Frymaster 24G Service Manual

24G Series Flatbottom

Service & Parts Manual

Gas Fryers

Models 1824G, 2424G and 1824/2424G

Systems with Built-In Filtration

PRINTED IN THE USA

NON-CE

&

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

24-Hour Service Hotline [phone] JUNE 2004

*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 SERVICE CENTER.

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 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

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 interference

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

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

CANADA

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

ICES-003 standard of the Canadian Department of Communications.

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

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

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

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
24GTI with Drain Safety Switch, and Boil Out Option Enabled
24GTI with Drain Safety Switch, and Boil Out Option Disabled
24G Series Single Fryers, CE Approved
24GTI Oil Return/Filter System

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

24G Series Flatbottom Gas Fryers

Service & Parts Manual

TABLE OF CONTENTS (cont.)

PAGE #

2.

2.1

2.2

2.3

2.3.1

2.3.2

2.3.3

2.4

2.5

2.5.1

2.5.2

2.6

2.7

PARTS LIST
Blower Assembly, Combustion Air
Burner Manifold and Related Components
Cabinetry

Backs, Bases, Casters, Sides, Etc.
Door Assemblies and Component Parts
Flue Caps, Top Caps, and Related Components

Control Panels, Wireways, and Related Components
Filtration

Under Fryer Filter (UFF) Components
ND90 Built-In Filter System Components

Frypot, Drain and Oil-Return Components
Wiring Connectors, Pin Terminals and Power Cords

2–1
2–1
2–2
2–4
2-4
2-6
2-8
2–10
2–12
2–12
2–15
2–18
2–20

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 at the front and 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

LP

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.

10

27.5

4

11

MODEL

1824/2424G

INPUT

(kW)

30,0

(88,000

BTU)

CE ONLY (Altitudes of 2000 feet or less)

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

1-1

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

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).

Pilot System Configuration

The pilot system is comprised of 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

Line Voltage

Line Voltage

The Pilot System

6

5

MELT CYCLE DISABLE

Thermatro n Temperat ure

Controller

14

NC

COM

RELAY

12 13

NO

11

10

PROBE

9

1A

8

7

EXT POT

3

AC2 3A 2A

2

AC1

1

120V

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

1-2

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

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
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. An interface 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, which 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

6

MELT CYCLE DISABLE

5

Thermatron Controller Board

14

NC

13

COM

RELAY

12

NO

11

10

PROBE

9

1A

8

7

EXT POT

3

AC2 3A 2A

2

AC1

1

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 ordinary binding wire (.052 inch diameter) 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 pressure­measuring 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 equilibrate 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 good grade 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 high-limit, remove screws
securing high-limit thermostat to wireway
box. Mark and remove wiring from high­limit housing.

11. 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.

12. 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,

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

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

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, remove the screws securing panel to fryer. Do not allow

the panel to hang on the switch wiring harness; use some type of support. If the switches are
located in a control box within the fryer, remove the screws securing the switch panel to the
control box. Do not allow the switch panel to hang from the switch wiring harness.

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. If replacing air prover 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.

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

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 – 4 to reinstall blower
assembly.

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.

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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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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

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.

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

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.

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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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

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.

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

Remove the
firebox back and
insulation from
back of frypot.

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.

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

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

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.

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).

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

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

3. Improper temperature control

4. Filtration problems

5. Leakage

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

The probable causes of each category are discussed in the following sections. Troubleshooting
guides are included in Section 1.9 to assist in identifying some of the more common problems.

1.8.1 Ignition Failures

Ignition failure occurs when the ignition module fails to sense a flame within the 11-second time
delay period and locks out. Turn the fryer off, locate and correct the problem, then turn fryer back
on to clear the module lock.

There are three primary reasons for ignition failure, listed in order of probability:

1. Problems related to the gas and/or electrical power supplies.

2. Problems related to the electronic circuits.

3. Problems related to the gas valve.

Problems Related to the Gas and/or Electrical Power Supplies

The main indicators of this are that an entire battery of fryers fails to light. Verify that the quick
disconnect hose is properly connected, the fryer is connected to power, the main gas supply valve is
open, and the circuit breaker for the fryer electrical supply is not tripped. Some fryers are equipped
with a fryer reset-switch that must be reset each time the fryer is turned off.

Problems Related to the Electronic Circuits

If gas and electrical power are supplied to the fryer, the next most likely cause of ignition failure is a
problem in the 24 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 an Under Fryer Filter
(UFF) filtration system, first verify that the drain valve is fully closed. (The valve is equipped with 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 24 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.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.8.2 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 (non-electronic ignition)

• Clogged burner orifices

• Clogged burners

• Inadequate make-up air

• Heat damage to the controller or ignition module

• An out-of-adjustment ignitor or broken ignition wire

• A defective ignition module

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 requirements listed in the Installation and Operation manual that came
with the fryer, and that the pressure remains constant throughout all hours of usage. Refer to
Adjusting Burner Manifold Pressure in Section 1.4 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 1 to 1½" long. Refer to Section 1.5 for pilot adjustment procedure.

On systems equipped with electronic ignition, verify that the ignitor is properly adjusted (electrode
tip and ignitor positioned properly over middle burner).

Clogged burners and burner orifices are also likely causes of delayed ignition. Clogged burners are
indicated by uneven flame or partial flame on the burner face. Clogged orifices are indicated by no
flame.

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, more air is being exhausted than is being replenished and the burners may be
starved for air.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

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, ensure the ignition wire is connected properly 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.

DANGER

MAKE SURE YOU ARE HOLDING THE INSULATED HANDLE OF THE SCREWDRIVER

AND NOT THE BLADE. THE SPARKING CHARGE IS APPROXIMATELY 25,000

VOLTS.

Check for proper operation by disconnecting the wire from the ignitor, inserting the tip of a
screwdriver 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 11 seconds.

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 systems starting and
stopping during the day. As air conditioning/ventilation systems start and stop, the pressure in the
kitchen may change from positive or neutral to negative, or vice versa. Changes in airflow patterns
may affect flame intensity.

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 1.4. An obstructed flue, which prevents the fryer from properly exhausting,
may also be the cause.

Excessively noisy burners, especially with flames visible above the flue opening, may indicate that
the burner gas pressure is too high or the gas valve vent-tube is blocked (if applicable). If the gas
pressure is correct, and the vent-tube is unobstructed (if applicable), the gas valve regulator is
probably defective.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.8.3 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 temperature probe. 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.

Failure to Control at Setpoint

In fryers equipped with a Thermatron temperature controller, the problem may be with the
temperature probe, the interface board, or the potentiometer. Possible causes are that the
potentiometer is out of calibration, or the temperature probe or interface board is defective. Refer to
Section 1.6 for instructions on calibrating the Thermatron temperature controller.

1.8.4 Filtration Problems

Whenever the complaint is "the pump is running, but no oil is being filtered", check the filter leaf
(screen) connections and ensure they are properly connected. Ensure the filter leaf is not clogged
with food debris or sediment, and is properly assembled.

If the pump motor overheats, a circuit breaker in the filter circuit will trip and the motor will not start
until it is reset. If the pump motor does not start after pressing the circuit breaker, press the red reset
switch located on the rear of the motor. If the pump then starts, something caused the motor to
overheat. Maybe several frypots were filtered one after the other and the pump got hot. Letting the
motor 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:

• Shortening was solidified in the filter leaf or filter lines.

• The operator attempted to filter unheated oil or shortening. 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. An incorrectly assembled
filter leaf allows food particles and sediment to pass through the filter pan and into the pump. When
sediment enters the pump, the gears bind up causing the motor to overheat, tripping the thermal
overload. Solidified shortening in the pump will produce the same result.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

A pump seized by debris or hard shortening must be disassembled, cleaned and reassembled as
follows:

1. Disconnect power to the filter system.

2. Remove the front cover of the pump to access the gears inside, if the pump is accessible while
still inside the cabinet. 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
setscrews to disengage the pump from the motor.

Remove these bolts (6) to

remove pump cover.

Remove debris or hardened

shortening to free gears.

3. Prior to reassembly, the inside housing must be clean and free of any sediment or debris. Failure
to completely clean the inside housing and ring gear will cause gear binding after reassembly.

4. During reassembly, partially install the housing bolts, leaving a ¼-inch (6.4 mm) gap between
the cover and housing flanges. Ensure there is no shortening or oil in the filter pan, and that the
filter pan is disconnected. Start the motor and slowly draw the cover in, evenly tightening the
housing bolts. When the cover is snug on the housing, turn the motor off, and tighten all bolts to
15 inch-lbs (1.7 Nm).

An incorrectly assembled or damaged filter leaf will allow food particles and sediment to pass
through and clog the pump. Particles large enough to clog the pump may indicate that the crumb
tray is not being used, and that the filter leaf is not properly assembled.

The electronics of the SUFF/UFF filtration systems are simple and straightforward. Microswitches,
attached to handles for each vat and wired in parallel, provide the 24 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.

Filter systems equipped with oil-return heaters are wired into the 120 VAC source, which remain
energized as long as the unit is plugged in.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.8.5 Leakage

Frypot leaks are usually due to improperly sealed high-limit, temperature probe or oil-return 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 corners of the frypot. When this occurs, the frypot must be repaired or replaced.

Frypot locations (indicated by arrows) where potential leaks could occur.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.9 Troubleshooting Guides

FACTORY APPROVAL MUST BE OBTAINED PRIOR TO ANY WARRANTY WORK BEING

DONE OR DEAN CANNOT BE HELD RESPONSIBLE.

The following procedures must be performed by Factory Authorized Service Technicians, and are
provided as an aid to expedite troubleshooting and repair of 24G Series frying systems.

1.9.1 Pilot Burner Malfunctions

PROBLEM CORRECTIVE ACTION

Pilot will not ignite; no
evidence of gas at pilot
burner.

Pilot burner ignites but
will not remain lit when
gas knob is released.

Pilot burner ignites
properly and burns
properly, but goes out
when the exhaust
blower comes on.

1. Ensure the combination gas valve is in PILOT position and that
gas is available at the control valve (check quick-disconnect
and/or gas-line connections).

2. Remove pilot gas supply line and check for dirt. Blow out with
compressed air if necessary, then reinstall.

3. Check pilot burner orifice for dirt.

1. Check that the lead from the thermocouple is tightly screwed
into the pilotstat power bushing on the gas control.

2. Remove end of thermocouple lead from pilotstat power unit
bushing and clean with fine sandpaper. Also check that
bushing is clean.

3. Thermocouple possibly defective (millivolt output should be 12­28mv); replace.

4. Pilot flame may be adjusted incorrectly. Adjust flame to 1-½"
high by turning pilot flow adjustment screw.

1. Pilot flame may be adjusted too low, even though it appears to
be satisfactory. Re-adjust higher as described earlier.

2. Pilot flame may be adjusted too high and is on the verge of
blowing out. Re-adjust lower.

3. With the exhaust blower in operation, the extra air causes the
pilot to blow out. The pilot assembly may be too low between
the burners. Adjust the pilot assembly to where the pilot hood
is above the burners.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.9.2 Main Burner Malfunctions

PROBLEM CORRECTIVE ACTION

Main burner will not
come on even though
air blower is in
operation; no gas
pressure at main
burner.

Air blower is not
operating, although
power is present at the
fryer.

1. Check that the combination gas valve is ON.

2. Check that the pilot is lit and is operating properly.

3. Check high temperature safety switch. Replace if defective.

4. Check air prover switch (sail switch) as follows:

Move actuating lever at switch to ensure it is not dragging in
the slots (use long tool to avoid burns). If so, bend the arm
carefully to clear the obstruction. Check the air prover switch
for continuity and replace if defective.

1. Cooked product or other material may have fallen into the flue

and lodged in the blower wheel, preventing it from turning.
Clean out flue and blower wheel.

2. Blower motor may have overheated and shut off. This

condition will correct itself when motor cools (20 minutes). If
problems with blower overheating persist, call for service.

3. If fryer is equipped with a Thermatron controller, the

temperature probe or the controller board may be defective.

Main burner flames are
small and appear lazy;
Oil does not come up
to temperature quickly.

Signs of excessive
frypot temperature;
Oil quickly becomes
discolored.

1. Check gas pressure at the pressure tap of the burner manifold.

Use a standard water-type U-gauge manometer. With the
burner in operation, the pressure should be about 4" W.C. on
natural and 11" W.C. on propane (LP) gases. If not, unscrew
the cover of the pressure regulator adjustment and turn the
adjusting screw clockwise to increase gas pressure (or
counterclockwise to decrease the pressure). Replace cover
and plug.

1. Check Thermatron controller; may be out of calibration. Re-

calibrate in accordance with instructions in Section 1.6.

2. Check gas pressure.

3. Oil of inferior quality or used too long. Replace with quality oil.

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.9.3 Indicator Lights

The fryer’s indicator lights serve a diagnostic purpose. All lights are lit when the fryer is working
properly. (The green light on the control panel will cycle on and off as the fryer calls for heat). Use
the following procedures to isolate problems indicated by light combinations.

Turn the temperature dial to 400°F (204°C) to ensure the sensor will demand heat. Check all
indicator lights in the fryer cabinet and on the control panel. [Older units may have power and reset
switches with different colored lights (orange, amber, red, etc.). Substitute the light color of the old
switch with the respective "green light" switch in the following troubleshooting procedures. The
control panel light colors haven’t changed.]

When turning the power switch "ON" and resetting the safety (reset) switch, check for the following:

LIGHT INDICATION PROBABLE CAUSE CORRECTIVE ACTION

GREEN LIGHT/POWER SWITCH IS
"ON"

GREEN LIGHT/SAFETY (RESET)
SWITCH IS "OFF"

GREEN LIGHT/CONTROL PANEL IS
"OFF"

RED LIGHT/CONTROL PANEL IS
"OFF"

GREEN LIGHT/POWER SWITCH IS
"OFF"

GREEN LIGHT/SAFETY (RESET)
SWITCH IS "OFF"

GREEN LIGHT/ CONTROL PANEL IS
"OFF"

RED LIGHT/CONTROL PANEL IS
"OFF"

1. The drain valve is open.

2. The drain switch is defective.

1. No power to fryer.

2. Fuse is blown.

3. Reset switch circuit defective.

1. Ensure the drain valve is
completely closed, and then
turn the reset switch to "ON".

1. Check power source, power
cords and breaker. Ensure that
electricity is available to the
fryer.

2. Replace fuse.

3. If fryer does not function after
resetting the reset switch,
contact a Factory Authorized
Service Center for assistance.

1-28

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10 WIRING DIAGRAMS

Note: The diagrams in this section depict wiring as of the date of manual publication.
It may not reflect design changes made to the equipment after publication. Always
refer to the wiring diagram affixed to the unit when actually troubleshooting this
equipment.

1.10.1 24G Series Single Fryers: Non-CE

GAS

VALVE

30C BRN

SPARK

IGNITOR

26C WHT

26C GRN/YEL

GND

VALVE

VALVE

(BURNER)

IGNITION

MODULE

25V

25V

(GND)

84C RED

69C RED

24V

TRANSFORM ER

ELECTRONIC IGNITION OPTION

GRN

WHT

BLK

115V

115V POWER SUPPLY

IGNITION OPTION

ELECTRONIC

BLK

WHT

BLUE

HI-LIMIT

THERMOSTAT

BLK

NC C

ORG

ORG

BLK

123

FUSE

2 AMP

BRN

BLK

ORG

78

SPST

POWER SWITCH

3

4

2

WHT

GRN

WHT

GRN

WHT

123456789

ORG

WHT

BRN

123

BLK

FUSE

BRN

BLK

ORG

7

8

POWER

SWITCH

3

2

WHT

P/N 807-3551

PUR

8073554

GAS

VALVE

THERMOCOUPLE

123456789

BRN

TRANS-

FORMER

AC

120 V

CABLE

IGNITION

BLUE

RED

GRN

BLK

WHT

GRN

RED

WHT

BRN

POT

6

4

RELAY

123578

YEL

RESET

SWITCH

AC

24 V

87

WHT

BLUE

PROVER

AIR

C

NO

YEL

GRN/YEL

BLK

MOTOR

WHT

120 VAC

ELECTRONIC

THERMOSTAT

CONTROLLER

BRN

3

7891011

1

2

PUR

12

13

YEL

ORG

BLK

WHTWHT

2

2

RED

VALVE SWITCH

2

3

GRN

11

BLK

DRAIN SAFETY SW ITCH OPTION

TEMP.

SENSOR

1-29

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.2 24GTI With Drain Safety Switch, and Boil-Out Option Enabled

BRN

GAS

VALVE

FLAME

SENSOR

WHT

TO RIGHT

FRYER

SYSTEM

WHT

GRN

GRN

GREEN

AIR

BLUE

SWITCH

PROVER

HIGH LIMIT

THERMOSTAT

RED

LIGHT

RED

MOTOR

ORG

NO

NC

2

3

WHT

BLK

BLK

WHT

GRN

WHT

BRN

WHT

C

SWITCH

BOIL- OUT

1

2

1

A

798
6
5
4
3

12

6
5

4

123

4

3

24V

RED

RED

A

115V

BLK

798
6
5

9 PIN

MOLEX

CONNECTOR

6

12345 12 43

6

8

7

5

RELAY

LIGHT

DSI IGNITION MODULE

LEAD

SPARK

IGNITOR

HIGH TENSION

OPTION

48 OHMS

RESISTOR

PUR

YEL

POT

ORG

BRN

RESET

SWITCH

RED

SWITCH

78

2

LIGHT

BRN

VALVE SW ITCH

3

2 AMP FUSE

POWER

SWITCH

7

3

2

8

LIGHT

SWITCH

WHT

PUR

120

VAC

YEL

TRANSFORMER

24

VAC

120 VAC

GAS

VALVE

A A

GRN

BRN

1

2

BRN

WHT

RED

43

43

21

12

THERMOCOUPLE

120 VAC

CONTROLLER

THERMATR ON

TEMPERATURE

9

8

7

3

PUR

12

11

10

13

YEL

ORG

BLK

WHT

2

1

AMP

2 PIN

1

2

CONNECTOR

WHT

BLK

TEMPERATURE

TYPE AND RATING

IT MUST BE OF TH E SAME

14

IF ANY WIRING I S REPLACED

PROBE

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.3 24GTI With Drain Safety Switch, and Boil-Out Option Disabled

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24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.4 24G Series Single Fryers: CE-Approved

Gas Valve

24 VAC/50 Hz

Valve Adapter

Threaded to Valve

Thermocouple

Assembly

G31 Propane (LP)

G20, G25 Nat Gas

BLU

ECO Connector

Solder

Connection

Drain Valve

Safety Switch

BLU

NO

NC

BRN

123456

Relay

24VAC

Air Prover Switch

WHT

BRN

PUR

BLU

PUR

78

RED

PUR

BRN

PUR

BRN

78

34

56

12

Relay

24VAC

RED

WHT

BLK #2

High-Limit

Thermostat

BRN

WHT

BLU

24VAC to Oil

Return Circuit

MOTOR

Assembly

Blower Motor

BLK

WHT

230V

BLK #2

WHT #2

Transformer

BLK

BLU

9

9

BLK

678

678

BRN

WHT

2345

2345

1

1

WHT

BLU

24V

POT

24V

Controller

Thermatron

3

7

8

1

10911

12

2

14

13

PUR

BLK

YLW

ORG

WHT

2

1

5 Amp Fuse

(Amp)

2

1

BLK

WHT

2 Pin Connector

Power Switch

SPST

WHT

BLK #2

Probe

GRN

BLK

Temperature

230 VAC

1-32

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.5 24GTI Oil Return/Filter System

YEL 91C

RED 88C

prior to 5/03

By-Pass Switch:

Only on units b uilt

BY-PASS SWIT CH

BLK 89C

NC

NO

24V

COM

NC

RED 87C

COM

YEL 92C

NC

RED 86C

COM

YEL 93C

RED 85C

YEL 94C

ADD ON

FOR RIGHT

NO

RH FRYER

OIL RETURN

NO

IN OFF POSITION

MICROSWITCH S HOWN

LEFT FRYER

OIL RETURN

ADD ON

FOR LEFT

SCF OIL RETU RN

TRANSFORMER/RELAY ASSY

BLK 79C

RELAY

BLK 81C

BLUE 83C

MOTOR

T3

LOW VOLTAGE SHOWN

T5T4T2

T8

P2

P1

LEADS T5 AND T8 ON THE MOTOR

FOR CHANGE OF ROTATION INTERCHANGE

120V

24V

FOR OIL FLUSH

BLK 80C

P2

T4

T5

T2T3T8

WHT 82C

WHT 74C

CB

BLK 78C

115V

INPUT

CIRCUIT

NC

NO

RED 85C

COM

YEL 94C

OIL FLUSH

7 AMP-115V

CIRCUIT BREA KER

BLK 77C

HIGH VOLTAGE SHOWN

WHT

WHT 75C

P1

JUNCTION BOX

HEAT TAPE - 25 WATT

BLK

BLK 76C

FUSE

J BOX

2 AMP

1-33

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.1 Blower Assembly, Combustion Air

6

3

5

2

1

4

ITEM PART # COMPONENT

1 Motor, Blower Assembly

807-3573 120V (Non-CE)

807-3920 230V (CE)
2 807-3746 Switch, Sail (Air Prover Switch)
3 823-3162 Duct Assembly, Inlet
4 200-1428 Gate, Air Flow
5 823-3166 Duct Assembly, Outlet
6 200-1471 Door, Outlet Duct Access

2-1

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.2 Burner Manifold and Related Components

19

8

9

10

11

20

7

5

6

1

2

2322

12

13

14

15

4

16

3

21

17

2-2

18

24

25

24G SERIES FLATBOTTOM GAS FRYERS

r

d

y

k

r

r

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 810-2129 Tube, Burne
2 200-1670 Support, Left or Right Manifol
3 810-2168 Burner Manifold Assembl
4 Orifice

810-2051 2.82mm (#34) Natural Gas

810-2317 1.78mm (#50) Propane (LP) Gas
5 813-0154 Plug, ⅛-inch NPT (Manifold Pressure Tap Plug)
6 813-0174 Union, ¾-inch NPT Pipe
7 813-0300 Nipple, ¾-inch NPT X 4½-inch
8 813-0066 Elbow, 90° X ¾-inch NPT
9 813-0112 Nipple, ¾-inch NPT X 2-inch

10 813-0168 Elbow, 90° X ¾-inch NPT Street
11 Valve, Gas

807-3555 24V Natural (G20/G25)

807-3690 24V Propane (LP) (G31)

810-2156 120V Natural (G20/G25)

810-2323 120V Propane (LP) (G31)

12 813-0763 Bushing, ¾-inch NPT to ½-inch NPT
13 813-0022 Nipple, ½-inch NPT X Close
14 813-0173 Union, ½-inch NPT Pipe
15 813-0165 Elbow, 90° X ½-inch NPT Street (for single fryers, use 45° 813-0342)
16 813-0265 Nipple, ½-inch NPT X 2½-inch
17 813-0062 Elbow, 90° X ½-inch NPT
18 813-0845 Nipple, ½-inch NPT X 29¾-inch (for single fryers, use 24½-inch 813-0788)

Electronic Ignition Components

19 106-1643SP Ignitor and Flame Sensor Assembly (does not include flame sensor wire)

* 106-1645SP Flame Sensor Wire

20 106-1644SP Ignition Cable

* 106-1983SP Ignitor and Cable Kit (Items 19 &20 plus 106-1645SP sensor wire)

21 807-3554 Module, Ignition (Spark Module)
22 826-1389 Screw, ¼-20 X ¾-inch (Pkg. of 10)
23 809-0823 Nut, ¼-20 Nyloc

* 807-3551 Transformer, Electronic Ignition

Pilot Ignition Components

24 Pilot Burne

810-2403 Non-CE Natural Gas

24153 Non-CE Propane (LP) Gas

812-1286 CE Natural Gas (G20/G25)

25 Thermocouple

807-3550 Non-CE

810-1152 CE
* 810-0703 Gas Line, ¼-inch X 17½-inch
* 200-1416 Bracket, Pilot Support

Piezo Ignitor Components (CE Units only)

* 810-1001 Trigge
* 807-3540 Electrode
* 200-1868 Bracket
* 807-3650 Lead, Trigger to Electrode

* Not illustrated.

2-3

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.3 Cabinetry

2.3.1 Backs, Bases, Casters, Sides, Etc.

4

1

2

Single Fryer Cabinet

8

3

9

10

5

6

7

18

14

17

13

12

11

2

19

23

24

15

16

20

21

22

27

Double Fryer Cabinet

3

10

8

26

25

2-4

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 Back, Single Fryer Cabinet

200-1608 Standard 1824G (for 2424G, use 200-2613)
200-2004 Short Flue 1824G (for 2424G, use 200-2005)

2 Panel, Left Side

823-3459 Stainless Steel
823-3168 Painted Mild Steel
823-3490 Filter-Ready Add-On Fryer

3 Panel, Right Side

823-3489 Stainless Steel
823-3169 Painted Mild Steel

823-3491 Filter-Ready Add-On Fryer
* 200-1471 Cover, Side Panel Access
4 210-1534 Rail, 1824G Cabinet Back Support (for 2424G, use Item 13)
5 200-2903 Channel, 1824G Front and Rear Base
6 823-4063 Support, Caster
7 Caster, 5-inch with Brake

810-0357 4-Hole Bolt Pattern

810-2405 Single Stud
8 Caster, 5-inch without Brake

810-0356 4-Hole Bolt Pattern (for fryers with legs in front, use 810-0378)

810-2406 Single Stud
* 810-2053 Leg, 6-inch Adjustable
9 200-1378 Bracket, Drain Nipple Storage

10 200-4511 Hinge, Universal Door (for filter-ready units, use 200-1675)
11 Back, Lower Cabinet

200-4154 Units with Built-in Filtration

200-4153 1824G Units without Built-in Filtration (for 2424G, use 200-4152)

12 200-4151 Back, 1824G Upper Cabinet (for 2424G, use 200-4150)

* 200-1607 Back, 2424G One-Piece (used on UFF units built before February 2003 only)

13 210-1406 Rail, 2424G Cabinet Back Support (for 1824G, use Item 4)
14 823-3581 Panel, Inner Cabinet (Left)
15 823-3582 Panel, Inner Cabinet (Right)
16 200-2632 Support, Inner Cabinet Panel Front
17 200-2624 Upright, Cabinet Rear
18 823-4149 Support, Flue
19 200-5210 Bridge, Filter Base
20 200-2717 Support, Filter Pump Motor
21 200-2643 Base, Filter
22 200-3356 Cover, Filter Base
23 200-5209 Brace, 2424G Rear Cross
24 200-4696 Channel, 2424G Left or Right Base
25 823-4064 Channel, Leg/Caster Support
26 810-1365 Caster with Brake, 3-inch Adjustable
27 106-2837SP Bracket, Filter Retainer

* Not illustrated.

2-5

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.3.2 Door Assemblies and Component Parts

6

11

10

9

8

B

6

2

7

5

4

3

1

A

ITEM PART # COMPONENT

* 809-0413 Spacer, Nylon (Universal Door Bushing)

A 106-2768SP **1824G Single-Pin Door Assembly (for 2424G, use 106-2769SP)

B 106-2816SP 1824G Double-Pin Door Assembly (for 2424G, use 106-2782SP)

1 824-1138 Panel, 1824G Single-Pin Outer Door (for 2424G, use 824-1137)
2 200-4548 Panel, 1824G Single-Pin Inner Door (for 2424G, use 200-4549)
3 810-0180 Handle, Door
4 819-0191 Washer, ¼-inch Lock
5 809-0918 Screw, 10-24 X ½-inch
6 810-1105 Magnet, Door
7 200-1301 Hinge Pin, Door
8 824-1146 Panel, 1824G Double-Pin Outer Door (for 2424G, use 824-1147)

9 200-4610 Panel, 1824G Double-Pin Inner Door (for 2424G, use 200-4546)
10 810-0275 Spring, Door Hinge
11 106-0554SP Hinge Pin and Keeper Assembly, Door

** Not illustrated.

** For units without inner door panels (built from 1993-2002), use 106-1751SP for 1824G fryers or

106-1649SP for 2424G fryers.

2-6

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

THIS PAGE INTENTIONALLY LEFT BLANK.

2-7

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.3.3 Flue Caps, Top Caps, and Related Components

4

17

6

2

3

5

13

16

12

10

15

9

11

1

7

14

8

2-8

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 106-3253SP Frame Assembly, Single Crumb Dump
2 106-1638SP Frame Assembly, Double Crumb Dump
3 823-4125 Insert, Crumb Dump
4 823-3189 Tray
5 106-2840SP Cover, 1824G Frypot (use 106-2839SP for 2424G Frypot)
6 210-6177 Hanger, Basket
7 Deflector, Flue Cap Oil

823-3579 For use on 1824G One-Piece Top Assembly (use 823-3474 for 2424G)
823-4147 For use on 1-1824G Fryer (use 823-4146 for 2424G)
823-4159 For use on 2-1824G with Crumb Dump
823-4007 For use on 2-2424G without Crumb Dump (use 823-4100 with crumb dump)
823-4122 For use on 3-2424G without Crumb Dump (use 823-4145 with crumb dump
823-4030 For use on 18L/24R without Crumb Dump (use 823-4102 with crumb dump
823-4008 For use on 18R/24L without Crumb Dump (use 823-4101 with crumb dump
823-4119 For use on 2-24L/18R without Crumb Dump (use 823-4153 with crumb dump
823-4145 For use on 2-24R/18L with Crumb Dump

8 Flue Cap

210-4803 For use on 1-1824G (use 210-4802 for 2424G)
210-4838 For use on 2-1824G (use 210-4303 for 2424G)
210-4800 For use on 3-2424G (3-Vat 2424G)
210-4827 For use on 2-24/18R (3-Vat 24/18 System)
210-4832 For use on 2-24/18L (3-Vat 24/18 System)
210-4302 For use on 24L/18R 4-Vat 24/18 System
210-4319 For use on 24R/18L 4-Vat 24/18System

9 210-4317 Edge Strip, Frypot
10 210-4313 Joiner Strip (joins frypots within a system)
11 210-4598 Joiner Strip (joins one fryer system to another)
12 823-3622 Top Assembly, One-Piece Short Flue 1824G (use 823-3473 for 2424G)
13 823-3699 Top Assembly, One-Piece Standard Flue 1824G (use 823-3264 for 2424G)
14 210-2028 Top Cap, 1-1824G (use 210-1438 for 2424G)
15 823-3807 Marine Edge for 1-1824G with Top Cap (use 823-3171 for 2424G)
16 Marine Edge (L-Shaped End-Cap)

823-3497 1-1824G Notched Both Ends (use 823-3195 for 2424G)
823-3969 2-2424G Notched Left End (use 823-3970 for notched right end)
823-3495 2-2424G Notched Both Ends
823-3496 3-2424G Notched Both Ends
823-3964 24L/18R 4-Vat Fryer Notched Left End (use 823-3965 for notched right end)

17 Marine Edge (Solid End-Cap)

823-4136 1-1824G Without Notches (use 823-4135 for 2424G)
823-4137 2-2424G Without Notches
823-4054 2-2424G Notched Left End (use 823-4058 for notched right end)
823-4139 3-2424G Without Notches
823-4150 3-2424G Notched Left End (use 823-4151 for notched right end)
823-4152 2-24/18L 3-Vat Fryer Without Notches

823-4056 24L/18R 4-Vat Fryer Notched Left End (use 823-4157 for notched right end)
* 803-0209 Brush, Frypot Cleaning
* 803-0293 Gloves, Neoprene Hot Oil

* Not illustrated.

2-9

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.4 Control Panels, Wireways, and Related Components

2

17 20

38

21 22 23 24

29 30

19 27 28

37

39

22 24 25 26

38

40

31 32 33

34 35 36

42

41

44

17 19

1817

1716

111098

12

3

1

4

5

6

7

13 14 15

43

48

45

50

51

52

45

46

49

54

53

47

2-10

24G SERIES FLATBOTTOM GAS FRYERS

y

)

)

r

g

d

Nut,

y

d

)

y)

y)

g

y

y

r

t

N

g

d

N

d

)

d

Nut,

t

)

k

r

)

)

r

t

t

)

)

)

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 106-0882SP Thermostat Assembl
2 824-1140 Vent, 1824G Wireway (use 824-1139 for 2424G
3 823-4001 Box, 1824G Wireway (use 823-4000 for 2425G
4 200-3167 Box, Remote Thermatron Adapte
5 807-1597 Fuse, 3-amp Slow-Blow
6 807-1321 Holder, Panel-Mount Fuse
7 807-3536 Potentiometer, Temperature Control
8 816-0217 Paper, Terminal Block Insulatin
9 810-1164 Terminal Block, 1-Piece Screwless

10 809-0354 Screw, 4-40 X ¾-inch Slotted Round Hea
11 809-0237
12 810-0045 Bushing. .875-inch
13 807-2469 Bushing, 1-inch
14 810-0678 Bushing, .375-inch
15 807-0125 Bushing, .50-inch
16 200-1671 Cover, Thermostat Entr
17 809-0361 Screw, #8 X .50-inch Slotted Hex Hea
18 809-0037 Clamp, Plastic Wire
19 807-3559 Thermostat, 335°F High-Limit w/Manual Reset (use 210°C 807-3560 for CE units
20 807-0800 Transformer, 120V/24V 50/60Hz 50VA
21 106-2058SP Relay Assembly, Boil-Out and Latch
22 807-3611 Relay, 24VAC Coil (Left Rela
23 807-3640 Relay, 120V Coil (Right Rela
24 807-3613 Spring, Relay Retainin
25 200-1337 Bracket, Oil Return Rela
26 106-1966SP Socket Assembly, 24V Oil Return Rela
27 816-0220 Insulation, Microswitch
28 807-2103 Microswitch, Straight Leve
29 106-2775 Plate Assembly, Microswitch Adjustmen
30 809-0247
31 200-4719 Plate, Interface Board Mountin
32 809-0853 Screw, 10-32 X 1.5-inch Slotted Pan Hea
33 809-0766
34 807-3566 Interface Board, 115V (use 807-3722 for 208-230V units
35 809-0839 Screw, 8-32 X .75-inch Slotted Pan Hea
36 809-0834
37 210-3275 Faceplate, 1824G Thermatron Blank (use 210-3168 for 2424G
38 802-2502 Label, Thermatron Faceplate
39 816-0534 Knob, Thermatron Control
40 210-1985 Faceplate, Single Fryer Thermatron Blan
41 820-0136 Faceplate with Label, Old-Style Single Frye
42 820-0135 Faceplate with Label, Old-Style SCF
43 210-3754 Control Panel, 1824G Two-Switch (use 210-4977 for 2424G
44 210-2716 Control Panel, 1824G Two-Lamp (use 210-2652 for 2424G
45 807-3574 Switch, Power ON/OFF Rocke
46 807-3576 Switch, Momentary Rese
47 807-3580 Switch, Boil-Ou
48 106-1978SP Lamp Assembly, Red 120V(106-4687 for 230/250V)(106-4730 for 24V white light
49 106-4686SP Lamp Assembly, Green 120V(106-4686 for 230/250V )(106-4729 for 24V
50 200-4602 Box, Single Fryer Control
51 210-2689 Plate, Single Fryer Control Panel
52 802-2085 Label, Single Fryer Control Panel
53 200-3901 Lid, Single Fryer Control Box
54 200-3356 Cover, Single Fryer Control Box Access

* 200-4612 Brace, 1824G Single Fryer Control Box (use 2004611 for 2424G

* Not illustrated.

4-40 Keps

ut, 8-32 Keps

ut, 10-32 Hex Hea

8-32 Hex Locknu

2-11

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.5 Filtration

2.5.1 Under Fryer Filter (UFF) Components

26

16

26

29

29

26

30

10

10

25

10

27

28

Right-Flush configuration
illustrated.

10

23

22

2

21

20

19

18

17

16

15

19

13

14

33

19

18

24

1

4

3

8

6

7

13

11

10

33

32

12

31

9

5

2-12

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 810-2100 Motor, 120-230VAC ⅓-HP Filter Pump
2 810-2098 Pump, 8 GPM Filter
3 810-2245 Hose, 16¾-inch Filter Pan to Pump
4 810-2173 Disconnect- Female, ½-inch
5 813-0735 Reducer, ½-inch to ⅜-inch NPT Bell
6 813-0632 Elbow, ⅜-inch NPT Street
7 810-2762 Disconnect, ⅜-inch Female with Radial Collar
8 810-2562 Coupling, Flare Tubing
9 810-2573 Tubing, Flush (Right-Flush Configurations)
* 810-2579 Tubing, Flush (Left-Flush Configurations)

10 813-0614 Fitting, ½-inch X ⅜-inch 37° Flare
11 106-3659SP Flush Valve Assembly, Complete

810-2125 Valve, ⅜-inch Flush
200-6089 Actuator Handle, Flush Valve (Left-Oriented Flush Valves Only)
200-6202 Actuator Handle, Flush Valve (Right-Oriented Flush Valves Only)

106-3604SP Bracket Assembly, Microswitch

807-2103 Microswitch, Straight Lever
816-0220 Insulation, Microswitch
901-2348 Cover, Microswitch (Left-Oriented Flush Valves Only)
902-2348 Cover, Microswitch (Right-Oriented Flush Valves Only)

†

†

12 810-2170 Disconnect, ½-inch Male
13 813-0022 Nipple, ½-inch X Close NPT
14 813-0165 Elbow, ½-inch X 90° NPT Street
15 813-0062 Elbow, ½-inch X 90° NPT
16 813-0625 Nipple, ⅜-inch X Close NPT
17 813-0006 Bushing, ½-inch to ⅜-inch NPT Hex
18 813-0156 Plug, ½-inch NPT Hex
19 813-0003 Tee, ½-inch NPT
20 813-0093 Nipple, ½-inch X 4-inch NPT
21 813-0173 Union, ½-inch NPT
22 813-0673 Nipple, ½-inch X 8.5-inch NPT
23 813-0087 Nipple, ½-inch X 1.5-inch NPT
24 813-0833 Nipple, ½-inch by 15.5-inch NPT
25 810-2270 Tubing, Filter Pump to Rear Oil Return
26 813-0730 Tee, ⅜-inch NPT
27 813-0644 Nipple, ⅜-inch X 1.5-inch NPT
28 813-0631 Elbow, ⅜-inch X 90° NPT
29 810-2262 Tubing, Rear Oil Return
30 813-0452 Plug, ⅜-inch NPT Pipe
31 810-2757 Handle, Drain Flush
32 816-0549 Sleeve, Blue Vinyl (Drain Flush Handle Cover)
33 200-6135 Bracket, Flush Handle (Mounts to Inner Panel)
34 813-0251 Nipple, ½-inch by 4.5-inch NPT

* Not Illustrated

†

Valve stem pointing to left- left-oriented; Valve stem pointing to right- right oriented.

†

†

2-13

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

5

4

3

2

1

ITEM PART # COMPONENT

1 106-1693SP Filter Pan Caddy Assembly

810-0005 Caster, 2-inch Rigid (use 810-0006 for 2-inch Swivel Caster)
809-0822 Bolt, ¼-20 X ½-Inch Hex Head

809-0823 Locknut, ¼-20
2 823-3480SP Filter Pan With Fittings
3 810-2237 Filter Leaf with Compression Cap & Riser Connection

810-2172 Quick Disconnect, ⅜-inch Male

813-0867

810-2760

Riser Standpipe Nipple, ⅜-inch X 6.5-inch S/S

Compression Cap
4 823-3509 Crumb Basket
5 823-3492 Lid Assembly, Filter Pan

* Not illustrated.

2-14

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.5.2 ND90 Built-In Filter System Components

NOTES: Early model 24G fryers were available only as single units. To create multi-fryer

batteries, a number of single fryers were battered together with top connecting strips.

To provide built-in filtration for these batteries, a filter (with a dump station above it) was placed
somewhere in the middle, as shown in the photograph below. The filter system is referred to as the
44210ND90, or simply as the ND90.

The first generation filter returned the shortening to the frypot using a hose and wand assembly.
Later versions used a so-called “hands free” plumbing assembly attached to the backsplash of the
dump station.

The ND90 filter option was discontinued in 1996 when the fryer design was changed to incorporate
the Under Fryer Filter (UFF) system. A large number of ND90-equipped fryers were produced and
Frymaster/Dean continues to support them with replacement systems and parts, with the exception
that the “hands free” plumbing components are no longer available.

A complete filter kit, illustrated below, may be ordered to replace existing ND90 filters in the field.
The kit does not include the oil return hose and wand assembly. See page 2-16 for this part.

Part Number 44210ND90003

2-15

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

NOTE: The parts illustrated below are available as individual parts only. See page 2-15 for the

complete replacement filter assembly.

11

10

9

21

13

14

13

12

34

18

16

15

17

18

4

20

18

22

18

19

5

6

13

8

1

7

2

3

26

27

35

33

32

31

29

22

15

13

27

25

28

26

30

22

38

13

23

39

24

37

36

40

41

42

DRAIN LINE PARTS

43

44

2-16

24G SERIES FLATBOTTOM GAS FRYERS

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Nipp

t

n

Nipp

)

t

)

t

t

t

Nipp

y

g

g

n

r

r

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CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 823-3637 Filter Frame Assembl
2 810-2135 Caster without Brake, 3-inch
3 810-2136 Caster with Brake, 3-inch
4 Filter Pump and Motor Components

810-2100 Motor, 120/230V 1/3 HP Filter Pum
810-2252 Pump, 5GPM (use 810-2098 for 8GPM Pump)
810-2395 Seal, Shaft (O-Rin
809-0822 Bolt, ¼-20 x ½-inch Hex Head (Motor Mount
809-0823

809-0189 Washer, ¼-inch Flat (Motor Mount
5 200-3097 Holder, Hose
6 200-3096 Support, Pipe (Polish and Return Assemblies
7 823-4078SP Pan Assembly, ND90 Series
8 810-2237 Filter Leaf Assembly (includes leaf to pump plumbing and port fittings
9 106-1939SP Cover with Handle, Filter Fron

10 823-3646 Holding Pan (for pan screen inserts
11 823-3651 Insert, Pan Screen (two required for Item 49
12 106-1831SP Connector with Collar, ⅜-inch Female Quick Disconnec

* 816-0550 O-Ring, ⅜-inch Quick Disconnect (use 8160545 for ½-inch)

13 813-0625
14 813-0632 Elbow, ⅜-inch X 90° NPT Stree
15 810-2125 Valve, ⅜-inch Ball

* 823-4105 Handle, Ball Valve

16 813-0634 Elbow, ½-inch to ⅜-inch NPT Reductio
17 813-0003 Tee, ½-inch NPT
18 813-0022
19 810-0278 Valve, ½-inch Ball
20 813-0345 Elbow, ½-inch X 45° NPT
21 810-2321 Hose Assembly, 7¾-inch (Polishing Hose
22 810-2172 Connector, ⅜-inch Male Quick-Disconnec
23 813-0735 Reducer, ½-inch X ⅜-inch NPT Bell (used with Item 24
24 810-2375 Hose Assembly, ½-inch X 32-inch
25 813-0165 Elbow, ½-inch X 90° NPT Stree
26 810-2170 Connector, ½-inch Male Quick-Disconnec
27 810-2173 Connector without Collar, ½-inch Female Quick-Disconnec
28 813-0654
29 823-3642 Spreader Bracket Assembl
30 201-3105 Bracket, Left Spreader Assembly Holdin
31 202-3105 Bracket, Right Spreader Assembly Holdin
32 813-0631 Elbow, ⅜-inch X 90° NPT
33 810-2113 Hose, ½-inch X ⅜-inch X 61.5-inch Wash-Dow
34 106-1454SP Wand Assembly, Wash-Down Hose (use 810-2188 for wand only)
35 210-3118 Bracket, Support- Wash-Down Hose
36 824-1090 Box, Switch/Circuit Breake
37 807-3574 Switch, Power ON/OFF Rocke
38 807-3577 Circuit Breaker, 120VAC 7-Amp (use 807-3538 for 230VAC 5-Amp)
39 807-1219 Receptacle, 120V 3-Wire
40 807-1224 Cordset, 120V 3-Wire
41 813-0770 Tee, 1½-inch X 1¼-inch Offset No Flush Drainpipe (use 813-0768 for units with flush)

* 813-0760 Tee, Drainpipe, 1½-inch X 1¼-inch (all except right end
* 813-0659 Cap, 1½-inch Pipe (used with Item 41

42 809-0884 Slip-Nut, 1½-inch Drainpipe
43 816-0544 O-Ring, Slip-Nut (two required per slip-nut
44 823-3652 Drainpipe, 1.625-inch Flanged(to left-hand filter

* 200-1838 Drainpipe, 1.625 x 17½-inch (use 200-1839 for 23½-inch)

* Not illustrated.

ut, ¼-20 Nylock (Motor Mount

le, ⅜-inch X Close NPT

le, ½-inch X Close NPT

le, ½-inch X 4-inch NPT

2-17

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.6 Frypot, Drain and Oil-Return Components

3-2424/1824G

on far right cabinet.)

(Plumbing with flush

with 1824G on Right

22

20

10

26

27

8

3-2424/1824G

on far left cabinet.)

(Plumbing with flush

with 1824G on Right

24 25

18

23

3-2424/1824G

16

far left cabinet.)

with 1824G on Left

(Plumbing with flush on

21

18

15

14

17

30

3

2

1

19

13

29

5

4

28

12

6

11

10

9

8

7

2-18

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 826-1823 Frypot Kit, 1824G (Front Drain, Front Return) (use 826-1821 for 2424G)
* 826-1822 Frypot Kit, 1824G (Front Drain, w/o Filtration) (use 826-1820 for 2424G)
* 826-1828 Frypot Kit, 1824G (Rear Drain, Front Return) (use 826-1842 for 2424G)
2 823-3934 Divider, Frypot
3 823-3174 Plug, Frypot Drain
4 823-3190 Baffle, Secondary Air
5 210-1409 Spreader, Side Flame
6 823-3504 Firebox Assembly, 1824G (use 823-3246 for 2424G)
* KIT5505SP Kit, 1824G Firebox Insulation (use KIT5507SP for 2424G)
* 200-2731 Back, 1824G Firebox (use 200-1391 for 2424G)
* 200-2612 Back, SCF 2424G Firebox
* 200-1546 Heat Shield, 1824G Front Firebox (use 200-1887 for 2424G)
7 823-3170 Guard, Firebox Bottom
8 813-0868 Plug, 1½-inch NPT Pipe

9 813-0732 Nipple, 1½-inch X 2-inch NPT Toe
10 813-0765 Tee, 1½-inch X 1¼-inch X 1½-inch
11 813-0391 Nipple, 1¼-inch X Close NPT
12 823-3463 Valve with Microswitch Holder, 1¼-inch Drain

* 814-0047 Sleeve, Red Valve Handle

* 807-2104 Microswitch, Drain Valve Roller Lever

* 902-2348 Guard, Microswitch

* 826-1366 Nut, 4-40 Keps (Pkg. of 25) (used for mounting microswitch)
13 813-0659 Cap, 1½-inch NPT Pipe
14 813-0143 Nipple, 1¼-inch X 2½-inch NPT Toe
15 813-0760 Tee, 1½-inch X 1¼-inch X 1½-inch NPT Drain
16 813-0686 Cap, Drain Flush End (1824G Left)
17 813-0165 Elbow, ½-inch X 90° NPT Street
18 200-1838 Tube, 1⅝-inch X 17½-inch Drain Manifold
19 813-0632 Elbow, ⅜-inch X 90° NPT Street
20 810-2125 Valve, ⅜-inch Oil Return Ball

* 823-3465 Handle, UFF Oil Return

* 816-0548 Cap, Yellow Vinyl Oil Return Handle
21 813-0614 Fitting, ½-inch X ⅜-inch 37° Flare
22 810-2556 Tube, Front Oil Return
23 200-1845 Tube, 1⅝-inch X 24½-inch Drain Manifold
24 816-0544 O-Ring
25 809-0884 Nut, Slip-Joint
26 813-0768 Tee, 1824G Right Drain Flush
27 810-2276 Nipple, UFF Drain Line
28 200-1411 Guard, Probe and High-Limit
29 210-1433 Clamp, Probe and High-Limit Bulb
30 823-4548 Retainer, Probe (used on units without Probe/High-Limit Bulb Clamp)

* Not illustrated.

2-19

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 2: PARTS LIST

2.7 Wiring Connectors, Pin Terminals and Power Cords

1 2

6

11

3

7 9 10

8

12

4

13

5

ITEM PART # COMPONENT

Power Cords

* 106-0913 Power Cord Assembly

Connectors

1 807-1068 2-Pin Female
2 807-0158 6-Pin Female
3 807-0156 9-Pin Female
5 807-0159 12-Pin Female
5 807-0875 15-Pin Female
6 807-1067 2-Pin Male
7 807-0157 6-Pin Male
8 807-0155 9-Pin Male

9 807-0160 12-Pin Male
10 807-0804 15-Pin Male
11 826-1341 Terminal, Female Split Pin (Pkg of 25)
12 826-1342 Terminal, Male Split Pin (Pkg of 25)
13 807-2518 Plug, Mate-N-Lock (Dummy Pin)

* Not illustrated.

2-20

THIS PAGE INTENTIONALLY LEFT BLANK

Frymaster/Dean, 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000

Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106

TEL [phone] FAX (Parts) 1-318-688-2220 FAX (Tech Support) 1-318-219-7135

PRINTED IN THE UNITED STATES

SERVICE HOTLINE

1-800-551-8633

819-6031

JUNE 2004