Service & Parts Manual Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. Price: $.00 -Hour Service Hotline -800-55-86 89-58 MAY 00
NOTICE IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER/DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER. DANGER Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or death. Read the installation, operating, and service instructions thoroughly before installing or servicing this equipment. DANGER For your safety, do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any other appliance. CAUTION Instructions explaining procedures to be followed MUST be posted in a prominent location in the event the operator detects a gas leak. This information can be obtained from the local gas company or gas supplier. This equipment is to be installed in compliance with the basic plumbing code of The Building Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the Food and Drug Administration. COMPUTERS FCC This device complies with Part 5 of the FCC rules. Operation is subject to the following two conditions: ) This device may not cause harmful interference, and ) This device must accept any interference received, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet the Class B limits. CANADA This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES-00 standard of the Canadian Department of Communications. Cet appareil numerique n emet pas de bruits radioelectriques depassany les limites de classe A et B prescrites dans la norme NMB-00 edictee par le Ministre des Communcations du Canada.
DANGER THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND/OR BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. Operation, installation, and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne particles of glasswool or ceramic fibers is known to the State of California to cause cancer. Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm. WARNING Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to on-site management operational procedures. WARNING No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the Frymaster/Dean Service Hotline at -800-55-86. CAUTION The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shortening material. Additional information can be obtained in the filtration manual included with the system. DANGER The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil. CAUTION Do not bang fry baskets or other utensils on the fryer s joiner strip. The strip is present to seal the joint between the fry vessels. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning. Frymaster fryers equipped with legs are for permanent installation. For moveable or portable installation, Frymaster optional equipment casters MUST be used. QUESTIONS? CALL -800-55-86.
TABLE OF CONTENTS CHAPTER : Service Procedures...-. Functional Description... - Pilot System Configuration... - Electronic Ignition Configuration... - Control Options... - Interface Boards... - Thermostats... -8. Accessing Fryers for Servicing... -8. Cleaning the Gas Valve Vent Tube... -9. Adjusting the Burner Manifold Gas Pressure... -9.5 Adjusting Ceramic Burner Target Spacing and Alignment... -.6 Adjusting the Pilot Flame... -.7 Calibrating the Thermostat Control... -.8 Replacing Fryer Components... -.8. Replacing the Controller or Computer... -.8. Replacing the Thermostat... -.8. Replacing the Temperature Probe... -.8. Replacing the High-Limit Thermostat in Fryers with Thermostat Controls... -5.8.5 Replacing the High-Limit Thermostat in Fryers with Temperature Probes... -5.8.6 Replacing Control Panel Power Indicator Light in Fryers with Thermostat Controls... -6.8.7 Replacing Power or Melt Cycle Switch in Fryers with Thermostat Controls... -6.8.8 Replacing Ceramic Burner Targets... -7.8.9 Replacing the Gas Valve... -8.8.0 Replacing the Pilot Assembly... -8.8. Replacing Gas Valve High-Limit Thermostat Wire Adapter... -9.8. Replacing the Frypot... -9.9 Troubleshooting and Problem Isolation... -.9. Ignition Failures... -.9. Improper Burner Functioning... -.9. Improper Temperature Control... -.9. Computer-Related Problems... -5.9.5 Filtration Problems... -6.9.6 Leaking... -9.9.7 Modular Basket Lift Malfunctions... -9.9.8 Interpretation of Digital Controller Lights... -.0 Troubleshooting Guides... -.0. Initial Troubleshooting... -.0. Troubleshooting the VAC Circuit: Electronic Ignition... -.0. Troubleshooting the VAC Circuit: Non-Electronic Ignition... -7.0. Troubleshooting the Temperature Probe... -9.0.5 Probe Resistance Charts... -0. Wiring Diagrams... -0
TABLE OF CONTENTS CHAPTER : Parts List... -. Accessories...-. Burner Manifold Assemblies and Component Parts...-. Burner Ignition System Components...-. Gas Valve Assemblies and Connection Components...-.5 Gas Manifold Assemblies...-5.6 Cabinet Assemblies and Component Parts...-6.6. Door Assemblies and Component Parts...-9.7 Component Box/Shield Component Parts...-0.8 Probes, High-Limits and Basket Lift Timers...-.9 Operating Thermostat and Related Components...-.0 Computers and Controllers...-. Filter Base Assembly- FootPrint III Series...-5. Filter Motors, Pumps and Related Components...-6. Filter Pan Assembly- FootPrint III Series...-8. Oil Return Manifolds and Related Components...-9.5 Oil Return Valve Assembly...-0.6 Drain Manifold Assembly and Related Components...-.7 Filter Component Box Assemblies...-.8 Flue Assemblies and Related Components...-.9 Frypot Assemblies and Related Components...-5.9. Frypot Components: Full-Vat...-5.9. Frypot Components: Dual-Vat...-7.0 Power Shower Components...-9. Drain Valve Components...-0.. Full-Vat Drain Valve Components...-0.. Dual-Vat Drain Valve Components...-. Modular Basket Lift Components...-. Gas Conversion Kits...-5 ii
CHAPTER : SERVICE PROCEDURES. Functional Description 7 Series fryers contain a welded stainless steel frypot that is directly heated by gas flames that are diffused evenly over its lower surface by ceramic targets. In full-vat configurations, the flames originate from orifices in a U-shaped burner manifold positioned beneath the frypot. In dual-vat configurations, the U-shaped manifold is replaced by a pair of J-shaped manifolds, one for each vat. The diameter of the orifices differs for natural and LP gas as indicated in the accompanying table. 7 Series Orifice Sizes Gas Drill Size Millimeters Natural 5.5 LP 65 0.86 An electromechanical gas valve regulates gas flow to the manifold(s). 7 Series fryers are equipped with a -volt valve system. Units with thermostat controls are equipped with a pilot ignition (millivolt) system. Units with other type controllers may be configured with either a pilot ignition (millivolt) system or an electronic ignition system. Pilot System Configuration The pilot system is comprised of the pilot orifice, pilot hood, and a thermopile. The pilot serves two purposes. The first is to light the burner, the second is to heat the thermopile. In operation, the thermopile is in contact with the pilot flame and generates millivolts. The millivolt output passes through a normally closed high-limit switch and energizes the gas valve pilot coil, which in turn opens the pilot valve. If the pilot flame is extinguished, voltage is lost to the gas valve pilot coil and the pilot valve closes. The gas valve is constructed so that the main valve will not open if the pilot valve is not open. The pilot flame must be manually lit when the fryer is first placed into operation. A separate -volt circuit, activated by the fryer ON/OFF switch, provides voltage through the thermostat or controller to the gas valve main coil, which opens the main valve. Controlling Thermostat or Controller Thermopile Pilot ON/OFF Switch Main Coil Gas Valve Pilot Coil VAC Transformer The Pilot System Line Voltage Line Voltage High-Limit Thermostat -
CHAPTER : SERVICE PROCEDURES. Functional Description (cont.) Electronic Ignition Configuration In units configured for electronic ignition, an ignition module connected to an ignitor assembly replaces the pilot system. The ignition module performs four important functions: it provides fuse protection for the -volt circuit, provides an ignition spark, supplies voltage to the gas valve, and proofs the pilot flame. The module contains a -second time delay circuit and a coil that activates the gas valve. The ignitor assembly consists of a spark plug, a pilot, and a flame sensor element. Inside the Ignition Module Out to Gas Valve To Alarm 5 V + Coil 5 V GND HV TD Ignition Wire Flame Sensor At start-up the ON/OFF switch is placed in the "ON" position, supplying VDC to the heat control circuitry in the controller or computer and to one side of the heat relay coil on the interface board. If resistance in the temperature probe indicates the temperature in the frypot is below 80 F (8 C), the current flows through a melt cycle circuit where a timer switch alternately closes for seconds and opens for seconds. If the temperature is 80 F (8 C) or above, the current flows through a heat circuit, bypassing the timer switch. In either case, current is supplied to the other leg of the heat relay coil which then closes an electronic switch in the VAC circuit to provide current to the ignition module. Circuitry in the ignition module sends VAC current to the gas valve via a normally closed highlimit switch and a drain safety switch. Simultaneously, the module causes the ignitor to spark for seconds to light the pilot flame. A flame sensor verifies that the pilot is lit by measuring the flow of microamps through the flame. If the pilot does not light (or is extinguished), current to the ignition module is cut, preventing the main valve from opening, and the ignition module "locks out" until the power switch is turned "OFF", then back "ON". -
CHAPTER : SERVICE PROCEDURES. Functional Description (cont.) A temperature probe monitors the temperature in the frypot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay. This in turn cuts off the VAC current to the ignition module, resulting in closure of the gas valve. Control Options 7 Series fryers may be equipped with thermostat controls, solid-state analog controls, solid-state digital controls, basket lift timers, or Computer Magic III computers. In fryers equipped with thermostat controls, the fryer and melt cycle are turned on and off by means of rocker switches and the temperature is set by means of a knob connected directly to the frypotmounted thermostat. These units have no interface board. In this type unit, once started, the melt cycle will continue until it is manually turned off regardless of the temperature in the frypot. Fryers equipped with other types of controllers have an interface board located in the component box (shield) behind the control panel. Interface Boards The interface board provides a link between the controller/computer and the fryer s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point. Two types of interface boards may be used in 7 Series fryers; the type used depends on the fryer configuration. In units configured for electronic ignition, P/N 806-5857 is used; the other board is P/N 06-086 (or 806-98 in units built before October 00). Each type is discussed in detail in the following pages. SOUND AL MV PV CMP PWR V PV MV AL 6 5 5 5 9 6 8 5 J 0 7 GND J SOUND 6 9 5 8 J 5 6 7 8 9 0 5 D6 V GND F Ignition AMP Module 6 9 5 8 D7 AIR J 7 0 7 0 J PWR GND V AL K HEAT RELAY 9 6 J 8 5 0 7 K STANDING PILOT RELAY K HEAT RELAY 9 6 8 5 0 7 J AL V GND PWR J5 GND VD PWR AD AS VS D D GV PWR K K D V Blower Motor Amp D D5 GV GND VD PWR ALR VS PWR GND K K GND 806-5857 806-98 and 06-086 -
CHAPTER : SERVICE PROCEDURES IFB 806-5857: The electronic ignition board contains two types of relays. Heat relays (K and K) operate at VDC output from the controller. They switch VAC to the main gas circuit when the unit calls for heat. The middle relay (K) switches VAC to the pilot circuit when the unit is powered up. The purpose of this relay is to allow the pilot to remain continuously lit. SOUND AL MV PV CMP PWR V PV MV AL 6 5 5 9 6 8 5 J 5 0 7 K K K J HEAT RELAY STANDING PILOT RELAY HEAT RELAY J5 PWR AL GND V V GND AL 9 6 9 6 PWR 8 5 J 8 5 J 0 7 0 7 INTERFACE BOARD 806-5857 FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD P/N 806-5857 Test Meter Setting Pins Test Results VAC Power to Controller 50VAC Scale and on J -8 VAC Power to Right Module 50VAC Scale on J5 and GROUND -8 VAC Power to Left Module 50VAC Scale on J and GROUND -8 VDC Power to Right MBL Relay 50VDC Scale 7 on J and 9 on J -8 VDC Power to Left MBL Relay 50VDC Scale 9 on J and 6 on J -8 VAC Power to Right High-Limit 50VAC Scale on J and GROUND -8 VAC Power to Left High-Limit 50VAC Scale on J and GROUND -8 Probe Resistance (Right)* R x 000 Ohms on J and 0 on J ** Probe Resistance (Left)* R x 000 Ohms on J and on J ** High-Limit Continuity (Right) R x Ohm on J and Wire C on Gas Valve 0 High-Limit Continuity (Left) R x Ohm on J and Wire C on Gas Valve 0 * Disconnect 5-pin harness from controller before testing probe circuit. ** See Probe Resistance Charts in this chapter. -
CHAPTER : SERVICE PROCEDURES The following table identifies the meaning associated with each of the LEDs arranged across the top of the interface board. NOTE: In full vat units, ignore the left-side LEDs. AL MV PV CMP V PWR P/N 806-5857 INTERFACE BOARD LED DIAGNOSTIC LIGHTS Indicates ignition module lockout Indicates VAC to main gas valve Indicates VAC to pilot valve Indicates VAC from transformer Indicates VAC from transformer Indicates VAC to ignition module INTERFACE BOARD VAC TO CPTR GROUND VAC RETURN J J PIN GROUND J PIN COMPUTER RT HT RELAY (K) COMPUTER VDC TO 5 RELAYS COMPUTER LT HT RELAY (K) COMPUTER NOT USED 6 7 J PIN 9 NOT USED COMPUTER CPTR-RT ALARM 8 9 J PIN 6 J5 PIN COMPUTER CPTR-LT ALARM 0 SOUND DEVICE J PIN COMPUTER J PIN 0 COMPUTER J PIN & J PIN COMPUTER J PIN 5 J J TEMP PROBE TEMP PROBE J PIN via HLS, DSS, and PILOT VALVE PILOT VALVE MAIN GAS VALVE BASKET LIFT NOT USED NOT USED NOT USED NOT USED GROUND NOT USED 5 6 7 8 9 0 J PIN 5 J PIN J PIN K K J PIN 9 NOT USED NOT USED NOT USED NOT USED GROUND NOT USED J PIN GROUND J PIN J5 PIN via K NOT USED NOT USED K K J PIN 7 J PIN J PIN J5 PIN 5 6 7 8 9 0 VAC XFMR PIN GROUND VAC XFMR PIN V XFMR PIN 8 NOT USED NOT USED PILOT VALVE MAIN GAS VALVE BASKET LIFT TEMP PROBE TEMP PROBE J PIN 7 via HLS, DSS, and PILOT VALVE J J5 MOD ALARM MOD VALVE TERM MOD 5V GROUND MOD 5V TERM J PIN J PIN GROUND J PIN via K J PIN 0 J PIN GROUND J PIN via K MOD ALARM MOD VALVE TERM MOD 5V GROUND MOD 5V TERM LEFT VAT FULL OR RIGHT VAT CURRENT FLOW THROUGH INTERFACE BOARD 806-5857 -5
CHAPTER : SERVICE PROCEDURES IFBs 806-98 and 06-086: The 7 Series of fryers has been in production for many years. Consequently, servicers are likely to encounter three different interface board designs. Although the boards differ slightly in appearance, basic functioning and electrical connections are the same from one to another. In the earlier design 806-98 interface board (used between June 996 and July 999), the diagnostic LEDs are arrayed in a row across the bottom of the board as shown in the lefthand illustration below. In later design 806-98 interface boards (and in the 06-096 interface boards that replaced them in current production fryers), the LEDs (labeled D though D7) are scattered around the board as shown in the right-hand illustration. The primary difference between the earlier design boards and the later design boards is the combining of the separate blower motor relay (K) and the heat relays (K and K) into a pair of replaceable relays (K and K) in the latter. Also, the 06-086 interface board has an additional fuse located in the upper right hand corner. Prior to June 996, a board with replaceable relays very similar in appearance to the 06-086 board was used. It is distinguished from the 06-086 board by the absence of fuses. On full vat units, the relay for the left vat (K in early 806-98 IFBs or K in later design 806-98 and 06-086 IFBs) is not present. On units with basket lifts, K and K5 (early 806-98) or K and K are present. NOTE: Although the printing on many boards indicates Amp fuses, Amp fuses (P/N 807-8) must be used. GND J SOUND 6 9 5 8 7 0 J 5 6 7 8 9 0 5 J GND 6 9 5 8 7 0 GND J SOUND 6 9 5 8 7 0 J 5 6 7 8 9 0 5 D6 V This Fuse is NOT present on 806-98 IFB. GND F Ignition AMP Module 6 9 5 8 7 0 D7 AIR J GND VD PWR AD AS VS HEAT RELAY K K BLOWER MOTOR RELAY K K 6 5 GND GV PWR AL V AIR V AL PWR GV GND EARLIER DESIGN INTERFACE BOARD P/N 806-98 K5 HEAT RELAY GND VD PWR ALR VS GND VD PWR AD AS VS D D GND GV HEAT RELAY PWR AND BLOWER MOTOR RELAY K K D K Blower Motor Amp HEAT V RELAY AND D BLOWER MOTOR RELAY K D5 GV GND VD PWR ALR VS PWR GND LATER DESIGN INTERFACE BOARDS P/N 806-98 and 06-086 These standard interface boards are also used in a number of fryer types besides the 7 Series. The information contained in this section applies to 7 Series applications ONLY. Earlier design 806-98 boards (used from June 996 through July 999) contain two heat relays (K and K) that switch VAC to the ignition and gas valve circuits when the computer/controller heat logic circuit calls for heat. Relay K switches 0VAC to the blower motor when either K or K closes. The relays on these boards are soldered on if one fails, the whole board must be replaced. The later design 806-98 (and 06-086 boards that replaced them in current production fryers) have only two relays. In this design, K and K are double-pole-double throw (dpdt) relays that supply VAC to the ignition and gas valve circuits, as well as 0VAC to the blower motor. The relays on this board plug into sockets. If a relay fails, it can be replaced. -6
CHAPTER : SERVICE PROCEDURES FREQUENTLY USED TEST POINTS FOR INTERFACE BOARDS P/N 806-98 and 06-086 Test Meter Setting Pins Test Results VAC Power to Controller 50VAC Scale and on J -8 VAC Power to Right Module 50VAC Scale 8 on J and GROUND -8 VAC Power to Left Module 50VAC Scale 8 on J and GROUND -8 VDC Power to Right MBL Relay 50VDC Scale 7 on J and 7 or 0 on J -8 VDC Power to Left MBL Relay 50VDC Scale 9 on J and 7 or 0 on J -8 VAC Power to Right High-Limit 50VAC Scale 9 on J and GROUND -8 VAC Power to Left High-Limit 50VAC Scale 9 on J and GROUND -8 Probe Resistance (Right)* R x 000 Ohms on J and 6 on J ** Probe Resistance (Left)* R x 000 Ohms on J and 6 on J ** High-Limit Continuity (Right) R x Ohm 9 on J and Wire C on Gas Valve 0 High-Limit Continuity (Left) R x Ohm 9 on J and Wire C on Gas Valve 0 * Disconnect 5-pin harness from controller before testing probe circuit. ** See Probe Resistance Charts in this chapter. -7
CHAPTER : SERVICE PROCEDURES INTERFACE BOARD J VAC TO CPTR J PIN GROUND 5 6 7 8 9 0 GROUND VAC RETURN J PIN COMPUTER COMPUTER COMPUTER COMPUTER NOT USED COMPUTER RT ALARM OUT** COMPUTER RT HT RELAY (K) VDC TO RELAYS LT HT RELAY (K) K NOT USED K ALR (RIGHT) SOUND DEVICE LT ALARM OUT* AD (LEFT) COMPUTER J PIN 6 COMPUTER J PIN & J PIN COMPUTER J PIN 6 5 * * Dual Vat configurations ** Full Vat configurations J J NOT USED TEMP PROBE NOT USED J PIN J PIN J PIN VAC XFMR PIN TEMP PROBE NOT USED NOT USED J PIN VAC XFMR PIN NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED TEMP PROBE BASKET LIFT (DN) VAC IN 5 6 7 8 J PIN 5 K PWR via K J PIN K PWR via K 5 6 7 8 TEMP PROBE BASKET LIFT (DN) VAC IN MAIN GAS VALVE VD VS OR VD MAIN GAS VALVE 9 9 via HLS via HLS BASKET LIFT (UP) AC COMMON 0 K AC COMMON K AC COMMON 0 BASKET LIFT (UP) AC COMMON NOT USED NOT USED NOT USED NOT USED MOD 5V GROUND GND GROUND MOD VD MOD 5V TERM DRAIN SWITCH (OPT) NOT USED VD PWR AD AS J PIN 9 J PIN 8 via K J PIN NOT USED GROUND J PIN 9 J PIN 8 via K J PIN 0 J PIN 9 GND VD PWR ALR VS MOD 5V GROUND MOD VD* MOD 5V TERM DRAIN SWITCH (OPT) MOD VS** NOT USED VS NOT USED LEFT VAT FULL OR RIGHT VAT CURRENT FLOW THROUGH INTERFACE BOARDS 806-98 AND 06-086 Like the 806-5857 interface board, LEDs are provided to assist in troubleshooting. NOTE: In full vat units, ignore the left-side LEDS. Thermostats P/N 806-98 and 06-086 INTERFACE BOARD LED DIAGNOSTIC LIGHTS V Indicates VAC from transformer V Indicates VAC from transformer GV Indicates VAC to gas valve PWR Indicates VAC to PWR via K (L) or K (R or F) AL Indicates "open" Drain Safety Switch (if installed) AIR Not Applicable to 7 Series Fryers Different types of thermostats are used in 7 Series fryers, depending on the fryers configuration. -8
CHAPTER : SERVICE PROCEDURES Fryers equipped with Thermostat Controls have an adjustable controlling thermostat. The temperature at which the thermostat opens and closes is adjusted by physically changing the setting of the thermostat itself by means of an attached knob. The Fenwal controlling thermostat used in the 7 Series fryers is sensitive to one-degree changes in temperature. CAUTION Fenwal thermostats are used in a number of Frymaster products. The thermostat for the 7 Series is inches long. Do not use -inch Fenwal thermostats in 7 Series fryers. Fryers equipped with all other type controls have a temperature probe. In this configuration, the probe resistance varies directly with the temperature. That is, as the temperature rises, so does resistance at a rate of approximately ohms for every ( F or C). Circuitry in the controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints). The temperatures are programmed by means of a keypad on the face of the controller. All 7 Series fryers are equipped with a high-limit thermostat. In the event that the fryer fails to properly control the oil temperature, the high-limit thermostat prevents the fryer from overheating to the flash point. The high-limit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 5 F to 50 F (8 C to C). The different types of thermostats have different part numbers for CE and Non-CE configured models, and are not interchangeable.. Accessing Fryers for Servicing DANGER Moving a fryer filled with cooking oil/shortening may cause spilling or splattering of the hot liquid. Follow the draining instructions included with the fryer before attempting to relocate a fryer for servicing.. Shut off the gas supply to the unit. Unplug the power cords. Disconnect the unit from the gas supply.. Remove any attached restraining devices.. Relocate the fryer for service accessibility.. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and plug in the electrical cords.. Cleaning the Gas Valve Vent Tube. Set the fryer power switch and the gas valve to the "OFF" position. -9
CHAPTER : SERVICE PROCEDURES. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened for ease in removal.. Pass a piece of ordinary binding wire (.05 inch diameter) through the tube to remove any obstruction.. Remove the wire and blow through the tube to ensure it is clear. 5. Reinstall tube and bend so that the opening is pointing downward.. Adjusting Burner Manifold Gas Pressure WARNING This task should be performed by qualified service personnel only.. Ensure that the gas valve knob is in the "OFF" position.. Remove the pressure tap plug from the gas valve (see arrows in photos below for location). Non-CE Pilot Ignition Valve Non-CE Electronic Ignition Valve CE Pilot Ignition Valve. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.. Place the gas valve in the "ON" position then place the fryer power switch in the "ON" position. When the burner lights and continues to burn, note gas pressure reading for correct pressure in accordance with the accompanying tables. -0
CHAPTER : SERVICE PROCEDURES Non-CE Standard Burner Manifold Gas Pressures Gas Natural LP Pressure.5" W.C. 0.8 kpa 8.5" W.C..5 kpa CE Standard Burner Manifold Gas Pressures Gas Pressure (mbar) Natural Gas Lacq (G0) under 0 mbar 8 Natural Gas Gronique * (G5) under 5 mbar 0 Propane (G) under 7 or 50 mbar * Belgian G5 = 7,0 mbar 5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct pressure. 6. Place the fryer power switch and the gas valve in the "OFF" position. Remove the fitting from the pressure tap hole and reinstall the pressure tap plug. -
CHAPTER : SERVICE PROCEDURES.5 Adjusting Ceramic Burner Target Spacing and Alignment DANGER Drain the frypot or remove the handle from the drain valve before proceeding further. Proper spacing of the top edge of the ceramic burner targets is ¾-inch ( mm) from the frypot side. To adjust target spacing, bend the brackets to which they are attached away or toward the frypot to the proper distance. (A length of board of the proper thickness is useful as a gauge to verify spacing and alignment.) Proper spacing of the rear ceramic burner target is inch from the frypot back. -inch (rear) Master Jet burner target alignment. ¾-inch (side) Frypot.6 Adjusting the Pilot Flame. Remove the cap from the pilot adjustment screw hole on the gas valve.. Using a small, flat-tipped screwdriver, turn the pilot adjusting screw counterclockwise to increase length of flame or clockwise to decrease length of flame. Adjust to obtain a flame from inch to ½ inches long.. Reinstall the pilot adjustment screw cap. -
CHAPTER : SERVICE PROCEDURES.7 Calibrating the Thermostat Control NOTE: The fryer control panel must be hinged down from the control panel mounting-frame to perform thermostat calibration. In order to hinge the control panel down, the thermostat knob must be removed from its shaft.. Fill the frypot to the lower OIL-LEVEL line with cooking oil/shortening. If solid shortening is used, it must be melted before starting the calibration procedure.. Ensure the fryer ON/OFF Switch is in the "OFF" position, then light the pilot. (Refer to Chapter for detailed lighting instructions.). Insert a good grade thermometer or pyrometer into the frypot so that it touches the thermostat guard.. Disconnect the solid extension shaft from the end of the flexible shaft using an appropriately sized Allen wrench. 5. Remove the flexible shaft from the thermostat shaft screw. 6. Place the fryer ON/OFF switch in the "ON" position. NOTE: If the burner does not light at this time, it does not mean the thermostat is defective. Recheck the wiring, and then slowly turn the thermostat adjusting screw counterclockwise until the burner lights. Turning the adjusting screw counterclockwise causes the burner to light and clockwise causes it to shut off. 7. When the cooking oil/shortening temperature reaches 5 F (6 C), turn the thermostat adjusting screw slowly clockwise until the burner shuts off. 8. Allow the fryer to sit for a few minutes, then slowly turn the thermostat adjusting screw counterclockwise until the burner lights. 9. Repeat steps 7 and 8 at least three times to ensure an accurate setting is obtained. The Thermostat Control is considered to be properly calibrated if the burner lights as the cooking oil/shortening cools to 5 F (6 C) not when the burner shuts off as the temperature rises. 0. Once the calibration point of 5 F (6 C) is determined, allow the burner to cycle on and off at least times to be sure it will light at the calibrated temperature.. After the calibration is complete, place the fryer power switch in the "OFF" position and disconnect the fryer from the electrical supply.. Carefully install the thermostat flexible extension on the thermostat shaft, ensuring that the setscrews are tight. -
CHAPTER : SERVICE PROCEDURES.7 Calibrating the Thermostat Control (cont.) CAUTION The thermostat adjusting screw must not be moved while installing the flexible extension shaft.. Install the solid metal extension shaft on the end of the flexible shaft with the stop pin at the o clock position. Ensure the stop pin and setscrews are tight to prevent slippage.. Reinstall and secure the fryer control panel. Loosen the temperature dial plate screws and rotate the dial until the 5 F (6 C)-index mark is at the o clock position, then retighten the screws. 5. Reinstall the thermostat knob with its pointer aligned with the 5 F (6 C)-index mark on the temperature dial plate. Tighten the thermostat knob set screws to prevent slippage..8 Replacing Fryer Components.8. Replacing the Controller or Computer. Disconnect the fryer from the electrical supply.. Unscrew the two control panel screws. The control panel is hinged at the bottom and will swing open from the top.. Unplug the fryer wiring harness from the back of the controller/computer.. Remove the controller/computer by lifting it from the hinge slots in the fryer control panel frame. 5. Reverse the procedure to install a new controller/computer..8. Replacing the Thermostat. Disconnect the fryer from the electrical supply.. Drain cooking oil/shortening below level of probe.. Remove thermostat knob. Remove the screws from the upper left and right corners of the control panel. The control panel is hinged at the bottom and will swing open from the top.. Disconnect the wiring plug(s)from the component shield/control box. 5. Remove the control panel from the fryer by disengaging its tabs from the hinge slots in the mounting frame. -
CHAPTER : SERVICE PROCEDURES.8. Replacing the Thermostat (cont.) 6. Remove the solid extension shaft from the end of the flexible shaft using an appropriately sized Allen wrench. Remove the flexible shaft from the thermostat shaft screw. 7. Disconnect leads from terminal block. 8. Unscrew the thermostat from the frypot and remove. 9. Apply Loctite PST567 thread sealant or equivalent to the replacement thermostat threads. 0. Reverse steps through 8 to install the replacement. CAUTION The Thermostat Control must be calibrated after installation is complete. Refer to Section.7 for calibration instructions..8. Replacing the Temperature Probe. Disconnect the fryer from the electrical supply.. Drain cooking oil/shortening below level of probe.. Remove the screws from the upper left and right corners of the controller panel. The controller is hinged at the bottom and will swing open from the top.. Unplug the wiring harness from the back of the controller and remove the controller from the fryer by disengaging its tabs from the hinge slots in the mounting frame. 5. Remove two screws and nuts from the base of the interface board mounting-bracket. 6. Disconnect the -pin plug from the back of the interface board and lay the board in the left end of the compartment with all other wires still connected. 7. Remove the -volt transformer from the component shield and lay it in the left end of the compartment with wires still connected. 8. Using a pin-pusher, remove the temperature probe wires from the -pin plug disconnected in step 7. 9. Unscrew the temperature probe from the frypot and remove. 0. Apply Loctite PST567 thread sealant or equivalent to new probe threads.. Reverse steps through 0 to install replacement probe. -5
CHAPTER : SERVICE PROCEDURES.8. Replacing the High-Limit Thermostat in Fryers with Thermostat Controls. Disconnect the fryer from the electrical supply.. Drain cooking oil/shortening below the level of the thermostat.. Remove the thermostat knob. Remove the screws from the upper left and right corners of the control panel. The control panel is hinged at the bottom and will swing open from the top.. Disconnect the wiring plug(s) from the component shield/control box. 5. Remove the control panel from the fryer by disengaging its tabs from the hinge slots in the mounting frame. 6. Remove the molded high-limit thermostat wire adapter from the gas valve pilot coil. 7. Unscrew the high-limit thermostat from the frypot and remove. 8. Apply Loctite PST567 thread sealant or equivalent to the replacement thermostat threads. 9. Reverse steps through 7 to install the replacement high-limit thermostat..8.5 Replacing the High-Limit Thermostat in Fryers with Temperature Probes. Disconnect the fryer from the electrical supply.. Drain cooking oil/shortening below the level of the thermostat.. Remove the screws from the upper left and right corners of the controller panel. The controller is hinged at the bottom and will swing open from the top.. Unplug the wiring harness from the back of the controller. 5. Remove the controller from the fryer by disengaging its tabs from the hinge slots in the mounting frame. 6. Remove two screws and nuts from the base of the interface board mounting-bracket. 7. Disconnect the -pin plug from the back of the interface board and lay board in the left end of compartment with all other wires still connected. 8. Remove the high-limit thermostat wires from the gas valve pilot coil and pull them up through the control shield. 9. Unscrew the high-limit thermostat from the frypot and remove. -6
CHAPTER : SERVICE PROCEDURES.8.5 Replacing the High-Limit Thermostat in Fryers with Temperature Probes (cont.) 0. Apply Loctite PST567 thread sealant or equivalent to new thermostat threads.. Reverse steps through 9 to install the replacement thermostat..8.6 Replacing Control Panel Power Indicator Light in Fryers with Thermostat Control. Disconnect the fryer from the electrical supply.. Remove the thermostat knob.. Remove the screws from the upper left and right corners of the control panel. The control panel is hinged at the bottom and will swing open from the top.. Unplug the control panel wiring harness from the component shield/control box. 5. Carefully press the light out of the control panel back side. Remove one wire terminal at a time and connect to the replacement light until all wires are transferred. 6. Carefully press the light back into the control panel back. 7. Reverse steps - to reassemble fryer..8.7 Replacing Power or Melt Cycle Switch in Fryers with Thermostat Controls. Disconnect the fryer from the electrical supply.. Remove the thermostat knob.. Remove the screws from the upper left and right corners of the control panel. The control panel is hinged at the bottom and will swing open from the top.. Unplug the control panel wiring harness from the component shield/control box. 5. Unsnap the chrome bezel from the rear of the switch and push the switch out through the rear of the control panel. 6. Remove wires one at a time from the switch and connect to the replacement switch until all wires are transferred. 7. Reverse steps -5 to reassemble fryer. -7
CHAPTER : SERVICE PROCEDURES.8.8 Replacing Ceramic Burner Targets DANGER Drain the frypot or remove the handle from the drain valve before proceeding further.. Disconnect fryer from electrical and gas supplies.. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate reconnections.. Remove the high-limit thermostat wires from the gas valve pilot coil.. Remove the pipe union collar at the left side of the gas valve. 5. Remove the burner heat shield hanger screws at the front of the burner and remove the heat shield. 6. Remove the burner hanger screws. 7. Lower the front of the main burner and pull it forward to clear the rear burner hanger. Lower the burner to the floor. 8. Raise the fryer enough to slide the burner from under the fryer cabinet. 9. To replace only the ceramic targets, straighten the target locking tabs with a pair of needle nose pliers or a screwdriver, and slide the target up and off the bracket. Slide the replacement target onto the bracket and bend the locking tabs down. To replace the entire target assembly, using a ½-inch box end wrench, remove the two brass orifices that hold the assembly to the burner manifold, replace the assembly, and replace the orifices. WARNING Use extreme care to prevent cross-threading and stripping when reinstalling the brass orifices. 0. Reverse steps -8 to reinstall the burner assembly. Check spacing and alignment of targets in accordance with Section.5. -8
CHAPTER : SERVICE PROCEDURES.8.9 Replacing the Gas Valve DANGER Drain the frypot or remove the handle from the drain valve before proceeding further.. Disconnect fryer from electrical and gas supplies.. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate reconnections.. Remove the high-limit thermostat wire from the gas valve pilot coil.. Remove the pilot gas line fitting from the gas valve. 5. Remove the pipe union collars to the left and right of the gas valve and remove the valve. 6. Remove the pipefitting from the old gas valve and install on the replacement valve, using Loctite PST567 or equivalent pipe thread sealant on threads. 7. Reverse steps -5 to install the replacement gas valve..8.0 Replacing the Pilot Assembly DANGER Drain the frypot or remove the handle from the drain valve before proceeding further.. Remove the burner assembly in accordance with Section.7.9.. Remove the pilot tubing from the bottom of the pilot assembly.. Bend the clip at the bottom of the pilot assembly and remove the pilot. Disconnect the pilot fitting from the gas valve pilot coil.. Remove the two pilot mounting screws from the pilot mounting-bracket and remove the pilot. 5. Reverse the procedure to replace the pilot assembly. -9
CHAPTER : SERVICE PROCEDURES.8. Replacing Gas Valve High-Limit Thermostat Wire Adapter. Remove the pilot electrical fitting from the gas valve pilot coil.. Lift the molded plastic wire adapter assembly and wires out of the pilot coil.. Cut the in-line splices from the wire adapter and high-limit thermostat wires.. Strip the wire insulation from the end of the high-limit thermostat wires and splice on a new high-limit thermostat wire adapter assembly. 5. Insert the new molded plastic wire adapter into the gas valve pilot coil. 6. Screw the pilot electrical fitting into the gas valve pilot-coil finger tight, and then /8-turn more with a wrench..8. Replacing the Frypot. Drain cooking oil/shortening from the frypot.. Remove all accessories, e.g., frypot covers, basket lift arms, etc. from the fryer.. Disconnect the fryer from gas and electrical supplies.. Remove the screws from the top cap above the control panel and lift it up and off the fryer(s). 5. If the fryer is equipped with other than a Thermostat Control, skip to Step 0. 6. Remove the thermostat knob. Remove the screws from the upper left and right corners of the control panel. Disconnect the control panel from the fryer wiring harness and remove it from the fryer. 7. Remove the thermostat flexible shaft from the thermostat shaft adjusting screw. 8. Remove the two screws and nuts from the thermostat shaft bracket and lift the thermostat flexible shaft and bracket out of the component box. 9. Disconnect both wires from the gas valve and the 0-hole terminal block. Skip to Step. 0. For fryers equipped with other than thermostat controls, remove the screws from the upper left and right corners of the control panel. Disconnect the controller from the fryer wiring harness and remove it from the fryer.. Remove the two screws and nuts from the base of the interface board bracket.. Disconnect the -pin plug from the back of the interface board and remove the temperature probe and high-limit thermostat wires from the plug using a pin pusher. -0
CHAPTER : SERVICE PROCEDURES.8. Replacing the Frypot (cont.). Lay the interface board and bracket on top of the control shield with wires still connected.. Remove the louvered frame above the control panel opening. 5. Remove screws and nuts securing the component box to the fryer. 6. Disconnect wires from components in component box and mark to facilitate reconnection. 7. Remove pilot generator fitting from gas valve pilot coil and lift the high-limit thermostat wire adapter from the slot. Pull the high-limit thermostat wires and adapter up through the grommet at the rear of the box. 8. Remove the wires from the gas valve terminal block. Mark each wire to facilitate reconnection. 9. For fryers equipped with Thermostat Controls, remove the thermostat wire from the gas valve and pull it up through the grommet at the rear of the box. Disconnect the other thermostat wire from the 0-hole terminal block. Mark each wire to facilitate reconnection. 0. Remove the cover from the safety drain switch, disconnect the wires from the switch, and pull them out of the switch box.. Pull up and forward on the component box to clear the rear-mounting stud on the front of the frypot.. Remove the component box from the fryer by rotating its right side up and to the left.. Remove the pipe union from the right side of the gas valve.. Remove the section of square drain from the drain valve of the frypot to be removed. 5. Remove the frypot hold down bracket. 6. Remove the screws from the flue cap sides and back and lift it clear of the fryer(s). 7. Remove the oil return hose or line from the front of the frypot to be removed. 8. Lift the frypot complete with burner, gas valve, flue, and drain valve from the fryer cabinet. 9. Transfer burner heat shield and burner to replacement frypot. 0. Remove drain valve, thermostat or temperature probe, and high-limit thermostat and install on replacement frypot.. Reverse steps -8 to reassemble fryer. -
CHAPTER : SERVICE PROCEDURES CAUTION Before installing thermostat/temperature probe, high-limit thermostat, and drain valve on replacement frypot, clean their threads and apply Loctite PST567 thread sealant or equivalent to the threads..9 Troubleshooting and Problem Isolation This section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment, and the probable causes of each. With this knowledge, the technician should be able to isolate and correct any problem encountered. Problems you are likely to encounter can be grouped into seven broad categories:. Ignition failures. Improper burner functioning. Improper temperature control. Computer-related problems 5. Filtration problems 6. Leakage problems 7. Modular basket lift malfunctions. The probable causes of each category are discussed in the following sections. Troubleshooting guides are included in Section.0 to assist in identifying some of the more common problems..9. Ignition Failures Ignition failure occurs when the ignition module fails to sense a flame within the -second time delay period and locks out. When this happens, the module sends VAC through the interface board alarm circuit to the controller/computer. Solid-state controllers indicate ignition failure by illuminating the heat light and trouble light simultaneously. Computer Magic III controls display " ". There are three primary reasons for ignition failure, listed in order of probability:. Problems related to the gas and/or electrical power supplies.. Problems related to the electronic circuits.. Problems related to the gas valve. -
CHAPTER : SERVICE PROCEDURES Problems Related to the Gas and/or Electrical Power Supplies The main indicators of this are that an entire battery of fryers fails to light and/or there are no indicator lights illuminated on the fryer experiencing ignition failure. Verify that the quick disconnect hose is properly connected, the fryer is plugged in, the main gas supply valve is open, and the circuit breaker for the fryer electrical supply is not tripped. Problems Related to the Electronic Circuits If gas and electrical power are being supplied to the fryer, the next most likely cause of ignition failure is a problem in the VAC circuit of fryers equipped with electronic ignition systems, or in the pilot system for those without electronic ignition. If the fryer is equipped with a FootPrint III filtration system, first verify that the drain valve is fully closed. (The valve is attached to a microswitch that must be closed for power to reach the gas valve. Often, although the valve handle appears to be in the closed position, the microswitch is still open.) If the valve is fully closed, or the fryer does not have a filtration system, refer to the troubleshooting guides in this chapter. Problems Related to the Gas Valve If the problem is not in the VAC circuit or pilot system, it is most likely in the gas valve itself, but before replacing the gas valve refer to the troubleshooting guides in this chapter..9. Improper Burner Functioning With problems in this category, the burner ignites but exhibits abnormal characteristics such as "popping", incomplete lighting of burner, fluctuating flame intensity, and flames "rolling" out of the fryer. "Popping" indicates delayed ignition. In this condition, the main gas valve is opening but the burner is not immediately lighting. When ignition does take place, the excess gas "explodes" into flame, rather than smoothly igniting. The primary causes of popping are: Incorrect or fluctuating gas pressure Misdirected or weak pilot flame Burner deflector targets out of alignment or missing Clogged burner orifices Inadequate make-up air Heat damage to the controller or ignition module A cracked ignitor or broken ignition wire A defective ignition module -
CHAPTER : SERVICE PROCEDURES.9. Improper Burner Functioning (cont.) If popping occurs only during peak operating hours, the problem may be incorrect or fluctuating gas pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the appropriate CE or Non-CE Standard found in Section. of this manual, and that the pressure remains constant throughout all hours of usage. Refer to Check Burner Manifold Pressure in Section. if burner manifold pressure is suspected of being incorrect. If popping is consistent during all hours of operation, verify that the pilot is properly positioned above the burner orifice and that the pilot pressure is correct. Correct pilot pressure is indicated by a flame to ½" long. Refer to Section.6 for adjustment procedure. Clogged burner orifices, especially those near the pilot, are also likely causes of delayed ignition. Clogged orifices are indicated by no flame, flames that are orange-colored, and flames that shoot out at an angle from the rest. Another cause of popping is an insufficient air supply or drafts that are blowing the pilot flame away from the burner. Check for "negative pressure" conditions in the kitchen area. If air is flowing into the kitchen area, this indicates that more air is being exhausted than is being replenished and the burners may be starved for air. If the fryer s gas and air supplies are okay, the problem most likely is with one of the electrical components. Examine the ignition module for signs of melting/distortion and/or discoloration due to excessive heat build-up in the fryer. (This condition usually indicates improper flue performance.). Also, examine the controller for the same conditions. A melted or distorted ignition module is automatically suspect and should be replaced, but unless the condition causing excessive heat in the fryer is corrected, the problem is likely to recur. Next, check to ensure the ignition wire is tightly connected at both ends and examine it for obvious signs of damage. Again, if damage is due to excessive heat in the fryer, that problem must also be corrected. Check for proper operation by disconnecting the wire from the ignitor (spark plug), inserting the tip of a screw driver into the terminal, and holding it near the frame of the fryer as the power switch is placed in the "ON" position. A strong, blue spark should be generated for at least seconds. DANGER MAKE SURE YOU ARE HOLDING THE INSULATED HANDLE OF THE SCREWDRIVER AND NOT THE BLADE. THE SPARKING CHARGE IS APPROXIMATELY 5,000 VOLTS. Examine the ignitor (spark plug) for any signs of cracking. A cracked ignitor must be replaced. The burner lighting on one side only may be caused by a missing or misaligned rear deflector target or improper burner manifold pressure. Clogged burner orifices are usually the cause of gaps in burner firing. -
CHAPTER : SERVICE PROCEDURES.9. Improper Burner Functioning (cont.) Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure, but may also be the result of variations in the kitchen atmosphere. Verify incoming gas pressure in the same way as for "popping", discussed in the preceding paragraphs. Variations in the kitchen atmosphere are usually caused by air conditioning and/or ventilation units starting and stopping during the day. As air conditioning/ventilation units start and stop, the pressure in the kitchen may change from positive or neutral to negative, or vice versa. Changes in airflow patterns that may affect flame intensity are caused by these variations. Flames "rolling" out of the fryer are usually an indication of negative pressure in the kitchen. Air is being sucked out of the fryer enclosure and the flames are literally following the air. If negative pressure is not the cause, check for high burner-manifold gas pressure in accordance with the procedures in Section.. An obstructed flue, which prevents the fryer from properly exhausting, may also be the cause. An excessively noisy burner, especially with flames visible above the flue opening, may indicate that the burner gas pressure is too high, or it may simply be that the gas valve vent-tube is blocked. If the gas pressure is correct and the vent-tube in unobstructed, the gas valve regulator is probably defective. Occasionally a burner may apparently be operating correctly, but nevertheless the fryer has a slow recovery rate [the length of time required for the fryer to increase the oil temperature from 50 F to 00 F ( C to 9 C)]. Primary causes are low burner-manifold pressure and/or misaligned or missing deflector targets. If both of these causes are ruled out, the probable cause is a misadjusted gas-valve regulator. Refer to the Check Burner Manifold Pressure procedure in Section. if gasvalve regulator is suspected of being out of adjustment..9. Improper Temperature Control Temperature control, including the melt cycle, is a function of several interrelated components, each of which must operate correctly. The principal component is the thermostat (in thermostat control units) or the temperature probe (in fryers equipped with other types of controllers). Depending upon the specific configuration of the fryer, other components may include the interface board, the controller itself, and the ignition module. Improper temperature control problems can be categorized into melt cycle problems and failure to control at setpoint problems. Melt Cycle Problems In fryers equipped with thermostat controls, a mechanical timer controls the melt cycle. There are three components that may fail, thus disabling the melt cycle. The melt-cycle timer itself, the meltcycle timer microswitch, or the control panel melt-cycle ON/OFF switch. In all cases, the defective component must be replaced. -5
CHAPTER : SERVICE PROCEDURES.9. Improper Temperature Control (cont.) In fryers equipped with other types of controllers, the problem may be with the controller itself, the temperature probe, or a malfunctioning heat relay on the interface board. For problem isolation techniques, refer to the troubleshooting guides in this chapter. Failure to Control at Setpoint In fryers equipped with thermostat controls, the problem will be with the thermostat itself. Possible causes are that the thermostat is out of calibration, the knob or flexible shaft is loose on the thermostat adjusting screw, a thermostat wire is disconnected, or the thermostat is defective. Refer to Section.7 for instructions on calibrating the thermostat. In fryers equipped with other types of controls, the problem may be with the temperature probe, the interface board, or the controller. Refer to the troubleshooting guides in this chapter..9. Computer-Related Problems Computer Magic III Features Sensitivity or "Stretch and Shrink Time" Sensitivity or stretch time is a programmable feature that increases or decreases the cook time countdown based on variations in the oil temperature from the setpoint. The sensitivity for each product button has 0 settings (0 through 9). A "0" sensitivity setting will disable the feature (no change in cooking time), while a nine will provide the highest sensitivity or most change. The correct sensitivity for any product is based on the product, its density, the setpoint temperature, and the customer s own requirements. Recovery Time or "Rate of Rise" Recovery time or rate of rise is a method of measuring a fryer s performance. Put simply, it is the time required for the fryer to increase the oil temperature from 50 F to 00 F ( C to 9 C). This range is used as a standard since ambient kitchen temperatures can effect the test if lower ranges are used. The Computer Magic III performs the recovery test each day as the fryer warms up. An operator can view the results of the test any time the fryer is above the 00 F (9 C) point by pressing the button and entering the code 65. The test results will be displayed in the computer s LED panel in minutes and seconds. The acceptable recovery time for the 7 Series of fryers is minutes. -6
CHAPTER : SERVICE PROCEDURES Common Computer Complaints Most problems concerning computers have to do with programming them. There are four common complaints. The complaints, their causes, and corrective actions are:. Fryer constantly displays " ". Cause: Setpoint incorrect or missing. Corrective Action: Press 6 5 0, enter the correct setpoint using keypad, then press to lock in the setpoint.. Temperature is displayed in Celsius. Cause: Computer is programmed to display in Celsius. Corrective Action: Press 6 5 8.. Temperature is constantly displayed. Cause: Computer is programmed for constant temperature display. Corrective Action: Press 6 5 L.. Computer times down too slowly or too quickly. Cause: Computer is compensating for oil temperature via the sensitivity setting. Corrective Action: Reprogram sensitivity setting for each product in accordance with programming instructions in the 7 Series Installation & Operation manual..9.5 Filtration Problems The majority of filtration problems arise from operator error. One of the most common errors is placing the filter paper on the bottom of the filter pan rather than over the filter screen. Whenever the complaint is "the pump is running, but no oil is being filtered", check the installation of the filter paper, including that the correct size is being used. While you are checking the filter paper, verify that the O-ring on the bottom of the filter pan is present and in good condition. A missing or worn O-ring will allow the pump to suck air and decrease its efficiency. If the pump motor overheats, its thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch located on the rear of the motor. If the pump then starts, something caused the motor to overheat. It may be just that several frypots were being filtered one after the other and the pump got hot. Letting the pump cool down for at least a half-hour is all that is required in this case. More often, the pump overheated for one of the following reasons: -7
CHAPTER : SERVICE PROCEDURES.9.5 Filtration Problems (cont.) Shortening was solidified in the pan or filter lines. The operator attempted to filter oil or shortening that was not heated. Cold oil and shortening are thicker and cause the pump motor to work harder and overheat. If the motor runs but the pump does not, there is a blockage in the pump. Incorrectly sized or installed paper will allow food particles and sediment to pass through the filter pan and into the pump. When sediment enters the pump, the gears can bind up causing the motor to overload, again tripping the thermal overload. Solidified shortening in the pump will also cause it to seize, with the same result. A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a screwdriver or other instrument.. Disconnect power to the filter system.. Remove the input plumbing from the pump.. Use a screwdriver to manually turn the gears Turning the pump gears backwards will release a hard particle and allow its removal. Turning the pump gears forward will push softer objects and solid shortening through the pump and allow free movement of the gears. Sediment Particle Sediment Particle Oil Flow Up for reverse Down for forward Unclogging a filter pump. Incorrectly sized or installed paper will also allow food particles and sediment to pass through and clog the suction tube on the bottom of the filter carriage. Particles large enough to block the suction tube may indicate that the crumb tray is not being used. Pan blockage can also occur if shortening is left in the pan and allowed to solidify. The heater strip on the suction tube is designed to prevent solidification of residual shortening left in the tube. It will not melt or prevent solidification of shortening in the pan. -8
CHAPTER : SERVICE PROCEDURES.9.5 Filtration Problems (cont.) Blockage removal can be accomplished by forcing the item out with an auger or drain snake. Compressed air or other pressurized gases should not be used to force out the blockage. Possible problems with the Power Shower include clogged openings, shortening solidified in the tubes, missing clean-out plugs, and missing or worn O-rings. Cleaning the unit and replacing missing plugs and missing or worn O-rings will correct these problems. The electronics of the FootPrint III Filter are simple and straightforward. Microswitches, attached to handles for each vat and wired in parallel, provide the VAC required to activate the pump relay coil when the handles are moved to the ON position. The activated pump relay coil pulls in the pump motor switch, supplying power to the pump motor. The suction tube heater and flexible hose heater are wired directly into the 0 VAC source. They remain energized as long as the unit is plugged in. VAC Line VAC All Heater Tapes (Original and Redesigned Models) (Heater Tapes have been removed from oil return lines in Redesigned Models) Solenoids (Redesigned Models Only) Microswitches Pump Relay Coil Relay Contacts Pump Motor M FootPrint III Simplified Wiring Diagram -9
CHAPTER : SERVICE PROCEDURES.9.6 Leaking Frypot leaking will almost always be due to improperly sealed high-limit thermostats, operating thermostats, temperature probes, and drain fittings. When installed or replaced, each of these components must be sealed with Loctite PST567 sealant or equivalent to prevent leakage. In very rare cases, a leak may develop along one of the welded edges of the frypot. When this occurs, the frypot must be replaced. If the sides and/or ends of the frypot are coated with oil/shortening, the most likely cause is spillage over the top of the frypot rather than leakage. The clamps, which hold the drain tube sections together, may loosen over time as the tubes expand and contract with heating and cooling during use. If the section of drain tube connected to the drain valve is removed for whatever reason, make sure that its grommet is in good condition and properly fitted around the nipple of the drain when it is reinstalled. Also, ensure the drain tube runs downward from the drain along its whole length and has no low points where oil or shortening may accumulate..9.7 Modular Basket Lift Malfunctions 7 Series fryers may optionally be equipped with automatic basket lifts to ensure uniform cooking times. The lifts may be configured for manual control or for control via a Basket Lift Timer or Computer Magic III computer. Basket lifts come in pairs, although each operates independently. A lift consists of a notched rod to which the basket lift arm is attached, a reversible-drive gear motor, and a pair of roller-activated microswitches. The gear motor engages the notches in the rod, moving it up or down depending upon the direction of rotation of the motor. Microswitches at the upper and lower limits of movement stop the motor when the basket is in the full up or full down position. In units configured for manual (push-button) controls, a mechanical timer controls voltage to the system. A rotary knob is turned to set the cook time, and pressing the button in the middle of the knob activates the motor by applying power through the lower microswitch. The motor drives the basket lift down. As the rod moves downward, it closes the upper microswitch, preparing the motor to run in the opposite direction when the cooking time has expired. When the rod contacts the lower microswitch, power to the motor is interrupted and the motor stops. BLACK RED BRW BLACK RED BRW A A MODULAR BASKET LIFT SECTION A - A -0
CHAPTER : SERVICE PROCEDURES.9.7 Modular Basket Lift Malfunctions (cont.) Computer/Controller Modular Basket Lift Simplified Schematic Manual (Push-Button) Modular Basket Lift Simplified Schematic H 5 N.O. Upper Limit Microswitch M N 6 H -Pole Mech Timer or 5 or 6 N.O. Upper Limit Microswitch M N or To computer/controller via interface board Basket Lift Relay N.C. Lower Limit Microswitch N.C. Lower Limit Microswitch When the timer times out, power is supplied to the opposite pole of the motor, through the upper microswitch. The motor drives the rod upward until it loses contact with the upper microswitch, cutting power to the motor and stopping the lift. In units configured for Basket Lift Timer Controllers or Computer Magic III computers, the process is almost identical. The difference is that the push button mechanical timer is replaced with timing circuitry in the computer or controller. The operator programs specific cook times (and other settings) into the computer/controller. When the product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power to the lower microswitch. As with the manually controlled units, the microswitch stops the motor at the lift s upper and lower travel limits and reverses the direction of current flow thus reversing the motor direction. Problems with the basket lift system can be grouped into three categories: Binding/jamming problems Motor and gear problems Electronics problems Binding/Jamming Problems Noisy, jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and their bushings. Apply a light coat of Lubriplate or similar lightweight white grease to the rod and bushings to correct the problem. Another possible cause of binding is improper positioning of the motor, which prevents the gear from correctly engaging the teeth in the rod. To correct the problem, loosen the screws that hold the motor in place and move it forward or backward until the rod has just enough slack to be rotated slightly. -
CHAPTER : SERVICE PROCEDURES.9.7 Modular Basket Lift Malfunctions (cont.) Motor and Gear Problems The most likely problem to be encountered in this category is erratic motion of the lift due to a worn drive gear. Failure to keep the lift rod and bushings properly lubricated will cause unnecessary wear of the gear. The problem is corrected by replacing the worn gear. If the lift cycles correctly but fails to remain in the up position (i.e., goes up, but then slowly settles back down into the frypot), the problem is a failed motor brake. A failed motor brake cannot be repaired and requires replacement of the motor itself. If power is reaching the motor but the motor fails to run, the motor is burned out and must be replaced. Electronic Problems This category encompasses problems with the relays, microswitches, capacitors, resistors, interface board, wiring, and controls. Troubleshooting the electronics of the modular basket lift is simply a process of verifying current flow through the individual components up to and including the motor. Using a multimeter set to the 50 VAC range, check the connections on both sides of the component for the presence of 0 VAC. The simplified wiring diagrams on the preceding pages identify the components and wiring connection points..9.8 Interpretation of Digital Controller Lights Power light on, heat light cycling, trouble light off, and melt light on: If fryer oil temperature is below 80 F (8ºC), the lights indicate the unit is operating normally. If the oil temperature is above 80ºF (8ºC) and the heat light continues to cycle as if in the melt cycle, this may indicate a defective probe circuit or low incoming VAC to the controller. Power light on, heat light on, trouble light off, and melt light off: If the fryer oil temperature is above 80ºF (8ºC) and below the setpoint temperature, the lights indicate the unit is operating properly. If the oil temperature is above the temperature set on the control knob and the heat light remains lit, this may indicate a defective probe circuit. -
CHAPTER : SERVICE PROCEDURES.9.8 Interpretation of Digital Controller Lights (cont.) Power light on, heat light off, trouble light on, and melt light off: If the fryer oil temperature is below 0 F (0 C), the lights indicate one of the following: a. The probe circuit is defective, or b. There is a connection problem on pins or 0 on the 5-pin wiring harness. If the fryer oil temperature is above 0 F (0 C), the lights indicate a run-away heating circuit..0 Troubleshooting Guides The following troubleshooting guides are intended to assist service technicians in quickly isolating the probable causes of equipment malfunctions by following a logical, step-by-step process..0. Initial Troubleshooting PROBLEM PROBABLE CAUSES CORRECTIVE ACTION Burner won t ignite. Light in ON/OFF switch is not illuminated. A. ON/OFF switch is off. A. Turn ON/OFF switch on. ON/OFF switch is on, A. No VAC output from transformer. A. Check VAC circuit. Replace but the switch light is not transformer if defective. illuminated. ON/OFF switch is on and the switch light is illuminated, but there is no output to gas valve. A. Drain microswitch circuit (filterequipped units) is open. B. VAC is present at ON/OFF switch, but continuity of the switch in ON position is not "0". C. Continuity of thermostat is not "0" (cooking oil/shortening temperature is at least 5 F below thermostat setting). A. Ensure drain valve is fully closed and microswitch is functioning. Replace microswitch if defective. B. ON/OFF switch is defective. Replace switch with a known working switch. C. Thermostat is defective. Replace with a known working thermostat. D. Gas valve is suspect. D. Go to burner troubleshooting. -
CHAPTER : SERVICE PROCEDURES.0. Initial Troubleshooting (cont.) PROBLEM PROBABLE CAUSES CORRECTIVE ACTION A. Pilot does not stay lit (fryer is on and thermopile output is approximately 00 millivolts. A. Check high-limit switch. Switch continuity should be "0". If not, highlimit switch is defective. Replace high-limit switch. No burner flame. Fluctuating or erratic lighting of burner flame. Thermostat will not adjust to correct temperature. B. Pilot does not stay lit (fryer is on and thermopile output is not approximately 00 millivolts. C. Pilot stays lit, and the high-limit and thermopile are known working, but burners fail to light. D. Gas valve is known to be good, but there is not VAC at the gas valve terminals. E. Continuity from terminal block to gas valve thermostat wire is not "0". A. Incoming gas supply pressures are not within range [Natural- 6-" W.C. (.9-.9 kpa); Propane- -" W.C. (.7-.9 kpa)] B. Air in gas supply lines (new installation). B. Inspect thermopile (units without interface board) and replace if defective. C. Inspect gas valve and replace if defective. D. Inspect thermostat body (while still in frypot) for damage. Remove and replace thermostat if bent, dented or cracked. Inspect leads for fraying, burning, breaks and/or kinks. If found, remove and replace thermostat. Remove leads from terminal block, allow oil to cool 5 F below thermostat setting and check continuity. If continuity is not "0", then thermostat has failed. Replace thermostat. E. Inspect wiring for breaks or shorts and repair if necessary. A. Inspect gas supply to fryer. Repair and/or replace faulty components (defective supply shut-off valves, incorrect piping size, etc.) B. Allow unit to cycle on and off for approximately 0 minutes to force air from gas manifold and lines. C. Missing or poor target alignment. C. Replace missing target(s) and/or ensure correct target alignment. A. Thermostat is out of calibration. A. Calibrate thermostat. Replace thermostat if calibration is not possible. -
CHAPTER : SERVICE PROCEDURES.0. Troubleshooting the VAC Circuit: Electronic Ignition Units VERIFY DRAIN VALVE(S) IS/ ARE FULLY CLOSED Place ON/OFF switch in "ON" position (analog controllers) or press ON/OFF button to activate computer. Is spark generated at the pilot assembly? Yes Malfunctioning gas valve. Refer to Initial Troubleshooting at the beginning of this section. No Is/are MV LED(s) lit? Yes Is VAC present on J Pin 8 (and J Pin 8, if dual-vat)? No Probable cause is failed interface board. Yes No Malfunctioning gas valve. Refer to Initial Troubleshooting at the beginning of this section. Is/are PV LED(s) lit? Yes Probable cause is failed heat relay. No Proceed to next page. -5
CHAPTER : SERVICE PROCEDURES.0. Troubleshooting the VAC Circuit: Electronic Ignition Units (cont.) Start here from preceeding page. Probable cause is failed pilot relay. Is/are PWR LED(s) lit? Yes Is VAC present on J5 Pin (and J Pin, if dual-vat)? No Probable cause is failed ignition module. Check module fuse before replacing module. No No Yes Is VAC present on J5 Pin (and J Pin, if dual-vat)? Yes Is V LED lit? Is VAC present on J Pin (and J Pin, if dual-vat)? No Probable cause is failed interface board. Yes No Yes Probable cause is failed interface board. Yes Is VAC present on J Pin? Is continuity of high-limit switch(es) "0"? No Probable cause is failed highlimit switch. No Yes Probable cause is failed - volt transformer. Is continuity on drain safety switch(es) "0"? No Probable cause is failed drain safety switch. Yes Probable cause is failed interface board. No Is VAC present on pilot valve (PV) terminal of the gas valve? Yes Malfunctioning gas valve. Refer to Initial Troubleshooting at the beginning of this section. -6
CHAPTER : SERVICE PROCEDURES.0. Troubleshooting the VAC Circuit: Electronic Ignition Units (cont.) VAC Transformer J PIN LED V K PILOT RELAY LED PWR J PIN Left Ignition Module/Fuse J5 PIN LED PWR Right Ignition Module/Fuse J PIN J PIN J5 PIN J PIN High- Limit Switch High- Limit Switch DRAIN SAFETY SWITCH DRAIN SAFETY SWITCH PILOT VALVE PILOT VALVE LED PV J PIN J PIN 7 LED PV K K LED MV J PIN 5 J PIN 8 LED MV LEFT VAT FULL OR RIGHT VAT VOLT CIRCUIT FOR ELECTRONIC IGNITION UNITS (IFB 806-5857) -7
CHAPTER : SERVICE PROCEDURES.0. Troubleshooting the VAC Circuit: Non-Electronic Ignition Units (With Computer Controls) Verify that drain valve(s) are fully closed, then turn controller on. Which LEDs are lit? None Either or both V LED and PWR LED only. GV LED (with or without other LEDs) Probable cause is failed -volt transformer. No Are there volts AC on J Pin 8 (and J Pin 8, if dualvat)? Yes Is there VAC on the PWR terminal(s)? Yes No Probable cause is failed interface board. Yes Yes Probable cause is failed drain safety switch. No Is continuity of drain safety switch(es) "0"? Is there VAC on VS (or VD and VD, if dual-vat)? No Are there volts AC on J Pin 9 (and J Pin 9, if Dualvat)? No Yes Yes Does unit have drain safety switch(es)? Is continuity of the high-limit switch "0"? Yes VAC circuit is good. Problem may be with gas valve. Refer to Initial Troubleshooting at the beginning of this section. No No Probable cause is failed interface board. Yes Is jumper in place between PWR and VS (VD and VD, if dual-vat), and is continuity "0"? Probable cause is failed high-limit switch. No Probable cause is missing or failed jumper. -8
CHAPTER : SERVICE PROCEDURES.0. Troubleshooting the VAC Circuit: Non-Electronic Ignition Units (With Computer Controls- cont.) VAC Transformer J PIN 8 J PIN 8 LED V K K LED PWR OPTIONAL DRAIN SAFETY SWITCH LED GV PWR VD J PIN 9 NOTE: If a Drain Safety Switch is not installed, a jumber is used to connect the PWR terminal to the VS/VD or VD terminal. PWR VS OR VD J PIN 9 LED PWR OPTIONAL DRAIN SAFETY SWITCH LED 5 GV High- Limit Switch High- Limit Switch GAS VALVE GAS VALVE LEFT VAT FULL OR RIGHT VAT VOLT CIRCUIT FOR NON-ELECTRONIC IGNITION UNITS (IFB 806-98) -9
CHAPTER : SERVICE PROCEDURES.0. Troubleshooting the Temperature Probe (With Computer Controls) While still in frypot, inspect probe bulb for damage. Remove and replace if bent, dented or cracked. Inspect leads for fraying, burning, breaks and/or kinks. If found, remove and replace probe. Determine temperature of cooking oil/shortening using a thermometer or pyrometer placed at tip of probe. P/N 806-5857 Which interface board is installed? P/N 806-98 Disconnect 5-pin harness from controller. Measure probe resistance using J Pin and J Pin 0 (and J Pin and J Pin, if dual-vat). Disconnect 5-pin harness from controller. Measure probe resistance using J Pins and 6 (and J Pins and 6, if dual-vat). Is resistance approximately equal to that given in the Probe Resistance Chart for corresponding temperature? No Yes Measure resistance through each of the previously tested pins to ground. Problem is not with probe. Yes Is resistance 5 megaohms or greater in each pin? No Probe has failed. -0
CHAPTER : SERVICE PROCEDURES.0.5 Probe Resistance Chart Probe Resistance Chart For use with H50 Series fryers manufactured with Minco Thermistor probes only. F OHMS C F OHMS C F OHMS C F OHMS C F OHMS C 60 059 6 0 0 5 00 50 9 70 9 0 6 7 65 070 8 5 6 57 05 6 96 75 50 5 5 6 7 70 080 0 6 60 0 7 99 80 5 8 50 65 77 75 09 5 7 6 5 8 0 85 5 55 66 79 80 0 7 50 7 66 0 9 0 90 5 60 67 8 85 9 55 58 68 5 0 07 95 5 6 65 68 85 90 60 68 7 0 0 00 55 9 70 69 88 95 5 65 78 7 5 05 56 5 75 70 9 00 8 70 89 77 0 6 0 57 5 80 7 9 05 5 75 99 79 5 8 5 58 57 85 7 96 0 6 80 09 8 50 5 0 59 60 90 7 99 5 7 6 85 0 85 55 6 5 60 6 95 7 0 0 85 9 90 0 88 60 7 7 0 6 66 00 75 0 5 95 5 95 0 9 65 8 9 5 6 68 05 76 07. Wiring Diagrams Note: The wiring diagrams in the pages that follow depict wiring as of the date of manual publication. It may not reflect design changes made to the equipment after publication. Refer to the wiring diagram affixed to the unit when actually troubleshooting this equipment. -
7 6 9 6 8 5 7 7 5 5 C C 9 8 5 7 5 8 6 9 6 7 7 SERIES GAS FRYERS CHAPTER : SERVICE PROCEDURES.. Standard Controls With Pilot Ignition SEE FILTER DIAG. FOR MORE WIRING (OPTIONAL) FILTER BLUE ORANGE WHITE GREEN BLACK H N 6 5 C TO NEXT OIL RETURN SWITCH C TO NEXT FRYER TERMINAL BLOCK 0P or 7P 8P 6P 8P P C C 0P P MELT CYCLE SWITCH/LIGHT HEATING LIGHT ON/OFF SWITCH 7P P 5P 5 6 9P 9P 6P P 0 7 7P 5P 9P T T T T 5C 9P FOR FULL POT ONLY * NOTE FOR NON-BASKET LIFT APPLICATION.) OMIT WIRING C, 7C, C, 5C, 9C, C 0C AND 9C..) OMIT LEFT HI-LIMIT T'STAT, LEFT GAS VALVE LEFT OPERATING T'STAT, LEFT MELT CYCLE TIMER AND LEFT TERMINAL BLOCK..) OMIT WIRING 0C, 9C, 8C, 6C, C, C, 6C, 5C AND C. 8P 0P 9c TO NEXT FRYER NO C 9c 09C TERMINAL BLOCK NC TO PAN RETURN HOSE 0C 9C 6C 6C LINE P/N 80776 VOLTS COM 00V 0V 0P or 7P VAC P 8P C 0C P MELT CYCLE SWITCH/LIGHT 6 C ON/OFF SWITCH HEATING LIGHT C 5C 9C 0C HI-LIMIT T'STAT 80C HI-LIMIT T'STAT 7P SEE BASKET LIFT DIAG. FOR MORE WIRING C BASKET LIFT (OPTIONAL) THERMOCOUPLE 8C THERMOCOUPLE GAS VALVE GAS VALVE C CAPACITOR C 0C 60C 9C C C VALVE V MELT C C C C SAFETY DRAIN OPTION SAFETY DRAIN OPTION C 9C V MELT VALVE CAPACITOR OPERATING T'STAT 5 NO 5 6 8 7 9 NO OPERATING T'STAT GND GND NC NC 08C MELT CYCLE TIMER 0C 6C 7C C 5C 9C 0C MELT CYCLE TIMER 08C SCREENED AREA FOR MELT CYCLE OPTION SCREENED AREA FOR MELT CYCLE OPTION C REMOVE IF NO MELT CYCLE REMOVE IF NO MELT CYCLE 9 8 7 6 5 6C 6C C C SOUND DEVICE SOUND DEVICE 7C 6C 5C C C 5C 5C 50C 9C 8C 8C C C 6 5 C 6C 9 8 C DISCONNECT PLUG DISCONNECT PLUG 5P 7 8 9 6P 7P 5 6 9P P C P P NC LINE N0 5P P P P C 7P 6P NC LINE N0 9P MELT CYCLE SWITCH/LIGHT 8050A M ON/OFF SWITCH 0P MELT CYCLE M ON/OFF M M SWITCH/LIGHT COM COM SWITCH 0P 6C 7C 8P 8P ELECT. TIMER B/L ELECT. TIMER B/L HEATING LIGHT LEFT RIGHT HEATING LIGHT -
CHAPTER : SERVICE PROCEDURES.. Computer/Controller with Pilot Ignition C 5C C FILTER (OPTIONAL) 5 6 09C 9C LEFT HIGH LIMIT LEFT SIDE, DUAL VAT ONLY REMOVE 50C WIRE FOR DRAIN SWITCH OPTION SEE INSET C C 9C 5 6 7 8 NC P NO LEFT PROBE 5 9 8 9 C TO NEXT OIL RETURN SWITCH 0C H C TRANSFORMER CHART TRANSFORMER VOLTAGE TERMINALS 00 80776 0 6 08 0 807999 0 5 0 6 6C J 6C REMOVE 9C WIRE FOR LED5 DRAIN SWITCH OPTION GND VD PWR ALRM VS GND BLACK GREEN WHITE ORANGE BLUE 5C BASKET LIFT (OPTIONAL) 88C 89C 87C C 86C 9C RIGHT HIGH LIMIT (DV) ONLY THERMOCOUPLE 6C GAS VALVE C 6C 7C 7C SOUND DEVICE (FOR CONTROLLERS ONLY) INSET 6 7 VAC C C 9 8 7 0 GND VD 9C PWR 0 VAC 0C 9C GND BLACK GREEN WHITE RED ORANGE BLUE THERMOCOUPLE GAS VALVE SOUND DEVICE SOUND J GND 6 9 5 8 J 7 0 GND LED 50C 6 5 J K VD ALRM VS GND K LED PWR A D A S LED VS GND K K RIGHT PROBE LED5 7 0 5 8 6 9 5 INTERFACE BOARD 6C TO NEXT FRYER TERMINAL BLOCK TO NEXT FRYER TERMINAL BLOCK T T T T COMPUTER OR CONTROLLER NC DRAIN SWITCH (OPTIONAL) NO 805057E C -
CHAPTER : SERVICE PROCEDURES.. Computer/Controller with Electronic Ignition 0V-No Basket Lifts V BLK GRN WHT T T CONTROLLER J SOUND AL MV PV CMP PWR V PV MV AL 5 9 6 0 J K K K RELAY RELAY RELAY J5 AL V GND PWR 8 0 7 J 0 7 J J 5 6 7 8 9 0 WHT RED HI-LIMIT TEMP PROBE N.C. N.O. COM. SAFETY DRAIN SWITCH MV MV/PV PV GAS VALVE 5V GND 5V IGNITOR ALARM VALVE VALVE GND (BURNER) 8C WHT 8050886B 9 6 5 6 8 7 5 9 8 5 6 5 ORG ORG GRN/YEL RED POWER SUPPLY V C RED C BLK WHT TO ADJACENT FRYER 6C 9C 6C WHT BLK BLK C 0C 9C FILTER (OPTIONAL) SEE FILTER DIAGRAM FOR MORE WIRING TO HOSE HEATER WHT C 5 6 BLU ORG C 0C C C 09C C 9C 9C 8C C 5C C NC NO TO NEXT OIL RETURN SWITCH BLK ORG WHT BLU C C 08 0 0 0 -
CHAPTER : SERVICE PROCEDURES.. Filter Box Wiring- FootPrint III 5C 5C C 0C TO PUMP MOTOR 6 9 5 8 7 T T RED RED C LINE TO PIN TO PIN TO PIN 7 TO PIN 9 C 8C C 0C C FILTER BOX WIRING DIAGRAM 9C PUMP HEATER PUMP SOLENOID 6C 7 8 5 6C 9C 9 6 805090C V/50VA T- 08C C 7C 5C -5
CHAPTER : SERVICE PROCEDURES..5 Modular Basket Lift Wiring LEFT SIDE M RIGHT SIDE M.5 µf -Ohm Resitors SEE NOTE BELOW..5 µf COM NC NO UPPER SWITCH COM NC NO COM NO NC COM NO NC UPPER SWITCH 6 5 LOWER SWITCH BLUE ORANGE RED WHITE GREEN BLACK LOWER SWITCH NOTE: 08-50V units have one 5-ohm and two 50-ohm resistors for each side of the basket lift. LEFT SIDE RIGHT SIDE M M 5 Ohm 5 Ohm 50 Ohm REFERENCES TO LEFT AND RIGHT ARE FROM THE REAR OF THE FRYER -6
CHAPTER : PARTS LIST. Accessories 5 6 7 8 9 0 ITEM PART # COMPONENT 80-009 Brush, Frypot Clean-out 80-00 Basket, Twin * 80-0099 Basket, Full 806-558 Frypot Cover, Full-Vat * 806- Frypot Cover, Split-Vat * 86-099SP Handle Kit, Frypot Cover (Full- and Split-Vat) 80-097 Frypot Clean-out Rod (Fryer s Friend) 5 806-8 Kit, -Leg * 806-50 Kit, -Leg 6 80-078 Caster, Rigid 7 80-056 Caster, 5", Without Brake 8 80-057 Caster, 5", With Brake * 86-0900 Chain Restraint Kit (for use with casters above) 9 90-557 Flue Deflector 0 80-0 Basket Support Rack, Full Vat * 80-08 Basket Support Rack, Dual Vat 80-0 Basket Hanger, Wireform * 809-07 Screw, Basket Hanger 8-6SP Drain Extension Pipe (for use on units without built-in filtration systems) * Not Illustrated -
CHAPTER : PARTS LIST. Burner Manifold Assemblies and Component Parts 0 5 5 6 7 8 9 8 9 6 7 ITEM PART # COMPONENT 806-597SP Burner Manifold Assembly, Full Vat, Complete * 806-598SP Burner Manifold Assembly, Dual Vat, Complete 90-07 Standoff, Target- Rear 90-0 Support, Target, Back Plate 809-099 U-bolt & Retainer- ¼-0 x -½" 5 80-0989 Manifold, Burner- Full-vat 6 809-0500 Screw, 0 SS, # 0 x ½, Hex Washer Head 7 809-098 U-bolt Square-bent- ¼-0 x -½" 8 90-0 Bracket, Manifold Mounting, Full Vat 9 86-7 Nut, ¼-0 w/grip (Qty: 0) 0 90-07 Standoff, Target- Front 80-0987 Burner Manifold, Dual Vat, Left 80-0988 Burner Manifold, Dual Vat, Right 90-0 Bracket, Manifold Mounting, Dual Vat, Rear 90-0 Bracket, Manifold Mounting, Dual Vat, Front 5 806-799 Burner Manifold Sub-Assembly (Target Assembly) 6 9-09 Support, Target, Left End 7 8-00 Burner Target, Ceramic 8 90-05 Bracket, Target Retaining 9 9-09 Support, Target, Right End * 86-57 Orifice, Burner Manifold, Natural Gas (Drill #5,.5mm Qty: 0) * 86-87 Orifice, Burner Manifold, LP Gas (Drill #65, 0.86mm Qty: 0) * Not Illustrated -
CHAPTER : PARTS LIST. Burner Ignition System Components Red dot here indicates LP gas only. ITEM PART # COMPONENT Pilot Assembly w/thermopile (for use w/non-ce Pilot Ignition Systems) 80-065 Natural Gas 80-066 Propane Gas 80-87 Thermopile Pilot Assembly w/thermocouple (for use w/ce Pilot Ignition Systems) 806-8688SP Natural Gas 806-8689SP Propane Gas 8-8 Thermocouple Ignitor Assembly, Honeywell (for use w/electronic Ignition Systems) 807-707 Natural Gas 807-708 Propane Gas 807-98 Electrode, Flame Sensor (for use w/electronic Ignition Systems) * 806-580SP Ignition Cable (Spark Plug Wire) * 86-55 Ignitor Kit, Piezo (Optional) * 80-00 Trigger * 807-906 Electrode Assembly * Not Illustrated -
CHAPTER : PARTS LIST. Gas Valve Assemblies and Connection Components ITEM PART # COMPONENT Gas Valve Assembly (for use w/ce Pilot Ignition Systems) 807-09 Natural Gas 807-7 Propane Gas 80-55 CE Accessory Kit- (Converts Inlet/Outlet Flanges to ½" NPT) Gas Valve Assembly (for use w/non-ce Electronic Ignition Systems) 80-0786 Natural Gas 80-0787 Propane Gas Gas Valve Assembly (for use w/non-ce Pilot Ignition Systems) 807-9 Natural Gas 807-95 Propane Gas (Full-vat Units) * 806-06 Capacitor,.00 µf (for use w/80-0786, 80-0787) * Vent Tube, Gas Valve 80-66 For use w/ce Gas Valves 807-09 and 807-7 80-069 For use w/non-ce Gas Valves 80-0786, 80-0787 * Hose, Flexible, Gas 80-008 ¾-inch (9.05mm) ID, 8 inches (.m) long 80-0085 -inch (5.mm) ID, 8 inches (.m) long * Quick Disconnect Fitting, Female 80-007 ¾-inch (9.05mm) 80-007 -inch (5.mm) * Quick Disconnect Fitting, Male 80-0070 ¾-inch (9.05mm) 80-007 -inch (5.mm) * Not Illustrated -
CHAPTER : PARTS LIST.5 Gas Manifold Assemblies 8 Gas valves can be found in Section. 7 6 5 ITEM PART # COMPONENT Gas Manifold 80-0995 FP7 80-0997 FP7-L 80-0996 FP7-R 80-0950 FP7-80-0960 FP7 80-099 FP7-L 80-097 FP7-R 80-099 FP7-L 80-099 FP7-R 80-099 FP7-6 80-9 MJ7-8-07 Union, ½" NPT Black Pipe 8-0087 Nipple, ½ x -½" NPT Black Pipe 80-669 Adapter, Female- 5/8 O.D. x ½" 5 80-668 Adapter, Male- 5/8 x ½" 6 8-0068 Elbow, Reducing- ¾ x ½" 7 Flexline 80-59 5" (Used for all but MJ7-) 80-067 8.5" (Used for MJ7- only) 8 8-009 Nipple, ½ x " NPT Black Pipe -5
CHAPTER : PARTS LIST.6 Cabinet Assemblies and Component Parts Cabinet Assembly (FP7 Illustrated) 5 0 6 7 5 9 8 8 7 9 0 6 5-6
CHAPTER : PARTS LIST ITEM PART # COMPONENT 900-959 Bracket, Filter Lock 809-0 Screw, FootPrint III Cover 900-957 Lock, Filter 809-089 Washer, ¼ Flat 5 86-7 Nut, Hex- ¼-0 Nickel Plated (Qty:0) 6 90-5 Rail, Lower- Unitary (Left or Right) 7 9-690 Rail, Filter, Top Left 8 9-690 Rail, Filter, Top, Right * 900-567 Support, Filter Hose (FP7 s) * 900-567 Shield, Heat (FP7 s) 9 806-750SP Base Assembly, FP7 * 806-75SP Base Assembly, FP7 * 806-79SP Base Assembly, FP7 * 900-568SP Base Assembly, MJ7 * 806-76SP Base Assembly, MJ7 * 806-77SP Base Assembly, MJ7 * 806-78SP Base Assembly, MJ7 0 90-98 Channel, Side Support- Left * 90-98 Channel, Side Support- Right 90-80 Gusset, Cabinet- Left * 90-80 Gusset, Cabinet- Right 90-7678SP Panel, Side, Left or Right, w/no Access Openings (S/S) * 900-7678SP Panel, Side, Left or Right, w/no Access Openings (CRS) * 9-7679SP Panel, Side, Left, w/ Access Openings (S/S) * 90-7679SP Panel, Side, Left, w/ Access Openings (CRS) 9-7679SP Panel, Side, Right, w/ Access Openings (S/S) * 90-7679SP Panel, Side, Right, w/ Access Openings (CRS) 900-56 Support, Cross Cabinet 5 900-77 Post, Long Cabinet 6 900-90 Brace, Top- Front, Unitary Cabinet 7 900-77 Post, Short- Door 8 900-779 Support, Cross Cabinet 9 900-797 Support, Cabinet- Rear 0 900-95 Brace, Top- Rear 900-76 Divider, Cabinet 900-798SP Back, Lower- FP & MJ7 * 900-799SP Back, Lower- FP & MJ7 * 900-88 Back, MJ7 * Not Illustrated List continued on following page. -7
CHAPTER : PARTS LIST ITEM PART # COMPONENT 900-95 Back, Upper- FP & MJ7 * 900-7658 Back, Upper- FP & MJ7 * 809-066 Screw, #0-/ Phillips Head, Zinc Plated 8-006 Top Cap, Triple * 8-007 Top Cap, Quad * 8-00 Top Cap, Single * 8-005 Top Cap, Double 5 8-5 Flue Cap, Triple Fryer Battery * 8-50 Flue Cap, Double Fryer Battery * 90-508 Flue Cap, Single Fryer * 90- Battery Strip, Flue Cap * 86-5 Nutsert (For Basket Hanger Screw- Qty:0) * 900-586 Support, Flue Cap To Back * 90-7 Strip, Top Connecting * Not Illustrated -8
CHAPTER : PARTS LIST.6. Door Assemblies and Component Parts 6 7 5 0 8 9 ITEM PART # COMPONENT 806-78SP Door Assembly, Left * 806-78SP Door Assembly, Right 900-85 Liner, Door, Left or Right 8-0580SP Panel, Door, Left or Right 809-055 Clip, Nylon Arrow 5 80- Handle, Door, Wireform 6 809-066 Screw, #0 x ½, Phillips, Zinc Plated 7 80-508 Hinge, Door 8 06-055SP Door Pin Assembly * 809-09 Washer, Nylon- Flat ¼" (Door Pin Bushing) 9 86- Spring, Door Hinge (Qty: 0) 0 80-05 Magnet, Door * Not Illustrated -9
CHAPTER : PARTS LIST.7 Component Box/Shield Component Parts 6 7 5 8 9-0
CHAPTER : PARTS LIST ITEM PART # COMPONENT 06-086 Board, Interface (Without Electronic Ignition) (also replaces 806-98) * 807-08 Relay, Heat (For 806-98) * 807-08 Relay, Basket Lift- V 5A (For 806-98) 806-5857 Board, Interface (With Electronic Ignition) * 809-09 Spacer, Aluminum- Interface Board- -mm x 6-mm * 807- Spacer, Aluminum- Interface Board - 5/8" Unthreaded * 806-660 Sound Device, High Output * 806-797 Buzzer, V 807-006 Module, Ignition, -Second Delay, Honeywell * 807-97 Module, Ignition, PCB (Australia Only) * 806-5879SP Wire Assembly, Ignition Module 807-76 Transformer, V/F Dual Voltage 00-0VAC * 807-999 Transformer, V/F Dual Voltage 08-0VAC 5 80-6 Block, Terminal (Screwless)- -Wire * 80-68 Block, Terminal (Screwless)- -Wire 6 Component Shield Assembly- Pilot Ignition * 806-6907SP 00-0V Full Vat- Includes Items #, # and #5 * 806-690SP 00-0V Dual Vat- Includes Items #, # and #5 * 806-685SP 0-0V Full Vat- Includes Items #, # and #5 * 806-68SP 0-0V Dual Vat- Includes Items #, # and #5 7 Component Shield Assembly- Electronic Ignition * 806-87SP 00-0V Full Vat- Includes Items #, #, # and #5 * 806-7988SP 0-0V Full Vat- Includes Items #, #, # and #5 * Component Shield Assembly- Solid State Melt Cycle Timer 806-6908SP 00-0V Full Vat- Includes Items #, #5 and #9 806-6905SP 00-0V Dual Vat- Includes Items #, #5 and #9 806-686SP 0-0V Full Vat- Includes Items #, #5 and #9 806-68SP 0-0V Dual Vat- Includes Items #, #5 and #9 * Component Shield Assembly- No Melt Cycle or Interface Board * 806-6909 00-0V Full Vat- Includes Items # and #5 * 806-6906 00-0V Dual Vat- Includes Items # and #5 * 806-687 0-0V Full Vat- Includes Items # and #5 * 806-68 0-0V Dual Vat- Includes Items # and #5 * 806-875SP Control Box Assy, FP/MJ-7, Full Vat, Electronic Ignition, 0V * 806-808SP Control Box Assy, FP/MJ-7, Full Vat, Electronic Ignition, 0V 8 806-07 Cable Assembly, 5-Pin, Computer to Interface Board * WIR06SP Cable Assembly, Transformer Box to Interface Board * 806-580SP Cable Assembly, Ignition (Spark Plug Wire) 9 86-56 Kit, Solid State Melt Cycle Timer * Not Illustrated -
CHAPTER : PARTS LIST.8 Probes, High-Limits and Basketlift Timers 6 5 ITEM PART # COMPONENT 806-06 Probe, Temperature Control (not for use with Thermostat Controllers) * 0-068 Probe Guard 806-7550 Thermostat, High-Limit (CE) 86-77 Thermostat, High-Limit (Non-CE) Timer, Basket Lift, Electric * 86-575 0V, 60 Hz, 5-Minute * 86-55 0V, 60 Hz, 5-Minute * 807-00 0V, 50/60 Hz, 8-Minute * 80-8 Knob, Electric Basket Lift Timer (Telechron) * 80-8 Push Button, Electric Basket Lift Timer (Telechron) 5 80-0585 Timer, Basket Lift, Mechanical, 5-Minute 6 80-87 Knob, Mechanical Timer * 86-00 Timer Service Kit (Includes Timer, Knob & Bezel) * Not Illustrated -
CHAPTER : PARTS LIST.9 Operating Thermostat and Related Components 5 7 6 8 9 0 ITEM PART # COMPONENT 806-08 Thermostat, Operating (for use with Thermostat Controller only) 80-0999 Shaft, Flexible 809-057 Set Screw 809-0050 Nut, Hex 5 86-6 Screw, Stop (Qty: 5) 6 80-076 Adapter, Shaft End 7 80-0 Knob, Thermostat 8 807-98 Switch, Rocker, Melt Cycle ON/OFF 9 Switch, Rocker, Melt Cycle I/O, w/v Lamp 807-96 Green (CE) 807-97 Amber (CE) 0 807-55 Light, V, White 80-0765 Label, Control Panel -
CHAPTER : PARTS LIST.0 Computers and Controllers ITEM PART # COMPONENT Computer Magic III * 06-9SP Full Vat * 06-8SP Dual Vat * 06-99SP Full Vat (CE) * 06-0SP Dual Vat (CE) Computer, Basket Lift Timer * 06-079SP Full Vat * 806-78SP Full Vat (CE) Analog Controller * 806-56 Dual Vat * 806-559 Full Vat Digital Controller * 06-5 Dual Vat * 06-50 Full Vat * Not Illustrated -