Frymaster 8196692 User Manual
GPC, GPCB, GPCR and GPCRB
Service and Parts Manual
Gas Cooker Models
Pasta Magic
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline
1-800-551-8633
*8196692*
NOV 2010
DANGER
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN
CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ THE INSTALLATION, OPERATING,
AND SERVICE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS
EQUIPMENT.
DANGER
FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR
VAPORS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
DANGER
POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE
USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING THE LOCAL
GAS SUPPLIER.
THIS EQUIPMENT IS TO BE INSTALLED IN COMPLIANCE WITH THE BASIC PLUMBING CODE
OF THE BUILDING OFFICIALS AND CODE ADMINISTRATORS INTERNATIONAL, INC. (BOCA)
AND THE FOOD SERVICE SANITATION MANUAL OF THE FOOD AND DRUG ADMINISTRATION.
COMPUTERS
FCC
This device complies with Part 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.
FRYMASTER FRYERS EQUIPPED WITH LEGS ARE FOR PERMANENT INSTALLATION. FOR
MOVEABLE OR PORTABLE INSTALLATION, FRYMASTER OPTIONAL EQUIPMENT CASTERS
MUST BE USED.
QUESTIONS??? CALL 1-800-551-8633.
Do not use deliming solution to clean water bath units. Use of deliming solution will damage all
stainless steel parts.
GAS COOKERS GPC, GPCB, GPCR and GPCRB
SERVICE & PARTS MANUAL
TABLE OF CONTENTS
CHAPTER 1: Service Procedures
1.1 Functional Description ....................................................................................................... 1-1
1.2 Accessing Equipment for Servicing ................................................................................... 1-4
1.3 Replacing Equipment Components .................................................................................... 1-4
1.3.1 Replacing the Controller ................................................................................................ 1-4
1.3.2 Replacing Electronic Components Other than the Controller ....................................... 1-4
1.3.3 Replacing a Water-Level Sensor or the Temperature Probe ......................................... 1-5
1.3.4 Replacing the Pressure Regulator or Solenoid Valve .................................................... 1-6
1.3.5 Replacing the Water Faucet ........................................................................................... 1-7
1.3.6 Replacing a Basket Lift Motor or Microswitch ............................................................. 1-7
1.3.7 Replacing Gas Supply System Components or Ignitor Assemblies .............................. 1-8
1.3.8 Replacing the Cookpot or Rinse Tank ......................................................................... 1-10
1.4 Troubleshooting ............................................................................................................... 1-11
1.4.1 How the Power Supply System Works ....................................................................... 1-11
1.4.2 How the Controller Works .......................................................................................... 1-11
1.4.3 How the Autofill/Autoskim System Works ................................................................ 1-11
1.4.4 How the Water Heating System Works ....................................................................... 1-12
1.4.5 How the Basket Lift System Works ............................................................................ 1-13
1.4.6 Technician Troubleshooting Guides ............................................................................ 1-13
1.4.7 Probe Resistance Chart and Wiring Diagrams ............................................................ 1-17
CHAPTER 2: Parts List
2.1 Accessories ........................................................................................................................ 2-1
2.2 Basket Lift Components .................................................................................................... 2-2
2.3 Cabinetry ............................................................................................................................ 2-4
2.4 Combustion System Components ...................................................................................... 2-8
2.5 Control Box and Related Components ............................................................................ 2-10
2.6 Controllers and Control Panel Components .................................................................... 2-12
2.7 Cookpot, Rinse Tank and Associated Components ......................................................... 2-13
2.8 Drain Components ........................................................................................................... 2-15
2.9 Gas Supply System Components ..................................................................................... 2-17
2.10 Water Supply Components .............................................................................................. 2-19
i
GAS COOKERS GPC, GPCB, GPCR AND GPCRB
SERVICE AND PARTS
CHAPTER 1: SERVICE PROCEDURES
1.1 Functional Description
The GPC, GPCB, GPCR and GPCRB Gas Cookers all have a 12.7-gallon (48.1-liter) stainless steel
cookpot. The water in the cookpot is heated by a high-efficiency infrared heating system that
requires approximately 43% less energy than conventional burner systems to heat the same volume
of water.
Two self-contained burners are located beneath the cookpot. Each burner is fitted with special
ceramic tiles that are heated by the burning of a forced air/gas mixture. The tiles transfer their heat
to the cookpot by means of infrared radiation, providing much more constant and uniform heat
dispersion over the surface of the cookpot than do conventional burners. Because relatively less heat
is lost to the atmosphere in the process, compared to “open-burner” designs, less fuel is required to
achieve and maintain a given cookpot temperature.
Gas flow to both of the burners is regulated by one electromechanical gas valve.
Inside GPC Cabinet
Model Description
GPC Cooker only, auto fill/skim, programmable timer
GPCR Separate rinse tank, auto fill/skim, hot/cold water inlets, programmable timer, faucet
GPCRB
GPCB Automatic basket lifts, auto fill/skim, programmable timer
Automatic basket lift, separate rinse tank, auto fill/skim, hot/cold water inlets, programmable
timer, faucet
Operational control of the burner system is accomplished through a solid-state SMS III Spaghetti
Magic controller. NOTE: The SMS III controller used in this model series is identical in
appearance to the SMS III controllers used in other model series, but differs internally. Use only the
part numbers listed in Chapter 2 when replacing controllers on this equipment.
1-1
SMS III Controller
The GPC, GPCB, GPCR and GPCRB controllers do not have a ten-time warm up cycle as previous
models did, but instead use a Fenwal ignition module (807-4943). The module will try to light for
four seconds. If unsuccessful, the blower will remain on for 15 seconds and try again. Once the
burner is lit and the flame is proved, the module ends the lighting sequence. If the flame is not
proved after eight tries, the module will lock out.
When the controller power switch is pressed, a logic circuit in the controller automatically checks
the water level in the cookpot. A normally closed solenoid valve on the water supply line
automatically opens if the normal water-level sensor is not grounded by contact with water in the
cookpot. When sufficient water has been added to ground the low water-level sensor, the unit
automatically enters the SIMMER mode and remains there unless the operator presses the BOIL
mode switch or turns the unit off. When the water level in the cookpot reaches and grounds the
normal water-level sensor, the solenoid valve in the water supply line closes. Anytime the water
level in the cookpot drops below the normal water-level sensor, the solenoid valve opens to refill the
cookpot to the proper level.
While in the simmer mode, logic circuits in the controller monitor the temperature of the water and
cycle the burners on and off to maintain the temperature at the setpoint programmed into the
controller. The cooker also has a low-water safety. If the water in the cookpot falls below the low
water-level sensor, the controller cuts power to the gas valve, causing it to close and cut off the gas
supply to the burners.
The autoskim and skim features are independent of each other. The autoskim feature (on units so
equipped) cannot be turned off. The autoskim feature adds water for approximately three seconds
once a minute.
The skim feature, when activated by pressing the skim button on the controller, delivers a continuous spray of water for approximately two minutes, then stops until the button is again pressed. In
both cases, the purpose is to cause the water in the cookpot to overflow into the drain, carrying floating starch with it. (A buildup of starch reduces the efficiency of the cooker and can cause erroneous
temperature and water level sensing.) NOTE: Do not use deliming solution to clean these units.
Use of deliming solution will damage all stainless steel parts.)
The operator enters a specified cooking time by pressing the number pads on the controller. When
the start switch is pressed, the controller begins to count down to zero. When the controller times
out, an alarm sounds briefly, then the timer reverts to the last time entered.
When the start switch is pressed to start the cooking cycle, logic circuits in the controller activate the
basket lift motors (on units so equipped), lowering the basket into the cookpot. As the motors drive
1-2
the basket lift arms down, a cam attached to the left motor eventually loses contact with a rolleractivated microswitch and power to the motors are cut. When the controller times out, logic circuits
reverse the switch positions so that the motor circuit is again completed and the motors are restarted,
raising the basket from the cookpot. At the fully raised position, the cam again makes contact with
the microswitch, cutting power to the motors and stopping the lift in the up position.
THE ELECTRONIC IGNITION SYSTEM
The ignition module, located in the component box, is connected to ignitor assemblies at each
burner. The ignition module performs three important functions: it provides an ignition spark,
supplies operating voltage to the gas valve, and proofs the burner flame. The GPC series use a
Fenwal ignition module.
The ignition module contains a 4-second time delay circuit and a coil that activates the gas valve.
The ignitor assembly consists of a spark plug, an enrichment tube, and flame sensor.
Module located in box below cookpot.
At start-up, the controller power switch is placed in the ON position. If the controller senses the
correct operating parameters (i.e., the correct water level in the cookpot), it sends a signal to the
24VAC relay in the component box to close the blower contacts. This supplies line voltage to the
blower motor. A centrifugal switch in the blower closes if the blower is operating correctly, which
allows 24VAC to flow through the closed contacts of the 24VAC relay to the ignition module.
Circuitry in the ignition modules sends 24VAC to the gas valve. Simultaneously, the module causes
the ignitors to spark for 4 seconds to light the burners. A flame sensor for each burner 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 cut, preventing the gas valve from opening,
and the ignition module “locks out” until the controller power switch is turned off and then back on.
A probe monitors the temperature in the cookpot. When the programmed setpoint temperature is
reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current to
the 24VAC relay, thus cutting line voltage to the blower. This cuts the 24VAC to the ignition
module, causing the gas valve to close.
1-3
1.2 Accessing Equipment for Servicing
DANGER
Moving this equipment while it is filled with hot water may cause spilling or
splattering of the hot water. Always drain the cookpot before attempting to relocate
this equipment for servicing.
1. Disconnect the unit from the electrical power supply, the gas supply and the water supply.
2. Disconnect any attached restraining devices.
3. Relocate the unit for service accessibility.
4. After servicing is complete, reconnect the unit to the water supply and the gas supply. Reattach
the restraining devices, and reconnect the unit to the electrical power supply.
1.3 Replacing Equipment Components
1.3.1 Replacing the Controller
1. Open the control panel by removing the two screws on the bottom of the bezel. Disconnect the
trouble light wires and lower the bezel. Remove the two screws in the upper edge of the controller and lower the controller and disconnect the 15-pin connector and ground wire. Remove the
control panel by lifting the panel out of the slots in the control panel frame.
2. Remove the failed controller from the control panel and replace with the new controller. Re-
verse steps to complete the process.
1.3.2 Replacing Electronic Components Other than the Controller
1. Drain the cookpot and disconnect the cooker form the electrical power supply.
2. The control box is mounted inside the bottom of the cabinet located beneath the cookpot.
3. On the component to be replaced, make a note of the wiring connection points. Disconnect the
wires and remove the failed component. Install the replacement component and reconnect the
wiring in accordance with the notes made, or with the wiring diagram on the door of the unit.
4. Replace the component box cover, and reinstall the controller being sure to reconnect the ground
wire and trouble light wires. Reconnect the cooker to the electrical power supply.
1-4
1.3.3 Replacing a Water-Level Sensor or the Temperature Probe
1. Drain the cookpot and disconnect the cooker from the electrical power supply.
2. Remove the screws in the upper edge of the control panel and swing the panel down. Disconnect
the 15-pin connector, trouble light wires, and ground wire, and lift the panel out of the slots in
the control panel frame.
3. Remove the topcap from the unit by removing the four screws (two on the front and two on each
end) that secure it to the cabinet.
4. Remove the control panel frame by removing the screws in the top and bottom corners and the
screw in the center bracket.
5. If replacing a water-level sensor (see illustration below):
a. Disconnect the sensor lead by pulling it from its terminal then remove the Keps nut, terminal,
and washer from the sensor.
b. Inside the cookpot, remove the screw from the sensor flange.
c. Carefully pull the failed sensor from the probe block and replace with the new sensor.
d. Reassemble the washer, terminal, and nut onto the sensor, and reattach the lead.
e. Reverse Steps 1-4 to complete the procedure.
If replacing the temperature probe, mark the wiring
harness leads and disconnect the probe leads at the
push on connectors.
Remove the s c r ews from the probe b ra c ket and
push the probe out t h e ba ck of the probe blo c k.
Temperature Probe
Water-Level Sensors
If replacing a water-level sensor, disconnect its
lead and remove it s K e ps nut, terminal and washer.
Remove the s c r ew fr om the senso r flange and
pull the sensor out the front of the probe block.
6. If replacing the temperature probe (see illustration above):
a. Mark the wiring harness leads and disconnect them from the probe leads at the push-on
connectors.
b. Remove the two screws in the probe bracket.
c. Carefully pull the probe from the probe block and replace with the new probe.
d. Reattach the leads and reverse Steps 1-4 to complete the procedure.
1.3.4 Replacing the Pressure Regulator or Solenoid Valve
1. Drain the cookpot and disconnect the cooker from the electrical power supply. Turn off or
disconnect the water supply to the cooker.
1-5
2. Disconnect the solenoid leads at the push-on connectors. Disconnect solenoid and regulator
subassembly at the compression fittings on the water lines running to and from these
components. Remove the two screws in the mounting bracket and remove the solenoid and
regulator subassembly from the unit. (NOTE: If the cooker is not equipped with the optional
Autofill feature, the cookpot water tube will be connected directly to the regulator and there will
be no solenoid valve.)
The incoming water line will be connected
Remove the two screws
at the bottom of this
bracket to dismount the
solenoid and regul a t o r
sub-assembly.
Solenoid Valve
used, disconnect the regulator at this point.
to the nipple at th e i nlet side of the
regulator using some type of field
connection fitting. Whatever type fitting is
Solenoid Valve
Remove the two
screws at the
bottom of this
bracket to
dismount the
solenoid and
regulator sub-
assembly.
Disconnect the water
tubes at thes e
compression fittings.
GSMS with Autofill Configuration GBC/GC with Autofill Configuration
Disconnect t h e wat er tube
at this compression fitting.
3. If replacing the regulator, adjust the replacement regulator output pressure to not more than 40
PSI (28.15 kg/cm2) before installation in the cooker.
4. Recover the fittings from the failed component (regulator or solenoid valve) and install them on
the replacement, using thread sealer on all connections.
5. Reverse Steps 1 and 2 to complete the procedure, being sure to apply thread sealer to all
connections.
1.3.5 Replacing the Water Faucet
1. Drain the cookpot and disconnect the cooker from the electrical power supply.
NOTE: Refer to the illustration below for the following steps.
2. Turn off the water supply to the cooker and disconnect the incoming water lines where they
attach to the stubs at the rear of the cooker.
3. Remove the two screws securing the access panel in place and remove the panel.
4. Disconnect the water supply line at the compression fitting where it attaches to the water inlet
manifold. Remove the screws from the faucet mounting plate and lift the faucet assembly from
the unit.
1-6
Remove the six screws in
the faucet mounting plate.
Remove this nut to separate the
faucet from the mounting plate.
Disconnect wate r line at
this compression fitting.
Loosen this nut to separate the
faucet from the water inlet manifold.
5. Separate the faucet from the water inlet manifold and mounting plate as shown in the illustration
above.
6. Reverse Steps 1-5 to complete the procedure.
1.3.6 Replacing a Basket Lift Motor or Microswitch
1. Disconnect the cooker from the electrical power supply.
2. If rigid water connections have been used, disconnect the cooker from the incoming water
supply.
3. Remove the basket lift arms from the lifter rods and then reposition the cooker to gain access to
the rear. Remove the upper and lower basket lift rear panels.
4. Disconnect the basket lift synchronizer link from the lifter cam (bell crank) assemblies one at a
time. When the link is disconnected from a cam, slip the corresponding lifter rod down and out
of the assembly (see illustration on below).
Lifter Rods
Note the collection of washers and
spacers between the li nk and lifter rods.
Synchronizer Link
Lifter Cams
1-7
Disconnect the basket lift synchronizer
link from the lifter cams and slip the lifter
rods down and out of the ass embly.
5. Remove the four bolts securing the motor mount to the frame, then remove the “motor and
mount assembly” from the unit. NOTE: It is possible to replace a motor or the microswitch
without removing the “motor and mount assembly”, but it is much more difficult.
6. Dismount the motor or microswitch as shown below and install the replacement.
NOTE: The right motor dismount s
in the same way as the left.
Loosen setscrew in
bottom of cam (bell crank)
7. Reverse Steps 1-6 to complete the procedure.
1.3.7 Replacing Gas Supply System Components or Ignitor Assemblies
1. Disconnect the cooker from the electrical power supply and from the gas supply. If necessary,
disconnect restraints to gain proper access to components.
2. Disconnect the component to be replaced (see illustration below) and install the replacement
component. NOTE: If replacing the gas valve, disconnect the enrichment tubes and gas supply
tubes at the valve, then unscrew the valve from the mounting bracket. Recover the fittings from
the failed valve and install them on the replacement valve using a thread sealer suitable for gas
appliances (Loctite™ PST 56765 is one example). Do not apply the sealer to the first two
threads of the fitting. This will help prevent clogging of the burner orifices and gas valve.
1-8
Burners Blower and plenum
removed
3. Reconnect the cooker to the gas supply and check all connections for leaks using a solution of
soapy water.
DANGER
DO NOT use matches, candles, or other ignition methods to check for leaks.
4. When satisfied that there are no leaks, reconnect the unit to the electrical supply, and reconnect
any restraints disconnected in Step 1.
1.3.8 Replacing the Cookpot or Rinse Tank
NOTE: The following procedure addresses removing the cookpot or rinse tank from a GPC unit.
The procedure is essentially the same for a GPC, GPCB, GPCR and GPCRB units, except that there
is no faucet on the GC, GPC or GPCB units. There are no basket lifts on the GC and GPC units.
1. Remove the basket lift arms from the lifter
rods.
2. Remove the faucet assembly from the cook-
er in accordance with Steps 1-4 of Section
1.3.5.
3. Remove the screws that secure each of the
rear corners of the backsplash assembly (see
illustration at right). NOTE: To access the
screw in the lower right corner (as viewed
from the rear) the upper basket lift back
panel must be removed.
4. Remove the screws along the top edge of the
swinging it downward. Disconnect the 15pin connector from the rear of the controller
and the wires attached to the trouble light,
and then lift the control panel out of the
control panel frame.
5. Remove the screws that secure the back-
splash sides to the cabinet sides then remove
the four screws that secure the topcap to the
cabinet.
6. Remove the top connecting strip.
7. Remove the screws attaching the standoff
brackets to the cookpot or rinse tank.
control panel and open the panel by
1-9
Remove these four screws.
Remove screws along the top edge of
control panel and dismount the panel.
Remove these screws to release
the pots from the standoff brackets.
Remove these
screws (on both
sides) and remove
backsplash and
topcap.
Remove the top
connecting strip .
8. If removing the cookpot, disconnect the enrichment tubes and gas supply tubes from the burner
assemblies. Disconnect the ignition cables and flame sensor wires from the ignitor assemblies
on each burner.
9. Remove the blower.
10. Lift the cookpot or rinse tank straight up and out of the cabinet.
11. Invert the cookpot or rinse tank on a suitable work surface and remove the salvageable
components (e.g., probe block assembly, drain plumbing, etc.). Install the recovered components
on the replacement cookpot or rinse tank, using thread sealer on all connections.
12. Reverse Steps 1 through 9 to complete the procedure.
1-10
1.4 Troubleshooting
Problems with this equipment maybe grouped into five broad categories:
1. Failure or malfunction of a Power-Supply System component.
2. Failure or malfunction of the Controller.
3. Failure or malfunction of an Autofill/Autoskim System component.
4. Failure or malfunction of a Water Heating System component.
5. Failure or malfunction of a Basket Lift System component.
Sections 1.4.1 through 1.4.5 briefly explain the functioning of each of the systems mentioned above.
Section 1.4.6 contains troubleshooting guides that provide systematic procedures to isolate and
identify the specific source of a problem. A wiring diagram is located at the end of the chapter.
1.4.1 How the Power-Supply System Works
Line voltage is supplied to the system via a power cord that is plugged or hard-wired into the store’s
electrical service. The power cord is connected to pins 1 and 5 of an 8-pin terminal block. Line voltage is supplied to a 24VAC transformer from pins 2 and 8 of the terminal block. Pin 7 supplies
24VAC to a heat relay, which controls line voltage to the blower motor and 24VAC to the gas valve
via the ignition module. The transformer supplies 24VAC to the controller, to the coils of the
24VAC relay, and to the solenoid valve on units equipped with the Autofill option. On units
equipped with basket lifts, line voltage is supplied to a 24VDC basket lift relay from pin 6 of the
power cord terminal block. Line voltage to the basket lift motors is supplied via the basket lift relay.
1.4.2 How the Controller Works
The SMS III controller provides the interface between the operator and the system components. The
controller is powered by 24VAC supplied through pins 1 and 2 of the wiring harness. Internal circuitry senses the water level and water temperature. Depending upon the conditions sensed, the controller energizes or de-energizes the solenoid valve which controls the water level. The 24VAC relay controls burner firing which controls water temperature. The controller also controls the lowering and raising of the basket lift, and activates an audible alarm to signal the operator that a cooking
cycle has completed. A rectifier in the controller converts 24VAC to the 24VDC required by the
basket lift relay. The controller signals for heat via pin 4, grounds the solenoid valve via pin 6, and
senses water level via pins 7 (low) and 9 (full). The temperature probe connects to pins 13 and 14.
The basket lift relay connects to pins 10 and 12. The sound device connects to pin 11.
1.4.3 How the Autofill/Autoskim System Works
The heart of the automatic filling (Autofill) system is a normally closed solenoid valve that opens
when 24VAC is applied.
The ground for the solenoid is supplied (via pin 6 of the controller wiring harness) so long as the
shorter of the two water-level sensors is not in contact with the water in the cookpot. When the
water in the cookpot reaches the shorter of the two water-level sensors, the sensor is grounded. This
causes the controller to break the solenoid ground, closing the valve. Starch or lime build-up on the
sensor may keep it from grounding, therefore always make sure the sensor is clean and its lead (pin 9
of the controller wiring harness) is firmly connected. Also, in order for the sensor to ground, there
must be some mineral content in the water (pure water is non-conductive). Consequently, the unit
will not operate correctly with distilled, highly filtered, or deionized water. If water of these types is
1-11
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