Plate FV Collector Mounting 6 220 2851 Brace FV Rear Insulation 7 220 2920 Brace Foam Deck Insulation 8 810 3435 Burner Universal Replacement Protector 9 812 0356 Insulation Burner Sight Glass 10 812 0357 Insulation Burner 11 812 0706 Insulation Upper Burner Rail 12 812 1029 Insulation Combustion Chamber Side 13 814 0048SP Glass Burner Sight 14 816 0730 Insulation FV Rear Lower 15 816 0731 Insulation FV LH RH Front Seal 16 816 0732 Insulation FV Lower Inner Front 17 816 0733 Insulation FV Front Upper 18 816 0734 Insulation FV Outer Front 19 816 0746 Insulation Foam Deck 20 823 6597 Frypot FV Protector 439 SS 21 823 6047 Retainer FV LH Upper Burner 22 823 6048 Retainer FV RH Upper Burner 23 823 6050 Retainer FV Front Insulation 24 823 6052 Retainer FV Outer Front 25 824 1826 LH Upper Seal W A 26 824 1827 RH Upper Seal W A 27 900 1031 Retainer Burner Sight Glass 28 930 0818 Bracket Flue to Pot 29 900 4253 Strip Fluecap Retainer 30 900 1049 Retainer Plenum Gasket 31 816 0057 Gasket Plenum 816 0059 Gasket Ignitor 32 823 6660 Plenum Full Vat LOV use 823 6940 for CE units t 910 2474 Pot to Pot Gap Clip Not illustrated 2 15 2 7 2 Assemblies and Associated Parts 5 See page 2 5 for Drain Valve 55 Assemblies ITEM PART COMPONENT 1 106 89785 Frypot Assembly Full Vat Protector Natural 106 89
73. r similar lightweight white grease to the rod and bushings to correct the problem Another possible cause of binding is improper positioning of the motor which prevents the gear from correctly engaging the teeth in the rod To correct the problem loosen the screws that hold the motor in place and move it forward or backward until the rod has just enough slack to be rotated slightly MOTORS AND GEARS The most likely problem to be encountered in this category is erratic motion of the lift due to a worn drive gear Failure to keep the lift rod and bushings properly lubricated will cause unnecessary wear of the gear Correct the problem by replacing the worn gear If the lift cycles correctly but fails to remain in the up position goes up but then slowly settles back down into the frypot the problem is a failed motor brake This cannot be repaired and the motor must be replaced If power is reaching the motor but the motor fails to run it is burned out and must be replaced ELECTRONICS Within this category are problems associated with the relays microswitches capacitors resistors interface board wiring and controls The most common problem in this category is a lift that continuously travels up and down This is usually caused by a microswitch that is out of adjustment Troubleshooting the electronics of the basket lift is the process of verifying current flow through the individual components up to and including the motor Usi
74. rs Disconnect the sound device lead from the interface board If working on the left frypot cut the wire tie on the wiring bundle and disconnect the main wiring harness 15 connector Remove the component box mounting screws Rotate the top of the component box out of the frame and carefully pull it out enough to disconnect the wiring harness plug from the back of the box This will leave one set of wires enclosed in spiral wrap connected to the component box Remove the box and set it atop the fryer to expose the temperature probe and high limit thermostat Unscrew the probe or thermostat from the frypot Apply Loctite PST56765 pipe thread sealant or equivalent to the replacement part threads and screw the replacement part into the frypot torquing to 180 inch pounds Connect the wires from the new component as follows a If replacing the temperature probe use a pin pusher to disconnect one at a time the red and white leads from the connector and insert the corresponding leads from the new probe into the plug b If replacing the high limit thermostat use a pin pusher to disconnect the lead running to the connector and insert the corresponding lead from the new thermostat Disconnect the other lead from the drain safety switch and connect the remaining lead from the new thermostat 17 Reverse steps 1 through 13 to complete the procedure 1 9 3 Replacing the Interface Board 1 22 3 DR
75. s listed above 806 8806SP Harness Assembly Blower Motor component of all blowers listed above 4 Orifice Burner 812 1137 1 95 mm Propane Butane G30 G31 0 4999 Ft 0 1524 M CE 810 1221 2 00 mm Propane Butane 0 4999 Ft 0 1524 M Japan only 810 0386 2 10 mm Propane Butane 0 4999 Ft 0 1524 M 810 0413 2 16 mm Propane Butane G30 G31 5000 6999 Ft 1525 2133 M 812 1028 2 20 mm Propane Butane G30 G31 7000 10 999 Ft 2134 3352 M 812 1134 3 10 mm Natural Gas G20 G25 0 4999 Ft 0 1524 M Japan only 810 0403 3 40 mm Natural Gas G20 G25 0 4999 Ft 0 1524 M 810 0437 3 60 mm Natural Gas G20 G25 5000 6999 Ft 1525 2133 M 812 1144 3 65 mm Natural Gas G20 G25 7000 8999 Ft 2134 2743 M 812 1145 3 70 mm Natural Gas G20 G25 9000 10 999 Ft 2744 3352 M 810 0642 5 95 mm Manufactured Gas 0 4999 Ft 0 1524 M 826 1196 Conversion Kit Natural Gas G20 G25 to Propane Butane G30 G31 CE only 826 1197 Conversion Kit Propane Butane G30 G31 to Natural Gas G20 G25 only 807 2263 Switch Air Pressure use 807 2262 in units with 100VAC power supply Not illustrated 2 18 2 9 Gas Valves and Associated Components NOTE Items 5 6 7 and 8 are used with both CE and Non CE gas valves Non CE Gas Valve Assembly NOTE The gas tube and SoA Typical enrichment tube fittings are assembled varying configurations depending upon the location of the valve and whether the assoc
76. sition any excess insulation toward the top of the frypot Avoid overhang past the bottom of the upper burner rail Overhang in this area will make future burner replacement more difficult Cover the insulation with the insulation retainer 24 and secure with 4 self tapping screws Reinstall probes drain valves high limit thermostats and other pipe fittings using Loctite PST56765 sealant or equivalent on the threads Cm I g 2 Re assembling Frypot Full Vat Illustrated 1 18 1 10 Troubleshooting and Problem Isolation Because it is not feasible to attempt to include in this manual every conceivable problem or trouble condition that might be encountered 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 With this knowledge the technician should be able to isolate and correct any problem encountered Problems you are likely to encounter can be grouped into six categories Ignition failure Improper burner function Improper temperature control Computer malfunctions Filtration malfunctions Leakage DAN e sa The probable causes of each category are discussed in the following sections A series of Troubleshooting Guides is also included at the end of the chapter to assist in solving some of the more common problems 1 10 1 Ignition Failure Ignition failure occurs when the ig
77. t the probable cause is an improperly adjusted or failed gas valve Adjust the valve by following the procedure Check Burner Manifold Pressure in Section 1 7 of this manual If the valve cannot be adjusted replace it b If outgoing gas pressure is correct the gas valve is okay 1 11 3 Troubleshooting the Temperature Probe A CAUTION Disconnect the CM7 computer before testing temperature probe resistances to avoid invalid readings Prior to checking for problems associated with the temperature probe inspect the probe body for damage while it is still in the frypot Remove and replace the probe if it is bent dented or cracked Also inspect leads for fraying burning breaks and or kinks If found replace the probe The following processes will assist you in troubleshooting the temperature probe and ruling it out as a probable cause Before testing the probe determine the temperature the cooking oil using another thermometer or pyrometer placed at the tip of the questionable probe e If resistance through J3 pins 2 and 6 is not approximately equal to that given in the Probe Resistance Chart on the following page for the corresponding temperature the probe has failed and must be replaced e If resistance through J3 pins 2 and 6 is approximately equal to that given in the Probe Resistance Chart on the following page for the corresponding temperature measure the resistance through each of the previously
78. temperature probe s high limit thermostat s RTD probes and Grasp the upper edge of each computer and swing the computer downward Unplug the computer wiring harness and grounding wire from the back of each computer Remove the computers by lifting them from the hinge slots in the control panel frame Disconnect the sound device wire from the interface board Disconnect the flame sensor wires by carefully pulling the push on terminals from the terminal strips on the ignitors Disconnect the gas enrichment tube at the ignitor end compression fitting Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you Remove the two mounting screws on each side of the component box and rotate the top of the box out of the frame Carefully pull it out enough to disconnect the wiring harness connector from the back of the box Cut any ties that prevent the box from being pulled out of the control panel frame Carefully pull the box clear of the frame and rest it on top of the fryer Using a pin pusher remove the temperature probe high limit thermostat wires and RTD probe wires from the plugs or terminals marking each wire to facilitate re assembly Remove the cover from the safety drain switch Disconnect the wires from the switch Remove the section s of drain from the drain valve s of the frypot to be removed Disconnect the gas lines from the burner orifices and ignitor assemblies Remove th
79. the blower housing Allow it to soak for five minutes Rinse the wheel and housing with hot tap water then dry with a clean cloth Wrap the motor and wires with plastic wrap or a plastic bag Blower Housing Blower Wheel 4 Remove the plastic wrap from the blower motor assembly Reassemble the blower motor assembly and blower housing Reinstall the blower shield 5 Reinstall the blower assembly in the fryer and reconnect the wiring disconnected in Step 1 6 Light the fryer in accordance with the procedure described in Chapter 3 Section 3 2 2 of the Protector Series Gas Fryer Installation and Operation Manual P N 819 6339 7 After the burners have been lit for at least 90 seconds observe the flames through the burner viewing ports located on each side of the combustion air blower Right Viewing Left Viewing Port is behind motor The air gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable table on page 1 6 and the burners display a bright orange red glow If a blue flame is observed or if there are dark spots on a burner face the air gas mixture requires adjustment 1 9 7 Adjusting the Air Gas Mixture On the side of the blower housing opposite the motor is a shutter plate with a locking nut Loosen the nut enough to allow the shutter to be moved then adjust the position of the shutter to open or close the air intake opening until a bright orange r
80. the high limit thermostat prevents the fryer from overheating to the flash point The high limit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 425 F to 450 F 218 C to 232 C The different types of thermostats have different part numbers for CE and Non CE models and are not interchangeable 1 5 Accessing Fryers for Servicing A DANGER Moving a fryer filled with oil may cause spilling or splattering of the hot liquid Follow the draining instructions in Chapter 5 of the Protector Series Gas Fryer Installation and Operation Manual P N 819 6339 before attempting to relocate a fryer for servicing 1 Shut off the gas supply to the unit Unplug the power cords Disconnect the unit from the gas supply 2 Remove any attached restraining devices and relocate the fryer for service accessibility 3 After servicing is complete reconnect the unit to the gas supply reattach restraining devices and plug in the electrical cords 1 4 1 6 Cleaning the Gas Valve Vent Tube Set the fryer power switch and the gas valve to the OFF position 2 Carefully unscrew the vent tube from the gas valve NOTE The vent tube may be straightened for ease of removal 3 Pass a piece of ordinary binding wire 052 inch diameter through the tube to remove any obstruction 4 Remove the wire and blow through the tube to ensure it is clear 5 Reinstall the tube and ben
81. tion 12 with the rectangular openings toward the drain valve nipple Install the lower inner front insulation retainer s 13 NOTE Full vat units have a two piece insulation retainer Dual vat units have a one piece retainer If necessary replace the sight glasses and insulation 14 Place one washer and one 1 888 inch spacer 15 on each stud NOTE There are three different sizes of spacers Verify the size to ensure the correct spacers are installed Insert the front lower insulation 16 into the front lower insulation retainer s 17 and install assembly on frypot Secure with 4 20 washer nuts If frypot uses two retainers connect them 30 31 32 33 34 35 36 together with two 4 self tapping screws NOTE Full vat units have a two piece insulation retainer and two pieces of insulation Dual vat units have one piece components Return to the rear of the frypot and fully tighten all washer nuts Remove and replace the plenum gaskets 18 Place a 0 938 inch spacer 19 on the plenum mounting studs and mount the plenum 20 Ensure the gaskets are clear of the burner tubes by pulling the plenum back slightly Place a washer on each stud and secure plenum with 20 lock nuts Install the upper oil zone insulation 21 by pressing it under the upper combustion chamber metalwork Secure the insulation with the bracket 22 and self tapping screws Install the upper burner rail blanket insulation 23 Po
82. ular Basket Lift 2 806 5964SP Motor Assembly Modular Basket Lift 3 807 2133 Capacitor 12 5 uFarad 250VAC Motor Run 4 807 2572 Microswitch 5 Resistor Assembly 806 8530SP 100 120V Modular Basket Lift see Note 2 in illustration 106 2771 208 250V Modular Basket Lift 6 809 0082 Ring Retaining 7 810 0172 Plug 5 8 inch Stainless Steel Hole 8 810 1012 Rod Modular Basket Lift 9 812 0442 Insulation Microswitch 10 813 0035 Bushing Bronze 640 ID 11 816 0033 Tie Wrap Screw Mount 12 900 5529 Gusset Modular Basket Lift Motor 13 901 8499 Chassis Modular Basket Lift Left 14 902 8499 Chassis Modular Basket Lift Right 15 910 4776 Cover S S Modular Basket Lift for CRS cover use 900 4776 16 823 06931 Rod Assembly Left Basket Lift 17 823 06932 Rod Assembly Right Basket Lift 18 806 9257SP Roller Assembly Basket Lift 19 910 8284 Bracket Basket Lift Roller 20 810 0194 Roller Basket Lift 21 810 0374 Spacer Basket Lift Roller 22 809 0508 Bolt 1 4 20 X 11 4 inch 23 809 0190 Washer 4 inch Flat 24 809 0047 Nut 1 4 20 Cap 807 0159 Connector 12 Pin Panel Mount Wire Assemblies i 106 1822SP For 100 120V Modular Basket Lift 106 1804SP For 208 250V Modular Basket Lift Basket Lift Assemblies see Note 1 in illustration 106 1807SP 100 120V w o Relay 106 1810SP 208 250V w o Relay Not illustrated 2 3 2 3 Doors Sides Flue Caps Caps and Casters 1 2
83. und 3 12VAC In 12 4 FV Heat Demand 5 V Relay 12VDC 6 DV Heat Demand 7 R H B L 12VDC 8 Analog Ground Black 8074199 9 L H B L 12VDC buenas SMT Computer to 10 ALARM oard to p Computer Board 11 Sound Device 5VDC amess 12 ALARM 13 FV Probe 14 Common Probes 15 DV Probe 16 17 18 19 20 1 Ground Black Previous CM7 8074546 2 CAN Lo Red J7 or Network Computer 3 CAN Hi White J6 Resistor Communication 4 807 4552 Harness 5 6 1 Ground Black 8074546 2 CAN Lo Red J7 ATO J1 or Computer 3 CAN Hi White Next CM7 J6 Communication 4 Harness 5 6 J9 1 Vat 1 Interface 8074573 2 Vat 2 J10 Board Ground Computer Locator SLS Black to Computer Harness 4 Vat 4 5 Vat 5 6 J11 SD Card 1 37 1 15 Loading and Updating Software Procedures Loading Software from an SD card to an CM7 Computer and ATO Board To update CM7 and ATO software follow these steps 1 m Switch all computers to FF Press the TEMP button to check current CM7 ATO software version Remove the two screws on the left side cover plate of the CM7 computer With the computer folded down insert the SD card with the contacts facing down and the notch on the bottom right see Figure 4 and 5 into the slot on the left side of the CM7 Once inserted F U U P D appears on the left display and SC C RC on the right Numbers count up on the right display The display then changes to F U L
84. ve c GAS VALVE REGULATOR CAP Place the fryer power switch and the gas valve in non CE fryers in the OFF position Remove the fitting from the pressure tap hole and reinstall the pressure tap plug 18 Measuring Flame Current When the burner flame is properly adjusted it will produce a current between 2 5 and 3 5 HA Flame current is measured by placing a microamp not milliamp meter in series with the sensing wire on the ignitor This is accomplished as follows 1 Place the fryer power switch in the OFF position 2 Disconnect the sensing wire from one of the burner ignitors and connect it to the positive lead of the meter Connect the negative lead of the meter to the terminal from which the sensing wire was removed Flame Sensor Wire Right Burner 3 Place the fryer power switch in the ON position to light the burners After the frypot temperature reaches 200 F 93 C wait at least one minute before checking the reading NOTE The closer the unit is to normal operating temperature the more accurate the reading will be 1 9 Replacing Fryer Components 1 9 4 Replacing the Computer or the Computer Wiring Harnesses 1 Disconnect the fryer from the electrical power supply 2 The computer bezel is held in place by tabs at the top and bottom Slide the metal bezel up to disengage the lower tabs Then slide the bezel down to disengage the upper tabs 3 Remove the two screws from the upp
85. y test each time the fryer warms up An operator can view the results of the test any time the fryer is above the 325 F 163 C point by pressing the INFO button once when the fryer is on The test results will be displayed in the computer s LED panel in minutes and seconds The maximum acceptable recovery time for Protector series gas fryers is two minutes and twenty five seconds 1 10 5 Filtration Malfunctions The majority of filtration problems arise from operator error One of the most common errors is placing the filter pad on the bottom of the filter pan rather than over the filter screen Whenever the complaint is the pump is running but no oil is being filtered check the installation of the filter pad including that the correct size is being used While you are checking the filter paper pad verify that the O rings on the filter pan suction tube are present and in good condition Missing or worn O rings will allow the pump to suck air and decrease its efficiency If the pump motor overheats its thermal overload will trip and the motor will not start until it is reset If the pump motor does not start press the red reset switch located on the front of the motor If the ump then starts something caused the motor to overheat It may be just that several frypots in a large battery of fryers were being filtered one after the other and the pump became hot Letting the pump cool down for at least a half hour is all that is required i
86. y water around each connection to check for gas leaks Eliminate any that are found F Position the pan rail assembly beneath the fryer and rest the rear end of the rail on the cabinet frame Install the two nuts and bolts behind the front face of the rail but do not tighten them Install the nut and bolt at the rear end of the filter rail and tighten securely G Reattach the screws for the pan rails Install the filter pan in the unit to make sure that all components are properly aligned H Reconnect the fryer to the electrical power supply and check for proper operation When proper operation has been verified reinstall the door removed in Step A ALL OTHER VALVES 4 Carefully unscrew the valve from the manifold NOTE Some models may have the valve attached to the manifold by means of a pipe union In such cases remove the valve by uncoupling the union Remove all fittings from the old gas valve and install them the replacement valve using Loctite PST56765 or equivalent pipe thread sealant Reconnect the gas valve assembly to the fryer using Loctite PST56765 or equivalent pipe thread sealant and reattach the flexible gas line s enrichment tube s and the vent tube on non CE units Reconnect the high limit thermostat wires and drain safety wires to the valve Reconnect the fryer to the gas supply and open the cut off valve Apply a solution of soapy water around each connection to check for gas leaks Eliminate any that ar
87. ze 1 14 2 CM7 Useful Codes To enter any of the following codes Press the UNLOCK Y button three times TECH is displayed Press the button is displayed Enter a code listed below for the appropriate function Enter Setup in Tech Mode Enter 13 18 Change from F to C Enter 1658 The computer displays OF F Turn the computer on and check temperature to see the temperature scale If the desired scale is not displayed repeat e Reset Factory Menu Enter 3322 The computer display flashes and quickly counts from 1 40 and switches to OFF NOTE This will delete any manually entered menu items Reset BADCRC Message Disconnect board locator plug 10 Reinsert plug Enter 9988 Computer display switches to OFF Remove and then restore power to the computer using the 20 pin plug e Reset RECOVERY FRULT CALL SERVICE Enter 0042 Reset CALL TECH Message Disconnect board locator plug 10 Reinsert plug Enter 1000 Computer display switches to Remove and then restore power to the computer using the 20 pin plug If this message appears at any time other than after upgrade from a previous version replace the computer PASSWORDS Program Mode Press the UNLOCK button once The computer displays PROGRAM Press the button ENTER CODE is displayed Enter 1650 Manager Mode Press the UNLOCK Y button twice The computer displays MANAGER Press the button ENTER CODE is displaye

Frymaster 8196345 Fryer User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents