Frymaster 2424G User Manual

24G Series Flatbottom

Service & Parts Manual

Gas Fryers

Models SCF/SCFC 1824G, 2424G and 1824/2424G

Systems with Built-In Filtration

NON-CE

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

PRINTED IN THE USA

service@frymaster.com

24-Hour Service Hotline

1-800-551-8633

www.frymaster.com

10/2016

*8196031*

Please read all sections of this manual and retain for future reference.

This product has been certified as commercial cooking equipment and MUST be installed by

professional personnel as specified. Installation, maintenance and repairs should be performed

by your FRYMASTER DEAN FACTORY AUTHORIZED SERVICER.

DANGER

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

other cooking appliance.

DANGER 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.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property

damage, injury or death. Read the installation, operating and maintenance instructions

thoroughly before installing or servicing this equipment.

DANGER

Safe and satisfactory operation of your equipment depends on proper installation. Installation

MUST conform with local codes, or in absence of local codes, with the National Fuel Gas Code,

ANSI Z223.1; The Natural Gas Installation Code, CAN/CGA-B149.1; The Propane Installation

Code, CAN/CGA-B149.2; or The latest edition of the National Electric Code, N.F.P.A. 70.

NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART F OR THIS MANITOWOC

FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART

PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS AUTHORIZED SERVICE

CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL

CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS

AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY

THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO

THE INSTALLATION OF ANY MODIFIED PART AND/OR PART RECEIVED FROM AN

UNAUTHORIZED SERVICE CENTER.

DANGER

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.

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 1-800-551-8633.

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 (WHERE APPLICABLE)

FCC

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:

1) This device may not cause harmful interference, and 2) This device must accept any interfere nce

received, including interference that may cause undesired operation. While this device is a verified Class

A device, it has been shown to meet the Class B limits.

CANADA

This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the

ICES-003 standard of the Canadian Department of Communications.

Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B

prescrites dans la norme NMB-003 edictee par le Ministre des 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

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.

24G Series Flatbottom Gas Fryers

Service & Parts Manual

TABLE OF CONTENTS

PAGE #

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.7.1

1.7.2

1.7.3

1.7.4

1.7.5

1.7.6

1.8

1.8.1

1.8.2

1.8.3

1.8.4

1.8.5

1.9

1.9.1

1.9.2

1.9.3

1.10

1.10.1

1.10.2

1.10.3

1.10.4

1.10.5

1.10.6

1.10.7

1.10.8

1.10.9

1.10.10

1.10.11

1.10.12

SERVICE PROCEDURES Functional Description Accessing Fryers for Servicing Cleaning Gas Valve Vent Tube Adjusting Burner Manifold Gas Pressure Adjusting Pilot Flame Calibrating the Thermatron Temperature Controller Replacing Fryer Components

Remove/Replace Temperature Probe or High-Limit Thermostat Removing /Replacing Rocker Switches Replacing the Gas Valve Replacing the Pilot Assembly or Direct Spark Ignitor Removing/Replacing Blower Assembly or Air Prover Switch Replacing the Frypot

Troubleshooting and Problem Isolation

Ignition Failures Improper Burner Functioning Improper Temperature Control Filtration Problems Leakage

Troubleshooting Guides

Pilot Burner Malfunctions Main Burner Malfunctions Indicator Lights

Wiring Diagrams

24G Series Single Fryers, Non-CE without Boil-Out Switch 24G Series Single Fryers, Non-CE with Boil-Out Switch 24GTI with Drain Safety Switch, and Boil-Out Option Enabled – LJS 24GTI with Drain Safety Switch, and Boil-Out Option Enabled – 120V non-LJS 24GTI with Drain Safety Switch, and Boil-Out Option Enabled – 250V non-LJS 24GTI with Drain Safety Switch, and Boil-Out Option Disabled – KFC 24GTI with Drain Safety Switch, and Boil-Out Option Disabled – non-KFC 24G Series Single Fryers, CE Approved Wiring, Standing Pilot - SCFC Models prior to May 2011 Wiring, Standing Pilot - SCFC Models after May 2011 24GTI Oil Return/Filter System

24G/18G Transformer Box Diagram

1–1 1–1 1–5 1–6 1–6 1–7 1–7 1–9 1–9 1–11 1–12 1–12 1–13 1–15 1–19 1–20 1–21 1–23 1–23 1–25 1–26 1–26 1–27 1–28 1–29 1–29 1–30 1–31 1–32 1–33 1–34 1–35 1–36 1–37 1–38 1–39 1-40

24G Series Flatbottom Gas Fryers

Service & Parts Manual

TABLE OF CONTENTS (cont.)

PAGE #

2.1

2.2

2.3

2.4

2.4.1

2.4.2

2.4.3

2.4.4

2.4.5

2.4.6

2.5

2.5.1

2.5.2

2.5.3

2.5.4

2.5.5

2.5.6

2.6

2.7

2.8

APPENDIX: ND90 Built-in Filter System

PARTS LIST Blower Assembly and Combustion Air Burner Manifold and Related Components Flue Caps, Top Caps, and Related Components Common Cabinet Components (SCFC Models)

Cabinetry Door Assemblies and Component Parts Control Panels, Wireways, and Related Components Oil Return and Suction Manifolds Filter Unit Frypot, Drain, and Oil Return Components

Previous Style (SCF Models)

Cabinetry Door Assemblies and Component Parts Control Panels, Wireways, and Related Components Oil Return and Suction Manifolds Filter Unit Frypot, Drain, and Oil Return Components

Drain Valve and Components Wiring Connectors, Pin Terminals, and Power Cords Screws, Nuts, and Fasteners

2–1 2–1 2–2 2–4 2–6 2–6 2–8 2–9 2–11 2–13 2–14 2–16 2–16 2–18 2–19 2–21 2–24 2–25 2–27 2–28 2–29 2–30

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

24G Series Flatbottom gas fryers contain a welded steel frypot (mild steel) with heat-transfer ducting on the frypot bottom for efficient heating of oil without scorching. A draft inducer draws air over the burners for combustion. Air movement directs the combustion products back and forth across the frypot bottom by means of a set of baffles, transferring the heat evenly. Cold air is prevented from entering the combustion chamber and cooling the oil during the coasting cycle.

Flames originate from orifices in three tubular burners positioned beneath the frypot. The diameter of the orifices differs for Natural (CE:G20/G25) and LP (CE:G31) gas as indicated in the table below.

NON-CE (Altitudes of 2000 feet or less)

MODEL

1824/2424G 120

INPUT

(BTU)

GAS TYPE

NAT

ORIFICE

[DRILL SIZE (MM)]

#34 (2.82) #50 (1.78)

ORIFICE

PART #

810-2051 810-2317

QTY

3 3

EQUIPMENT

PRESSURE

MBAR INCH W.C.

27.5

CE ONLY (Altitudes of 2000 feet or less)

MODEL

1824/2424G

INPUT

(kW)

30,0

(88,000

BTU)

GAS TYPE

G20 G25 G31

ORIFICE

(MM)

2,50 2,50 1,60

ORIFICE

PART #

810-2628 810-2628 810-2317

QTY

3 3 3

EQUIPMENT

PRESSURE

MBAR INCH W.C.

14,5 21,0 31,0

5,8 8,4

12,44

An electromechanical gas valve regulates gas flow to the manifold. 24G Series Flatbottom gas fryers are equipped with either a 120-volt valve system (standing pilot) or a 24-volt valve system (electronic ignition or CE standing pilot). Units may be configured with either a pilot ignition system

(standing pilot) or an electronic ignition system (direct spark ignition).

1-1

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Pilot System Configuration

The pilot system is the pilot orifice, pilot hood, and a thermocouple. The pilot serves two purposes. The first is to light the burner, the second is to heat the thermocouple. In operation, the thermocouple is in contact with the pilot flame and generates millivolts. The millivolt output 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 circuit, activated by the fryer ON/OFF switch, provides voltage through the Thermatron temperature controller to the gas valve main coil, which opens the main valve.

Main Coil

Gas

Valve

Pilot Coil

Thermocouple

High-Limit

Thermostat

Pilot

ON/ OFF

Switch

The Pilot System

120V

Line Voltage

MELT CYCLE DISABLE

Thermatron Temperature

Controller

COM

RELAY

12 13

PROBE

EXT POT

AC2 3A 2A

AC1

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 three important functions: it provides an ignition spark, supplies voltage to the gas valve, and proofs the burner flame.

The module contains a time delay circuit and a coil that activates the gas valve. The ignitor assembly consists of a spark plug and a flame sensor element.

At start-up the ON/OFF switch is placed in the "ON" position, supplying 115 VAC or 230 VAC, according to system configuration, to the Thermatron interface board. The voltage is stepped down via transformer to 24 VAC before entering the ignition module. If resistance in the temperature probe indicates the temperature in the frypot is below 150°F (66°C), the current flows through a melt

1-2

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

cycle circuit where a switch alternately closes for approximately 4 seconds and opens for approximately 20 seconds. If the temperature is 150°F (66°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 24 VAC circuit to provide current to the ignition module.

Circuitry in the ignition module sends 24 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 up to 11 seconds to light the burner flame. A flame sensor verifies that the burner is lit by measuring the flow of microamps through the flame. If the burner does not light (or is extinguished), current to the ignition module is interrupted, preventing the main valve from opening, and the ignition module "locks out" until the power switch is turned "OFF", then back "ON".

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 interrupt current flow through the heat relay. This in turn interrupts the 24 VAC to the ignition module, resulting in closure of the gas valve.

Control Options

24G Series Flatbottom gas fryers are equipped with Thermatron temperature controller. The fryer is turned on and off by means of a rocker switch and the temperature is set by adjusting a potentiometer. The Thermatron board is located in the wireway box behind the control panel, or in a component box inside the cabinet (depending on fryer configuration).

The Thermatron temperature controller operates by comparing resistance between the potentiometer setting and the temperature probe. If the resistance values don’t match, an on-board relay energizes, sending voltage to the gas valve that supplies fuel to the burners. When the resistance values are equal, the on-board relay de-energizes, interrupting voltage to the gas valve, which stops the fuel flow.

Depending on the system configuration and destination, 24VAC, 115VAC or 208/230VAC controller boards are used.

1-3

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Not used

MELT CYCLE DISABLE

13 12 11 10 9 8 7 3

COM NO

PROBE 1A

AC2 3A 2A

AC1

RELAY

EXT POT

Thermatron Controller Board

Line voltage enters the interface board at terminals 1 and 3. The temperature controls (potentiometer) are connected to terminals 7, 8 and 9. The sensor probe circuit is connected to terminals 10 and 11. The high-limit and gas valve routes through terminal 12. Terminals 2 and 13 are jumped out. Terminals 5 and 6 are the melt-cycle disable circuit. The melt cycle is enabled unless terminals 5 and 6 are jumped out.

1-4

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Safety Components

All 24G Series Flatbottom gas 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 flash point. The high-limit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 410°F [(210°C)- CE] to 435°F [(224°C)- Non-CE]. CE and non-CE high-limits are not interchangeable.

Frying systems with built-in filtration are equipped with drain microswitches that disable the fryer if the drain valves are not completely closed. Opening a drain valve (i.e. filtering or draining the fryer) automatically opens the reset switch circuit. The drain valve must be fully closed prior to resetting the safety switch.

1.2 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.

NOTE: Perform the following only if the fryer cannot be serviced in its installed location. Some of

the following service procedures require the fryer to be connected to the gas and/or electrical supply.

1. Shut off the gas supply to the unit. Unplug the power cords. Remove any attached restraining

devices.

2. Disconnect the unit from the gas supply.

3. Relocate the fryer for service accessibility.

4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and

plug in the electrical cords.

1-5

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.3 Cleaning the Gas Valve Vent Tube (if applicable)

1. Set the fryer power switch and the gas valve to the "OFF" position.

2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened

for ease in removal.

3. Pass a piece of wire through the tube to remove any obstruction. Remove the wire and blow

through the tube to ensure it is clear.

4. Reinstall tube and bend so that the opening is pointing downward.

1.4 Adjusting Burner Manifold Gas Pressure

WARNING

This task should be performed by qualified service personnel only.

1. Ensure that the gas valve knob is in the "OFF" position.

2. Remove the pressure tap plug from the

burner manifold.

3. Insert the fitting for a gas pressure-

measuring device into the pressure tap hole.

Remove pressure tap from burner manifold to check burner manifold pressure.

4. 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 table on page 1-1.

1-6

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct

pressure (arrows).

Pilot Ignition Valve (Line Voltage)

Non-CE Electronic Ignition Valve

CE Pilot Ignition Valve

6. Place the fryer power switch and the gas valve in the "OFF" position. Remove the pressure-

measuring device fitting from the pressure tap hole and reinstall the pressure tap plug.

1.5 Adjusting the Pilot Flame (where applicable)

1. Remove the cap from the pilot adjustment screw hole on the gas valve.

2. 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 1 to 1-½ inches long.

3. Reinstall the pilot adjustment screw cap.

1.6 Calibrating the Thermatron Temperature Controller

1. Fill the frypot to the proper oil-level line with cooking oil/shortening. If solid shortening is used,

ensure that the shortening is properly packed and melted in the frypot before proceeding.

2. Ensure the fryer ON/OFF switch is in the "OFF" position, and then light the pilot.

3. Place the fryer ON/OFF switch in the "ON" position. Set the Thermatron dial to 325°F (162°C).

4. Allow the oil/shortening to stabilize at setpoint temperature. This is evident when the burners

have cycled on and off several times.

1-7

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

5. Insert a thermometer or pyrometer into the frypot within 3 inches of the probe bulb. Ensure the

tip of the thermometer/pyrometer does not touch the bottom or sides of the frypot.

6. If the temperature on the thermometer is higher or lower than 325°F (162°C), the dial is out of

calibration.

7. Calibrate the dial by first loosening two

setscrews in the dial (arrows). After loosening both setscrews, slowly turn the dial to match the temperature reading of the thermometer. Tighten each setscrew, ensuring the dial does not move on the shaft during tightening.

8. Allow burners to cycle on and off several

times, then recheck oil temperature as described in step #5. If the Thermatron dial temperature matches the thermometer temperature, the controller is calibrated. If not, repeat step #7.

9. After calibration is complete, place the

fryer power switch in the "OFF" position and disconnect the fryer from the electrical supply.

Loosen two setscrews in dial (arrows) to recalibrate controller.

1-8

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7 Replacing Fryer Components

1.7.1 Remove/Replace Temperature Probe or High-Limit Thermostat

1. Disconnect the fryer from the electrical supply.

2. Allow the frypot to cool for 10 minutes before draining. Drain cooking oil/shortening from the

frypot. Allow the frypot to cool completely before proceeding.

3. Remove the fryer door(s) for access to control panel screws. Lift door up, disengage rod from

lower door bracket, and then remove door. (Current production models have spring-loaded door pins. Disengage bottom pin from the hinge, and then remove door.)

4. Remove the marine edge (where applicable) from the topcap.

5. Support the control panel and remove

screws securing the panel to the wireway box. Remove the control panel.

6. On units with switches/indicator lights on

the control panel, mark and unplug the wiring, and then remove the control panel.

7. Remove screw securing probe/high-limit

access cover to wireway box. Remove access cover and set aside.

Note: Some systems have a wiring terminal

block mounted on the access cover. Mark and disconnect the wiring to the terminal block before removing access cover.

1-9

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

8. Remove the sensor bulb guard to access the

probe and high-limit. Current production systems have a sensor bulb clamp that must be removed prior to removing the probe or high-limit from the frypot.

9. On the sensor bulb being removed, loosen

and unscrew completely the compression nut, then the pass-through nut from the frypot. Carefully remove the sensor bulb from the frypot, being careful not to damage the remaining sensor bulb.

10. If removing the high-limit, remove the

screws securing it to the wireway box. Mark and remove the wiring from the highlimit housing.

Temperature probe. High-limit.

High-limit.

11. Reverse steps to install new temperature probe or high-limit. If reinstalling high-limit, ensure the

capillary tube is properly routed around the temperature probe before tightening (see photo, Step #8). Reconnect wiring removed from defective high-limit.

1-10

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

IMPORTANT (High-Limit): When installing new high-limit, ensure the capillary tube and

bulb are positioned properly with the mounting hardware installed prior to tightening the

compression nut. Once tightened, the capillary tube cannot be repositioned.

IMPORTANT (Temperature Probe):

When installing new temperature probe, ensure probe is positioned properly with the mounting hardware installed (current production systems), or 1/8" from frypot bottom (older systems), prior to tightening

the compression nut. Once tightened, the

In older fryers, ensure probe tip is 1/8" from frypot bottom for proper temperature sensing.

Frypot Bottom

probe cannot be repositioned.

1.7.2 Removing/Replacing Rocker Switches

1. Disconnect the fryer from the electrical supply.

2. If switches are located on front panel or control box, remove the screws securing panel. Do not

allow the panel to hang on the switch wiring harness; use some type of support.

3. Depress the retaining clips (see illustration below) and push the switch out of the slot. If there is

a switch-guard present, retain it for installation of the replacement switch.

When connecting wires to replacement switch, pass the wires through the switch guard (if applicable) before connecting to switch.

Depress clips on each end to remove switch from control panel.

4. Remove wires one at a time from the switch being removed and connect to the replacement

switch until all wires are transferred.

5. Reverse the above steps for reassembly.

1-11

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.3 Replacing the Gas Valve

DANGER

Drain the frypot or remove drain valve handle to prevent accidental opening before

proceeding further.

1. Disconnect fryer from electrical and gas supplies.

2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate

reconnections. For 120VAC gas valves, disconnect the black wire from the high-limit, then remove the bombtail connecting the white wire.

3. Remove the high-limit thermostat wire from the gas valve pilot coil (all but 120VAC

valves).

4. 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. Do not apply sealant to the first two pipe threads. Doing so will clog and damage the gas valve.

7. Reverse steps 1-5 to install the replacement gas valve.

1.7.4 Replacing the Pilot Assembly or Direct Spark Ignitor

1.7.4.1 Replacing Pilot Assembly

1. Remove the burner shield from the burner-box slots.

2. Remove the pilot tubing from the bottom of the pilot assembly.

3. Remove the mounting screw from the pilot mounting-bracket and remove the pilot.

4. Reverse the procedure to replace the pilot assembly. Ensure the replacement assembly is

properly positioned above the center burner tube before tightening mounting-bracket screw.

NOTE: The above procedure is applicable to standing pilot assemblies only.

1-12

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.4.2 Replacing Direct-Spark Ignitor Assembly (Units with Electronic Ignition Only)

1. Remove the burner shield from the

burner-box slots.

2. Disconnect sense wire and ignition cable

from the ignitor.

3. Remove the mounting screw from the

ignitor mounting-bracket and remove the ignitor.

4. Reverse the procedure to replace the

ignitor assembly. Ensure the ignitor is properly positioned in relation to the center burner before tightening mounting screw.

NOTE: The above procedure is applicable to fryers equipped with

Ensure ignitor is properly positioned (arrow) over the center burner prior to tightening the mounting screw.

electronic ignition systems only.

1.7.5 Removing/Replacing Blower Assembly or Air Prover Switch

1. Remove back panel. On systems with

built-in filtration, use care not to damage the oil-return heat-tape wiring insulation when removing backs (multi-batteried systems after 02/03 have two-piece back panels; remove both to access blower assembly).

Multi-batteried systems after 02/03 have upper and lower back panels, which must be removed to access the blower assembly (fryer above shown with upper back panel removed).

1-13

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

2. Remove blower assembly by removing

four screws (two screws securing the flue outlet to the firebox, and two screws securing the blower inlet housing to the firebox). Pull the assembly out of the slot and lower to the side. Do not remove the electrical connections at this time.

3. Replacing air prover switch: Pressure switch: Remove junction box

cover and mark and disconnect wiring to the switch. Unscrew fitting connecting sampling tube to pressure switch, being careful not to kink the tube. Remove two screws from bracket that attaches pressure switch to junction box to remove switch. Install new pressure switch with bracket. Reattach sampling tube and wires removed from old switch and replace

junction box cover.

Sail switch: Remove junction box cover,

mark and disconnect wiring to the switch. Remove screws securing the switch to the junction box, and then remove the switch from the blower housing. Install new switch, ensuring the switch flap is correctly positioned in the blower housing. Reattach wires removed from old switch and replace box cover.

4. If replacing blower, remove junction box

cover, mark and disconnect each wire, and remove conduit fitting from junction box. Reinstall conduit fitting on new blower and reconnect wiring. Replace box cover.

5. Reverse steps 1 – 2 to reinstall blower

assembly.

After removing screws (arrows), remove blower assembly from firebox by pulling outward.

Blower junction box wiring. Mark wire locations before disconnecting each wire.

1-14

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.6 Replacing the Frypot

Unit should be at room temperature, disconnected from gas and electrical service, and empty of oil or shortening prior to beginning procedure.

1.7.6.1 Frypot Baffle Inspection

1. Remove cabinet door(s) by holding door and lifting up on hinge pin. Current production model

doors have spring-loaded pins that must be disengaged from the control panel and the bottom hinge. Remove marine edge (if applicable) by lifting up and off topcap and set aside.

2. The burner-tube retainer strip and burner tubes must be removed from the frypot/firebox being

inspected. Remove the burner-tube shield and the burner-tube retainer from the burner-box and set aside. Lift the burner tubes up over each orifice and then pull outward to remove.

3. Disconnect the pilot gas-supply tube and

remove the pilot assembly (without electronic ignition), or disconnect the sense wire and ignition cable and remove the direct-spark ignitor assembly (with electronic ignition). Inspect frypot baffles for signs of burn-through or damage. If baffle burn-through or damage is visible, proceed to the next section. If not, and no further service to frypot/firebox is required, reverse the above steps to reassemble the fryer.

Inspect frypot baffles through burner tube opening (arrow) for signs of burn-through or damage.

1-15

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.6.2 Frypot/Firebox Removal/Replacement Procedure

1. Perform Procedure 1.7.5, Removing/Replacing Blower Assembly or Air Prover Switch, Steps 1

– 4.

2. Disconnect the union at the gas valve.

Remove four bolts connecting the burner manifold brackets to the burner box. Remove the burner manifold assembly and set aside.

3. Mark and disconnect drain-valve

microswitch wiring. Remove elbow or drain-tee assembly, and then remove the drain valve/microswitch assembly.

Disconnect union at gas valve and remove four bolts (two per side) to remove burner manifold.

Remove drain elbow and drain valve assembly from the frypot.

Disconnect union at gas valve and remove four bolts connecting burner manifold brackets to firebox, elbow and drain valve assembly from frypot.

4. Remove two screws from control panel and lower, using care not to stretch or distort

switch/indicator light wiring (if applicable). If control panel is equipped with switches (see Section 1.7.2, Removing/Replacing Rocker Switches, for detail), or indicator lights, mark and disconnect wiring and set control panel aside.

Note: If equipped with indicator lights, use a pin-pusher to remove pins from main-harness connector, and then remove control panel.

5. Perform Procedure 1.7.1, Remove/Replace Temperature Probe or High-Limit Thermostat, Steps

7 – 11.

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6. Remove two screws securing topcap to

wireway box. Remove topcap. Remove four screws securing wireway box to fryer cabinet (arrows) and carefully lower wireway box out of the way. Use care not to stretch or distort the wiring.

7. Remove two screws from the firebox heat

shield (arrows), remove heat shield and set aside.

NOTE: Steps 8 and 9 must be performed prior to frypot removal, especially on systems with built-in filtration. Failure to perform these steps will make frypot removal extremely difficult, and cause possible damage to firebox components during removal.

8. Remove the burner box baffle by pushing

the baffle up into the burner box until the baffle studs are clear of the slots. Tilt the baffle at an angle and remove it from the burner box.

9. Remove screws (two) securing the flame

spreader to the burner box. Allow the spreader to drop down to clear the frypot baffles.

Remove topcap, wireway box and front heat shield to access firebox and frypot.

After removing burner-box baffle, remove screws (two) securing the flame spreader to the burner box. Allow the flame spreader to drop down in the burner box to clear the frypot baffles. Repeat for both sides.

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10. Remove firebox back, along with

insulation from back of frypot. From the rear of the unit, use a prying bar to carefully pry the top assembly from the frypot and cabinet frame (single units only), and set aside. (The top assembly is secured to the frypot with high-temp silicone sealant.) On systems, remove individual pieces on the frypot being removed.

11. Pull the frypot back and up to remove. On

fryers with built-in filtration systems, ensure the front oil-return inlet is clear of the firebox front before lifting frypot out of cabinet.

If the Firebox Requires Replacement:

12. Remove screws (12) securing the firebox

to the cabinet braces (arrows). Lift the firebox assembly back and up to remove from cabinet.

Use a prying bar to remove top assembly from frypot (single units only).

Remove the firebox back and insulation from back of frypot.

Remove screws (arrows) securing the firebox to the cabinet.

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13. Install new firebox into cabinet. Replace

screws (12) removed during removal of

the old firebox. Use spray adhesive (Zep

Aero Tac High-Strength Spray Adhesive or equivalent) to install new insulation in firebox bottom as shown. The insulation must not go above the top of the burnerbox center flange.

NOTE: Ensure the strip of insulation is properly affixed to the front blowerhousing flange (arrow) prior to installing frypot. Failure to install the insulation strip will result in frypot-baffle burnout, blower damage and fryer malfunction, and will void all applicable warranties.

Install new insulation in firebox using spray adhesive, ensuring good contact between insulation and metal surfaces.

14. Install new frypot, using care not to

damage the firebox insulation. Ensure the blower-housing insulation strip remains in place after installing the new frypot (arrow).

Reverse the above steps to reassemble the fryer. Use high-temp silicone to re-install the top assembly (single fryers) or joiner strips, flue caps, etc. (systems).

Ensure blower-housing insulation strip remains in place after installing the new frypot (arrow).

1.8 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 with 24G Series Flatbottom fryers can be grouped into five categories:

1. Ignition failures

2. Improper burner functioning

4. Filtration problems

5. Leakage

3. Improper temperature control

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