Frymaster 1824E User Manual

*8196115*

Flatbottom Series Electric Fryers

(Models 1824E, 2424E and Combinations)

Service & Parts Manual

Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.

24-Hour Service Hotline 1-800-551-

8633

SEPTEMBER 2011

NOTICE IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS MANITOWOC FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR EXP ENSES INCUR RED B Y 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 SERVICER.

DANGER

Copper wire suitable for at least 167°F (75°C) must be used for power connections.

DANGER

The electrical power supply for this appliance must be the same as indicated on the

rating and serial number plate located on the inside of the fryer door.

DANGER

This appliance must be connected to the voltage and phase as specified on the rating

and serial number plate located on the inside of the fryer door.

DANGER

All wiring connections for this appliance must be made in accordance with the wiring

diagrams furnished with the equipment. Wiring diagrams are located on the inside of

the fryer door.

DANGER

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this

or any other appliance.

WARNING

Do not attach accessories to this fryer unless fryer is secured from tipping. Personal

injury may result.

WARNING

Frymaster fryers equipped with legs are for permanent installations. Fryers fitted with legs must be lifted during movement to avoid damage and possible bodily injury. For a moveable or portable installation, Frymaster optional equipment casters must be used.

Questions? Call 1-800-551-8633

WARNING

Do not use water jets to clean this equipment.

DANGER

All wiring connections for this appliance must be made in accordance with the wiring

diagrams furnished with the equipment. Wiring diagrams are located on the inside of

the fryer door.

WARNING

This equipment is intended for indoor use only. Do not install or operate this

equipment in outdoor areas.

Flatbottom Series Electric Fryers

TABLE OF CONTENTS

Page

CHAPTER 1 – SERVICE PROCEDURES 1-1

1.1 General 1-1

1.2 Calibrating the Thermatron Controller

1.3 Accessing the Control Box Electronics

1.4 Replacing an Thermatron Temperature Control Board 1-3

1.5 Replacing a Transformer 1-3

1.6 Replacing a Contactor 1-4

1.7 Replacing a Safety Drain Relay 1-4

1.8 Replacing a Breaker 1-4

1.9 Replacing a Thermatron Potentiometer 1-4

1.10 Replacing a Temperature Sensor and High-Limit Thermostat 1-5

1.11 Replacing Heating Elements inside Frypot 1-6

1.12 Replacing Heating Element under the Frypot 1-7

1.13 Replacing a Frypot 1-7

1.14 Cleaning a Seized Pump 1-7

1.15 Probe Resistance Chart 1-9

1.16 Element Wattage/Amperage Calculation Charts 1-9

1.17 Troubleshooting Guides 1-10

1.18 Wiring Diagrams 1-13

CHAPTER 2 – PARTS LIST 2-1

2.1 Accessories 2-1

2.2 Cabinetry

2.3 Control Panels, Wireways and Related Components 2-8

2.4 Electronics Components 2-10

2.5 Filter Components

2.6 Elements and Related Components 2-16

2.7 Harnesses 2-17

2.8 Oil Discharge Assembly

2.9 Oil Return Assembly 2-20

2.10 Drain Valves and Associated Parts

2.11 Drain and Oil Return Components 2-22

2.12 Wiring Connectors, Pin Terminals and Power Cords

1-1 1-3

2-2

2-12

2-19

2-21

2-25

iii

FLATBOTTOM SERIES ELECTRIC FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 General

Before performing any maintenance on your Frymaster Dean Flatbottom Electric fryer, you must disconnect the electrical power supply.

When electrical wires are disconnected, it is recommended that they be marked to facilitate reassembly.

DANGER

Hot cooking oil will cause severe burns. Never attempt to move this appliance when filled

with hot cooking oil, or to transfer hot cooking oil from one container to another.

DANGER

This equipment should be unplugged when servicing, except when electrical circuit tests are

required. Use extreme care when performing such tests.

This appliance may have more than one electrical power supply connection point.

Disconnect all power cords before servicing.

Inspection, testing and repair of electrical components should be performed by an

authorized service agent only.

A Thermatron system incorporates a temperature-control circuit board, a potentiometer, and a temperature probe.

1. Thermatron with Melt Cycle Option Enabled: Set Thermatron to the working temperature. The

elements will cycle on approximately 5 seconds, and off for approximately 15 seconds until the temperature reaches 66°C (150°F). The Thermatron will then switch to normal operation.

1.2 Thermatron Calibration

If the Thermatron controller requires adjustment, do the following:

1. Set Thermatron controller dial to the desired shortening temperature and wait for the shortening

temperature to stabilize.

2. When shortening temperature reaches setpoint (elements will cycle on and off, indicating

setpoint temperature has been reached), check the temperature with a high-quality immersion thermometer.

3. Loosen the knob setscrew and rotate the knob to the correct temperature setting on the

Thermatron faceplate.

4. Check the temperature again with a high-quality immersion thermometer to confirm that the

setting is correct.

5. Re-tighten the knob setscrew at the calibrated position.

1-1

Rocker

Switch

Panel

Control Box

Access

Drain Nipple

Extension

Bracket

IDENTIFYING PARTS

Drain

Breakers

Thermatron

Controller

Contactor

Safety Drain

Relay

Transformer

Control Box

Breaker

Terminal Block

Thermatron Board

1-2

1.3 Accessing the Control Box Electronics (Interface Board, Transformer, Contactor, Breakers, Transformer and Relay)

1. Unplug all power cords.

2. Open front door of cabinet and remove the two bolts holding down the drain nipple extension

bracket.

3. Remove the three screws from bottom of control box access panel.

4. Remove the four screws in the corner of rocker switch access panel. Twist the rocker panel and

push through the access panel opening.

5. Unplug the Thermatron connector and remove access panel and set aside.

1.4 Replace Thermatron Board

1. Unplug all power cords. Perform Procedure 1.3, Steps 1-5, Accessing Control Box Electronics.

2. Remove all wiring from the terminals of the Thermatron board, ensuring that each wire is

marked for reattachment.

3. Remove the nuts from each corner of the Thermatron temperature control board and slide the

board from the studs. Ensure that standoffs remain in place on studs, prior to installing new board. Install the new board by reversing the previous procedures. Ensure that wiring and wire harnesses are connected to the proper terminals.

1.5 Replace Transformer

1. Unplug all power cords. Perform Procedure 1.3, Steps 1-5, Accessing Control Box Electronics.

2. Remove all wiring from the terminals of the transformer to be replaced.

3. Remove the screws that secure the transformer to the component box.

4. Install the new transformer by reversing the preceding procedures. Make sure you reconnect the

wiring to the proper terminals and the harnesses to the correct connectors.

1-3

1.6 Replace Contactor

1 Unplug all power cords. Perform Procedure 1.3, Steps 1-5, Accessing Control Box Electronics.

2. Identify faulty contactor. Remove all wiring connected to the contactor terminals inside the

component box. Tape wire-pairs together and mark each wire-set or wire for reassembly.

3. Remove contactor-mounting screws and remove the contactor.

4. Install the new contactor and connect the wiring removed in Step 2.

5. Reassemble in reverse order.

1.7 Replace Safety Drain Relay

1. Unplug all power cords. Perform Procedure 1.3, Steps 1-5, Accessing Control Box Electronics.

2. The safety drain relay is located in the top left corner of the access cabinet.

3. Carefully remove the relay hold down spring.

4. Pull relay to the left and out of the socket.

5. Install the new relay by reversing the preceding procedures.

1.8 Replace Breakers

1. Unplug all power cords. Perform Procedure 1.3, Steps 1-5, Accessing Control Box Electronics.

2. Identify faulty breaker. Remove all wiring connected to the breaker terminals inside the

component box. Tape wire-pairs together and mark each wire-set or wire for reassembly.

3. Remove breaker-mounting screws and remove the breaker.

4. Install the new breaker by reversing the preceding procedures.

1.9 Replace Thermatron Potentiometer

1. Unplug all power cords.

2. Open front door of cabinet and remove the four screws in corners of potentiometer panel.

3. Unplug connector.

4. Install the new potentiometer by reversing the preceding procedures.

1-4

1.10 Replace Temperature Sensor and High-Limit Thermostat Probes

1. Unplug all power cords.

2. Drain the cooking oil from the frypot and

leave the drain open.

3. Lift up and remove the element

guardplate.

4. Remove the two screws from the bottom

of the faceplate cover.

5. After removing screws, gently tilt up and

lower faceplate. Note that when lowering

Element Guardplate

the faceplate, the door will lower and swing out to be set aside as well.

6. Remove the six screws from the top access

cover.

7. After removing screws, remove panel by

lowering down the front of the frame and pushing in on the high-limit reset switch so that it will slide down. To make reassembly easier, push out the black grommet and snap back in when completely reassembled.

8. Remove the screws securing the probe

bracket to the elements and remove the

Underside of faceplate has two screws.

Top access cover has six screws.

probe bracket.

9. Remove the metal clamps securing the

probe to the elements.

10. Disconnect the wire plug containing the

probe wiring.

11. Using an open end wrench, loosen the

temperature probe. Thread the probe wire through the hole and remove the probe.

Remove the screws from probe brackets.

1-5

12. Thread the new probe wire through the

hole in front of the fryer. The probe assembly should be oriented in the same manner as the probe being replaced. Place the new probe assembly onto the element, and ensure that the probe extends 1” beyond the front of the bracket before securing the bracket. Also ensure that the springs are on each probe under each bracket.

13. Apply Loctite PST567 sealant to

replacement threads.

14. Screw the replacement probe into the

frypot and tighten 170-180 inch-pounds torque. DO NOT OVERTIGHTEN.

15. Reattach the connector and reassemble in

High-Limit Thermostat Temperature

Sensor

reverse order.

1.11 Replace Heating Elements inside Frypot

1. Perform Procedure 1.10, Replace

Temperature Probe, Steps 1-9.

2. Remove the four screws from the two

brackets in the rear of the frypot that secure the element to the frypot.

3. Remove wires from the elements by

loosening and removing the nuts.

4. Remove element using an open-end

wrench or other suitable tool to loosen the compression fitting.

Remove screws here.

5. Gently remove the element by sliding out into the frypot and lifting up as you remove it.

6. Insert new element and reassemble in reverse order.

1-6

1.12 Replace Heating Element under the Frypot

1. Perform Procedure 1.10, Replace Temperature Probe, Steps 1-9.

2. Remove the wires from the element by removing the nuts on each end of the element.

3. Remove the screws attaching the element bracket to the cabinet.

4. Gently slide the element out by pulling towards the front of the fryer.

5. Insert new element and reassemble in reverse order.

1.13 Replace Frypot

1. Perform Procedure 1.10, Replace Temperature Probe, Steps 1-9.

2. Perform Procedure 1.3, Accessing the Control Box Electronics, Steps 1-5.

3. Perform Procedure 1.8, Replace High-Limit, Steps 1-4.

4. Disconnect the element wires.

5. Remove the screws holding the back panels to the frame.

6. Remove the screws securing the frypot to the front frame of the fryer.

7. Carefully lift the frypot from the cabinet.

8. Remove the drain valve from the old frypot and install on the new frypot.

9. Apply Loctite Sealant PST 567 to the high-limit threads. Install high-limit into the new frypot.

10. Follow the preceding steps in reverse to install the new frypot into the fryer.

11. NOTE: Apply Loctite Sealant PST 567 to all pipefittings prior to installation.

1.14 Cleaning a Seized Pump

If the pump motor overloads, a circuit breaker will trip and the motor will not start until the breaker is reset. If the pump motor does not start, press the white reset button located under the component box, inside the cabinet.

If the pump starts after resetting the breaker, then something is causing the motor to overload. A major cause of overload is filtering several frypots sequentially, creating thermal overload on the

1-7

motor. Allow the pump motor to cool at least 30 minutes before resuming operation, and allow time for the motor to cool between frypots. Motor overload can be caused by:

• Solidified shortening in the pan or filter lines,

• Attempting to filter unheated oil.

Cold oil is more viscous, causing the pump motor to trip a breaker. Always filter with the oil at operating temperature [~350°F (177°C)].

If the motor runs but the pump does not, there is a blockage in the pump or lines. Incorrectly sized or installed paper/pads will allow food particles and sediment to pass through the filter pan and into the pump. When sediment enters the pump, the gears bind, causing the motor to overload, again tripping the breaker. Shortening that has solidified in the pump will produce the same result.

A pump seized by debris or hard shortening must be disassembled, cleaned, and reassembled. Use the following procedure:

1. Disconnect power to the filter system.

2. Remove the front cover of the pump to access the gears inside (see illustration below- 8-GPM

pump shown), if the pump is accessible inside the cabinet.

Remove bolts to remove

pump cover.

Remove debris or hardened

shortening to free gears.

3. If the front cover is not accessible, the pump must be removed from the pump motor (remove

input/output plumbing from the pump prior to removing pump). Remove three setscrews from the pump-shaft housing to disengage the pump from the motor. Remove the gears and thoroughly clean all internal components. Ensure the inside of the pump housing is free of any debris or hardened shortening before reassembling. Failure to completely clean the inside housing and ring gear will cause gear binding after reassembly.

Filter paper/pads that are the wrong size or installed incorrectly will also allow food particles and sediment to pass through and clog the suction tube in the bottom of the filter pan. Particles large enough to block the suction tube may indicate that the crumb tray is not being used.

1-8

1.15 Probe Resistance Chart

Use the chart below when testing temperature probes and probe circuits for proper operation.

Probe Resistance Chart

Current-Style Thermatron Systems (Probe wire

color: Two Black Wires or Two Brown Wires) ° Celsius ° Fahrenheit Ohms (± 3%)

21 70 108130 27 80 84606 32 90 66721 38 100 53020 43 110 42452 49 120 34206 54 130 27735 60 140 22641 66 150 18588 71 160 15349 77 170 12741 82 180 10635 88 190 8925 93 200 7527

99 210 6391 104 220 5470 110 230 4705 116 240 4030 121 250 3441 127 260 2967 132 270 2583 138 280 2255 143 290 1977 149 300 1729 154 310 1496 160 320 1320 166 330 1170 171 340 1051 177 350 942 182 360 840 188 370 750 193 380 676 199 390 605 204 400 541

1-9

1.16 Element Wattage/Amperage Calculation Charts

Use the charts below when changing voltages or determining amperage for a given element configuration.

Three Phase

Amperage

L2 L3

To determine Three Phase Amperage, solve for Single Phase first:

Wattage Voltage

Then divide the Single Phase Amperage by 1.73 to determine Three Phase Amperage.

Example:

17,000W

= 40.944 Amps per Phase

= Single Phase Amps

70.833 Amps

240V

1.73

To compute the New Wattage Rating of an element if a different voltage is applied, use the following formula:

New Voltage

[]

Old Voltage

= New Wattage Rating

Example:

If 208V supply is applied to a 17 kW element rated for 240V, the calculation is as follows:

208V

[]

240V

= 12.77 kW

Three Phase

Wattage

L2 L3

kW Listed

17,000 Watts

1.17 Troubleshooting

1.17.1 Control and Heating Problems Problem Probable Causes Corrective Action

A. Power cord is not plugged in or circuit

breaker is tripped.

B. Controller has failed.

Controller won't

activate.

C. Power supply component or

temperature control board has failed.

A. Plug power cord in and verify that

circuit breaker is not tripped.

B. If available, substitute a controller

known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller.

C. If any of the components in the

power supply system (including the transformer and temperature control

oard) fail, power will not be supplied to the controller and it will not function.

1-10

Problem Probable Causes Corrective Action

Fryer does not heat.

Fryer repeatedly

cycles on and off when

first started.

Fryer heats until high-

limit trips with heat

indicator ON.

Fryer heats until high-

limit trips without

heat indicator ON.

Fryer stops heating

with heat indicator

ON.

A. Controller has failed.

B. One or more other components have

failed.

Fryer is in melt-cycle mode.

Temperature probe or controller has failed.

Contactor, element or controller has failed.

The high-limit thermostat or contactor has failed.

A. If available, substitute a controller

known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller.

B. If the circuitry in the fryer control

system cannot determine the frypot temperature, the system will not allow the element to be energized or will de-energize the element if it is already energized. If the contactor, element, or associated wiring fails, the element will not

energize. In fryers equipped with Thermatron controllers, burners cycle on approximately 5 seconds and off for 15 seconds until the temperature reaches 66°C (150°F).

If available, substitute a controller known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller. If the substitution of the controller does not resolve the problem, the most likely cause is a failed temperature probe. If available, substitute a controller known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller from FAS. If the substitution of the controller does not resolve the problem, the most likely cause is a contactor that has failed in the closed position or an element that has failed.

The fact that the heat indicator is ON indicates that the controller is functioning properly and is calling for heat. The high-limit thermostat functions as a normally closed switch. If the thermostat fails, the "switch" opens and power to the elements is shut off. If the contactor fails to close, no power is supplied to the elements.

1-11

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