SERVICE MANUAL CFE 415

Transcription

1 Narrow Open Fryer Electric SERVICE MANUAL CFE 415 FM06 076A

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3 Table of Contents Safety and Compliance... vii Chapter 1 Overview Technical Support Dimensions Clearance Data Plate Location Features...2 Chapter 2 Unpack and Install Unpack the Fryer Select the Fryer Location Install the Fryer Level the Fryer Ventilate the Fryer Electrical Requirements...7 Chapter 3 Operation User Interface Controls & Indicators Control Board Inputs and Outputs Rear Panel Interface Fill or Add Oil Manually Fill an Empty Vat Top Off a Vat Fill the Reserve Oil Tank Cook Cycle Manual Mode Info Button Stats Care of Oil Express Filter Automated Express Filter Forcing an Express Filter to Reset the Filter Count Daily Filtering Filter Menu Oil Disposal Drain to Pan Fill From Pan Fill From Reserve Oil Tank Drain Pan Assembly...29 Chapter 4 Maintenance Clean-Out Mode Preventative Maintenance Schedule Daily Cleaning Between and Behind Fryers Weekly Reserve Oil Tank Cleaning Quarterly Drain Pan O-Ring Replacement Quarterly Filter Screen O-Ring Replacement...39 Chapter 5 Software Settings...41 Contents i

4 Contents 5.1 Clock Set Manually Setting New Or Used Oil Language Selection Special Programming...42 Chapter 6 Information and Reporting Modes Menu Overview Information Mode Details Diagnostic Mode Diagnostic Mode Details...68 Chapter 7 Operational Troubleshooting Cooking Troubleshooting Guide Warning Messages Error Messages...86 Chapter 8 Troubleshooting and Diagnosing Issues Tech Modes Wi-Fi Radio Wi-Fi Connection Radio Status Radio Info Mode Radio to Fryer Communication State Description WAN (Radio External IP Address) LAN (Radio Internal IP Address) LOC (Fryer Internal (Local) IP Address) AP (Radio Application Version Number) RF (Radio System Firmware Version Number) IM (Radio Fryer Communication Protocol Version Number) Reboot the Radio Chapter 9 Component Replacement Procedures Control Panel Replacement Reset Circuit Breaker Replacement Power Switch Replacement Momentary Switch Replacement USB Port Replacement High Limit Module Replacement Primary Contactor Replacement Heat Contactor Replacement AIF Multi-Tab Transformer Replacement AIF Board Replacement Control Board Transformer Replacement Drain Valve Replacement Drain Valve Removal Procedure Remove the Old Drain Valve Disassemble the Old Drain Valve Drain Valve Installation Procedure Assemble the New Drain Valve Install the New Drain Valve Filter Motor Replacement Filter Motor (Pump) Removal Check New Filter Motor Wiring Migrate an Old Filter Pump to a New Filter Motor ii

5 Remove the Filter Pump Install the Filter Motor Seal Kit Install New Rollers Install the Filter Pump Filter Pump/Motor Installation Filter Pump Check Valve Replacement JIB / ATO Pump Replacement Flex Line Replacement Replace the Heating Element Assembly Prepare the Fryer Remove the Old Heating Element Assembly Bench Build the New Heating Element Assembly Install the Element Test and Assemble the Fryer Temperature Level Probe Replacement High Limit Thermocouples Replacement Drain Pan Microswitch Replacement Wi-Fi Radio Wi-Fi Power Supply Chapter 10 Illustrated Parts Catalog Chapter 11 Annual Inspection and Checklist Required Tools Required Parts Chapter 12 Wiring Diagram Chapter 13 Oil Flow and Plumbing Contents iii

6 List of Tables Table 3-1 User Interface Controls & Indicators...10 Table 3-2 Operating Components...12 Table 3-3 Connection Locations and Descriptions...13 Table 3-4 Info Button Stats...19 Table 4-1 Preventative Maintenance Schedule...35 Table 5-1 Special Programming Mode Details...43 Table 6-1 Information Mode Details...48 Table 6-2 Left Cook Data...60 Table 6-3 Right Cook Data...61 Table 6-4 Today s Data Log...62 Table 6-5 Prev-Day-Sun...63 Table Day Totals...64 Table 6-7 Oil Data...65 Table 6-8 Prev Oil Data...66 Table 6-9 Diagnostic Modes...68 Table 6-10 Diagnostic Mode Details...69 Table 7-1 Cooking Troubleshooting Guide...79 Table 7-2 Warnings...85 Table 7-3 Error Messages...86 Table 8-1 Tech Modes...91 Table 10-1 Components, Front Table 10-2 Drain Pan Assembly Table 10-3 Drain Valve Assembly Table 10-4 Heating Element Assy Table 10-5 Thermocouple and Probes Table 10-6 Control Shroud Table 10-7 Motors and Plumbing Components Table 10-8 Accessories Table 10-9 Wi-Fi Table 11-1 Annual Inspection Checklist List of Figures Contents Figure 1-1 Dimensions...1 Figure 2-1 Unpacking...4 Figure 2-2 Installing the Hinges...5 Figure 2-3 Fryer Positioning...6 Figure 2-4 Cable Restraint...8 Figure 3-1 User Interface Controls & Indicators...9 Figure 3-2 Operating Components Figure 3-3 Connection Locations and Descriptions...13 Figure 3-4 Level Indicator Lines...16 iv

7 Figure 3-5 Reserve Oil Tank...17 Figure 3-6 Filter Envelope Installation...30 Figure 3-7 Drain Pan Assembly...31 Figure 4-1 Reserve Oil Tank Shelf Slots...37 Figure 4-2 Engaging The Reserve Oil Tank...38 Figure 9-1 Rod Assembly Connection Figure 9-2 Valve Stem Stack Figure 9-3 Pump Seal Kit Placement Figure 9-4 Pump Rollers Figure 9-5 Marking the Upper heating Element Figure 9-6 High Limit Clip and Clamp Install Figure 9-7 Spreader Bar Installation, Right Side Figure 9-8 Spreader Bar Installation, Left Side Figure 9-9 Heating Element Assembly O-Ring Installation Figure 9-10 Positioning Heating Element Assembly Into Fryer Figure 9-11 Heating Element Assembly Hardware Install Figure 9-12 Thermocouple Installation, Right Side Figure 9-13 Spreader Bars Installation, Right Side Figure 9-14 Spreader Bars Installation, Left Side Figure 9-15 Element Guard Installation Figure 9-16 Element Contactor Wiring Figure 10-1 Components, Front Figure 10-2 Drain Pan Assembly Figure 10-3 Drain Valve Assembly Figure 10-4 Heating Element Assy Figure 10-5 Thermocouple and Probes Figure 10-6 Control Shroud Figure 10-7 Motors and Plumbing Components Figure 10-8 Accessories Figure 12-1 Wiring Diagram Figure 13-1 Oil Flow and Plumbing vcontents

8 Contents vi

9 Safety and Compliance Henny Penny fryers have many safety features incorporated. However, the only way to ensure safe operation is to fully understand the proper installation, operation, and maintenance procedures. The instructions in this manual have been prepared to aid you in learning the proper procedures. Where information is of particular importance or is safety related, the words DANGER, WARNING, CAUTION, or NOTICE are used. Their usage is described as follows: DANGER! indicates hazardous situation which, if not avoided, will result in death or serious injury. DANGER! WARNING! indicates hazardous situation which, if not avoided, could result in death or serious injury. WARNING! CAUTION! indicates hazardous situation which, if not avoided, could result in moderate or minor injury. CAUTION! NOTICE NOTICE is used for information considered important regarding property damage. Preface vii

10 These are the original version controlled Henny Penny instructions for Chick-fil-A Electric (CFE) model 415 (CFE 415). This manual is available on the Henny Penny Public website ( Read these instructions completely prior to installation and operation of this appliance to ensure compliance to all required installation, operation and safety standards. Read and obey all safety messages to avoid damage to the appliance and personal injury. This fryer must be installed and used in a way that water does not contact the oil which can cause splashing and boiling over of oil and steam leading to personal injury; excludes normal product moisture. Burn risk! Do not move the fryer or filter drain pan while containing hot oil. Personal injury or serious burns can result from splashing hot oil. This appliance is intended for commercial use in kitchens of restaurants, bakeries, hospitals, etc. but not for the continuous mass production of food such as in a factory setting. During use the units airborne A-weighted emission sound pressure is below 70 db(a). All repairs must be performed by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. Always use strain relief. The provided power cord must be installed with a strain relief in a way that if the strain relief fails, wires L1, L2, L3 and N must draw taunt and fail first. If the supplied power cord or an existing one becomes damaged, do not use it; rather, replace it with a known good power cord. The powercord must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. Proper daily, weekly, monthly, quarterly and yearly maintenance must be performed on this appliance to ensure safe and continuous operation. This appliance must never be cleaned with a water jet or steam cleaning tool. Cleaning brushes are shipped with the appliance and proper cleaning instructions are included in this manual. Preface Proper maintenance also increases the usable life of the appliance and oil, which reduces lifetime operating costs. Additionally, old oil increases the possibility of surge boiling and fire due to the reduced flash point of the oil. The oil temperature must never exceed 450 F (230 C). This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a viii

11 person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. This appliance is not intended to be operated by means of an external timer or a separate remote control system. Preface ix

12 Preface x

13 Chapter 1 Overview This chapter outlines basic information needed by installers and operators to safely install and operate the appliance. 1.1 Technical Support Call your local service provider or distributor first. For additional help, call or Henny Penny (HP) Technical Support at: Inside the U.S.: or technicalservices@hennypenny.com. Outside the U.S.: or intltechsupport@hennypenny.com. 1.2 Dimensions Figure 1-1 Dimensions 1.3 Clearance The CFE 415 fryer attaches to the PFE 500 fryer and can not be used as a standalone fryer. Following the clearance guidelines of the PFE 500 fryer and the installation recommendations for proper operational clearance, see Figure 2-3 Fryer Positioning, page 6 within the 2.3 Install the Fryer, page 4 section of this document. 1Overview

14 1.4 Data Plate Location The data plate contains information about your fryer that Henny Penny Technical Support needs to assist with issues and the ordering of parts and filters. The data plate is a sticker that is located on the upper-right, outer shroud. 1.5 Features The Henny Penny model CFE 415 fryer has many features to allow operators to produce consistent, high quality products. The controls monitor not only cooking times and temperatures, but also oil condition, product weights, product temperatures, and many other operational variables. The controls may vary the actual oil temperature and cook times, based on changes of the operational variables. The controls also have very extensive self-diagnostic functions which alerts the operator to both component and procedure problems. Some unique features of the fryer are listed below: Diagnostic Function: provides summary of fryer and operator performance, see 6.3 Diagnostic Mode, page 67. Warnings and Error Messages: provides immediate feedback for operator error or fryer malfunction, see 7.2 Warning Messages, page 85. Information Mode: gathers and stores historic information on the fryer and operator performance, and can be viewed by the operator, see 6.2 Information Mode Details, page 48. Manual Program Mode: operator can set time and temperature for nonstandard products, see Manual Mode, page 18. Language Selection: Easily toggle between English and Spanish operation, see 5.3 Language Selection, page 42. Clean-Out Mode: a pre-programmed function for cleaning the vat, see 4.1 Clean- Out Mode, page 33. Overview 2

15 Chapter 2 Unpack and Install 2.1 Unpack the Fryer Unpack the fryer in a careful manner following the instructions as listed. Shock hazard. Do not puncture the fryer with any objects such as drills or screws as component damage or electrical shock could result. Installation of this unit should be performed only by a qualified service technician. NOTICE Any shipping damage should be noted in the presence of the delivery agent and signed prior to his or her departure. 1) Carefully cut and remove banding straps. 2) Lift the main box off the fryer. This procedure should be performed in an area with high ceilings to avoid damage to the unit and ensure sufficient clearance. 3) Remove the two hex head bolts from the temporary front left leg and remove leg (1), see Figure 2-1 Unpacking, page 4. Save the leg and bolts for re-installation. 4) Unlatch and remove drain pan from under fryer. Place in a location clear of unpacking area (2). NOTICE Remove filter pan from under fryer before removing fryer from pallet or damage to unit may result. 5) Re-install the left front leg (3). 6) Cut and remove plastic banding strap from around the fryer that is laced through the pallet wood blocking. 7) Tilt the fryer to one side and knock out the wood blocking on the opposite side (4). This will take two individuals, one for the tilting and second one to remove the wood blocking. 8) Once the wood blocking is removed, relax fryer on pallet. Carefully push fryer sideways in the direction of the removed wood blocking to clear the second blocking that is left in plan. WARNING! The fryer weighs about 280 lbs. Use two people to maneuver otherwise serious injury may result. 9) Continue to slowly push fryer in the same sideways direction. make sure the casters are rolling on the pallet deck board surfaces. Do not allow casters to drop between pallet surface spaces. Ease fryer off the pallet edge and clear of pallet. 3Unpack and Install

16 Figure 2-1 Unpacking 2.2 Select the Fryer Location To prevent fryer from tipping and splashing hot oil, fryer must be attached with supplied hinges only to the right side of an existing PFE 500 and positioned on a flat level surface to prevent tipping or movement, otherwise severe burns may result. Restraining ties may be used for stabilization. To avoid fire and ruined supplies, the area under the fryer should not be used to store supplies. The location of the open fryer should allow clearances for servicing and proper operation. Unpack and Install 2.3 Install the Fryer The CFE 415 must be attached to the right side of an existing PFE 500 with supplied hinges. A flat level surface is required for installation. The unit must be attached to the right side of a PFE 500 fryer with the supplied hinges per these instructions. Failure to do so may cause the unit to be unstable which could lead to severe burns and/or injury. Close and secure the PFE 500 fryer lid so hot oil does not splash while installing the CFE ) Disconnect power from the PFE 500 that the CFE 415 will be connected to. 4

17 2) Place the PFE 500 at about a 45 angle of the CFE 415, see Figure 2-2 Installing the Hinges, page 5. 3) Rotate the hinges aligning them on the rear PFE 500 fryer frame rail. 4) Secure the pivot hinge to the PFE 500 by installing the single screw (1) in each hinge (2). 5) Install two screws (3) in each hinge, securing the hinges to the PFE 500 fryer. Figure 2-2 Installing the Hinges INFO: When units are side by side the front of the units will not be flush. 6) Rotate both fryer units so that they are side by side, see Figure 2-3 Fryer Positioning, page 6. 5Unpack and Install

18 Figure 2-3 Fryer Positioning 7) Plug in both fryers. Unpack and Install 2.4 Level the Fryer For proper operation, the open fryer should be level from side-to-side and front-toback. Using a level placed on the flat areas around the vat collar, on the middle well, adjust the casters until the unit is level. 2.5 Ventilate the Fryer The fryer should be located with provision for venting into an adequate exhaust hood or ventilation system. This is essential to permit efficient removal of the steam exhaust and frying odors. Special precaution must be taken in designing an exhaust canopy to avoid interference with the operation of the fryer. We recommend you consult a local ventilation or heating company to help in designing an adequate system. NOTICE Ventilations must conform to local, state, and national codes. Consult your local fire department or building authorities. 6

19 2.6 Electrical Requirements To avoid electrical shock, do not disconnect the ground (earth) plug. This fryer must be adequately and safely grounded (earthed). Refer to local electrical codes for correct grounding (earthing) procedures or in absence of local codes, with The National Electrical Code, ANSI/NFPA No. 70-(the current edition). In Canada, all electrical connections are to be made in accordance with CSA C22.2, Canadian Electrical Code Part 1, and or local codes. To avoid electrical shock, this appliance must be equipped with an external circuit breaker which will disconnect all ungrounded (unearthed) conductors. The main power switch on this appliance does not disconnect all line conductors. (for equipment with CE mark only!) To prevent electric shock hazard, this appliance must be bonded to other appliances or touchable metal surfaces in close proximity to this appliance with an equipotential bonding conductor. This appliance is equipped with an equipotential lug for this purpose. The equipotential lug is marked with the equipotential symbol shown in Safety and Compliance, page vii. An all pole, separate disconnect switch, with proper capacity fuses or breakers must be installed at a convenient location between the fryer and the power source, and must be installed according to national and local codes. It should be an insulated copper conductor rated for 600 volts and 90 C. For runs longer than 50 feet (15.24 m), use the next larger wire size. CE units require a minimum wire size of 6 mm to be wired to the terminal block. NOTICE Always check the data plate, mounted on the right-hand side of shroud to determine the correct power supply prior to making any electrical connection, or damage to components may result. It is recommended that a 30 ma rated protective device such as a residual current circuit breaker (RCCB), or ground fault circuit interrupter (GFCI), be used on the fryer circuit. Permanently connected electric fryers with casters must be installed with flexible conduit and a cable restraint, when installed in the United States. See illustration at below. Holes are available in the rear fryer frame for securing the cable restraint to the fryer. The cable restraint does not prevent the fryer from tipping. I-bolt to be secured to the building using acceptable building construction practices Figure 2-4 Cable Restraint, page 8. 7Unpack and Install

20 Figure 2-4 Cable Restraint INFO: FOR DRYWALL CONSTRUCTION secure I-bolt to a building stud. Do not attach to drywall only. Preferred installation is approximately six inches to either side of service. Cable restraint must be at least six inches shorter than flexible conduit. The supply power cords shall be oil-resistant, sheathed flexible cable, no lighter than ordinary polychloroprene or other equivalent synthetic elastomer-sheathed cord. Unpack and Install 8

21 Chapter 3 Operation 3.1 User Interface Controls & Indicators Controls and indicators can be found in this section. The controls and indicators are show in Figure 3-1 User Interface Controls & Indicators, page 9 and described in Table 3-1 User Interface Controls & Indicators, page 10. Figure 3-1 User Interface Controls & Indicators 9Operation

22 Table 3-1 User Interface Controls & Indicators Item No. Description Functions 1 Heat On LED Oil heats when illuminated. 2 Digital Display Displays functions of the cook cycle, Program Mode, Diagnostic Mode and alarms. 3 Wait LED Flashes when the oil is either too cool or too hot to drop product. 4 Ready LED Illuminates when oil temperature is 5 F below set point to 15 F above set point, signaling product can now be cooked. 5 Info Button Press to display current fryer information and status; if pressed in the Program Mode, it shows previous settings. Pressing this along with the program button accesses the Information Mode which has historic information on the operator and fryer performance. 6 Filter Button Used to access the Filter Menu; also used for up or down buttons. 7 Program Button Press to access Program Mode; once in the Program Mode it is used to advance to the next setting. If pressed along with the info button, it accesses the Information Mode which has historic information on the operator and fryer performance. It also allows access to the English-Spanish settings, diagnostics, Clean-Out Mode, and Manual Mode, if pressed before the appropriate button. 8 Timer Button Used to stop cook cycles and to stop the timer at the end of the Hold cook cycle. It is also used to program a Manual Program for nonstandard products. 9 Menu Strip Shows name of food product selected. The menu strip is located behind the decal. 10 Product Select Button Press to select food products to be cooked, as well as answering Display prompts. If you press the program button before selecting a product selection number; 4 accesses the diagnostics; 5 accesses the Clean-Out Mode; and 6 toggles between English-Spanish display. 11 Filter Light A filter light is found beside each black drain knob. When the light is solid blue, the oil requires filtering. When this indicator is flashing, the drain requires opening or closing. Operation 12 Power Switch When the power switch is turned to the on position, power is supplied to the controls and pumps. 10

23 Operating components can be found in this section. The operating components are show in Figure 3-2 Operating Components, page 11 and described in Table 3-2 Operating Components, page 12. Figure 3-2 Operating Components Operation 11

24 Table 3-2 Operating Components Item No. Description Functions 1 Vat Cover Covers the vat when not in use. 2 USB Port Used to download information from controls and perform firmware updates. 3 Drain Valve Knob 4 Reserve Oil Tank 5 Filter Drain Pan Assembly 6 Quick Disconnect Pull out black knob to open drain valve and oil drains from vat; Push in to close drain valve and oil can be pumped into vat. Used to hold new oil for the automatic oil top-off feature. Oil is drained into this pan and then is pumped through the filter to help prolong the use of the oil. Connection for rinse hose when disposing oil. o INFO: This connection is only used when disposing oil. 7* Basket Each vat accommodates two 1/2 baskets or one full-size nugget or tiered basket. *Not Shown 3.2 Control Board Inputs and Outputs The control panel (board) can be seen as the brains of the fryer and provides technicians with a user interface that consists of buttons for inputting data, and LEDs which provides data outputs. The control panel monitors onboard sensors and systems, and then provides feedback on the state of the fryer. Onboard memory in the form of an SD card stores operational data and allows for the extraction of data in the form of reports. Coupled with the Wi-Fi radio system the data can flow in and out of the control panel via remotely hosted software applications. Operation The control panel also provides information for diagnosis and repair of issues. Built in sensors monitor the various systems within the fryer, and then reports the status back to the control panel in the form of signal voltage. This data is then compared to the operational settings and if required, outputs in the form of signal voltage are sent out to adjust various system parameters or to alert operators to an out of parameter state Rear Panel Interface This section is an overview of the rear control panel inputs and outputs, refer to Chapter 3 Operation, page 9 for information about the front side of the control panel interface, 9.1 Control Panel Replacement, page 107 for replacement procedures, Figure 10-1 Components, Front, page 140 for part numbers, and Chapter 12 Wiring Diagram, page 163 for connection details. 12

25 Not Used USB Temp. Probes Wi-Fi Figure 3-3 Connection Locations and Descriptions Table 3-3 Connection Locations and Descriptions Item No. Description Functions P1 Control Transformer Position 1-5, left to right: volts from transformer to control volts from transformer to control. 3. Line voltage from control to transformer. 4. Line voltage from control to transformer. 5. Line voltage from control to transformer. P2 Power Input Connector Incoming line voltage (208v), position 1-3, left to right: P4 Full Right Vat Only Line Voltage 1. Line voltage in, to control. 2. Not Used 3. Line voltage in, to control. Position 1-4, left to right: 1. Right-side full vat oil return valve. 2. Right-side full vat oil return valve. *Unnumbered on Decal Operation 13

26 Item No. Description Functions 3. Not Used 4. Not Used P8 Filter Control Board Position 1-7, left to right: 1. 24V Com. 2. Data Out 3. Data Out 4. 24V DC In 5. Data In 6. Data In 7. Data In P10 Drain Switch Drain switch and contactor circuit: - SH: Shunt Contactor - RS: Safety Contactor - HI: Hi Limit Contactor - RH: Heat Contactor P14 LED Outputs Full vat LED filter beacon: -14 ma. limit; White +/ Black - * Current Sensor Used on Chick-fil-A units only to measure AMPs. Wires have a ferrite ring around the to prevent radio wave interference. * Main Power Switch Incoming voltage (P2 to P1) is stepped down to 24V, and then from the control panel to the power switch. Based on the position of the switch: - OFF: Allows limited access to control panel menus but no access to fryer functions. - ON: Allows full access to all fryer functions and control panel menus. * Temp. Probe Position 1-12, upper left to lower right: Operation 1. Not Used 2. Not Used 3. Temperature Probe 4. Temperature Probe *Unnumbered on Decal 14

27 Item No. Description Functions 5. Not Used 6. Not Used 7. Protection Probe 8. Protection Probe 9. Not Used 10.Not Used 11.Top off temperature probe 12.Top off temperature probe * USB Connection Used to manually flash firmware or load software directly on to the control panel. * Wi-Fi Connection Used to connect the power cable from the control panel to the radio, and the data cable from the radio to the control panel. *Unnumbered on Decal 3.3 Fill or Add Oil Wear Personal Protective Equipment (PPE) including heat and oil resistant gloves, apron and face shield to avoid serious burns when pouring oil into hot vat. Oil and all metal parts that are in contact with the oil are extremely hot; take care to avoid splashing, or serious burns may result. The oil level must always be above the heating elements when fryer is heating and at the proper oil level indicator on the rear of vat. Failure to follow these instructions may result in a fire and/or damage to the fryer. Solid shortening is not recommended. Solid shortening could cause clogging and pump failure Manually Fill an Empty Vat The fryer s vat has two level indicator lines inscribed on the rear wall of the vat, see Figure 3-4 Level Indicator Lines, page 16: upper (1) and lower (2). The upper fill line indicates proper oil level at set point temperature. The lower fill line indicates proper oil level at room temperature. When filling an empty vat with room temperature oil, fill to the center of the lower fill line (2). As oil heats, it expands to the upper fill line (1). Operation 15

28 Figure 3-4 Level Indicator Lines Operation Top Off a Vat The fryer includes an auto top off feature which safely replenishes oil to the fill line throughout the day from the reserve oil tank. Auto top off activates in between cook cycles when the oil is heated to set point temperature and the fryer sits idle for 60 seconds or longer. In cases where cook cycles continuously run without a pause for an extended period of time, new oil may be manually added to the vat from the reserve oil tank through the FILL FROM RESRV option in the filter menu Fill From Reserve Oil Tank, page 29. This feature in enabled only when there are no cook cycles running and no filter cycles activated. Use either of these features instead of manually pouring new oil into a vat that contains hot oil Fill the Reserve Oil Tank During morning start-up procedures and between busy periods, fill the reserve oil tank. Fill the reserve oil tank also if FILL RESERVE OIL, or E-1 appears in the display. Best Practice: Check the reserve oil tank not only during opening procedures, but also between busy periods and top off the tank if oil is low. This keeps team members focused on delivering quality product rather than having to fill the reserve oil tank during busy periods. This also helps prevent an E-1 low oil error code. The following instructions describe filling the reserve oil tank: 16

29 1) Pull reserve oil tank(3) forward and open cover (2), see Figure 3-5 Reserve Oil Tank, page 17. 2) Pour oil into reserve oil tank and fill to the fill line (1). 3) Close cover (2) and gently push reserve oil tank back into position. Figure 3-5 Reserve Oil Tank 3.4 Cook Cycle 1) Fill the reserve oil tank. See Fill the Reserve Oil Tank, page 16. 2) Turn the power switch to on. The unit automatically enters a melt cycle until the oil temperature reaches 230 F (110 C). After reaching 230 F, the heat remains on until the oil temperature is 5 F below set point. Upon initial start-up, CLOCK SET may show in the display. Set the clock to your time following prompts on the display. See 5.1 Clock Set, page 41. The control may ask if the oil is NEW or OLD when first turned on depending on special circumstances the fryer may have encountered when it last powered off or was reset. Press button 1 if the oil is new and button 3 if the oil is old. Use the up and down buttons to set the age of oil in days. INFO: The controls automatically offset the oil temperature higher than set point temperature for new oil. As the oil ages, the temperature of the oil decreases to match the set point temperature. 3) Once the fryer exits melt at 230 F (110 C), the wait LED flashes until the oil is 5 below set point temperature (plus any offset temperature). Operation 17

30 4) The control prompts STIR VAT when the temperature of the oil is slightly below set point. Carefully stir the oil to avoid splashing using the removable basket handle. Thoroughly mix the oil by stirring it from bottom to top, clockwise and counter clockwise. If the control prompts to STIR VAT additional times, continue stirring until the prompt disappears. 5) Once the controls detect a stir, the timer will count down. Continue stirring during this time. 6) Unit will return to flashing the wait LED. When vat has heated or cooled to cooking temperature, the ready LED illuminates and the first product shows in the display. Best Practice: Before loading product, make certain the ready LED is lit as this indicates the oil is at the correct cooking temperature. This helps prevent under or over cooking. INFO: The heat cook cycles on and off near the set point temperature to help prevent overshooting the set point temperature (proportional control). The control automatically offsets the oil temperature higher than set point temperature for new oil. As the oil ages, the temperature of the oil decreases to match the set point temperature. 7) If the oil was not filtered the night before at shutdown, perform a daily filter prior to cooking, see Daily Filtering, page 23. 8) Follow the steps in Chick-fil-A s training materials to load the product. 9) Press a desired product button to start a cook cycle. If cooking on the left side of the vat, select a left product button. If cooking on the right side of the vat, select a right product button. The display counts down the cooking time on the side the product button was pressed. INFO: Press the info button to view the current oil temperature. To stop a cook cycle, press the timer button. Cook times may count down faster or slower than real time, compensating for oil age, product weight, product temperature, and other operational variables. 10)At the end of the cook cycle, an alarm sounds, and the display flashes DONE. Press the timer button to stop the alarm. 11)Follow the steps in Chick-fil-A s training materials to unload the product and check for doneness. 12)Before frying next load, allow for oil to reheat and the ready LED light. Operation Manual Mode This allows the operator to quickly program a time and press temperature for nonstandard products that are not on the menu card. This is to be a temporary setting and disables most of the advanced features of the controls. Use the following instructions to enter Manual Mode: 1) Once out of the Melt cook cycle, press the program button then the timer button. 18

31 2) Use the up or down button to set cook time. 3) Press the program button and use the up or down button to set temperature. 4) Press the program button to start Manual Mode. Display shows MANUAL. 5) Press product selection 2 to exit Manual Mode Info Button Stats Table 3-4 Info Button Stats Menu Step Description Actual Oil Temperature Set-Point Temperature Remaining Cook Cycles Before Filter Lockout Average Cook Temperature Current Temp & Rate of Temp Rise Today s Date Probe Temperature Press the info button one time and display shows the actual oil temperature for each vat. Press the info button two times and display shows SP along with the set point (preset) temperature of each vat. Press the info button three times and display shows the number of remaining cook cycle before Filter Lockout. This count resets to 5.00 after performing an Express Filter. Each full basket of product cooked decreases this value by approximately 1. Each half basket of product cooked decreases this value by approximately 0.5. Press the info button four times and display shows Average Cook Temperature. Press the info button five times and display shows Current Temp. Probe Reading and Rate of Temp. Rise. Press the info button six times and display shows Today s Date. Press the info button seven times and display shows: P= Protection Probe Temperature L= Level Probe Temperature Main Probe Temperature INFO: If not button is pressed within five seconds in any of stats mode, the controls revert back to normal operation. Operation 19

32 3.5 Care of Oil With prolonged use, the flashpoint of oil is reduced. Dispose oil if it shows signs of excessive smoking or foaming. Serious burns, personal injury, fire, and/or property damage could result. Follow the instructions below to avoid oil overflowing the vat, which could result in serious burns, personal injury, fire, and/or property damage. To protect the oil when the fryer is not in immediate use, the fryer should be turned off. NOTICE Frying breaded products requires filtering to keep the oil clean. oil should be skimmed frequently throughout the day and filtered thoroughly once a day, see Daily Filtering, page 23. Dispose oil if display shows CHANGE OIL SOON or if oil shows signs of excessive foaming or smoking. Maintain the oil at the proper cooking level. Check and fill the reserve oil tank throughout the day. Do not overload the baskets with product, or place product with extreme moisture content into baskets Express Filter An Express Filter is the fryer s terminology for a quick clean. The Express Filter is a quick way to ensure that excess coater in the vat gets removed to keep it from scorching and degrading the oil Automated Express Filter After about five to ten cook cycles based on usage, or after three hours, the Filter Light illuminates on the front of the fryer, and FILTER LOCKOUT / YOU *MUST* FILTER NOW shows in the display. The control refuses further cook cycles until the vat is filtered. 1) Press product button 1. to start the Express Filter. Display shows OPEN DRAIN. Pull drain knob (1) out, display shows DRAINING and oil drains from vat. Operation 20

33 INFO: if the drain is clogged, the display shows VAT EMPTY. Use straight white brush to clear drain. Visually check vat is empty and press the product selection 1 button to proceed with filtering process. 2) WASHING is displayed. The filter pump motor automatically turns on and oil jets on the bottom of the vat wash excess coater down the drain. CLOSE DRAIN appears after the wash cycle, push in on drain knob to close drain. Display shows FILLING and vat refills with oil. Best Practice: Use a brush to loosen and remove excess coater from the heating elements and gently from the temperature sensors during the wash. Operation 21

34 3) Once vat is filled, display may show POT FILLED? YES NO. Make sure vat is full to at least the lower fill line and then press product button 1. The display will show WAIT while the vat heats to set point temperature. 4) If the oil has not pumped back to the proper level in the vat during the Express Filter process, press product button 3 and pump runs for another minute. This ensures that all of the oil is pumped out of the drain pan and back up to the vat. See 5) Then the display shows IS POT FILLED? YES NO. Make sure vat is full to at least lower fill line or press product selection 3 to continue filling more, press product selection 1. The control returns to normal operation. You can try to fill the vat 3 times. After that, FILL DONE will display to allow manually running the pump to refill the vat. Best Practice:To help ensure vat fills completely, clean the filter pan at least once a day, change the filter envelope at least once a day, and make sure the reserve oil tank is full and that the o-rings on the filter pan are not damaged or missing Forcing an Express Filter to Reset the Filter Count Operation An Express Filter can be started befor the fryer goes into filter lockout. To reset the filter count back to 5.0, press and hold the filter button and FILTER MENU and 1. EXPRESS FILTER display. Press product button 1 and display shows CONFIRM, followed by YES NO. Press product button 1. to start, see Automated Express Filter, page 20 for procedure. Best Practice: Manually initiating an Express Filter is beneficial to do between busy periods as it resets the fryer back to five full cooks (5.0). By doing this, the fryer can continue to cook without interruption during busy periods. 22

35 3.5.2 Daily Filtering A Daily Filter is the fryer s terminology for a thorough clean and should be done once a day. The Daily Filter is similar to an Express Filter however it adds steps to scrub the vat and to rinse the vat. It also includes options to repeat the wash cycle. This procedure can be performed during any non-frying periods. Burn Risk! To avoid burns from hot oil, use approved safety equipment including an apron, face shield, and gloves before starting the filtering procedure. 1) Check Filter Pan: A new filter envelope should be used on the first filter of each day, but the same filter envelope can be used for the rest of the day. Make sure that filter pan cover is in place., filter drain tube is secured, and filter drain pan is pushed into place. if filter drain pan and cover are not latched into place, the display displays CHK PAN. 2) Press and hold the filter button until display shows 1.EXPRESS FILTER? 3) Press the down button and display shows 2.DAILY FILTER? 4) Press product button 1 and display shows CONFIRM, followed by YES NO. 5) Press product selection 1 for yes; display shows OPEN DRAIN. Pull out on the drain knob. The display shows DRAINING and the oil drains form the vat, (or press product selection 3 and controls return to normal operation. 6) While washing, use a brush to remove crumbs and coater from the sides, heating elements and the bottom of the vat. Be gentle when cleaning around the temperature sensors. Operation 23

36 NOTICE Do not use steel wool, other abrasive cleaners or cleaners/ sanitizer containing chlorine, bromine, iodine, or ammonia chemicals, as these will deteriorate the stainless steel material and shorten the life of the unit. Do not use a water jet (pressure sprayer) to clean the unit, or component damage could result. 7) Once the vat is clean and display shows SCRUB VAT COMPLETE? YES NO. 8) Press product selection 1, display shows WASHING and oil circulates through vat for several minutes. When wash cook cycle is complete, display shows WASH AGAIN? YES NO. 9) Press product selection 1 if another wash is needed, otherwise press product selection 3 and the display shows CLOSE DRAIN. Push in on drain knob to close drain, the display shows RINSING and vat fills with oil. Operation 10)Once the vat is filled, OPEN DRAIN shows in display. Pull out on drain knob to open the drain and display shows RINSING. When rinsing is complete, display shows RINSE AGAIN? YES NO. 11)Press product selection 1 if another rinse is needed, otherwise press product selection 3. Display shows POLISH? YES. 12)Press product selection 1 for YES and oil is polished by circulating it through the filtering system. The display shows 5:00 NO=STOP. If desired, press product selection 3 button to stop the polishing, otherwise the oil is polished for 5 minutes. Once the oil is polished, the display shows FILL VAT? YES. 24

37 13)Press product selection 1 and display shows CLOSE DRAIN Push in on drain knob to close drain, display shows FILLING and vat then refills with oil. 14)Once full, display shows IS POT FILLED? YES NO. Press product selection 1; fryer returns to normal operation. 15) If product selection 3 is pressed, display shows FILLING. You can try to fill vat four times and then control shows ADD QUIT. 16)Press left timer button and JIB pump runs 60 seconds, filling vat from reserve oil tank. When vat is full, press the right timer button and display shows IS POT FILLED? YES NO. Press product selection 1 and fryer returns to normal operation. 3.6 Filter Menu Along with Express Filter and Daily Filter, here is a listing of all the Filter Menu items available. Press and hold the filter button to enter the filter menu: 1. Express Filter 2. Daily Filter 3. Dispose 4. Drain To Pan 5. Fill From Pan 6. Fill From Resrv (reserve oil tank) 7. Exit Oil Disposal This procedure requires the use of an oil disposal shuttle intended for use with hot oil and the filter rinse hose. Dispose oil from vat by following these instructions: 1) Locate disposal shuttle or filter rinse hose and attach to fryer. Operation 25

38 2) Press and hold the filter button until display shows *FILTER MENU*, along with 1.EXPRESS FILTER? 3) Press the down button twice until display shows 3.DISPOSE. Press product selection 1; display shows DISPOSE? YES NO. 4) Press product selection 1; DRAIN VAT? YES NO shows in display. Press product selection 3 if draining the vat is not desired and skip to step 9. 5) Press product selection 1 and Filter Light flashes and display shows OPEN DRAIN. Pull out black drain knob to open drain and display shows DRAINING. Operation 26

39 6) Oil drains from vat into drain pan and then display shows VAT EMPTY YES NO. Verify that vat is empty, and press product selection 1. 7) Display shows CLEAR OLD OIL FROM OIL LINES DISPOSE DONE. Press and hold the left timer button for a few seconds to clear old oil. Once cleared, press the right timer button and display shows DONE. 8) Display shows CLN VAT COMPLETE YES NO. Once vat is clean, press product selection 1. 9) Display will read HOSE READY? Ensure the hose is connected to fryer and aimed into disposal shuttle. WARNING! Burn Risk! Always wear PPE including heat and oil resistance gloves, an apron and face shield to prevent burns caused by hot surfaces and by splashing of hot oil. 10)Press and hold product selection 1 to dispose. 11)YES= Pump NO= Done. 12)Once oil is no longer pumping from drain pan, press the right product selection 3 button. Blue Filter Light flashes and display shows CLOSE DRAIN and push in the black drain valve knob to close drain.burn Risk! Always wear PPE including heat and oil resistance gloves, an apron and face shield to prevent burns caused by hot surfaces and by splashing of hot oil. Operation 27

40 13)Display shows MANUAL FILL VAT, followed by IS POT FILLED?, along with YES NO. Fill the vat to the lower indicator line on the rear of the vat. See Filling or Adding Oil instruction from 3.3 Fill or Add Oil, page 15Press product selection 1 if the vat is filled to the lower level line and fryer returns to normal operation. If product button 3. is pressed, vat displays KEEP OFF UNTIL FILLED Drain to Pan DRAIN TO PAN drops the oil to the drain pan. The oil will not pump back up to the vat until step 5. FILL FROM PAN is used. This step is used for special circumstances such as service of a component in the vat. Overflow risk! Ensure the drain pan is empty before draining the oil, otherwise hot oil will overflow the drain pan. Severe burns may result. Operation 1) Press and hold the either filter button until display shows *FILTER MENU* followed by 1.EXPRESS FILTER. 2) Press the down button three times until 5. DRAIN TO PAN shows in display. 3) Press product selection 1; OPEN DRAIN is displayed if the drain pan is positioned under the fryer. If CHK PAN displays insert the drain pan and push it back as far as possible under the fryer. 4) Pull the drain handle to drain the oil Fill From Pan FILL FROM PAN pumps oil from the drain pan back up to the vat. This step can be helpful to troubleshoot whether the filter pump motor runs, or to ensure that all oil is pumped out of the drain pan if the pan is to be removed from the fryer. 28

41 1) Press and hold the either filter button until display shows *FILTER MENU* followed by 1.EXPRESS FILTER. 2) Press the down button four times until 5. FILL FROM PAN shows in display. 3) Press product selection 1; FILL & DONE is displayed. 4) Press the left timer button; display shows FILLING and oil is pumped from the drain pan to the vat. Stop the pump by pressing the left timer button again Fill From Reserve Oil Tank If oil level is a little low, oil can be added to vat at any time from reserve oil tank to raise oil level to proper level by following steps below. This procedure is not to be used to fill an empty vat. 1) Press and hold the either filter button until display shows *FILTER MENU* followed by 1.EXPRESS FILTER. 2) Press the down button five times until 6.FILL FRM RESRV shows in display. 3) Press product selection 1; FILL & DONE is displayed. 4) Press and hold left timer button; display shows FILLING and oil is pumped from the reserve oil tank to the vat. 5) Once vat is full, release the timer button; FILL & DONE displays. Press the right timer button and then product selection 3 for normal operation. 3.7 Drain Pan Assembly Remove and clean the drain pan assembly at the end of the night. The drain pan should be clean prior to closing. Assemble the clean, dry drain pan using the following instructions: 1) Slide a filter envelope (3) onto the filter screen (2) so the plug is protruding through the hole, see to Figure 3-6 Filter Envelope Installation, page 30. Best Practice: During assembly, be sure to apply new oil to all o-rings to lubricate to help prevent tears and damage. See Quarterly Drain Pan O-Ring Replacement, page 38. 2) Fold the open end of the filter envelope inward, then fold the end down to seal off the opening, see detail A. 3) Slide the two handle clamps (1) onto the ends of the filter screen assembly with the handles facing the same direction of the plug. Operation 29

42 Figure 3-6 Filter Envelope Installation Operation 4) Place the filter screen (3) into the bottom of the drain pan (4) with the plug side up, see Figure 3-7 Drain Pan Assembly, page 31. 5) Lining up the hole of the pickup tube (5) with plug of the filter screen (3), press the tube down. 6) Position the pickup tube (5) so that the guides slide into the notches located on the holder in the front of the drain pan (4), then press down on the pickup tube to confirm it is fully engaged on the filter screen plug (3) and in the holder. 7) Place the crumb basket (2) into the drain pan (4) so the legs straddle the filter screen (3). 8) Place lid (1) onto drain pan. Slide the bent side of the drain pan lid (1) into the lip end of the drain pan base first. 30

43 9) Lubricate the o-rings on the filter tube with cold oil before placing the drain pan assembly back into position. Figure 3-7 Drain Pan Assembly 10)Push the drain pan into place and lock it into place using the locking latch. Operation 31

44 11)To remove the drain pan for cleaning, reverse this procedure. Operation 32

45 Chapter 4 Maintenance The following cleaning procedures ensures the fryer is sanitary, while keeping product quality high and downtime to a minimum. For controls and indicators information, see 3.1 User Interface Controls & Indicators, page Clean-Out Mode The clean-out mode removes carbon build up from the inside of the fry vat. The cleanout mode should be performed on a monthly basis to remove this accumulation, otherwise carbon will transfer a burnt flavor to the oil and decrease the accuracy of the sensors in the vat. 1) Turn the power switch off. Hot water and cleaner may splash when performing this procedure, wear Personal Protective Equipment (PPE) including heat and oil resistant gloves, apron and a face shield when performing this procedure, or severe burns may result. 2) Cover adjoining vats to avoid splashing water and cleaner from coming into contact with oil. NOTICE Do not cook product in adjoining vat when clean-out mode is in progress to avoid contaminating oil and/or product. 3) If hot oil is present in the vat, pull out black drain knob and drain oil into drain pan (or, pump oil into disposal shuttle). An E-15 will appear on the control display indicating if the drain is open. WARNING! Burn risk! The filter drain pan must be as far back under fryer as it will go, and the cover in place. Be sure the filter drain pan is latched into place and the hole in the cover lines up with the drain before opening the drain. Personal injury or serious burns can result from splashing hot oil. Burn risk! Do not move the fryer or filter drain pan while containing hot oil. Personal injury or serious burns can result from splashing hot oil. 4) After oil has been drained, close the drain by pushing in the black knob and proceed with normal oil dispose procedure. 5) After allowing the drain pan to cool, remove the filter pan. Remove the filter screen and dispose the old filter pad. Replace filter screen. 6) Place filter pan assembly back under unit. 7) Follow the directions in Chick-fil-A s training materials and fill the vat to the level indicator line with cleaning solution. Maintenance 33

46 NOTICE Do not scrape, use green scouring pads, or steel wool on the heating elements (heating coils), Scratching or abrasions on the surface of the element cause breading to stick and burn and will quickly degrade the oil. Do not use steel wool, other abrasive cleaners, or cleaners/ sanitizers containing chlorine, bromine, iodine, or ammonia chemicals as these will deteriorate the stainless steel material and shorten the life of the unit. Do not use a water jet (pressure sprayer) to clean unit or component damage could result. 8) Turn the power switch to on. Then press the program button followed by product selection 5, CLEAN-OUT? then 1=YES 3=NO shows in display. Press product selection 1 to start Clean-Out Mode. The fryer displays *CLEAN-OUT MODE* and heats up to a preprogrammed temperature, then automatically begins a 15 minute timed countdown. Use the up or down button if necessary, to adjust the temperature and keep the cleaning solution from boiling over. NOTICE If the cleaning solution in the vat starts to foam and boil over, immediately turn the power switch to off, or damage to components could result. Maintenance 9) Using the fryer brush (Henny Penny part number 12105), scrub the inside of the vat, and around the countertop of the fryer. Never use steel wool or green scrub pad to scrub the fryer. Place basket in vat with cleaning solution and scrub basket. 10)After the cleaning mode has completed, turn the power switch to off. Pull out drain handle and drain the cleaning solution from the vat and dispose. See Chick-fil-A guidelines for proper disposal of water and cleaner. An E-15 code will appear indicating the drain is open. Take drain pan and basket support to sink to be cleaned. 11)Re-install the drain pan under the fryer. 12)Close drain and refill the vat with gallons of cold water. 13)If a high alkaline cleaner is used during the clean-out procedure, add approximately 8 ounces of distilled vinegar and re-start the Clean-Out Mode as described in step 8, otherwise skip to step 18. Refer to the cleaner product label for rinsing procedure. 14)Using a clean brush, scrub the interior of the vat to neutralize the alkaline left by the cleaning compound. 15)Drain the vinegar rinse water into the drain pan by pulling the drain handle. Close the drain after pot has emptied. 16)Remove the drain pan with the water/vinegar solution and dispose down the drain. Place the drain pan assembly back under the fryer. 34

47 17)Perform a final rinse of the vat. Drain the water into the drain pan by pulling the drain handle. After the rinse water has drained, close the drain valve, remove the drain pan assembly and discard rinse water. 18)Dry the drain pan and vat thoroughly. Install the basket support. 19)Make sure drain is closed and return filter pan assembly, with new filter envelope, to the fryer. Fill the vat with oil following Filling or Adding Oil instructions from Fill the Reserve Oil Tank, page 16 Best Practice: Make sure the vat and all components of the drain pan are completely dry before adding oil. This keeps oil from quickly degrading and ensure that oil will flow through the filter in the drain pan. INFO: After completing a Clean-Out Mode, the controls assume fresh oil is now in the vat and adjust the temperature accordingly. If the Clean-Out Mode was aborted before starting the 15 minute cook cycle or if fresh oil is not in the vat, set the controls to NEW or USED oil per 5.2 Manually Setting New Or Used Oil, page Preventative Maintenance Schedule As in all food service equipment, the Henny Penny open fryer does require care and proper maintenance. The table below provides a summary of scheduled maintenance procedures to be performed by the operator. Table 4-1 Preventative Maintenance Schedule Procedure Frequency Performing a Daily Filter Daily Filtering, page 23. Cleaning the drain pan and changing the filter envelope 3.7 Drain Pan Assembly, page 29. Clean in-between and behind fryers Daily Cleaning Between and Behind Fryers, page 36. Remove clean and re-install reserve oil tank Weekly Reserve Oil Tank Cleaning, page 36. Daily Daily Daily Weekly Lubricate filter pan o-rings 3.7 Drain Pan Assembly, page 29. Changing of oil Oil Disposal, page 25. Clean-out procedure 4.1 Clean-Out Mode, page 33. Every filter envelope change. When CHANGE OIL SOON is displayed. Immediately after every change of oil. Maintenance 35

48 Procedure Frequency Replace drain pan o-rings Quarterly Drain Pan O-Ring Replacement, page 38. Replace reserve oil tank o-rings Weekly Reserve Oil Tank Cleaning, page 36. Quarterly Quarterly Daily Cleaning Between and Behind Fryers Clean between and behind the and adjacent PFE 500 to remove oil accumulation and debris daily. 1) Place the vat cover over the vat of the CFE 415 and close the lid on the adjacent PFE 500 to keep oil from splashing out of the vat. 2) Carefully roll the pair of fryers forward and separate the CFE 415 from the PFE 500 from the front of the unit. 3) Remove all oil accumulation between the fryers and then clean behind the fryers to remove any oil accumulation and debris. 4) join the two fryers and gently roll back into position to avoid oil splashing Weekly Reserve Oil Tank Cleaning Remove/Clean the reserve oil tank by following these instructions: 1) Pull the reserve oil tank forward until it stops. 2) Push back and lift up on the tank slightly until the studs in the bottom of the tank disengage from the slots (1) in the shelf, see Figure 4-1 Reserve Oil Tank Shelf Slots, page 37. Maintenance 36

49 Figure 4-1 Reserve Oil Tank Shelf Slots 3) Discard any remaining oil from the tank to an approved oil disposal unit. 4) Clean the interior and exterior of the reserve oil tank at a sink with soap and water. 5) Clean the reserve oil tank shelf. 6) Replace any damaged, or missing o-rings on the reserve oil tank. INFO: Replace o-rings every 90 days to ensure consistent topping off of the vat (use a small flat-blade screwdriver to pry up on the old o-ring and pull off end of tube. Roll new o-ring over tube until it snaps into o-ring groove on tube). 7) Lubricate o-rings with new oil before placing the reserve oil tank back into position. 8) Place the reserve oil tank onto the shelf. Ensure the studs on the bottom of the reserve oil tank are aligned with the slots (1) in the shelf, see Figure 4-1 Reserve Oil Tank Shelf Slots, page 37. 9) Gently push the reserve oil tank back until the tube is aligned with the receiver. Maintenance 37

50 Figure 4-2 Engaging The Reserve Oil Tank Quarterly Drain Pan O-Ring Replacement To prevent oil leaking, and to keep filtering process operating properly, the filter drain pan and filter screen o-rings should be replaced every three months. Drain pan could be hot! Wear PPE heat and oil resistant gloves, or severe burns could result. 1) Push down on the drain pan latch and pull out the drain pan assembly, using the handle on the drain pan. 2) Replace o-rings using a small flat-bladed screwdriver. Pry up on o-ring and pull off the end of tube. Maintenance 3) Roll new o-ring into notch on tube. Lubricate o-rings on filter tube with fresh, cold oil and push filter drain pan into position (lubricate first before installing). 38

51 4.2.4 Quarterly Filter Screen O-Ring Replacement To prevent oil leaking, and to keep filtering process operating properly, the filter drain pan and filter screen o-rings should be replaced every three months. Drain pan could be hot! Wear PPE heat and oil resistant gloves, or severe burns could result. 1) Push down on the drain pan latch and pull out the drain pan assembly, using the handle on the drain pan. 2) Remove the contents from the drain pan, see 3.7 Drain Pan Assembly, page 29 to access the Filter Screen. 3) To replace o-rings, use a small flat-bladed screwdriver and pry up on each o- ring, grasp o-ring with fingers and pull off the end of tube. 4) Lubricate and then roll new o-rings into notch on tube. Lubricate o-rings on filter tube with fresh, cold oil and push filter drain pan into position. Maintenance 39

52 Maintenance 40

53 Chapter 5 Software Settings This chapter covers sections from the controls where fryer settings can be changed and configured. For controls and indicators information, see 3.1 User Interface Controls & Indicators, page 9. INFO: Programming access is unavailable for Level 1 programming and Level 2 CFA Programming. Product set point updates require a USB with set point file. See USB support step in6.2 Information Mode Details, page Clock Set INFO: Upon initial start-up or control board replacement, if CLOCK SET automatically appears in the display, skip steps 1, 2, and 3. 1) Press and hold the program button for 5 seconds until LEVEL 2 shows in display. 2) Release the program button, then press the program button twice. CLOCK SET, then ENTER CODE shows in display. 3) Press 1, 2, and 3. 4) Display shows CS-1 then SET then MONTH, with the month flashing. 5) Press the up or down button to change the month. 6) Press the program button. Display shows CS-2 then SET then DATE, with the date flashing. 7) Press the up or down button to change the date. 8) Press the program button. Display shows CS-3 then SET then YEAR, with the year flashing. 9) Press the up and down button to change the year. 10)Press the program button. Display shows CS-4 then SET then HOUR with the hour and AM or PM flashing. 11)Press the up or down button to change the hour and AM/PM setting. 12)Press the program button. Display shows CS-5 then SET then MINUTE, with the minutes flashing. 13)Press the up or down button to change the minutes. 14)Press the program button. Display shows CS-6 then CLOCK MODE along with 1.AM/PM. 15) 1.AM/PM is 12 hour time, 2.24-HR is 24 hour time. Press the up or down button to change. 16)Press the program button. Display shows CS-7 then DAYLIGHT SAVINGS ADJ, along with 2.US. 17)Press the up or down button to change to the following: Software Settings 41

54 1.OFF = No automatic adjustments for Daylight Savings Time. 2.US = Automatically applies United States Daylight Savings Time adjustment. DST activated on the first Sunday in April. DST de-activated on the last Sunday in October. 3.EURO = Automatically applies European (CE) Daylight Savings Time adjustment. DST activated on the last Sunday in March. DST de-activated on the last Sunday in October. 3.FSA = First Sunday in April (this is the old U.S. DST). 18)Clock Set is now complete. Press and hold the program button to exit. 5.2 Manually Setting New Or Used Oil 1) Turn the power switch to off. 2) Press and hold product selection 5 while turning the power switch to on, until IS OIL NEW OR USED? shows in the display. 3) Press product selection 4 for new oil, or product selection 5 for used oil. 4) If product selection 4 was pressed, OIL IS NEW? shows in the display. 5) Press product selection 1 for YES, and THANK YOU shows in the display, and controls resume to normal operation. 6) If product selection 5 was pressed, OIL IS USED? shows in display. 7) Press product selection 1 for YES, and HOW OLD IS OIL? shows in display. 8) Press the up or down button to set the age of the oil. 9) Press the timer button. THANK YOU shows in the display and controls resume normal operation. Software Settings 5.3 Language Selection Pressing the program button then product selection 6 allows the operator to choose to display the information in English or Spanish. 5.4 Special Programming Special programming includes advanced settings such as volume control, audio effect, language selection, etc., see Table 3-1 User Interface Controls & Indicators, page 10 for reference to button locations. Press and hold the program button for about five seconds to enter special programming (SP PROG). CFA PROG appears in the display. Press the program button one time and SP PROG appears. Enter the code 1,2,3 using the left product buttons. Use the program and info buttons to scroll through the steps and the up and down buttons change the step parameters. 42

55 Table 5-1 Special Programming Mode Details Menu Display Name Function SP-1 TEMP UNITS Press the down button to change display units from F to C. SP-2 LANGUAGE Press the down button to select between the following display languages: ENGL (English), FRAN (French), DEUT (German), ESPA (Spanish), or PORT (Portuguese). SP-3 DO SYSTEM INIT This step allows all programmable settings to be initialized to factory preset values. Press and hold the down button for about five seconds to reset. INFO : Statistics, oil wear and the E-log will not be affected by this initialization. SP-4 AUDIO VOLUME Press the up and down buttons to adjust the volume level of the control between 1 and is the loudest setting. SP-5 AUDIO TONE (HZ) Speaker frequency ( Hz, in 50 Hz steps) adjustable by pressing the up and down buttons. Sets the tone of the Pwr-up, Alarm, and End-of- Cycle beeps, etc. The tone of each controller can be programmed to a different value to allow each piece of equipment to be identified by its own, unique sound. 1100Hz is default. SP-6 AUDIO EFFECT Audio effects setting (0-3): 0 = Normal (No effect) 1 = Fast Pulsed Beeps 2 = Slower Pulsed Beeps 3 = Warble (Freq. Shifting) Allows an audio effect to be applied to Alarm and End-of-Cycle beeps, to help distinguish one piece of equipment from another. Audio effects setting (0-3) adjustable by pressing the up and down buttons: 0 = Normal (No effect) 1 = Fast Pulsed Beeps 2 = Slower Pulsed Beeps 3 = Warble (Freq. Shifting) Allows an audio effect to be applied to Alarm and End-of-Cycle beeps, to help distinguish one piece of equipment from another. Software Settings 43

56 Menu Display Name Function SP-7 SP-8 SP-8A SP-8B MELT CYCLE SELECT IDLE MODE ENABLED? IDLE SETPT TEMP AUTO-IDLE MINUTES Shortening/oil type setting (1.SOLID, 2.LIQ). Liquid (2.LIQ) is the default setting for the fryer. The "1. SOLID" setting uses a very conservative melt cycle for safely melting solid shortening. The "2.LIQ" setting allows a more aggressive heatup rate, but should only be used if liquid oil is in the frypot. Idle mode enable setting (YES, NO). Press the down button to change from YES to NO. Idle mode regulates the oil at a lower temperature to save energy and extend shortening life during low demand periods If enabled, the Idle mode may be activated either automatically or by manual pushbutton selection, depending on the [SP 8B] and [SP 8C] settings below. Cook mode is resumed by pressing any product button. Press up and down buttons to set the temperature (190 F F) for Idle mode. Default temperature is 250 F. Period of inactivity (OFF, 1-60 min.) that triggers activation of Idle mode. This timer starts when the fryer recovers back to set point temperature. SP-8C USE 6 FOR IDLE Manual Idle button enable by pressing the down button (YES, NO). If set to YES, and Idle Mode is enabled, then the "6" button is used as a Manual Idle button: pressing the "6" button while in Cook mode will immediately activate Idle (setback) mode. Software Settings SP-9 PRODUCT BUTTONS 1. COOK: Pressing a product button selects and immediately starts a cook cycle for that product. The Timer button is used to stop cook cycles. The appropriate product button must be pressed each time a cook cycle is started. This is the default setting. 2.SELECT: Pressing a product button only selects that product for cooking. The Timer button must be used to start a cook cycle. The Timer button is also used to stop a cook cycle. Subsequent cook cycles 44

57 Menu Display Name Function SP-10 COOKING DISPLAY for the same product can be started by simply pressing the Timer button again, as the product is already selected and its name is shown on the display. Press the down button to select what is displayed during the cook cycle: TIME = Count Down Timer TM+ID= Timer and Product ID Alternate NM+TM= Product Name and Timer Alternate SP-11 QUALITY TMR Press the down button to select what displays, if the quality timer is enabled for products (not used on CFE 415): NONE=No Quality Timer Display QT+ID= Quality Timer and Product ID Alternate NM +QT= Product Name and Quality Timer Alternate SP-12 LONGER FILL- TIME ENABLED? The default setting for this step is NO. Press the down button to select YES. If YES is selected, filtration will be extended if oil is not detected during filling. SP-13 SP-14 SP-15 LET USER EXIT FILL? SKIP SKIM PROMPT 2 STAGE WASH ENABLED? The default setting for this step is YES. Press the down button to select NO. If YES is selected, filling can be cancelled during filtration. Press down button to change this setting from YES to NO. If YES is selected, the skim prompt at the start of an Express Filter can be bypassed by pressing the timer button. The default setting for this step is NO. Press the down button to select YES. If YES is selected, The Express Filter will include a second wash cycle. SP-16 DISPOSE RE- QUIRES CODE? Use the up and down buttons to change between YES and NO. If YES is selected, the manager code is entered prior to disposing oil. SP-17 POLISH MM:SS Use the up and down buttons to set the polish duration during the daily filter. The default setting for this is 5:00, but can be set between 0:00 and 15:00. Software Settings 45

58 Software Settings 46

59 Chapter 6 Information and Reporting Modes 6.1 Menu Overview The following historic information can be recorded and used for operational and technical help: 1. E-Log 2. P-Log 3. Heat-Ups 4. Left Cook Data 5. Right Cook Data 6. Today s Date 7. Prev Day 8. 7-Day Totals 9. Oil Data 10.Prev Oil Data 11.Input Info 12.Output Info 13.Pot Temperature 14.Level Temperature 15.Protection Temperature 16.CPU Temperature 17.Analog Info 18.AC Volts 19.Amps Info 20.Oil Levels 21.AIF Info 22.Activity Log 23.Secondary Contactor Counts 24.Version & Source 25.USB Support Information and Reporting Modes 47

60 26.Radio Info 6.2 Information Mode Details INFO: Not all Information Mode functions are discussed in this section. to ensure proper operation of fryer, please consult Henny Penny Corp. before changing any of these settings. For more information on these functions, contact Technical Support at , or Menu Table 6-1 Information Mode Details Description Information and Reporting Modes 1. E-Log (Error Code Log) 2. P-Log (Power-Up Log) 1. Press the program button and the info button at the same time and *INFO MODE* shows in the display, followed by 1. E-LOG. 2. Press the program button and the info button to exit Information Mode at any time. 3. Press the down button and A. (date & time) *NOW* shows in the displays. This is the present date and time. 4. Press the down button and if an error was recorded, B. (date, time, and error code information) shows in display. This is the latest error code that the controls recorded. Sometimes the characters L: and R: appear in front of the error code on the display which refers to the left or right vat of a split vat. 5. Press the down button and the next latest error code information is seen. Up to 10 error codes (B to K) can be stored in the E-Log section. 6. Press the program button to continue to P-Log. 1. Press the down button and 2A. (date & time) *NOW* shows in display. This is the present date and time. 2. Press the down button and the latest power-up is shown, 2B. (date & time) PWR-UP. 3. Press the down button and the next latest power-up date is shown. Up to 10 power-ups (2B to 2K) can be stored in P-Log section. 4. Press the program button to continue onto the heatup log. 48

61 Menu Description 3. Heat-Ups 1. Press the down button and 3A.(date & time) *NOW* shows in display. This is the present date and time. 2. Press the down button and the latest heat-up is shown, along with the heat-up rate, ex: 3B MAY-22, 8:37A The heat rate is the maximum rate ( /second) the controller recorded during the shown time frame. 3. Press the down button and the next latest heat-up is shown. Up to 10 heat-ups (3B to 3K) can be stored in the Heat-Up Log. 4. Press the program button to continue onto the Cook Data log. 4. Left Cook Data 1. Press the down button to step through the following data, see Table 6-2 Left Cook Data, page 60): Time of last cook cycle started. Product (last product cooked). Ready (fryer ready before start)? Drop detect status. Drop adjust (real time seconds). Cook time adjust (clock adjust). Actual elapsed cook time (seconds). Stopped: time remaining, or secs past done. Slow cook for this cook cycle? Overloaded (bad batch)? Avg temp. during cook cycle. Max voltage during cook cycle. Min voltage during cook cycle. Max amps during cook cycle. Min amps during cook cycle. Load size figured for cook cycle 2. Press the program button to continue onto the Right Cook Data log. Information and Reporting Modes 49

62 Menu Description 5. Right Cook Data 1. Press the down button to step through the following data, see Table 6-3 Right Cook Data, page 61): Time of last cook cycle started. Product (last product cooked). Ready (fryer ready before start)? Drop detect status. Drop adjust (real time seconds). Cook time adjust (clock adjust). Actual elapsed cook time (seconds). Stopped: time remaining, or secs past done. Slow cook for this cook cycle? Overloaded (bad batch)? Avg temp. during cook cycle. Max voltage during cook cycle. Min voltage during cook cycle. Information and Reporting Modes Max amps during cook cycle. Min amps during cook cycle. Load size figured for cook cycle 2. Press the program button to continue onto Today s Data log. 6. Today s Data 1. Press the down button to step through the following data, see Table 6-4 Today s Data Log, page 62): Today s date. Time of day last heat-up was completed. Peak heat-up rate ( F/Sec) for last heat-up. Was last heat-up acceptable? Heat Cap. status (based on last 4 heat-ups). Number of monitored heat-ups today. Number of slow heat-ups. Max time to heat 270 F to 310 F today. 50

63 Menu Description Lowest peak rate for today s heat-ups. Maximum voltage today (when fryer on). Minimum voltage today (when fryer on). No. of low voltage warnings generated. Maximum amp draw today. Minimum amp draw today. Number of low amps warnings today. Non-cooking time (hh:mm) fryer was on. Oil wear accumulated so far today. Total number of cook cycles today. Number of cook cycles started before ready. No. cook cycles quit early, 0:11 or more rem. No. cook cycles beeped *DONE* 0:21 or more after. Individual product cook counts. Individual product not detected counts. Individual product slow cook counts. Individual product overloaded. 2. During steps 6V through 6Y, press the product buttons (or manual Program button) to see data on individual product items. 3. Press the program button to continue onto Prev-Day- Sun log. 7. Prev-Day-Sun 1. Press the down button to steps through the following data, see Table 6-5 Prev-Day-Sun, page 63): Day this data was recorded for. Time of day last heat-up was completed. Peak heat-up rate ( F/Sec) for last heat-up. Was that day s last heat-up acceptable? Heat Cap. status (based on last 4 heat-ups). Number of monitored heat-ups that day. Information and Reporting Modes 51

64 Menu Description Number of slow heat-ups. Max time to heat 270 F to 310 F that day. Lowest peak rate for that day s heat-ups. Maximum voltage that day (when fryer on). Minimum voltage that day (when fryer on). No. of low voltage warnings generated. Maximum amp draw that day. Minimum amp draw that day. Number of low amps warnings that day. Non-cooking time (hh:mm) fryer was on. Oil wear accumulated that day. Total number of cook cycles that day. Number of cook cycles started before ready. No. cook cycles quit early, 0:11 or more rem. Information and Reporting Modes No. cook cycles beeped *DONE* 0:21 or more after. Individual product cook counts. Individual product not detected counts. Individual product slow cook counts. Individual product overloaded. INFO: During each step, press the program button to choose the day of the week, of the past 7 days. During steps 7V through 7Y, press the product buttons (or Manual program button) to see data on individual product items. 2. Press the program button to continue onto 7-Day Totals log Day Totals 1. Press the down button to step through the following data, see Table Day Totals, page 64: Oldest day in the previous days history. 52

65 Menu Description Number of days with data included in totals. Number of monitored heat-ups. Number of slow heat-ups. Max time to heat 270 F to 310 F. Lowest peak rate of all heat-ups. Maximum voltage. Minimum voltage. No. of low voltage warnings generated. Maximum amp draw. Minimum amp draw. Number of low amps warnings. Non-cooking time (hrs) while fryer was on. Total oil wear accumulated. Total number of cook cycles. Number of cook cycles started before ready. 9. Oil Data Current Batch Resets By Clean-Out Mode No. cook cycles quit early, 0:11 or more rem. No. cook cycles beeped *DONE* 0:21 or more after. Individual product cook counts. Individual product not detected counts. Individual product slow cook counts. Individual product overloaded. INFO: During steps 8V through 8Y, press the product buttons (or Manual program button) to see data on individual product items. 2. Press the program button to continue onto Oil Data log. 1. Press the down button to step through the following data, see Table 6-7 Oil Data, page 65: The day current batch of oil was started. Number of days with data included in totals. Information and Reporting Modes 53

66 Menu Description Number of monitored heat-ups. Number of slow heat-ups. Max time to heat 270 F to 310 F. Lowest peak rate of all heat-ups. Maximum voltage. Minimum voltage. No. of low voltage warnings generated. Maximum amp draw. Minimum amp draw. Number of low amps warnings. Non-cooking time (hrs) while fryer was on. Total oil wear accumulated. Total number of cook cycles. Number of cook cycles started before ready. No. cook cycles quit early, 0:11 or more rem. Information and Reporting Modes 10. Prev Oil Data Moved Here From Oil Data Log. Assumes New oil No. cook cycles beeped *DONE* 0:21 or more after. Individual product cook counts. Individual product not detected counts. Individual product slow cook counts. Individual product overloaded. INFO: During steps 9V through 9Y, press the product buttons (or Manual program button) to see data on individual product items. 2. Press the program button to continue onto Prev Oil Data log. 1. Press the down button to step through the following data, see Table 6-8 Prev Oil Data, page 66: The day previous batch of oil was started. Number of days with data included in totals. Number of monitored heat-ups. 54

67 Menu Description Number of slow heat-ups. Max time to heat 270 F to 310 F. Lowest peak rate of all heat-ups. Maximum voltage. Minimum voltage. No. of low voltage warnings generated. Maximum amp draw. Minimum amp draw. Number of low amps warnings. Non-cooking time (hrs) while fryer was on. Total oil wear accumulated. Total number of cook cycles. Number of cook cycles started before ready. No. cook cycles quit early, 0:11 or more rem. 11. Input Info INP A_VHDSF_M No. cook cycles beeped *DONE* 0:21 or more after. Individual product cook counts. Individual product not detected counts. Individual product slow cook counts. Individual product overloaded. INFO: During steps 10V through 10Y, press the product buttons (or Manual program button) to see data on individual product items. 2. Press the program button to continue onto Input Info check. This mode displays the status of components and inputs. if the input signal is detected, an identifying letter is displayed (see below). If the signal is not detected, _ is displayed. 1. With the power switch turned to on, and all inputs detected, H_P_A_VHDSF_M shows in the display. See below for definition of codes. Information and Reporting Modes 55

68 Menu Description A= Power switch turned to on. V= Volts - 24 VAC detected. H= High Limit - If H is present, the high limit is good; if H is missing, the high limit is tripped (overheated) or faulty. D= Drain Switch - If D is present, the drain handle is closed; if D is missing, the drain is open or faulty. S= Power switch on interlock circuit - if S is present, the power switch is in the on position; if the S is missing, the power switch is either off, failed, or wired incorrectly. F= Fan. M= MV - Detects 24 V jumper to MV terminal. Information and Reporting Modes 12. Output Info OUTP B-S-H* 2. Press the down button to view the specific status of each input of each terminal. A _ indicates the input is not presently detected. A indicates the signal is detecting a normal input. A blinking X indicates the signal is presently detected, but is detected as a halfwave (partially failed) input. INFO: The V, H, D, S, F, and M signals below are wired in series. The first signal missing out of this sequence will generally cause all signals to the right of it to be missing as well. 3. Press the program button to continue onto Output Info check. This mode displays the status of components and outputs. If the output signal is detected, an identifying letter is displayed (see below), followed by an *. If the output is off, _ is displayed. B= (not used on this model) S= Safety Contactor Output H= Heat Contactor Output If the heat is on, H shows in display. If heat is off, H_ shows in display. If control senses a problem with the heat output, H* shows in display with the * flashing. 1. Press the down button to view the outputs and inputs together. 56

69 Menu Description 2. Press the program button to continue onto the Pot Temperature reading. 13. Pot Temp. This step shows the present oil temperature. The display shows 13. POT TMP (temp). 1. Press the program button to continue onto the Level Temperature reading. 14. Level Temp. This step shows the present level probe temperature. 1. Press the program button to continue onto the Protection Temperature reading. 15. Protection Temp. This step shows the present protection probe temperature. 1. Press the program button to continue onto the CPU Temperature reading. 16. CPU Temp. This step shows the present PC board temperature. 1. Press the program button to continue onto the Analog reading. 17. Analog Info <1> 2344 This step displays the present status of any channel of the controller s a-to-d converted. This feature may be useful to a technician troubleshooting the fryer or controller. 1. The displayed value can be toggled between volts and bits by pressing product selection 1. If the displayed value has a decimal point, it is voltage (0 to 5 VDC). If no decimal point is shown, the value is a- to-d bits (0-4095). 2. Press the program button to continue onto AC Volts reading. 18. AC VOLTS This step displays the present status of the line voltage supply to the fryer. This displayed value is averaged over a 10 second period, so brief dips or fluctuations in the voltage might not show up in the display. 1. The voltage is normally displayed as a percent of nominal value where 100% would indicate that voltage is right on the nominal value (i.e. 208 volts for a 208v fryer). The display can be toggled to an actual voltage value by pressing product selection 6. Information and Reporting Modes 57

70 Menu Description 2. Press the program button to continue onto Amps Info reading. 19. Amps Info For electric fryers, this display shows the present readings from the fryers amps sensors, which monitor the electrical current supplied to the heaters. On open fryers, these values indicate the current through each individual heater coil. on 208 or 240 volt units, this value should be close to the value on the data plate. On 480 volt fryers, this value should be the value on the data plat multiplied by The amps values should normally cook cycle on and off with the heat on light, and all three values should be about the same. Press the program button to continue onto Oil Levels reading. Information and Reporting Modes 20. Oil Levels Displays the status of the ATO (auto top off) system. FULL or LOW is displayed depending on the ATO status. Press the down arrow one time and the display shows three readings ex. 1F, L=314, 315. The 1F is the difference between the level probe and the temperature probe if this difference is 15 degrees or greater, the vat is low and an L is displayed next to this reading. L=314 is the level sensor reading and 315 is the main temperature reading in the vat. Press the program button to continue onto AIF Info. 21. AIF Info Information from the AIF (automatic intermittent filtration) board is available in this step. AIF software is displayed similar to this format: 20: 1. Press the down arrow and CPU position 1 of 1 displays 2. Press down again. INP PAN displays. The control displays a if the drain pan is detected and an X if the drain pan is not detected. 3. Press down 3 more times and PAD=XXHR FLTRS=0 displays. The XXHR displays how long since the last filter envelope replacement. Press product button 1. to view the date of the last filter change and the 2. product button to view the time of the last filter 58

71 Menu Description change. FLTRS=X tracks how many filters have been performed since the last filter change. 4. Press the program button to continue onto Activity Log. 22. Activity Log This step for internal use. Press the program button to continue. 23. Secondary CNTS Counts each time secondary contactor is energized. Press the program button to continue. 24. Ver. & Source This step for internal use. Press the program button to continue. 25. USB Settings Transfer reports to USB, and product settings to and from USB. 1. PRINT REPORT: Press the program button to choose between the following reports: NORMAL, ACTIVITY, ALL, STATS, SET+STATS, STATS. Once the report is selected, press the right timer button and the report will be added to the USB. IF no USB is available NO DRIVE is displayed. A USB will need to be inserted into the USB port. Use a Phillips head screwdriver to open the USB access panel, then insert the USB. See Figure 3-2 Operating Components, page 11 for USB location. 2. READ SP FROM USB: Uploads set points from the USB to the control. The set point file needs to be formatted correctly otherwise UNKNOWN displays. Press the left timer to upload the set point file 3. UNMOUNT USB: Press the left timer button to safely remove the USB without risk of losing data. A 60 second timer is given when it is safe to remove the USB. 4. SAVE SP TO USB: Press the left timer to download the setpoint file from the control to the USB. Press the program button to continue. 26. Radio Info Wi-Fi set up mode for future use. Information and Reporting Modes 59

72 Function Table 6-2 Left Cook Data Display Example Time of last cook cycle started. 4A. STARTED 10.25A Product (last product cooked). 4B. PRODUCT -1- Ready (fryer ready before start)? 4C. READY? YES Drop detect status. 4D. DETECT X NO Drop adjust (real time seconds). 4E. DROP ADJ T-14 Cook time adjust (clock adjust). 4F. CK TM ADJ -13 Actual elapsed cook time (seconds). 4G. ACT TIME 2:23 Stopped: time remaining, or secs past done. 4H. STOP DONE +1 Slow cook for this cook cycle? 4I. SLOW? NO Overloaded (bad batch)? 4J. OVRLD? NO Avg temp. during cook cycle. 4K. AVG TMP 343 F Max voltage during cook cycle. 4L. MAX VOLT 99% Min voltage during cook cycle. 4M. MIN VOLT 99% Max amps during cook cycle. 4N. MAX AMPS 33 Information and Reporting Modes Min amps during cook cycle. 4O. MIN AMPS 33 4P. LOAD SIZE 60

73 Table 6-3 Right Cook Data Function Display Example Time of last cook cycle started. 5A. STARTED 10.25A Product (last product cooked). 5B. PRODUCT -1- Ready (fryer ready before start)? 5C. READY? YES Drop detect status. 5D. DETECT X NO Drop adjust (real time seconds). 5E. DROP ADJ T-10 Cook time adjust (clock adjust). 5F. CK TM ADJ -13 Actual elapsed cook time (seconds). 5G. ACT TIME 2:23 Stopped: time remaining, or secs past done. 5H. STOP DONE +1 Slow cook for this cook cycle? 5I. SLOW? NO Overloaded (bad batch)? 5J. OVRLD? NO Avg temp. during cook cycle. 5K. AVG TMP 343 F Max voltage during cook cycle. 5L. MAX VOLT 99% Min voltage during cook cycle. 5M. MIN VOLT 99% Max amps during cook cycle. 5N. MAX AMPS 33 Min amps during cook cycle. 5O. MIN AMPS 33 Information and Reporting Modes 61

74 Table 6-4 Today s Data Log Function Display Example Today s date. 6A. DATE APR-12 Time of day last heat-up was completed. 6B. LAST HEAT 9:45A Peak heat-up rate ( F/Sec) for last heat-up. 6C. LAST RATE 0.82 Was last heat-up acceptable? 6D. LAST OK? YES Heat Cap. status (based on last 4 heat-ups). 6E. HEAT CAP GOOD Number of monitored heat-ups today. 6F. HEAT-UPS 2 Number of slow heat-ups. 6G. SLOW HT S 0 Max time to heat 270 F to 310 F today. 6H. MAX HT TM 1:17 Lowest peak rate for today s heat-ups. 6I. MIN RATE 0.82 Maximum voltage today (when fryer on). 6J. MAX VOLT 99% Minimum voltage today (when fryer on). 6K. MIN VOLT 95% No. of low voltage warnings generated. 6L. LO VOLT S 0 Maximum amp draw today. 6M. MAX AMPS 35 Minimum amp draw today. 6N. MIN AMPS 33 Information and Reporting Modes Number of low amps warnings today. 6O. LO AMPS 0 Non-cooking time (hh:mm) fryer was on. 6P. IDLE HRS 1:23 Oil wear accumulated so far today. 6Q. OIL WEAR 3 Total number of cook cycles today. 6R. TOT CK S 11 Number of cook cycles started before ready. 6S. NOT RDY S 2 No. cook cycles quit early, 0:11 or more rem. 6T. QUIT No. cook cycles beeped *DONE* 0:21 or more after. 6U. DONE Individual product cook counts. 6V. Px CK CT 2 Individual product not detected counts. 6W. Px NO DET 0 Individual product slow cook counts. 6X. Px SLO CT 0 Individual product overloaded. 6Y. Px OVRLD 0 62

75 Table 6-5 Prev-Day-Sun Function Display Example Day this data was recorded for. 7A. DATE APR-8 Time of day last heat-up was completed. 7B. LAST HEAT 8:15A Peak heat-up rate ( F/Sec) for last heat-up. 7C. LAST RATE 0.88 Was that day s last heat-up acceptable? 7D. LAST OK? YES Heat Cap. status (based on last 4 heat-ups). 7E. HEAT CAP GOOD Number of monitored heat-ups that day. 7F. HEAT-UPS 7 Number of slow heat-ups. 7G. SLOW HT S 0 Max time to heat 270 F to 310 F that day. 7H. MAX HT TM 1:11 Lowest peak rate for that day s heat-ups. 7I. MIN RATE 0.67 Maximum voltage that day (when fryer on). 7J. MAX VOLT 102% Minimum voltage that day (when fryer on). 7K. MIN VOLT 98% No. of low voltage warnings generated. 7L. LO VOLT S 0 Maximum amp draw that day. 7M. MAX AMPS 35 Minimum amp draw that day. 7N. MIN AMPS 34 Number of low amps warnings that day. 7O. LO AMPS 0 Non-cooking time (hh:mm) fryer was on. 7P. IDLE HRS 7:09 Oil wear accumulated that day. 7Q. OIL WEAR 39 Total number of cook cycles that day. 7R. TOT CK S 18 Number of cook cycles started before ready. 7S. NOT RDY S 2 No. cook cycles quit early, 0:11 or more rem. 7T. QUIT No. cook cycles beeped *DONE* 0:21 or more after. 7U. DONE Individual product cook counts. 7V. Px CK CT 12 Individual product not detected counts. 7W. Px NO DET 1 Individual product slow cook counts. 7X. Px SLO CT 0 Individual product overloaded. 7Y. Px OVRLD 1 Information and Reporting Modes 63

76 Table Day Totals Function Display Example Oldest day in the previous days history. 8A. SINCE APR-5 Number of days with data included in totals. 8B. DAYS CT 6 Number of monitored heat-ups. 8C. HEAT-UPS 30 Number of slow heat-ups. 8D. SLOW HT S 1 Max time to heat 270 F to 310 F 8E. MAX HT TM 3:25 Lowest peak rate of all heat-ups 8F. MIN RATE 0.47 Maximum voltage. 8G. MAX VOLT 102% Minimum voltage. 8H. MIN VOLT 91% No. of low voltage warnings generated. 8I. LO VOLTS 0 Maximum amp draw. 8J. MAX AMPS 35 Minimum amp draw. 8K. MIN AMPS 32 Number of low amps warnings. 8L. LO AMPS 0 Non-cooking time (hrs) while fryer was on. 8M. IDLE HRS 43 Total oil wear accumulated. 8N. TOT WEAR 278 Information and Reporting Modes Total number of cook cycles. 8O. TOT CKS 125 Number of cook cycles started before ready. 8P. NOT RDYS 7 No. cook cycles quit early, 0:11 or more rem. 8Q. QUIT No. cook cycles beeped *DONE* 0:21 or more after. 8R. DONE Individual product cook counts. 8S. Px CK CT 77 Individual product not detected counts. 8T. Px NO DET 3 Individual product slow cook counts. 8U. Px DLO CT 0 Individual product overloaded. 8V. Px OVRLD 1 64

77 Function Table 6-7 Oil Data Display Example The day current batch of oil was started. 9A. SINCE APR-1 Number of days with data included in totals. 9B. DAYS CT 10 Number of monitored heat-ups. 9C. HEAT-UPS 75 Number of slow heat-ups. 9D. SLOW HT S 2 Max time to heat 270 F to 310 F 9E. MAX HT TM 3:25 Lowest peak rate of all heat-ups 9F. MIN RATE 0.43 Maximum voltage. 9G. MAX VOLT 102% Minimum voltage. 9H. MIN VOLT 91% No. of low voltage warnings generated. 9I. LO VOLTS 0 Maximum amp draw. 9J. MAX AMPS 35 Minimum amp draw. 9K. MIN AMPS 32 Number of low amps warnings. 9L. LO AMPS 0 Non-cooking time (hrs) while fryer was on. 9M. IDLE HRS 43 Total oil wear accumulated. 9N. TOT WEAR 278 Total number of cook cycles. 9O. TOT CKS 125 Number of cook cycles started before ready. 9P. NOT RDYS 7 No. cook cycles quit early, 0:11 or more rem. 9Q. QUIT No. cook cycles beeped *DONE* 0:21 or more after. 9R. DONE Individual product cook counts. 9S. Px CK CT 77 Individual product not detected counts. 9T. Px NO DET 3 Individual product slow cook counts. 9U. Px DLO CT 0 Individual product overloaded. 9V. Px OVRLD 1 Information and Reporting Modes 65

78 Function Table 6-8 Prev Oil Data Display Example The day previous batch of oil was started. 10A. BEGAN MAR-9 Number of days with data included in totals. 10B. DAYS CT 18 Number of monitored heat-ups. 10C. HEAT-UPS 98 Number of slow heat-ups. 10D. SLOW HT S 0 Max time to heat 270 F to 310 F 10E. MAX HT TM 1:31 Lowest peak rate of all heat-ups 10F. MIN RATE 0.57 Maximum voltage. 10G. MAX VOLT 101% Minimum voltage. 10H. MIN VOLT 96% No. of low voltage warnings generated. 10I. LO VOLTS 0 Maximum amp draw. 10J. MAX AMPS 35 Minimum amp draw. 10K. MIN AMPS 33 Number of low amps warnings. 10L. LO AMPS 0 Non-cooking time (hrs) while fryer was on. 10M. IDLE HRS 62 Total oil wear accumulated. 10N. TOT WEAR 1523 Information and Reporting Modes Total number of cook cycles. 10O. TOT CKS 653 Number of cook cycles started before ready. 10P. NOT RDYS 25 No. cook cycles quit early, 0:11 or more rem. 10Q. QUIT No. cook cycles beeped *DONE* 0:21 or more after. 10R. DONE Individual product cook counts. 10S. Px CK CT 466 Individual product not detected counts. 10T. Px NO DET 31 Individual product slow cook counts. 10U. Px DLO CT 0 Individual product overloaded. 10V. Px OVRLD 5 The day previous batch of oil was started. 10A. BEGAN MAR-9 Number of days with data included in totals. 10B. DAYS CT 18 Number of monitored heat-ups. 10C. HEAT-UPS 98 Number of slow heat-ups. 10D. SLOW HT S 0 Max time to heat 270 F to 310 F 10E. MAX HT TM 1:31 Lowest peak rate of all heat-ups 10F. MIN RATE

79 Function Display Example Maximum voltage. 10G. MAX VOLT 101% Minimum voltage. 10H. MIN VOLT 96% No. of low voltage warnings generated. 10I. LO VOLTS 0 Maximum amp draw. 10J. MAX AMPS 35 Minimum amp draw. 10K. MIN AMPS 33 Number of low amps warnings. 10L. LO AMPS 0 Non-cooking time (hrs) while fryer was on. 10M. IDLE HRS 62 Total oil wear accumulated. 10N. TOT WEAR 1523 Total number of cook cycles. 10O. TOT CKS 653 Number of cook cycles started before ready. 10P. NOT RDYS 25 No. cook cycles quit early, 0:11 or more rem. 10Q. QUIT No. cook cycles beeped *DONE* 0:21 or more after. 10R. DONE Individual product cook counts. 10S. Px CK CT 466 Individual product not detected counts. 10T. Px NO DET 31 Individual product slow cook counts. 10U. Px DLO CT 0 Individual product overloaded. 10V. Px OVRLD Diagnostic Mode The fryer s controller provides diagnostic functions that let an operator review operating and performance data for the fryer. The information provided by Diagnostic Mode can be used to monitor procedural errors such as, not waiting for the READY light before starting a cook cycle, canceling cook cycles early, etc. In addition, diagnostic mode allows slight adjustment to product color, reports the age and accumulated wear of the oil, and reports information about the performance of the line voltage supply. To activate Diagnostic Mode, press and release the program button, then press product selection 4. The controller display shows *DIAGNOSTIC* *REPORT*. When this introduction message is finished, the controller displays Diagnostic step D1. Some basic diagnostic mode navigation functions are: Use the up or down buttons to step through the report items. To toggle between English and Spanish Display Mode, press the program button then press product selection 6. Information and Reporting Modes 67

80 To exit Diagnostic Mode at any point, press product selection 2. On several of the screens you may have to press product selection 1 or 2 to respond to questions asked Diagnostic Mode Details To view summaries of the fryer and operator performance, press the program button then product selection number four. Press the up or down button to view the following functions: Table 6-9 Diagnostic Modes Special Functions D1 D2 D3 D4 D5 D6 D7 Description Adjust product color for all products (not individually). The age of the oil and life remaining. Outlet voltage monitoring. Fryer s heating performance. Cook Times Today. Cooked Before Ready. Cook cycles stopped more than 10 seconds before end of cook cycle. Information and Reporting Modes D8 D9 D10 Cook cycles not ended within 20 seconds after expired time. Number of times loading product took too long. Programmed variables changed by operator. 68

81 Table 6-10 Diagnostic Mode Details Menu Step D1: Color Adjustment Description This step lets the user make slight adjustments to the product color. D1: Color Adjustment contains the following information: The first step of this item asks IS PRODUCT COLOR OK? If product color is okay and no change is desired, press product selection 1 or press the down button to move on to the next item. If a change is desired, press product selection 3 (i.e. color is not okay). The controller shows ADJUST DARKNESS, then display the darkness control slider: LT DK. A blinking asterisk * indicates the current position. The info button and program button are used to adjust the darkness setting. To make the product darker, press the program button to move the blinking * toward the DK (darker) side. To make the product lighter, press the info button to move the blinking * toward the LT (lighter) side. When done adjusting, press product selection 2 to exit and return to normal operating mode. D2: Oil Wear Report Any temperature adjustment activated by the Color Adjustment feature will be reflected in the normal set point display as part of the offset from the basic product cook temperature. To view the present regulating temperature, press the info button twice. In the example, SETPT = 315 F + 6 the product cook temperature is 315 F and has an additional offset of 6 F to compensate for the age of the oil, how long the fryer sits idle, and any color adjustments. This section displays information about the age of the present batch of oil. The controller only counts days in which the fryer is in use. The first step shows how many days of use this oil has: D2: THIS OIL IS D2: 4 DAYS OLD. To navigate the to D2: Oil Wear Report: Press the down button to move on to the second step. This step shows the age of the oil by percentage of its expected lifetime. The oils present, accumulated wear is compared to the wear setting at which the controlled will prompt for the oil to be change. D2: THIS OIL IS D2: 16% USED. This information can be used as the oil nears the end of its life (i.e. 95%), to plan ahead for when a clean-out will be required. Press the down button to move on to the next section. Information and Reporting Modes 69

82 Menu Step D3: Line Voltage Performance Report Description This section displays information about how good the line voltage supply has been for the present day and for the present batch of oil. The controller continually monitors the line voltage supplied to the fryer (when the fryer is on). If the line voltage drops below [90%] of its nominal value, the controller signals a LOW VOLTAGE alarm. This alarm sounds at the end of each cook cycle for which low voltage has been detected. While not cooking, the low voltage alarm can sound as frequently as every 30 minutes. The D3: Line Voltage Performance Report contains the following information: If no low voltage warnings have been detected for the present day the controller shows: D3: VOLTAGE OK D3: TODAY. If one or more low voltage warnings have been detected for the present day the following sequence example could be displayed: D3: YOU HAD 2 D3: LOW VOLTAGE D3: WARNINGS D3: TODAY. Press the down button. D3: MIN VOLTAGE D3: TODAY = 83%. Press the down button. D3: MAX VOLTAGE D3: TODAY = 101%. Press the down button. Information and Reporting Modes D4: Heating Capacity Report If one or more low voltage warnings have been detected before today, the following sequence is displayed: D3: BEFORE TODAY D3: 27 LOW VOLT D3: WARNINGS D3: ON THIS OIL. Press the down button. D3: MIN VOLTAGE D3: BEFORE TODAY D3: = 85%. Press the down button. D3: MAX VOLTAGE D3: BEFORE TODAY D3: = 105% Press the down button to advance to the next section. [ ] around a value, such as [90%], means this value is programmable and might change with later software versions. This section reports the present status of the heating system. The controller examines a history of heat-up data and determines whether or not the heating system is operating normally. The heat capacity is said to be bad only if the most recent heat-up failed to meet the expected heat-up rate and three of the last four heat-ups also failed to achieve the expected rate. That is, a single slow heat-up will not trigger a slow heat warning. The slow heat warning is activated only after repeated low-rate heat-ups is observed. The controller can t assess the integrity of the heating system if the fryer has been experiencing voltage problems. Low heat rates observed in this situation might be due to voltage problems rather than 70

83 Menu Step Description heater problems. The D4: Heating Capacity Report displays the following information: If the fryer has witnessed two or more low voltage warnings today, the following report is displayed: D4: CAN T TEST D4: HEAT CAPACITY D4: DUE TO D4: VOLTAGE D4: PROBLEMS. Otherwise, if the assessed heat capacity rating is presently good and at most only one heat-up today that failed to achieve the expected rate, the following report is displayed: D4: HEATING D4: CAPACITY D4: IS FINE. Otherwise, if the heat capacity is presently assessed as bad, or presently assessed as good but two or more heat-ups today have not reached the expected heat-up rate, the following report sequence is generated: D4: YOU HAD 75% D4: SLOW HEATS D4: TODAY. Press the down button. D4: HAVE 20% D4: SLOW HEATS D4: THIS OIL". Press the down button. D4: HAD 0% D4: SLOW HEATS D4: LAST OIL. Press the down button. D5: Cook Times (Slow Cooks) Report If the heat capacity is assessed as bad (low heat-up rate on last heatup, and on three of the last four heat-ups), then the heating coils are suspect and the following is displayed: D4: CHECK COILS, D4: CONTACTORS, D4: AND WIRING. Otherwise, the heating coils are presumed to be good and the following messages appear: D4: HEATER COILS D4: APPEAR OK. Press the down button. D4: CHECK D4: CONTACTORS, D4: CONNECTIONS, D4: AND WIRING This summarizes the slow cooking status for each product. Actual cook times for cook cycles can vary from the programmed cook time setting, due to the load compensation feature. Load compensation slows the cook timer down when the actual oil temperature is below a reference value, and speeds up the cook timer countdown when oil temperature is above the reference. When the oil temperature is lower than expected during a cook cycle, the overall cook time will be longer than normal. The D5: Cook Times Report contains the following information: If the actual cook time stretches beyond a programmed limit, the controller counts a SLOW COOK event and sounds an alarm at the end of the cook cycle. Information and Reporting Modes 71

84 Menu Step Description If low voltage or low amps are detected during the cook cycle, the warning message indicates LOW VOLTAGE or LOW AMPS, but the cook cycle will still count as a slow cook. If the voltage and amps have been fine during the cook cycle but the cook cycle was started before the Ready light came on, then the warning message indicates SLOW COOK WAIT FOR READY LIGHT. Otherwise, the slow cooking problem will be attributed to a bad batch of product: cooking too much in one load, or cooking product that is too cold. Information and Reporting Modes If none of the products has more than 5% slow cook cycles today, the following report is made: D5: COOK TIMES D5: LOOK OK D5: TODAY. Otherwise, if one or more cook products have generated a slow cook warning more than 5% of the time, but four or more low voltage or slow heat-up warnings (any combination) have been generated today, then the report is as follows: D5: SOME SLOW D5: COOKS TODAY D5: MAY BE DUE TO D5: VOLTAGE OR D5: COIL PROBLEMS. Such a report is saying the slow cooking may be the result of low voltage (which significantly reduces heat capacity) or the result of other problems with the heating system. In this case, the slow cook problems might not have anything to do with user error. Otherwise, the slow cooking is generally attributed to user error: cooking too much product in one load, cooking frozen product (in the pressure fryer) when it should be fresh, or cooking before the Ready light illuminates, etc. An individual XXXXX IS COOKING SLOWLY TODAY report item is generated for each product that has had more than 5% slow cook warnings today. This report item is triggered based solely on the number of slow cooks for that product, whether those slow cooks are due to voltage or heating problems, or due to cooking before ready, cooking too much, or cooking frozen product. D5: (Product Name) D5: COOKING SLOW D5: TODAY. Press the down button. If any of the slow cooks for this product are suspected as being due user error, a second, bad batch report is generated for the product. D5: (Product Name) D5: COOKING SLOW D5: TODAY. Press the down button. D5: POSSIBLE D5: OVERSIZED D5: OR FROZEN D5: BATCH OF D5: (Product Name) D5: DETECTED D5: 3 TIMES D5: TODAY. Press the down button. 72

85 Menu Step Description D5: POSSIBLE D5: OVERSIZED D5: OR FROZEN D5: BATCH OF D5: (Product Name) D5: DETECTED D5: 5 TIMES D5: TODAY. D6: Cooked Before Ready Report This section shows how many cook cycles were started before the READY light was on. This is strictly a user error. If the fryer was in the ready range when the user begins to load product, but is out of the ready range by the time the cook cycle is started, the control will not give you an alarm. The D6: Cooked Before Ready Report contains the following information: If the fryer wasn t ready before loading, an alarm sounds and WAS NOT READY warning is generated. The number of times this has happened today is indicated by the following report item: D6: COOKED D6: BEFORE READY D6: 11 TIMES D6: TODAY. Press the down button. The number of WAS NOT READY warnings for this batch of oil is also reported. Note that this value does not yet include the not ready warnings generated today. D6: BEFORE TODAY, D6: COOKED D6: BEFORE READY D6: 8 TIMES D6: ON THIS OIL. Press the down button. D7: Stopped Too Soon Report Finally, the controller identifies how many times the not ready warning was generated for the previous batch of oil: D6: LAST OIL, D6: COOKED D6: BEFORE READY D6: 24 TIMES This section shows how many cook cycles were stopped early by the user, before the cook timer had counted down to 0:00 and the *DONE* was displayed. This is a user error. cook cycles that are canceled after cooking for less than 30 seconds are not counted here. For example, if a cook cycle is accidentally started, and the cook cycle is canceled after just a few seconds, this cook cycle will not be counted as a Stopped Too Soon cook cycle. Also, some allowance is given for stopping a cook cycle a little early. The user can cancel the cook cycle up to 10 seconds early without penalty. Otherwise, however, any cook cycle that was stopped with more than 10 seconds remaining (0:10) on the cook clock with be counted as a STOPPED TOO SOON cook cycle. The D7: Stopped Too Soon Report contains the following information: The first item displays what percent of cook cycles today were stopped with more than 0:10 remaining. All products are grouped into one count. D7: 8% OF LOADS D7: WERE STOPPED D7: TOO SOON D7: TODAY. Press the down button. Information and Reporting Modes 73

86 Menu Step Description The number of Stopped Too Soon cook cycles for this batch of oil is reported next. Note that this value does not yet include the cook cycles from today. D7: BEFORE TODAY" D7: 3% OF LOADS D7: WERE STOPPED D7: TOO SOON D7: ON THIS OIL. Press the down button. Finally, the controller identifies percentage of Stopped Too Soon cook cycles for the previous batch of oil: D7: LAST OIL D7: 5% OF LOADS D7: WERE STOPPED D7: TOO SOON. D8: Beeped *DONE* Too Long Report Diagnostic Report section 8 reveals how many cook cycles beeped *DONE* for more than 20 seconds before the user pressed the timer button to stop the cook cycle. This is strictly a user error. The controller cannot detect when the product is actually removed from the fryer. It only identifies how long the controller beeped *DONE* before the user pressed the timer button to stop the alarm. The D8: Beeped *DONE* Too Long Report contains the following information: Information and Reporting Modes The first item displays the percent of today s cook cycles that beeped *DONE* for more than 20 seconds before the user pressed the timer button to stop it. All products are grouped into one count. D8: 10% OF LOADS D8: BEEPED DONE D8: TOO LONG D8: TODAY. Press the down arrow. The number of Beeped DONE Too Long cook cycles for this batch of oil is reported next. Note that this value does not yet include the cook cycles from today. D8: BEFORE TODAY" D8: 7% OF LOADS D8: BEEPED DONE D8: TOO LONG D8: ON THIS OIL. Press the down button. Finally, the controller identifies percentage of Beeped DONE Too Long cook cycles for the previous batch of oil: D8: LAST OIL D8: 6% OF LOADS D8: BEEPED DONE D8: TOO LONG 74

87 Menu Step D9: Irregular Loading Report Description For most cook cycles, the controller determines when the product was placed into the oil. This report identifies the percentage of cook cycles for which this determination was not successful. This drop detection detects most loads, but can fail for several reasons. Anytime the detection routine fails to find the true drop point, the controller logs an irregular loading count. Examples of failed drop detection might be: the operator takes too long to load the product to the time he presses the start button, or the operator cooks a very light product load, one or two filets, for example. In these instances, no drop point will be found and that cook cycle counts as an Irregular Loading cook cycle. Only products that have more than 5% of loads with missed detection s are reported. Loading Report For Today Loading Report For Today contains the following information: If no products have a failed to detect rate of more than 5%, the controller shows: D9: LOADING D9: LOOKS OK D9: TODAY. Otherwise, for each product that has more than 5% of loads in which the controller failed to detect the drop point, the following message is displayed: D9: IRREGULAR D9: LOADING D9: FOR 8% OF D9: (Product Name)" D9: TODAY. Loading Report for Present Batch of Oil The data for this batch of oil does not yet include cook cycles from today. Loading Report for Present Batch of oil contains the following information: If no products have a failed to detect rate of more than 5%, the controller shows: D9: LOADING D9: LOOKS OK D9: THIS OIL. Otherwise, for each product that has more than 5% of loads in which the controller failed to detect the drop point, the following message is displayed: D9: FOR THIS OIL, D9: IRREGULAR D9: LOADING D9: FOR 12% OF D9: (Product Name)". Loading Report for Previous Batch of Oil Loading Report for Previous Batch of Oil contains the following information: If no products have a failed to detect rate of more than 5%, the controller shows: D9: LOADING D9: LOOKED OK D9: PREVIOUS OIL. Otherwise, for each product that has more than 5% of loads in which the controller failed to detect the drop point, the following message is Information and Reporting Modes 75

88 Menu Step Description displayed: D9: PREVIOUS OIL, D9: IRREGULAR D9: LOADING D9: FOR 6% OF D9: (Product Name)". D10: Non- Standard Program Items Report The last section in the Diagnostic Report identifies how many programmable settings have been altered from their original, factory default settings. For each of the various program modes, the controller either reports that all settings match original values or reports N items do not match original values. This report makes it easy to see if any cook parameters or other settings have been changed from CFA settings. Some programming items may have been changed from original values under the direction of CFA corporate headquarters. In some cases, a controller should have values that don t match original values. A report that all items match original values could actually be an indication that something isn t set right. Keep in mind also that the number of such approved alterations might be different for different versions of software. The D10: Non-Standard Program Items Report contains the following information: If all product cook settings match the original, factory default values, the controller displays the following message: 10: ALL PROD S 10: MATCH 10: ORIG. VALUES. Information and Reporting Modes If any of the product settings do not match original values, the following message is displayed (with one or more of the product numbers blinking): 10: PROD S : DO NOT MATCH 10: ORIG. VALUES. In this case, the blinking numbers indicate which products do not match original settings. If the numbers 3 and 5 are the only numbers blinking, then product #3 and product #5 each have at least one setting changed from their factory preset values. Products 1, 2, 4, and 6 are confirmed to exactly match their original settings. The second item in section 10 identifies how many items in CFA Programming Mode have been changed from their original values. These Chick-fil-A settings mainly deal with special Chick-fil-A controller features like Oil Wear, Heat-up Monitoring, New Oil Compensation, Oil Idle Compensation, Drop Detection, Clean-out Mode, and Amps and Voltage alarms. If all items in CFA Prog. Mode match their original, factory preset values, the following report is made: 10: ALL CFA ITEMS 10: MATCH 10: ORIG. VALUES. If any of the items in CFA Prog. Mode do not match their original values, the following message is displayed (with the actual number of changed items): 10: 2 CFA ITEMS 10: DO NOT MATCH 10: ORIG. VALUES". 76

89 Menu Step Description A similar report is made for Special Program Mode. Special Program (SP) Mode settings deal with F/ C display, speaker tone and volume, Melt and Idle Modes, and how the product buttons function (start cook or merely select product). 10: ALL SP ITEMS 10: MATCH 10: ORIG. VALUES or 10: 1 SP ITEMS 10: DO NOT MATCH 10: ORIG. VALUES. The final item in section 10 identifies if any changes have been made to the heat control settings. These settings affect the fryer s heating algorithms, and include the PC factors, rate-of-rise compensations, and heat pulse cook cycle time, etc. 10: ALL HC ITEMS 10: MATCH 10: ORIG. VALUES or 10: 3 HC ITEMS 10: DO NOT MATCH 10: ORIG. VALUES. Information and Reporting Modes 77

90 Information and Reporting Modes 78

91 Chapter 7 Operational Troubleshooting This section provides troubleshooting information in the form of easy to read tables. If a problem occurs during the initial operation of a new fryer, recheck Chapter 2 Unpack and Install, page 3 and Chapter 3 Operation, page 9. For controls and indicators information, see 3.1 User Interface Controls & Indicators, page 9. To isolate a problem, do the following: Clearly define the symptom and when it occurs. Locate any warnings, errors or symptoms from the tables below and follow the correction. If a problem cannot be resolved, call your local service provider or distributor first. For additional help, call or Henny Penny (HP) Technical Support at: Inside the U.S.: or technicalservices@hennypenny.com. Outside the U.S.: or intltechsupport@hennypenny.com. 7.1 Cooking Troubleshooting Guide Table 7-1 Cooking Troubleshooting Guide Problem Cause Correction Cooking Section - Product Color Incorrect: A. Too dark (some batches). Temperature programmed too high. Coater or carbon build up covering temperature sensor. Breading product too far ahead. Done alarm ignored for more than 20 seconds. Wrong product button pressed. Set point tampering possible. D10. See 6.3 Diagnostic Mode, page 67; if temperature settings have been tampered with, have the controls reinitialized. Thoroughly remove all debris from the temperature probe. Bread product just before frying. If the fryer hasn t been used since the problem batch, see 6.2 Information Mode Details, page 48 4H and 5H; for more information on this problem, see 6.2 Information Mode Details, page 48 6U, 7U, 8R, or 10R. Be sure to press the correct product button; if the fryer hasn t been used since the problem batch, see 6.2 Operational Troubleshooting 79

92 Problem Cause Correction Information Mode Details, page 48 4B and 5B, to see what product was selected. Too dark (all batches). Temperature probe out of calibration, incorrect heaters, or improper voltage. Oil too old. See D1 of Diagnostic Mode Details, page 68 to adjust color of product. Check temperature probe calibration; if less than 15 degrees off, have probe calibrated (service manual required); if more than 15 degrees off, replace probe. Have heating elements checked. If oil is smoking or has burnt taste, change oil. See D2 of Diagnostic Mode Details, page 68; change oil if controls indicate it should be changed. Operational Troubleshooting Too light (all batches). Oil too dark. Faulty probe; E-6. If oil is smoking or has burnt taste, change oil. Filter oil. Perform clean-out procedur 4.1 Clean-Out Mode, page 33. If probe can t be re-calibrated, have probe replaced. Temperature probe out of calibration. See D1 of Diagnostic Mode Details, page 68 to adjust color of product. Slow fryer heat-up/recovery. Check temperature probe calibration; see Check Temperature Probe Calibration Section; if less than 15 degree off, have probe calibrated; if more than 15 degrees off, replace probe. See D4 of Diagnostic Mode Details, page 68, for present day s performance; or see

93 Problem Cause Correction Information Mode Details, page 48 for more information on this problem. Low voltage; see D3 of Diagnostic Mode Details, page 68 for present day s voltage performance; for more information see 6.2 Information Mode Details, page 48 Too light (some batches). Oil usage wasn t set for new oil. Temperature programmed too low. Product placed in oil before proper temperature. See D2 of Diagnostic Mode Details, page 68 for the age of the oil; see 3.4 Cook Cycle, page 17 for setting the age of the oil. See D10 of Diagnostic Mode Details, page 68 if temperature settings have been changed without authorization; have the controls reinitialized. If fryer hasn t been used since problem batch, see 6.2 Information Mode Details, page 48 4C and 5C; for more information see 6.2 Information Mode Details, page 48 6S, 7S, 8P, 9P, and 10P. Dryness of product. Wrong product button pushed. Cook cycle aborted before alarm and DONE flashes. Too large of a product batch. If fryer hasn t been used since problem batch, see 6.2 Information Mode Details, page 48 4B and 5B to see what product was selected. If fryer hasn t been used since problem batch, see 6.2 Information Mode Details, page 48 4C and 5C; for more information see 6.2 Information Mode Details, page 48 6S, 7S, 8P, 9P, and 10P. No more than 15 lbs. of product per batch; see D5 to see if the controls sensed any overloaded batches. Moisture loss prior to cooking. Use fresh product. Cover product to reduce evaporation. Over-cooking the product. Done alarm ignored for more than 20 seconds; if the fryer Operational Troubleshooting 81

94 Problem Cause Correction hasn t been used since the problem batch, see 6.2 Information Mode Details, page 48 4H and 5H; for more information on this problem, see 6.2 Information Mode Details, page 48 6U, 7U, 8R, 9R, or 10R. See D2 of Diagnostic Mode Details, page 68 for the age of the oil; see 3.4 Cook Cycle, page 17 for setting the age of the oil. Time of cook cycle set too long. Wrong product button pushed. See D10 of Diagnostic Mode Details, page 68; if time settings have been tampered with, have the controls re-initialized. If fryer hasn t been used since problem batch, see 6.2 Information Mode Details, page 48 4B and 5B to see what product was selected. Burned taste. Burned oil flavor. Replace oil and perform a clean out 4.1 Clean-Out Mode, page 33. Oil needs filtering. Filter oil more often. Vat not properly cleaned. Drain and perform Daily Filter Daily Filtering, page 23. Operational Troubleshooting Product not done. Incorrect heating elements or improper voltage. Cook cycle aborted before alarm and DONE flashes. Too large of a product batch. Wrong cook button pushed. Temperature programmed too low or not programmed. Have heating elements and voltage checked. See D7 of Diagnostic Mode Details, page 68 to see how many times the cook cycle was stopped before the end of the cook cycle. No more than 15 lbs. of product per batch; see D5 of Diagnostic Mode Details, page 68 to see if the controls sensed any overloaded batches. If fryer hasn t been used since problem batch, see 6.2 Information Mode Details, page 48 4B and 5B to see what product was selected. See D10 of Diagnostic Mode Details, page 68; if temperature settings have been changed, have the controls re-initialized. 82

95 Problem Cause Correction Temperature probe out of calibration. Slow fryer heat-up/recovery. Check temperature probe calibration; see Checking Temperature Probe Calibration section; if between 5 and 15 degrees off, calibrate probe; if more than 15 degrees off, replace probe. See D4 of Diagnostic Mode Details, page 68 for the present day s performance; or see 6.2 Information Mode Details, page 48 for more information on this problem. Low voltage; see D3 of Diagnostic Mode Details, page 68 for present day s voltage performance; for more information see 6.2 Information Mode Details, page 48 Power Section With power switch in on position, fryer is completely without power. Filter motor runs but pumps oil slowly. Filter pump motor does not run. Open circuit. Pump clogged. Filter System Section O-rings worn, damaged, or missing. Clogged filter envelope Wet filter envelope Reset filter pump motor Check to see if fryer is plugged in. Check wall circuit breaker or fuse. Have a qualified service technician check power supply and power switch. Have pump cleaned. Replace drain pan o-ring Quarterly Drain Pan O-Ring Replacement, page 38. Clean drain pan, empty crumb basket, and replace filter envelope 3.7 Drain Pan Assembly, page 29. Dry drain pan and replace filter envelope 3.7 Drain Pan Assembly, page 29. Allow 15 minutes for filter pump motor to cool, remove the reserve oil tank, then use the tip of a screwdriver to press in on the red reset Operational Troubleshooting 83

96 Problem Cause Correction button on the motor. INFO: Use a screwdriver tip to press this button in as it is difficult to get it to reset by hand. Defective motor. Pump motor breakers tripped Have motor checked. Press both white reset breakers. Motor hums but will not pump. Clogged lines or pump removed. Have pump and lines cleaned. Have pump seal, rotor, and rollers replaced. Oil will not heat. Blown fuse or tripped circuit breaker at supply box. Reset breaker or replace fuse. Operational Troubleshooting Faulty cord and plug. Faulty control board. Faulty or tripped high limit; E-10. Drain valve open; E-15. Possible faulty probe; E-6. Possible faulty connector. Faulty power switch. Faulty drain switch; E-15. Check cord and plug, and check power at wall receptacle. Have control panel checked. Reset high limit per 3.1 User Interface Controls & Indicators, page 9; if high limit doesn t reset, have it checked. Close drain valve. Have temperature probe checked. See D4 of Diagnostic Mode Details, page 68; if CHECK COILS, CONTACTORS AND WIRING shows on display, have contactors and wiring checked. 84

97 Problem Cause Correction See 11. Input Info of 6.2 Information Mode Details, page 48 and check to see if the input code is present; if not, have fryer check by a certified service technician. Oil heating slowly. Low or improper voltage. See D3 and D4 of Diagnostic Mode Details, page 68 for present day s voltage and heating performance; for more information on this problem, see 6.2 Information Mode Details, page 48. Wire(s) loose. Faulty PC board. Heating element damage or open circuit. Burnt or charred connectors. Faulty contactor. Have wires tightened. Have control panel checked. See D4 of Diagnostic Mode Details, page 68; see if CHECK COILS, CONTACTORS AND WIR- ING shows on display; if so, have fryer checked by a certified service technician. 7.2 Warning Messages The control monitors procedural problems and system failures with warning and error codes. The display shows the warning or error code, and an alarm sounds. Pressing product selection 2 cancels most warnings and pressing any control button stops most error code alarms. But there are some exceptions, see below. The display shows the error until the situation is corrected. Table 7-2 Warnings Display Cause Correction W-1 LOW VOLTAGE W-2 SLOW HEAT-UP W-3 WAS NOT READY Incoming supply voltage too low. Faulty components or connections. Product loaded into vat before the ready LED lights. Check to make sure plug is pushed in all the way. If Low Voltage continues, contact Henny Penny Support to check fryer configuration and settings. Check to make sure plug is pushed in all the way. Have elements, connections, and contactors checked. Wait until oil is at proper temperature before loading product. Operational Troubleshooting 85

98 Display Cause Correction W-4 SLOW COOKING W-5 SLOW COOKING W-6 SLOW COOKING W-7 LOW AMPS W-9 DISCARD PRODUCT OIL TOO HOT Too much product in vat. Product loaded into vat before ready LED lights. Faulty components or connections. Faulty components or connections. Product overcooked. (May appear after a SLOW COOKING warning.) Didn t allow oil to drop to current product s set point temperature. Fill baskets following Chick-fil-A guidelines. Do not overfill baskets. Wait until oil is at proper temperature before loading product. Have elements, connections, and contactors checked. Check to make sure plug is pushed in all the way. Have elements, connections, and contactors checked. Discard product immediately. Cancel button stops this warning; once the oil drops to set point temperature, the alarm automatically stops. Remove carbon build up and / or coater from temperature sensors. Operational Troubleshooting 7.3 Error Messages In the event of a control system failure, the digital display shows an error message. The message codes are shown in the display column below. A constant tone is heard when an error code is displayed, and to silence this tone, press any button. E-1 Table 7-3 Error Messages Display Cause Correction E-4 CPU TOO HOT Low oil in vat. Control board overheating. Check oil in reserve oil tank. Turn off fryer. Carefully add oil to vat. Turn on. If E-1 occurs and oil level is full, perform a clean out procedure and ensure all sensors in the vat are clean. Turn switch to off position, then turn switch back to on; if display shows E-4, the control board is getting too hot; check the louvers on each side of the unit for obstruction. 86

99 Display Cause Correction E-5 FRYER TOO HOT Oil overheating. Turn switch to off position, then turn switch back to on; if display shows E-5, the heating circuits and temperature probe should be checked. E-6A FRYER TEMP SENSOR Temperature probe open. Turn switch to off position, then turn switch back to on; if display shows E-6A, the temperature probe should be checked. E-6B FRYER TEMP SENSOR Temperature probe shorted. Turn switch to off position, then turn switch back to on; if display shows E-6B, the temperature probe should be checked. E-10 HIGH LIMIT TRIPPED High limit. Allow heating elements to cool (15-20 minutes) and reset high limit by pressing the high limit reset button for 3 seconds. If high limit does not reset, have the electronic high limit circuit checked. E-15 DRAIN IS OPEN E-18 LEVEL SENSOR FAILED E-19 PROTECTION SENSOR FAILED E-25 HEAT AMPS WERE TOO HIGH Drain switch. Upper temperature probe open or shorted. Protection temperature probe (against heating element) open or shorted. Wrong or faulty elements, wiring problem, setting or configuration problem. Make sure drain knob is completely pushed-in; if E-15 persists, have drain switch checked. Turn switch to off position and then back to on; if display still indicates a failed sensor, have sensor checked. Turn switch to off position, then turn switch back to on. If display shows E-19, the protection temperature probe should be checked. Have electrical supply, wiring, and elements checked. NOTICE: Keep fryer off if this error persists, or wiring damage could result. Operational Troubleshooting 87

100 Display Cause Correction E-26 HEAT AMPS ARE LOCKED ON Faulty contactors or PCB. Have the contactors and PC board checked. NOTICE: This error code could be displayed even with the power switch turned off. Unplug fryer or shut-off the wall circuit breaker to disconnect electrical power to fryer. Operational Troubleshooting E-27 HEAT AMPS WERE TOO LOW E-28 AMP SENSORS NOT DETECTED E-29 SHUNT BREAKER TRIPPED CALL FOR SERVICE E-41 E-46 Faulty contactors, PCB, or incoming power. Current sensor board not connected. Shunt circuit breaker tripped. Programming failure. 1. Check to make sure plug is pushed in all the way. 2. Have the contactors, current sensors, PCB, incoming wiring, and electrical supply checked. Have current transducer wiring and sensors checked. Have circuit breaker and contactors checked. Service Tech must enter a code and physically reset the shunt device to clear the error. Press power button to vat off and back on again, if either error codes show on display, have the controls re-initialized; if error code persists, have the control board replaced. E-47 Analog converter chip or 12 volt. Press power button to vat off and back on again, if E-47 persists; if the wait LED and ready LED do not light up when the 8888 s are displayed, have the control board replaced. Amp sensor in backwards. Faulty PCB. Have positions of amp sensors checked. Have control panel replaced. E-48 Input system error. Have control replaced. E-60 AIF PC board not communicating with control PC board. Press power button to turn vat off, wait 15 seconds, and turn back on again. If E-60 persists, have connector between the PCB's checked; replace AIF PCB 88

101 Display Cause Correction or control PCB board, if necessary. E-70 PWR SW OR WIRES FAILED E-75 HEAT RELAY NEAR END OF LIFE E VOLT FUSE Faulty power switch or switch wiring; faulty I/O board. Normal wear on secondary contactor. Blown 24 volt controller fuse, or bad 14-pin cable connection. Have power switch checked, along with its wiring; have I/O board checked Have heat contactor replaced. Have the 14-pin cable connector or fryer checked for a short to ground in components such as the drain switch, or high limit and wiring. Operational Troubleshooting 89

102 Operational Troubleshooting 90

103 Chapter 8 Troubleshooting and Diagnosing Issues 8.1 Tech Modes Use Tech mode to diagnose issues. With the fryer -OFF-, press and hold P for 6 seconds to enter Level 2 programming. Use P or I to navigate to Tech Mode. Type to enter the Tech Mode menu. Table 8-1 Tech Modes Mode Provides Operation and Display Description T-1 View Software ID s PM/ID/SRL: - Press and hold [1]: HP P/N = 24913X - Press and hold [2]: ID = CFA - Press and hold [3]: SRL = P HP part number for programmed software chip. - The specific customer or model number, etc. - Software release level (version) for this software. T-2 Fryer Type ELEC Fryer type which is auto-detected by the controller. T-3 Push Button Test BTNS: Press buttons to test: L IDUP R 789ABC T-4 All-On Display Test ALL Press and release any button other than I (Info) or P (Program) to activate test mode. The main display shows an indicator letter for each button that is pressed: - Left-side timer, number buttons 1-6, Info, Down, Up, Program Right-side timer. - Right-side number buttons 1-6 are shown as 7, 8, 9, A, B, C in the same digits as left side 1-6. Press and hold any number button to cause all display digit segments, decimal points, LED's, and light bars to be lighted. Release button to return to normal mode. Troubleshooting and Diagnosing Issues 91

104 Mode Provides Operation and Display Description T-5 Segments Test SEGS Tests each individual display segment or all digits simultaneously in order to assess whether any segments might be bridged together. Press and release any number button to step through the test sequence manually, or press and release the timer button to run the test sequence automatically one time through. Troubleshooting and Diagnosing Issues T-6 Digits test DIGS Tests each individual display digit (all segments on, one digit at a time) in order to assess whether any solder bridges between digits exist. T-7 Decimal Point Test D-PTS Press and release any number button to step through the test sequence manually, or press and release the timer button to run the test sequence automatically one time through. This step tests each individual display digit decimal point. Press and release any number button to step through the test sequence manually, or press and release the timer button to run the test sequence automatically one time through. 92

105 Mode Provides Operation and Display Description T-8 LED s Display Test LEDS This step tests each individual discrete LED. The test pattern is as follows: Wait, Ready, Left timer, Heat, Info, Down, Up, Prog, Right Timer, L1, L2, L3, L4, L5, L6, R1, R2, R3, R4, R5, R6. Press and release any number button to step through the test sequence manually, or press and release the timer button to run the test sequence automatically one time through. T-9 Pot Temp Calibration & Offset T-10 Level Temp Calibration & Offset CALIB/OFFSET/ HIGHEST: - Press and hold [1]: CALIB ADJ 357 F - Press and hold [2]: OFFSET ADJ +2 F - Press and hold [3]: HIGHEST 367 F CALIB/OFFSET/ HIGHEST: - Press and hold [1]: CALIB ADJ 87 F - Press and hold [2]: OFFSET ADJ +0 F - Press and hold [3]: HIGHEST 121 F View/set calibration offset for temperature probe and view/reset max recorded pot temperature: - UP/DOWN to adjust calibration viewed as a temp. - UP/DOWN to adjust calibration viewed as an offset. - View highest recorded pot temperature. Reset max temp by pressing the DOWN button while viewing. View/set calibration offset for temperature probe and view/reset max recorded pot temperature: - UP/DOWN to adjust calibration viewed as a temp. - UP/DOWN to adjust calibration viewed as an offset. Troubleshooting and Diagnosing Issues 93

106 Mode Provides Operation and Display Description - View highest recorded pot temperature. Reset max temp by pressing the DOWN button while viewing. Troubleshooting and Diagnosing Issues T-11 Pro Temp Calibration & Offset T-12 CPU Control Temp Calibration & Offset T-13 Fryer Supply Volts CALIB/OFFSET/ HIGHEST: - Press and hold [1]: CALIB ADJ 87 F - Press and hold [2]: OFFSET ADJ +0 F - Press and hold [3]: HIGHEST 121 F CALIB/OFFSET/ HIGHEST: - Press and hold [1]: CALIB ADJ 87 F - Press and hold [2]: OFFSET ADJ +0 F - Press and hold [3]: HIGHEST 121 F 208V NOM View/set calibration offset for temperature probe and view/reset max recorded pot temperature: - UP/DOWN to adjust calibration viewed as a temp. - UP/DOWN to adjust calibration viewed as an offset. - View highest recorded pot temperature. Reset max temp by pressing the DOWN button while viewing. View/set calibration offset for CPU board temperature and view/ reset max recorded CPU board temperature: - UP/DOWN to adjust calibration viewed as a temperature. - UP/DOWN to adjust calibration viewed as an offset. - View highest recorded CPU temperature. Reset max by pressing the DOWN button while viewing. View/set the fryer's nominal line voltage (Unknown, 120V, 208V, 240V, 480V). 94

107 Mode Provides Operation and Display Description All Line Voltage inputs are handled internally as percent of nominal values, based on a nominal 24VAC output from the secondary of the transformer. This parameter simply allows conversion of percent values to AC Volts for various data displays. T-14 Line Volts Loading LV LD If this parameter is set incorrectly the line volts display shown as AC Volts will be wrong, but this parameter has absolutely no effect on actual operation or cooking. This test step acquires some of the calibration data needed for the Line Voltage input. INFO: This test requires the heating elements to be disconnected! Unplug the fryer, remove the three wires from the top of the mercury contactor, and tape the bare wire ends before performing this calibration. Activating this function with the elements connected will not damage anything but will result in inaccurate voltage readings later when the heat is on. The fryer monitors line voltage by monitoring Troubleshooting and Diagnosing Issues 95

108 Mode Provides Operation and Display Description the voltage from the secondary coil of the 24 VAC transformer. In order to interpret the status of the line voltage supply, the fryer must first analyze the effects of all the various loads on the 24 VAC transformer. Troubleshooting and Diagnosing Issues T-15 Line Volts - Calibrate Offset / Highest CALIB/OFFSET/ HIGHEST: - Press and hold [1]: CALIB ADJ 98% - Press and hold [2]: OFFSET ADJ +0% - Press and hold [3]: HIGHEST 103% If re-calibration is necessary, follow the instructions above regarding disconnecting the heating elements: 1. Power the fryer on again, activate Tech mode, and advance to this step. 2. Press the Timer button. The controller will perform an automated test sequence, turning on various combinations of outputs and displays and testing the effect they have on the 24 VAC supply. 3. When the calibration sequence is complete, turn the fryer off, unplug it, and reconnect the heating element wires. View/set calibration offset for Line Voltage input and view/reset max recorded Line Voltage value: - UP/DOWN to adjust calibration, viewed as % of nominal. - UP/DOWN to adjust calibration, viewed as an offset - View highest recorded line volts value. 96

109 Mode Provides Operation and Display Description Reset max by pressing the DOWN button while viewing. INFO: If item T-11 is set correctly, the line voltage display can be toggled between percent of nominal values and AC Volts by pressing the right side number 6 button. T-16 View A-D Channels <0> CPU temperature (thermistor) <1> Safety Circuit Comparator Ref. <2> Safety Circuit Comparator Output <3> Aux. RTD input (unused) <4> Pot Tmp RTD input <5> Line Volts (P6-14) <6> Unused (P10-6) <7> Unused (P10-5) <8> Amp sensor #3 (P10-4) <9> Amp sensor #1 (P10-2) <A> Amp sensor #2 (P10-3) <B> 1/2 Scale (2.5v) <C> Neg Vref (0.0v) <D> Pos Vref (5.0v) This feature allows direct viewing of any channel of the analogto-digital converter chip. This is mainly useful for troubleshooting. - The channel can be selected using the UP or DOWN buttons. - The displayed value can be toggled between Volts and Bits by pressing the number 1 button. - If the displayed value has a decimal point, it is voltage (0 to 5 VDC). - If no decimal point is shown, the value is a- to-d bits (0-4095). T-17 Digital Inputs A V H D S View the status of the 24 VAC interlock circuit digital inputs. Each interlock input has an associated indicator digit: - If the input signal is currently detected, an identifying letter is displayed. - If the signal is not detected, an underscore (_) is displayed. Troubleshooting and Diagnosing Issues 97

110 Mode Provides Operation and Display Description Troubleshooting and Diagnosing Issues A = Power switch ON input signal. There are two power switch on input signals. This one is not dependent on the interlock chain, so the controller is always able to read the On/Off status of the power switch even if the high limit is tripped or the drain is open. V = VOLTS: 24 VAC detected at start of interlock chain. If V is missing, the 24 VAC current protector (fuse) might be tripped. This fuse device (located on the I/O board) automatically resets as soon as the short condition is fixed. H = HIGH LIMIT: If H is present, the high limit is good. If H is missing, the high limit is tripped out (overheated) or disconnected. D = DRAIN SWITCH: If D is present, the drain handle is closed. If D is missing, the drain is open or disconnected. S = POWER SWITCH: on interlock circuit. If S is present, the power switch is in the ON position. If the S is missing, the power switch is either off, failed, or wired incorrectly. INFO: The VHDS inputs are wired in series as listed from left to right. The first signal that is missing causes 98

111 Mode Provides Operation and Display Description all signals to the right of it to also be missing. If a V, H, or D signal is missing and yet other signals do appear to the right of it, it is likely that the voltage sensor for the missing signal has failed or that something is not wired correctly. Example: A V _ D S This example is abnormal, because the H signal is missing and yet the D and S signals appear to the right of it. It might be that the voltage sensor chip for the H input has failed, or it might be that the wiring for the High Limit and the Drain switch are incorrect. T-18 Output Test Electric: H* View/set the status of the controller outputs: - If an output is currently on, an asterisk (*) displays after the ID letter. - If an output is currently off, a line displays after the ID letter. Electric: H = HEAT OUTPUT: The heat output may be manually controlled using the number 1 button. Under manual control on either type of fryer, the Heat output will shut off automatically if no buttons are pressed for 30 seconds. Troubleshooting and Diagnosing Issues 99

112 Mode Provides Operation and Display Description T-19 Amps Calibrate (inputs) Electric: The amp sensors monitor the current (amperes) in the heating elements. In the Open Fryer, each amps reading corresponds directly to the current in one of the heating element coils. Consequently, the amps readings here will not match an amps readings on the line cord wires, since each phase on the line cord normally drives two elements (120 out of phase). Troubleshooting and Diagnosing Issues T-20 Do Total Initialization INIT This step allows all programmable settings and all statistics and event logs to be initialized to factory preset values. To totally initialize the controller Including all cook settings back to factory default values, press and hold the DOWN button for about 2 seconds. Calibration data will not be affected by this initialization, unless values are found to be outside of acceptable limits. INFO: Statistics values, the E-Log, Oil Wear, etc., will be reset by this total initialization. All of the operating history data will be lost. For this reason, the normal Init step in Special Program mode is 100

113 Mode Provides Operation and Display Description generally recommended, unless one intends to completely reset all the statistics data. This initialization function will cause the controller to activate Clock Set mode at the next power up, and to also ask IS THIS NEW OIL?. T-21 AIF Info AIF 20 - AIF : Means normal communications between the AIF PCB and the control PCB. - AIF XX: Means a problem with the communications between the PCBs. T-22 Pumps and Valves Press the down-arrow, and LIGHTS DLT_ displays. Press the down-arrow, and VALVES DcRc displays. Press 7 to open and close the return valve: - DcRc means valve is closed. - DcRo means valve is open. Press the down-arrow, DISCARDc / JIBFILLc displays: - Press 1 to open / close the RTI discard valve. DISCARDo displays when open. - Press 2 to open / close the RTI JIB fill valve. JIBFILLo displays when open. Press the down-arrow, PUMP FP_ / JP_ NP_ displays: Troubleshooting and Diagnosing Issues 101

114 Mode Provides Operation and Display Description Troubleshooting and Diagnosing Issues - Press 1 to turn filter pump off / on. FP* displays when on. - Press 2 to turn JIB pump off / on. JP* displays when on. Press 3 to turn new oil pump off / on if available. NP* displays when on. Press the down-arrow, AIF REQ / RQ=Y OK= Y displays. - REQ=Y means control is currently requesting control of the AIF Board outputs. - OK= Y means the AIF Board has granted this control the authority to control the AIF Board outputs. Press the down-arrow, FILR IN / USE BY 1 displays. Displays which controls are using the filtering system: - USE = 0: not in use - USE = 7: used by AIF - USE = 1 to 5: used by control PCB Press the down-arrow, CPU POSN / 1 OF 3 displays. Displays which controls are plugged into which port on the AIF board. For example, the left control should be plugged into port 1, and on a 3 control fryer, shows 1 OF 3 on the display. If the right control is unplugged, then the left control would show 1 OF 2 instead of 1 OF 3. Press the down-arrow, INP E_P_ / JL_Rx DF_ displays. 102

115 Mode Provides Operation and Display Description Press the down-arrow, OUT F_J_ / N_DI_oJF displays. T-23 Reset Secondary Contactor Counts T-24 Shunt Breaker Tripped T-25 Copy Trace Log from Internal Storage to USB T-26 Delete Trace Log from Internal Storage YES / NO CPY TRC DEL TRC 8.2 Wi-Fi Radio Use the following information to diagnose and correct Wi-Fi issues Wi-Fi Connection Once the fryer is turned on the Wi-Fi radio begins to search for a connection to the LAN. There are no user configuration steps within the fryer menu. The configuration and connection to the LAN is seamless and typically needs no intervention. Initial connection can take up to 30 minutes Radio Status INFO: The radio status light only reflects communication between the fryer and the radio, and not the Local Area Network (LAN) or the Internet. On the opposite side of the radio module s antenna connection, there is a green LED. This LED is used for basic diagnostics with the following guideline: Off: Radio is booting or power is disconnected. Fast blink: Radio is attempting communications with the fryer. Slow blink: Radio is successfully communicating with the fryer Radio Info Mode As part of the standard two-button Info Mode feature of the fryer, a menu item provides information about and basic diagnostics of the radio module from the fryer s front control panel. Enter Info Mode by pressing the P and i buttons simultaneously, then scroll to item 26. RADIO INFO using the up and down arrow keys. Options within the menu include: Troubleshooting and Diagnosing Issues 103

116 Communications status between the radio and fryer controller. Communications status between the radio and the Internet. Radio s external IP address as seen by the Internet/access point (WAN). Radio s IP address as seen by the fryer controller (LAN). Fryer s IP address as seen by the radio (local or LOC). Radio module application version number (AP). Radio module system software version number (RF). Radio/fryer communication protocol version number (IM). Ability to force a soft reboot of the radio module Radio to Fryer Communication State Description The control board communicates with the Wi-Fi radio separate from the Local Area Network (LAN) and Internet. The radio and control board passes operational data back and forth to ensure a seamless connection between them. The first step in diagnosing a communication issue is to ensure the radio and fryer are communicating together. Various states are as follows: Troubleshooting and Diagnosing Issues Idling: This state indicates the fryer software is initializing its software stack and delaying before contacting the radio. The fryer adds in a short time delay to allow the radio module time to initialize itself before communication is attempted. Connecting: This state indicates the fryer software is starting to communicate with the radio module. This state checks that there is a radio module attached and tells the module a fryer control is attached in order to begin full communications. Negotiating: This state indicates the fryer software has successfully communicated to a radio module and next begins determining security properties of the communications link. This includes first authenticating to each other to help prevent unauthorized modules from being attached. It also determines method of encryption of subsequent data, if any. Waiting for Fryer: This state indicates the fryer software is doing very early initialization of the basic communications stack. You should never see this state because this is normally done very early on in the boot process. Waiting for Radio: This state indicates the fryer software has opened a successful communications connection to the radio module, but the radio software needs time to fully complete the connection. During this time, the radio module is attempting to establish a connection to the Internet. It also has built-in time delays to allow the fryer to boot and initialize. Depending on the sequence of events, this state may be very short or may be up to several minutes long. Connected: This state indicates the fryer and radio module are successfully communicating to each other. This is the desired state for actively being able to send and receive data during normal operations. Ending: This state indicates the fryer software or radio module has asked to terminate the data communications link. This usually occurs if the radio module has received an update for itself and needs to reboot to complete the update. 104

117 Disconnected: This state indicates the fryer and radio module are not communicating anymore. This state is very short, as the fryer will almost immediately move back to Idling before attempting to reestablish communications WAN (Radio External IP Address) This screen shows the radio s IP address as seen by the world as assigned by DHCP from the local access point or wireless router. It may be a routable or non-routable address, but is used for communications between the radio module and the outside world (e.g. the Internet). INFO: This address is only updated when the fryer and radio are successfully communicating. If communications is interrupted, the screen will continue to show the last known IP address of the radio. This can help with troubleshooting to see the last known address, but must be used with caution because the radio could acquire a new address (via DHCP) while communications is down between it and the fryer LAN (Radio Internal IP Address) This screen shows the radio s IP address as seen by the fryer. It is a non-routable, internal-only address used for communications between itself and the fryer controller. The last digit of the address also indicates which port the fryer controller is connected. For example, if the LAN address is shown as , then this fryer controller is connected to Port 2 on the radio module. INFO: This address is only updated when the fryer and radio are successfully communicating. If communications is interrupted, the screen will continue to show the last known internal IP address of the radio. This can help with troubleshooting to see the last known address LOC (Fryer Internal (Local) IP Address) This screen shows the fryer s local IP address as seen by the radio module. It is the other end of the internal network for communications between the radio and fryer. The last digit of the address also indicates which port the fryer controller is connected. For example, if the LOC address is shown as , then this fryer controller is connected to Port 1 on the radio module. INFO: This address is generally only updated when the fryer and radio are successfully communicating. If communications is interrupted, the screen may continue to show the last known local IP address of the fryer. This can help with troubleshooting to see the last known address AP (Radio Application Version Number) This screen shows the version number of the main application software running on the fryer module. This software is primarily responsible for managing the communications between the fryer and the Internet. Troubleshooting and Diagnosing Issues 105

118 INFO: This value is only updated when the fryer and radio are successfully communicating. If communications is interrupted, the screen will continue to show the last known radio application version number RF (Radio System Firmware Version Number) This screen shows a single version number for the radio module s primary system package, which includes OS, boot loader, and other device driver software and firmware. INFO: This value is only updated when the fryer and radio are successfully communicating. If communications is interrupted, the screen will continue to show the last known radio firmware version number IM (Radio Fryer Communication Protocol Version Number) This screen shows the version number for the proprietary protocol used to send data between the radio and fryer as reported by the radio module. INFO: This value is only updated when the fryer and radio are successfully communicating. If communications is interrupted, the screen will continue to show the last known radio communications protocol version number. Troubleshooting and Diagnosing Issues Reboot the Radio This screen allows the operator to manually cause a graceful reboot of the radio. This option is available because the radio module is always powered whenever the fryer itself is powered. 106

119 Chapter 9 Component Replacement Procedures This section provides replacement procedures, for common parts of the fryer. Do not move the fryer with hot oil in the vat or filter pan. Severe burns can result from splashing hot oil. 9.1 Control Panel Replacement Refer to Figure 10-1 Components, Front, page 140 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the old control panel, and then rotate the panel down. 3) Obtain the new control board and note the label on the back, which identifies the connection locations. 4) One by one remove the connectors from the old control panel and plug them in to the new control panel. 5) Replace the old control panel with the new control panel, and then rotate the new control panel up and install the two securing screws. 6) Test the new control panel to ensure it works properly. 9.2 Reset Circuit Breaker Replacement Refer to Figure 10-1 Components, Front, page 140 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Using a 9/16 in. wrench, loosen and remove the locknut on the outside (shroud) of the reset button. Component Replacement Procedures 107

120 4) Pull the reset button out of the hole in the shroud, and disconnect the wires. 5) Attach the wires to the new reset button, and then install the new reset button into the hole in the shroud. 6) Using a 9/16 in. wrench, install the locknut on the outside (shroud) of the reset button. 7) Test the new circuit breaker to ensure it works properly. 9.3 Power Switch Replacement Refer to Figure 10-1 Components, Front, page 140 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Component Replacement Procedures INFO: Set the multimeter to ohms for this procedure. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Place the power switch in the on position, and then using a multimeter test across the switch terminals. 4) Place the power switch in the off position, and then using a multimeter test across the switch terminals. With the switch in the ON position, the circuit should be closed. With the switch in the OFF position, the circuit should be open. If the switch checks defective, replace by continuing with this procedure. 5) Disconnect the wires from power switch, and then push in on tabs to remove from the front panel. 6) Press the new switch in to the front panel, and then reconnect the wires. 7) Install the control panel, and then test the new switch to ensure it works properly. 9.4 Momentary Switch Replacement Refer to Figure 10-1 Components, Front, page 140 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. INFO: Set the multimeter to ohms for this procedure. 1) Ensure power is removed from the fryer. 108

121 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Place the momentary switch in the on position, and then using a multimeter test across the switch terminals. 4) Place the momentary switch in the off position, and then using a multimeter test across the switch terminals. With the switch in the ON position, the circuit should be closed. With the switch in the OFF position, the circuit should be open. If the switch checks defective, replace by continuing with this procedure. 5) Disconnect the wires from momentary switch, and then push in on tabs to remove from the lower-front panel. INFO: Reverse the order by removing the part, and then wires if easier. 6) Press the new switch in to the front panel, and then reconnect the wires. 7) Install the control panel, and then test the new switch to ensure it works properly. 9.5 USB Port Replacement Refer to Figure 10-1 Components, Front, page 140 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Disconnect the wires from the USB port, and then push in on tabs to remove from the front panel. 4) Press the new USB port in to the front panel, and then reconnect the wires. 5) Install the control panel, and then test the new USB port to ensure it works properly. 9.6 High Limit Module Replacement Refer to Figure 10-6 Control Shroud, page 150 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Component Replacement Procedures 109

122 INFO: The transformer reduces voltage down to accommodate those components with low voltage. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Remove the wires from the high limit module. 4) Using a Phillips head screwdriver, remove the screws securing the high limit module. 5) Install the new module, reconnect the wires, and then install the control panel. 6) Test the new part to ensure it works properly. 9.7 Primary Contactor Replacement Refer to Figure 10-6 Control Shroud, page 150 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Component Replacement Procedures INFO: The transformer reduces voltage down to accommodate those components with low voltage. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Remove the wires from the contactor. 4) Using a Phillips head screwdriver, remove the screws securing the contactor. 5) Install the new contactor, reconnect the wires, and then install the control panel. 6) Test the new part to ensure it works properly. 9.8 Heat Contactor Replacement Refer to Figure 10-6 Control Shroud, page 150 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. INFO: The transformer reduces voltage down to accommodate those components with low voltage. 1) Ensure power is removed from the fryer. 110

123 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Remove the wires from the contactor. 4) Using a Phillips head screwdriver, remove the screws securing the contactor. 5) Install the new contactor, reconnect the wires, and then install the control panel. 6) Test the new part to ensure it works properly. 9.9 AIF Multi-Tab Transformer Replacement Refer to Figure 10-6 Control Shroud, page 150 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. INFO: The transformer reduces voltage down to accommodate those components with low voltage. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Trace the wire(s) from the transformer to the connection on the AIF board, and then remove. 4) Using a Phillips head screwdriver, remove the two screws securing the transformer. 5) Install the new transformer, reconnect the wire(s) to the AIF board, and then install the control panel. 6) Test the new part to ensure it works properly AIF Board Replacement Refer to Figure 10-6 Control Shroud, page 150 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure power is removed from the fryer. 2) Standing in front of the fryer, use a Phillips head screwdriver to remove the right-side panel to access the AIF board. 3) As required, use a Phillips head screwdriver to remove the right-front sheet metal shroud, which contains the AIF board. Component Replacement Procedures 111

124 4) Note the locations of the wire connectors on the AIF board. 5) One by one remove the connectors from the old AIF board and plug them in to the new AIF board. 6) Use a Phillips head screwdriver to install the right-front metal shroud, containing the new AIF board. 7) Use a Phillips head screwdriver to install the side panel(s). 8) Test the new part to ensure it works properly Control Board Transformer Replacement Refer to Figure 10-6 Control Shroud, page 150 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Component Replacement Procedures INFO: The transformer reduces voltage down to accommodate those components with low voltage. 1) Ensure power is removed from the fryer. 2) Using a Phillips head screwdriver, remove two screws in the front of the control panel, and then rotate the panel down. Remove if necessary. 3) Trace the wire from the transformer to the connection on the control board, and then remove. 4) Using a Phillips head screwdriver, remove the two screws securing the transformer. 5) Install the new transformer, reconnect the wire to the control board, and then install the control panel. 6) Test the transformer operation Drain Valve Replacement Refer to Figure 10-3 Drain Valve Assembly, page 144 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Ensure the oil is drained from the fryer s vat, and that all metal surfaces are cool to the touch before performing this procedure. Working on the fryer while hot oil or surfaces are present may cause severe injury. 112

125 Drain Valve Removal Procedure This procedure has two main steps, remove the drain valve assembly from the vat s drain, and then disassemble the drain valve Remove the Old Drain Valve 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Standing in front of the fryer, use a Phillips head screwdriver to remove the leftside panel to access the drain valve. 3) Disconnect the wires (connector) from the micro switch on the drain valve lever. Do not remove the micro switch. 4) Disconnect the drain rod from the drain valve lever. See Figure 9-1 Rod Assembly Connection, page 113. Figure 9-1 Rod Assembly Connection 5) Using an adjustable wrench, remove the drain valve from the drain Disassemble the Old Drain Valve Notice the orientation of the components attached to the drain valve, and also the sequence of parts stacked on the stem. Notate the position of all the components before disassembly. 1) Note the order of parts on the valve stem. 2) Remove all the hardware from the stem stack. Do not remove the switch from the bracket. 3) Remove the o-ring from the inside top of the drain valve. Component Replacement Procedures 113

126 Drain Valve Installation Procedure This procedure has two main steps, assemble the drain valve, and then install the drain valve assembly to the vat s drain Assemble the New Drain Valve The new drain valve is shipped with two washers and a nut installed on the drain stem. These same parts are removed in step 2 of Disassemble the Old Drain Valve, page 113. Technicians should replace the old parts with the new parts during the assembly of the drain valve. 1) Remove the nut and washers from the drain valve stem and set aside. 2) Insert o-ring in to the bottom of the drain valve. See Figure 10-3 Drain Valve Assembly, page 144 for correct orientation. 3) Install the following components on the drain valve stem in the following order: Component Replacement Procedures 1. Switch bracket with micro switch 2. Containment washer 3. Teflon thrust washer 4. Compression washer 5. Valve rotation stop/trigger 6. Belleville washers (washer orientation: () ) 7. Nut 1/2-20 (from step 1) 114

127 Figure 9-2 Valve Stem Stack 4) Tighten the 1/2-20 nut to snug (zero torque) on the drain valve stem, and then add 1/4 to 1/2 half turn with a wrench. Do not overtighten. 5) Install linkage arm, and then lock nut on the drain valve stem. 6) Tighten the lock nut to snug (zero torque) on the drain valve stem, and then add 1/4 to 1/2 half turn with a wrench. Do not overtighten. 7) Ensure the linkage can move smoothly through the entire range of motion Install the New Drain Valve Ensure the drain valve stem is oriented toward the notch in the insulation tray. 1) Using white Loctite and an adjustable wrench, install the drain valve to the drain. Ensure the drain valve stem is oriented toward the notch in the insulation tray, that is on the bottom of the vat. 2) Connect the drain rod to the drain valve lever. See Figure 9-1 Rod Assembly Connection, page ) Connect the wires (connector) to the micro switch on the switch bracket. See Figure 9-2 Valve Stem Stack, page ) Install the drain pan, fill the vat with oil, and then return power to the fryer. Component Replacement Procedures 115

128 5) Test the drain valve operation. 6) Using a Phillips head screwdriver to install the left-side panel Filter Motor Replacement Filter motors can be replaced independent of the filter pump or together as an assembly. When replacing just the filter motor, seal kit must be ordered. Also, when reusing an old filter pump, it is recommended to replace the filter pump rollers. Order filter pump roller kit Refer to Figure 10-7 Motors and Plumbing Components, page 152 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Ensure the oil is drained from the fryer s vat, and that all metal surfaces are cool to the touch before performing this procedure. Working on the fryer while hot oil or surfaces are present may cause severe injury. Component Replacement Procedures Filter Motor (Pump) Removal 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Remove the left and right side panels to access the filter pump motor. 3) Using an adjustable wrench, disconnect plumbing from the inlet and outlet sides of the filter pump. See Figure 10-7 Motors and Plumbing Components, page 152 for connection, configuration and orientation. 4) Using a Phillips head screwdriver, remove the access cover on the rear of the old motor. 5) Note the location of the L1 and L2 power wires, and then disconnect. 6) Remove the jam nut holding the wire conduit to the side of the filter motor and remove the conduit and wires. 7) Remove the four nuts and washers that hold the filter pump and motor to the frame and then remove Check New Filter Motor Wiring There is a wiring diagram on the pump motor s data plate. One side displays a low voltage wiring application and the other is for high voltage applications. Most pumps are pre-wired for high voltage applications; however, to ensure the pump is wired correctly, do the following: 1) Using a Phillips head screwdriver, remove the wiring access cover on the rear of the new pump motor. 116

129 2) Note the location of the wire connections, and then compare them to the wiring diagram on the pump motor s data plate. 3) Ensure the wires are connected according to the application requirement. If not, use the wiring diagram on the motor s date plate to change the wiring as applicable. 4) Leave the wiring cover plate off so power wires can be attached later in the installation Migrate an Old Filter Pump to a New Filter Motor The filter pump attaches to the end of the filter motor. These instructions also include the seal and the roller kit replacement procedures. Refer to Figure 10-7 Motors and Plumbing Components, page 152 for location, illustration and part numbers. If an old filter pump is being reused on a new filter motor, order and install seal kit on the new filter motor. Also, replace the old rollers and o-ring in the old filter pump with If the entire filter pump and motor assembly is being replaced, continue to Filter Pump/Motor Installation, page Remove the Filter Pump With the old filter pump and motor on a flat sturdy work surface, do the following: 1) Remove the two screws connecting the filter pump to the face of the filter motor. 2) Separate the pump and motor assemblies Install the Filter Motor Seal Kit The oil seals prevent oil from migrating into the motor assembly. With the new filter motor on a flat sturdy work surface, using seal kit 17476, install the pump seal components on to the new filter pump motor as shown in Figure 9-3 Pump Seal Kit Placement, page 118. Component Replacement Procedures 117

130 Component Replacement Procedures Install New Rollers Figure 9-3 Pump Seal Kit Placement The rollers inside the filter pump that create the oil pressure, wear and require replacement. Using kit to replace the rollers by doing the following: 1) Remove the four screws attaching the cover to the filter pump, and then remove the cover. 2) Replace the five old rollers with the new rollers. 3) Replace the cover s old o-ring with the new o-ring. 4) Install the cover using four screws on to the filter pump. 118

131 Figure 9-4 Pump Rollers Install the Filter Pump Installing the filter pump to the filter motor is difficult because the internal pump propeller is offset slightly. To easily assemble the filter pump to the motor, do the following: 1) Place the new filter motor on a flat, sturdy flat surface. 2) Obtain the filter pump, and orient it so the double notches on the housing are facing down. 3) With one sharp motion or snap, give the filter pump a downward shake. The rollers and propeller snap in to alignment. 4) Without changing the orientation of the filter pump, slide it on to the filter motor s shaft, ensuring it is fully engaged. 5) Install the four screws holding the filter pump to the filter motor Filter Pump/Motor Installation Install the filter pump/motor assembly by doing the following: 1) Install the filter pump/motor using four nuts and washers that hold the pump to the frame, and leave loose. 2) Install the wire conduit and jam nut, which holds the wire conduit to the side of the filter motor. 3) Connect the L1 and L2 power wires from the conduit to the filter motor connections. Refer to the wiring diagram on the data plate for specific locations and connections. 4) Using a Phillips head screwdriver, install the access cover on the rear of the filter motor. Component Replacement Procedures 119

132 5) Using an adjustable wrench and Loctite where applicable, connect the inlet and outlet plumbing. See Figure 10-7 Motors and Plumbing Components, page 152 for connection, configuration and orientation. 6) Tighten the four nuts and washers holding the filter pump/motor to the frame. 7) Replace the drain pan, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 8) If leaks are discovered, repair as necessary. 9) Install the left and right side panels Filter Pump Check Valve Replacement Refer to Figure 10-7 Motors and Plumbing Components, page 152 for location, illustration, part numbers, configuration, and orientation of the plumbing components. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Component Replacement Procedures Ensure the oil is drained from the fryer s vat, and that all metal surfaces are cool to the touch before performing this procedure. Working on the fryer while hot oil or surfaces are present may cause severe injury. 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Access the pump motor check valve on the back of the fryer and note the plumbing configuration. See Figure 10-7 Motors and Plumbing Components, page 152 for connection and orientation. 3) Using a crescent wrench, disconnect the old check valve. 4) Add white Loctite to the non-compression fitting threads on the new check valve and plumbing. Do not use Loctite on compression fittings. 5) Using a crescent wrench, connect the new check valve. 6) Replace the drain pan, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 7) If leaks are discovered, repair as necessary JIB / ATO Pump Replacement Refer to Figure 10-7 Motors and Plumbing Components, page 152 for location, illustration and part number. 120

133 Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Ensure the oil is drained from the fryer s vat, and that all metal surfaces are cool to the touch before performing this procedure. Working on the fryer while hot oil or surfaces are present may cause severe injury. 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Standing in front of the fryer, remove the right-side panel to access the filter pump motor. 3) Using an adjustable wrench, disconnect the flex lines from the inlet and outlet sides of the JIB / ATO filter pump. See Figure 10-7 Motors and Plumbing Components, page 152 for connection, configuration and orientation. 4) Using a wrench, remove the two locknuts holding the JIB / ATO pump mount (base) to the fryer s frame. 5) Using a wrench, remove the two locknuts holding the JIB / ATO pump cover to the mount (base) to access the wiring. 6) Remove the pump cover, and then disconnect the wiring as required. 7) Using a wrench, remove the four locknuts holding the JIB / ATO pump to the mount, and then remove the JIB / ATO pump. 8) Insert four new grommets, included with the JIB / ATO pump kit, through the bottom of the JIB / ATO pump base. 9) Using a wrench, install the new JIB / ATO pump to the mount securing with four locknuts. 10)Reconnect the JIB / ATO pump wiring, and then reinstall the pump cover. 11)Using a wrench, install the pump cover to the pump mount (base) securing with two locknuts. 12)Using a wrench, install the JIB / ATO pump mount (base) to the fryer s frame securing with two locknuts. 13)Using an adjustable wrench, connect the flex lines to the inlet and outlet sides of the JIB / ATO filter pump. Torque to 32 ft. lbs. (43.39 Nm). 14)Replace the drain pan, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 15)If leaks are discovered, repair as necessary. 16)Install the right-side panel. Component Replacement Procedures 121

134 9.16 Flex Line Replacement Refer to Figure 10-7 Motors and Plumbing Components, page 152 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. Ensure the oil is drained from the fryer s vat, and that all metal surfaces are cool to the touch before performing this procedure. Working on the fryer while hot oil or surfaces are present may cause severe injury. 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Remove panels as necessary to access the flex lines. 3) Using an adjustable wrench, disconnect the flex lines. See Figure 10-7 Motors and Plumbing Components, page 152 for connection, configuration and orientation. Component Replacement Procedures INFO: Do not bend flex lines more than three times in the same spot or bend in to a radius tighter than the diameter of a golf ball. Doing so degrades the tubing material and requires replacement. 4) Bend the flex line in to the required shape. 5) Using an adjustable wrench, connect the flex line. 6) Torque 1/2 inch size line to 32 ft. lbs. (43.39 Nm) and 3/4 inch size line to 35 in. lbs. (3.95 Nm). 7) Replace the drain pan, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 8) If leaks are discovered, repair as necessary Replace the Heating Element Assembly This section contains the replacement procedures for the heating element assembly. The assembly contains two elements which are joined together by hardware. There is an upper burner and lower element. The elements are identical and interchangeable. Both elements must be removed from the fryer as an assembly in order to replace one or both elements. Refer to Figure 10-4 Heating Element Assy, page 146 for location, illustration and part number. 122

135 Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury Prepare the Fryer Various panels on the fryer must be removed to gain access to the heating element wiring and the temperature probes. The electric and oil must be removed from the fryer. To prepare the fryer, do the following: 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the reserve oil tank and set aside. 2) Remove power (electric) from the fryer at the power source. 3) Remove the control panel, front shroud, both left and right-side panels, and left and right-side AIF boards Remove the Old Heating Element Assembly The heating element assembly, which consists of two of the same heating elements bound together by spreader bars, must be removed as an assembly from the vat. Whether replacing one or both elements the entire assembly must be removed. 1) Note how and where the heating elements and temperature probes protrude through the front side of the vat. 2) Loosen all four spreader bar sets but do not remove the screws completely. 3) Disconnect all the thermocouple probe wire leads, which are located behind the control panel. 4) Remove each of the compression nuts connecting the thermocouple probes to the vat. 5) Disconnect the upper and lower heating element wire leads from both contactors, which are located on the inside shroud behind the control panel. 6) Remove each of the nuts connecting the heating elements to the vat. 7) Remove the o-ring that seals the element to the vat. 8) Lift up the rear of the heating element assembly and remove from the vat. 9) Place the heating element assembly on a flat, sturdy work surface and disassemble Bench Build the New Heating Element Assembly 1) Place both heating elements on a flat, sturdy work surface. 2) Draw the following marks on the upper heating element, see Figure 9-5 Marking the Upper heating Element, page 124. Draw a mark (1) on the left front side of the upper heating element five inches rear of the connector flange. Component Replacement Procedures 123

136 Draw a mark (2) on the left and right side of the upper heating element 3 1/8 inches forward of the rear of the heating element. Draw a mark (3) on the right front side of the upper heating element 4 1/2 inches rear of the connector flange. Draw a mark (4) on the right front side of the upper heating element 4 inches rear of the connector flange. Component Replacement Procedures inches from connector flange inches from rear of heating element inches from connector flange 4 inches from connector flange Figure 9-5 Marking the Upper heating Element 3) Position one high limit clip (1) on the top front right side of both heating elements, see Figure 9-6 High Limit Clip and Clamp Install, page

137 1 High Limit Clip Figure 9-6 High Limit Clip and Clamp Install 4) Place upper heating element (4) on top of the lower heating element (5). See Figure 9-7 Spreader Bar Installation, Right Side, page ) Position angled spreader (2) and straight spreader (3) over the high limit clips on the front right side of the heating elements. 6) Position angled spreader (2) and straight spreader (3) on the rear right side mark on the heating element. 7) Insert four Allen screws (1) into the right side spreader bars (2) and (3) to keep them together. Component Replacement Procedures 125

138 Component Replacement Procedures 1 Allen Screw, Upper Heating Element 2 Angled Spreader 5 Lower Heating Element 3 Straight Spreader Figure 9-7 Spreader Bar Installation, Right Side 8) Position one angled spreader (2) and one straight spreader (1) on each mark on the left side of the heating element assembly, see Figure 9-8 Spreader Bar Installation, Left Side, page 127. Do not tighten the Allen screws all the way. The screws are permanently tightened when the heating element assembly is placed in the vat. 9) Insert four Allen screws (3) into the left side spreader bars (1) and (2) to keep them together. 126

139 1 Allen Screw, Angled Spreader 3 Straight Spreader Figure 9-8 Spreader Bar Installation, Left Side 10)Place four o-rings (3) over the wires onto the four connectors, see Figure 9-9 Heating Element Assembly O-Ring Installation, page )Label the wires (1) on the upper heating element B and label the wires (2) on the lower heating element A. Component Replacement Procedures 127

140 1 Upper Element Wires, Label B Component Replacement Procedures 2 Lower Element Wires, Label A 3 O-Ring Figure 9-9 Heating Element Assembly O-Ring Installation Install the Element 1) Position heating element assembly (1) in the vat at an angle with the front end first, see Figure 9-10 Positioning Heating Element Assembly Into Fryer, page ) Route wiring (2) thru holes in the front of the vat. 128

141 1 Heating Element Assembly 2 Heating Element Wiring Figure 9-10 Positioning Heating Element Assembly Into Fryer 3) Place two washers (2) on the threaded end of each heating element connector (3). See Figure 9-11 Heating Element Assembly Hardware Install, page ) Place a nut (1) on the threaded end of each heating element connector securing the heating element assembly to the fry pot. 5) Tighten all four nuts. Apply 32 ft. lbs. (43.39 Nm) of torque. Component Replacement Procedures 129

142 1 Nut 2 Washer 3 Connector Component Replacement Procedures Figure 9-11 Heating Element Assembly Hardware Install 6) Apply white Loctite to the threads of the compression nut on the thermocouple probe (1), and then insert thru spreader (3) opening. See Figure 9-12 Thermocouple Installation, Right Side, page ) Apply white Loctite to the threads of the compression nut on the thermocouple probe (2), and then insert thru spreader (3) opening. 8) Tighten the thermocouples by hand to snug (zero torque), and then add 1/4 to 1/ 2 half turn with a wrench. Do not overtighten. 130

143 1 Thermocouple Probe, Upper 2 Spreader, Front Right 3 Thermocouple Probe, Lower Figure 9-12 Thermocouple Installation, Right Side 9) Tighten both Allen screws (2) on the front right spreader assembly (1) securing the spreader to the heating element assembly (3). Apply 32 in. lbs. (3.62 Nm) of torque. See Figure 9-13 Spreader Bars Installation, Right Side, page )Position rear right spreader bar assembly (4) 3.5 inches from rear vat wall. 11)Tighten Allen screws (5) securing rear right spreader bar assembly (4) to the heating element assembly (3). Apply 32 in. lbs. (3.62 Nm) of torque. Component Replacement Procedures 131

144 Component Replacement Procedures 1 2 Spreader Assembly, Front Right Allen Screw, Front Right Spreader 3 Heating Element Assembly 4 5 Spreader Assembly, Rear Right Allen Screw, Rear Right Spreader Figure 9-13 Spreader Bars Installation, Right Side 12)Route heat probe (5) thru front left spreader bar assembly (3). 13)Position the tip of the heat probe (5) 4 inches from the vat wall (4). 14)Position front left spreader bar assembly (3) inches from the front vat wall (4). See Figure 9-14 Spreader Bars Installation, Left Side, page )Tighten Allen screws (6) securing front left spreader bar assembly (3) to the heating element assembly (2). Apply 32 in. lbs. (3.62 Nm) of torque. 16)Position rear left spreader bar (1) 3.5 inches from rear vat wall (8). 17)Tighten Allen screws (7) securing rear left spreader bar assembly (1) to the heating element assembly (2). Apply 32 in. lbs. (3.62 Nm) of torque. 132

145 1 Spreader Assembly, Rear Left 2 Heating Element Assembly 6 3 Spreader Assembly, Front Left 5 Heat Probe 7 Allen Screw, Front Left Spreader Allen Screw, Rear Left Spreader 4 Front Vat Wall 8 Rear Vat Wall Figure 9-14 Spreader Bars Installation, Left Side 18)Place rear guard element (1) and rear element guard clamp (2) on the rear of the heating element assembly. See Figure 9-15 Element Guard Installation, page )Install three screws (3) securing the rear guard element (1) and the rear element guard clamp (2) to the heating element assembly. 20)Place front guard element (5) and front element guard clamp (6) on the front of the heating element assembly. 21)Install three screws (4) securing the front guard element (5) and the rear element guard clamp (6) to the heating element assembly. Apply 32 in. lbs. (3.62 Nm) of torque. Component Replacement Procedures 133

146 1 Rear Guard Element 4 Screw, Component Replacement Procedures 2 Rear Element Guard Clamp 5 Front Guard Element 3 Screw, Front Element Guard Clamp Figure 9-15 Element Guard Installation 22)Route wire LL1A from lower heating element, and wire LL3B from upper heating element, and then connect to terminal T1 on contactor. 23)Route wire LL3A from lower heating element, and wire LL2B from upper heating element, and then connect to terminal T2 on contactor. 24)Route wire LL2A from lower heating element, and wire LL1B from upper heating element, and then connect to terminal T3 on contactor. 25)Route wire RL3A from lower heating element, and wire RL2B from upper heating element, and then connect to terminal 6T3 on contactor. 26)Route wire RL1A from lower heating element, and wire RL3B from upper heating element, and then connect to terminal 4T2 on contactor. 27)Route wire RL2A from lower heating element, and wire RL1B from upper heating element, and then connect to terminal 2T1 on contactor. 134

147 Figure 9-16 Element Contactor Wiring Test and Assemble the Fryer 1) Replace the drain pan, reserve oil tank, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 2) If leaks are discovered, repair as necessary. 3) Test the new element(s) by dropping a load of product and running a cook cycle to ensure proper operation. 4) If operational issues are discovered, repair as necessary. 5) Once test results are positive, install the front shroud, control panel, both left and right-side panels, and left and right-side AIF boards Temperature Level Probe Replacement Refer to Figure 10-5 Thermocouple and Probes, page 148 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Remove the reserve oil tank and set aside. Component Replacement Procedures 135

148 3) Note how and where the old temperature probe protrudes through the front side of the vat. 4) Lower or remove the front control panel as needed for access. 5) Remove front, left or right-side panels as needed for access. 6) Disconnect the temperature probe wire lead, which is located behind the control panel. 7) Remove the nut connecting the temperature probe to the vat. 8) Apply white Loctite to the threads of the compression nut on the new temperature probe, and then insert thru opening. See Figure 9-12 Thermocouple Installation, Right Side, page ) Tighten the temperature probe compression nut by hand to snug (zero torque), and then add 1/4 to 1/2 half turn with a wrench. Do not overtighten. 10)Connect the wire lead. 11)Install the drain pan, reserve oil tank, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 12)If leaks are discovered, repair as necessary. 13)Test the temperature probe to ensure it works properly. 14)Replace all the panels. Component Replacement Procedures 9.19 High Limit Thermocouples Replacement Refer to Figure 10-5 Thermocouple and Probes, page 148 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Remove the reserve oil tank and set aside. 3) Note how and where the old thermocouple(s) protrudes through the front side of the vat, and then through the spreader bar assembly. 4) Lower or remove the front control panel as needed for access. 5) Remove the front shroud, left or right-side panels as needed for access. 6) Loosen the Allen screws holding together the spreader bar. Do not remove completely. 7) Disconnect the thermocouple wire lead, which is located behind the control panel. 8) Remove the compression nut connecting the thermocouple to the vat. 136

149 9) Apply white Loctite to the threads of the compression nut on the new thermocouple, and then insert thru opening. See Figure 9-12 Thermocouple Installation, Right Side, page )Tighten the thermocouple compression nut by hand to snug (zero torque), and then add 1/4 to 1/2 half turn with a wrench. Do not overtighten. 11)Connect the wire lead. 12)Install the drain pan, reserve oil tank, reconnect the power, add oil to the vat, and then run a filter cycle while checking for leaks. 13)If leaks are discovered, repair as necessary. 14)Test the thermocouple to ensure it works properly. 15)Replace all the panels Drain Pan Microswitch Replacement Standing in the front of the fryer, the drain pan switch is bolted to the left-rear-bottom of the frame with two serrated edge lock nut. Refer to Figure 10-2 Drain Pan Assembly, page 142 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure the oil is drained from the vat and drain pan, remove the drain pan and set aside, and then remove the power from the fryer. 2) Using a wrench or ratchet with socket, remove two serrated edge lock nuts from beneath the drain switch. 3) Pull the drain switch out of the back of the fryer, and then disconnect the lead wire by separating the pin connector. 4) Remove the frame wire ties as necessary to completely remove the drain switch. 5) Bolt the new drain pan switch in place but leave it loose. 6) Insert the drain pan back in to the fryer. 7) Adjust the drain switch so it is fully engaged. 8) Tighten both serrated edge lock nuts, from beneath the drain switch to snug (zero torque), and then add 1/4 to 1/2 half turn with a wrench. 9) Connect the pin connector. 10)Install the frame wire ties as necessary. 11)Test the new drain pan switch to ensure it works properly Wi-Fi Radio Refer to Table 10-9 Wi-Fi, page 157 for location, illustration and part number. Component Replacement Procedures 137

150 Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure power is removed from the fryer. 2) Test the radio to ensure it works properly Wi-Fi Power Supply Refer to Table 10-9 Wi-Fi, page 157 for location, illustration and part number. Unplug the fryer from the power source before performing this procedure. Voltage is present, which may cause severe injury. 1) Ensure power is removed from the fryer. 2) Test the power supply to ensure it works properly. Component Replacement Procedures 138

151 Chapter 10 Illustrated Parts Catalog The following diagrams and lists of parts represents the approved serviceable parts. If you have questions about parts that are not listed here or pricing call your local service provider or distributor first. For additional help, call or Inside the U.S.: or Outside the U.S.: or Illustrated Parts Catalog 139

152 Illustrated Parts Catalog Figure 10-1 Components, Front 140

153 Table 10-1 Components, Front Item No. Part No. Description Qty COVER, WELD ASSY, CFE ASSY-CFX, ARM CONTROL DECAL, CFE CONTROL, NARROW 1 4* DRIVE, USB, FLASH ATO BOX ASSY, OIL, CFA 1 6* O-RING, -116 SUCTION LINE, LVX 3 UPA 7 EF FUSE HOLDER, 20A, 250V 1 8* FA FUSE, 0.5 AMP, TIME DELAY SWITCH, MOMENTARY, SPLASH PROOF 1 10 EF BREAKER, PUSH-BUTTON RESET CASTER, 3 INCH, TOE LOCK 1 12* CASTER, 3 INCH, SWIVEL STEM DISCONNECT, RINSE HOSE, MALE LED, 5MM, BLUE COVERED POWER SWITCH 1 * = Not shown A/R = As Required UPA = Unit Per Assembly Illustrated Parts Catalog 141

154 Illustrated Parts Catalog Figure 10-2 Drain Pan Assembly 142

155 Table 10-2 Drain Pan Assembly Item No. Part No. Description Qty ASSY, DRAIN PAN COVER, DRAIN PAN 1 UPA CRUMB CATCHER 1 UPA SCREEN, FILTER 1 UPA DRAIN PAN, WELD ASSY, 1 UPA CASTER, 2 IN SWIVEL 4 UPA 6 NS LOCKNUT, 1/4-20, SERRATED FLANGE 16 UPA CLIP, FILTER, WELD ASSY 2 UPA O-RING 5 UPA STANDPIPE 1 UPA 10* SWITCH, DRAIN PAN 1 UPA * = Not shown A/R = As Required UPA = Unit Per Assembly Illustrated Parts Catalog 143

156 Illustrated Parts Catalog Figure 10-3 Drain Valve Assembly 144

157 Table 10-3 Drain Valve Assembly Item No. Part No. Description Qty DRAIN ROD, WELD ASSY KNOB-SPINDLE, BLACK VALVE ASSY, DRAIN O-RING 1 UPA MICRO SWITCH, LEVER 1 UPA 6 NS NUT, HEX 2 UPA * = Not shown A/R = As Required UPA = Unit Per Assembly Illustrated Parts Catalog 145

158 Figure 10-4 Heating Element Assy Illustrated Parts Catalog 146

159 Table 10-4 Heating Element Assy Item No. Part No. Description Qty HEATING ELEMENT ASSY HEATING ELEMENT 2 UPA 2 SC SCREW, X 5/8 8 UPA CLIP, HIGH LIMIT 2 UPA O-RING 4 UPA SPREADER, HI LIMIT, TAP PLATE, RH 2 UPA SPREADER, HI LIMIT, ANGLED, RH 2 UPA SPREADER, TAP PLATE, LH 2 UPA SPREADER, ANGLED, LH 2 UPA 9 SCO-178 SCREW, #10-32 X 14 6 UPA GUARD, ELEMENT, REAR 1 UPA GUARD CLAMP, ELEMENT, REAR 1 UPA 12* GUARD, ELEMENT, FRONT BACK 1 UPA GUARD CLAMP, ELEMENT, FRONT 1 UPA 14 NS NUT, HEX, 5/8-18 B 4 UPA 15 WA WASHER 5/8 TYPE A-SERIES N 8 UPA * = Not shown A/R = As Required UPA = Unit Per Assembly Illustrated Parts Catalog 147

160 Illustrated Parts Catalog Figure 10-5 Thermocouple and Probes 148

161 Table 10-5 Thermocouple and Probes Item No. Part No. Description Qty KIT, TEMPERATURE PROBE THERMOCOUPLE, HI LIMIT KIT, PROTECTION PROBE KIT, LEVEL PROBE 1 * = Not shown A/R = As Required Illustrated Parts Catalog 149

162 Illustrated Parts Catalog Figure 10-6 Control Shroud 150