Frymaster BIGL30 Operators Manual

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This equipment chapter is to be

installed in the Fryer Section of the

Equipment Manual.

MANUFACTURED

SERVICE AND PARTS

FRYMASTER BIGL30 SERIES MANUAL LOV™

GAS FRYER

Do Not Store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

FOR YOUR SAFETY

8700 Line Avenue.

SHREVEPORT, LOUISIANA 71106

PHONE: 1-318-865-1711

TOLL FREE: 1-800-551-8633

1-800-24 FRYER

FAX: 1-318-219-7135

Frymaster L.L.C., 8700 Line Avenue, Shreveport, LA 71106

PHONE 318-865-1711 FAX 318-219-7135

PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-24-FRYER 03/2016

www.frymaster.com Email: service@frymaster.com *8196968*

NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS MANITOWOC FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER OR ANY OF ITS FACTORY AUTHORIZED SERVICERS, 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

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

DANGER

The electrical power supply for this appliance must be the same as indicated on the rating and serial number plate located on the inside of the fryer door.

DANGER

This appliance must be connected to the voltage and phase as specified on the rating and serial number plate located on the inside of the fryer door.

DANGER All wiring connections for this appliance must be made in accordance with the wiring diagrams furnished with the equipment. Wiring diagrams are located on the inside of the fryer door.

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

WARNING Do not attach accessories to this fryer unless fryer is secured from tipping. Personal injury may result.

WARNING Frymaster fryers equipped with legs are for permanent installations. Fryers fitted with legs must be lifted during movement to avoid damage and possible bodily injury. For a moveable or portable installation, Frymaster optional equipment casters must be used. Questions? Call 1-800-551-8633 or email at service@frymaster.com.

WARNING

Do not use water jets to clean this equipment.

WARNING

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

outdoor areas.

DANGER Adequate means must be provided to limit the movement of this appliance without depending on or transmitting stress to the electrical conduit. A restraint kit is provided with the fryer. If the restraint kit is missing contact your local KES.

DANGER Prior to movement, testing, maintenance and any repair on your Frymaster fryer, disconnect all electrical power from the fryer.

BIGL30 SERIES GAS FRYERS

TABLE OF CONTENTS

WARRANTY ....................................................................................................................................... i

CHAPTER 1: Service Procedures

1.1 Functional Description ..................................................................................................... 1-1

1.2 The Electronic Ignition System ........................................................................................ 1-1

1.3 Interface Board ................................................................................................................ 1-2

1.4 Thermostats .................................................................................................................... 1-4

1.5 Accessing Fryers for Servicing ........................................................................................ 1-4

1.6 Cleaning the Gas Valve Vent Tube ................................................................................. 1-5

1.7 Checking the Burner Manifold Gas Pressure .................................................................. 1-5

1.8 Measuring Flame Current ............................................................................................... 1-6

1.9 Replacing Fryer Components ......................................................................................... 1-7

1.9.1 Replacing the Controller or the Controller Wiring Harness .............................. 1-7

1.9.2 Replacing the Temperature Probe or High-Limit Thermostat ........................... 1-7

1.9.3 Replacing the Interface Board .......................................................................... 1-8

1.9.4 Replacing an Ignition Module ........................................................................... 1-8

1.9.5 Replacing an Igniter Assembly ......................................................................... 1-8

1.9.6 Replacing or Cleaning a Combustion Air Blower.............................................. 1-9

1.9.7 Adjusting the Air/Gas Mixture ......................................................................... 1-10

1.9.8 Replacing a Gas Valve ................................................................................... 1-11

1.9.9 Replacing a Burner Assembly ........................................................................ 1-12

1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve ........ 1-13

1.9.11 Replacing the Frypot ...................................................................................... 1-13

1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails ................................. 1-14

1.10 Troubleshooting and Problem Isolation ......................................................................... 1-17

1.10.1 Ignition Failure ................................................................................................ 1-18

1.10.2 Improper Burner Function .............................................................................. 1-18

1.10.3 Improper Temperature Control ....................................................................... 1-20

1.10.4 Computer Malfunctions .................................................................................. 1-20

1.10.5 Filtration Malfunctions .................................................................................... 1-20

1.10.6 Leakage .......................................................................................................... 1-21

1.11 Troubleshooting Guides ................................................................................................ 1-21

1.11.1 Troubleshooting the 24 VAC Circuit ............................................................... 1-22

1.11.2 Troubleshooting the Gas Valve ...................................................................... 1-24

1.11.3 Troubleshooting the Temperature Probe ....................................................... 1-25

1.11.4 Replacing the Transformer, Reset Switch or Filter Relay ............................... 1-25

1.12 Probe Resistance Chart ................................................................................................ 1-26

1.14 M3000 Computer Service Procedures .......................................................................... 1-27

1.14.1 M3000 Computer Troubleshooting ................................................................. 1-27

1.14.2 M3000 Useful Codes and Passwords ............................................................ 1-30

BIGL30 SERIES GAS FRYERS

TABLE OF CONTENTS cont.

1.14.4 Error Log Codes ............................................................................................. 1-31

1.14.5 M3000 Menu Summary Tree .......................................................................... 1-32

1.14.6 M3000 Controller Pin Positions and Harnesses ............................................. 1-33

1.15 Loading and Updating Software Procedures ................................................................ 1-34

1.16 Principal Wiring Connections ........................................................................................ 1-35

1.17 Wiring Diagrams ............................................................................................................ 1-36

1.17.1 BIGL230/430 Wiring ....................................................................................... 1-36

1.17.2 BIGL330 Wiring .............................................................................................. 1-37

1.17.3 BIGL430 Extra Transformer Box Wiring ......................................................... 1-38

1.18 Simplified Wiring Diagrams ........................................................................................... 1-39

1.18.1 BIGL30 Series Full Vat Single Spark Module ................................................. 1-39

1.18.2 BIGL30 Series Dual Vat Single Spark Module ............................................... 1-40

1.18.3 BIGL30 Series Data Network Flowchart ......................................................... 1-41

CHAPTER 2: Parts List

2.1 Accessories ..................................................................................................................... 2-1

2.2 Doors, Sides, Flue Caps, Top Caps and Casters ........................................................... 2-1

2.3 Drain System Components ............................................................................................. 2-3

2.3.1 Drain Valves and Associated Parts .................................................................. 2-3

2.3.2 Drain Tube Sections and Associated Parts ...................................................... 2-4

2.4 Electronics and Electrical Components ........................................................................... 2-5

2.4.1 Computers and Associated Components ......................................................... 2-5

2.4.2 Control Box ....................................................................................................... 2-6

2.4.3 Transformer Box ............................................................................................... 2-8

2.5 Wiring….…. ..................................................................................................................... 2-9

2.5.1 Main Wiring Harnesses .................................................................................... 2-9

2.5.2 M3000 Communication Wiring Harnesses ..................................................... 2-10

2.6 Frypots and Associated Components ........................................................................... 2-11

2.6.1 Full-Vat Frypot Components........................................................................... 2-11

2.6.2 Dual-Vat Frypot Components ......................................................................... 2-13

2.6.3 Frypot Probes and Thermostats ..................................................................... 2-15

2.7 Gas Valves, Supply and Combustion System Components ......................................... 2-16

2.8 Filtration System Components ...................................................................................... 2-18

2.9 Filter Pump, Motor and Associated Components .......................................................... 2-19

2.10 Frypot Assemblies and Associated Parts ...................................................................... 2-20

2.11 Oil Return System Components .................................................................................... 2-21

2.12 Wiring Connectors, Pin Terminals, and Tools ............................................................... 2-22

2.13 Fasteners ...................................................................................................................... 2-23

1.14.3 Service Required Errors ................................................................................. 1-30

MANUAL LOV™ GAS WARRANTY STATEMENT

Frymaster, L.L.C. makes the following limited warranties to the original purchaser only for this equipment and replacement parts:

A. WARRANTY PROVISIONS - FRYERS

1. Frymaster L.L.C. warrants all components against defects in material and workmanship for a

period of two years.

2. All parts, with the exception of the frypot, O-rings and fuses, are warranted for two years after installation date of fryer.

3. If any parts, except fuses and filter O-rings, become defective during the first two years after installation date, Frymaster will also pay straight-time labor costs up to two hours to replace the part, plus up to 100 miles/160 km of travel (50 miles/80 km each way).

B. WARRANTY PROVISIONS - FRYPOTS

1. Frymaster warrants the frypot assembly for fifteen (15) years. First ten (10) years parts and labor. Years eleven (11) through fifteen (15) frypot only. Components attached to the frypot, such as the high-limit, probe, gaskets, seals, ignitors and related fasteners, are also covered by the fifteen year warranty if replacement is necessitated by the frypot replacement. Components that are not part of the frypot assembly, such as the blower, gas valve, micro switches, doors and cabinetry are not covered by the frypot warranty. Leaks due to abuse or from threaded fittings such as probes, sensors, high-limits, drain valves or return piping are not included. If the frypot is found to be defective, Frymaster will replace the frypot, allowing up to the maximum time per the Frymaster time allowance chart hours of straight-time labor plus up to 100 miles/160 km of travel (50 miles/80 km each way) to change the frypot.

2. This warranty is limited to fryers operating on natural or propane (LP) gas. Fryers that operate on manufactured gas (also known as town gas or high-hydrogen gas) have a lifetime frypot warranty, parts only.

C. WARRANTY PROVISIONS – COMBUSTION CHAMBERS

1. Frymaster L.L.C. warrants the combustion chambers against defective material or workmanship for a period of ten years from the original installation date, parts and labor.

2. The combustion chamber consists of the infrared burners and the structural components to mount the burners. This warranty does not cover ancillary components, including the igniter, blower, high-limit thermostat, and temperature probe.

3. This warranty is limited to fryers operating on natural or propane (LP) gas.

E. PARTS RETURN

All defective in-warranty parts must be returned to a Frymaster Authorized Factory Servicer within 60 days for credit. After 60 days, no credit will be allowed.

F. WARRANTY EXCLUSIONS

This warranty does not cover equipment that has been damaged due to misuse, abuse, alteration, or accident such as:

 improper or unauthorized repair (including any frypot which is welded in the field);  failure to follow proper installation instructions and/or scheduled maintenance procedures as

prescribed in your MRC cards. Proof of scheduled maintenance is required to maintain the warranty;

 improper maintenance;  damage in shipment;  abnormal use;  removal, alteration, or obliteration of either the rating plate or the date code on the heating elements;  operating the frypot without shortening or other liquid in the frypot;  no fryer will be warranted under the ten-year program for which a proper start-up form has not been

received.

This warranty also does not cover:

 transportation or travel over 100 miles/160 km (50 miles/80 km each way), or travel over two

hours;

 overtime or holiday charges;  consequential damages (the cost of repairing or replacing other property which is damaged), loss of

time, profits, use or any other incidental damages of any kind.

There are no implied warranties of merchantability or fitness for any particular use or purpose.

This warranty is applicable at the time of this printing and is subject to change.

BIGL30 SERIES GAS FRYER

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

BIGL30 series gas fryers contain a welded stainless steel frypot that is directly heated by a high efficiency infrared burner system, requiring approximately 43% less energy than conventional burners to cook the same volume.

Self-contained combustion chambers (referred to as “burners”) are fitted into rails attached to the sides of the frypot, one on each side. Each combustion chamber is fitted with special ceramic tiles that are heated by the burning of a forced air/gas mixture. The tiles transfer heat to the frypot by means of infrared radiation, providing much more constant and uniform heat dispersion over the surface of the frypot than conventional burners. Because 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 frypot temperature.

In full-vat units, gas flow to both of the burners is regulated by one electromechanical gas valve. All fryers in this series are equipped with 24 VAC gas valve systems, and all are configured with electronic ignition.

1.2 The Electronic Ignition System

An ignition module mounted below the component box (located behind the control panel) is connected to an ignitor assembly at the burner. The ignition module performs five important functions: it provides fuse protection for the 24-volt circuit, provides an ignition spark, supplies voltage to the gas valve, provides the alarm circuit (24V) to the controller and proofs the burner flame. The module contains a four second time delay circuit and a coil that activates the gas valve.

The ignitor assembly consists of a spark plug, an enrichment tube, and a flame sensor. At start-up, the power switch is placed in the ON position,

supplying approximately 12-volts DC to the heat-control circuitry in the controller and to one side of the heat relay coils on the interface board. If resistance in the temperature probe indicates the temperature in the frypot is below 180ºF (82ºC), the current flows through a melt cycle circuit where a timer switch alternately closes for six seconds and opens for 24 seconds. If the temperature is 180ºF (82ºC) or above, the current flows through a heat circuit, bypassing the timer switch. In either case, ground is supplied to the other leg of the heat relay coils, which closes electronic switches in the 24 VAC circuit to provide current to the ignition module. Circuitry in the ignition module sends 24 VAC to the gas valve via a normally closed high-limit switch. Simultaneously, the module causes the ignitor to spark for four seconds to light the burner. A flame sensor verifies the burner ignition 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, the gas valve closes, and the ignition module “locks out” until the power switch is turned off and then back on. A normally closed drain switch is attached to the rear of the controller. If the drain is opened, the heat circuit is opened and all heating is discontinued. A probe monitors the temperature in the frypot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay. This in turn cuts off the 24 VAC to the ignition module, causing the gas valve to close.

1-1

1.3 Interface Board

All fryers in this series have an interface board located in the component box behind the control panel. The interface board provides a link between the controller and the fryer’s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point.

K2 and K3 are double-pole-double throw (DPDT) relays that supply 24VAC to the ignition and gas valve circuits, as well as 120VAC to the blower motor. The relays on this board plug into sockets. If a relay fails, that relay can be replaced.

LEDs (labeled D1 through D7) are arrayed around the board to assist in troubleshooting.

INTERFACE BOARD

LED DIAGNOSTIC LIGHTS

D1 24 VAC to left gas valve (dual vat only) D2 24 VAC to left ignition module (dual vat only) D3 24 VAC from transformer D4 24 VAC to right ignition module D5 24 VAC to gas valve (right valve if dual vat) D6 12 VAC from transformer D7 CE and Japanese units only: air switch closed

NOTE: In full-vat fryers, the relay for the left side (K2) may not be present.

The chart on the following page illustrates current flow through the board, and the table at the top of page 1-4 identifies frequently used test points.

1-2

1-3

FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD

TEST

12VAC Power to Controller 50VAC Scale 1 and 3 on J3 or J2 12-18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GROUND 22-28 120 VAC Power 250VAC Scale 11 on J3 and GROUND 110-125 120 VAC Power to Blowers 250VAC Scale 12 on J3 and GROUND 110-125 24VAC Power to Full or Right vat High-Limit 50VAC Scale 9 on J3 and GROUND 22-28 24VAC Power to Left High-Limit (if present) 50VAC Scale 9 on J1 and GROUND 22-28 Probe Resistance (Full or Right Vat) * R x 1000 OHMS 2 and 6 on J3 or 13 and 14 on J2 ** Probe Resistance (Left - if present) * R x 1000 OHMS 2 and 6 on J1 or 14 and 15 on J2 ** Probe Isolation R x 1000 OHMS 6 on J1 or J3 and GROUND *** High-Limit Continuity (Full or Right Vat) R x 1 OHM 9 on J3 and Wire 13C on Gas Valve 0 High-Limit Continuity (Left - if present) R x 1 OHM 9 on J1 and Wire 12C on Gas Valve 0

* Disconnect 15-pin harness from controller before testing probe circuit. ** See Probe Resistance Chart on page 1-28. *** 5 mega-Ohms or greater.

METER

SETTING

PINS RESULTS

1.4 Thermostats

BIGL30 series gas fryers have temperature probes located on the front centerline of each frypot. In this type of thermostat, the probe resistance varies directly with the temperature. That is, as the temperature rises, so does resistance, at a rate of approximately 2 ohms for every 1º F. Circuitry in the controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints).

BIGL30 series gas fryers are also equipped with a high-limit thermostat. In the event that the fryer fails to properly control the oil temperature, the high-limit thermostat prevents the fryer from overheating to the flash point. The highlimit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 425ºF to 450ºF (218ºC to 232ºC). The different types of thermostats have different part numbers for CE and Non-CE models, and are not interchangeable.

1.5 Accessing Fryers for Servicing

DANGER Moving a fryer filled with oil may cause spilling or splattering of the hot liquid. Follow the draining instructions in Chapter 5 of the BIGL30 Series Gas Fryer Installation and Operation Manual before attempting to relocate a fryer for servicing.

1. Shut off the gas supply to the unit. Unplug the power cords. Disconnect the unit from the gas supply.

2. Remove any attached restraining devices and relocate the fryer for service accessibility.

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

electrical cords.

1-4

1.6 Cleaning the Gas Valve Vent Tube

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 of

removal.

3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any obstruction.

4. Remove the wire and blow through the tube to ensure it is clear.

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

1.7 Checking the Burner Manifold Gas Pressure

1. On non-CE fryers only ensure that the gas valve knob is in the OFF position.

Honeywell

OFF

2. Remove the pressure tap plug from the gas valve assembly.

Pressure Tap Plug

Typical Non-CE Valve Assembly

Typical CE Valve

Assembly

3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.

4. On non-CE fryers only , place the gas valve in the ON position.

5. Place the fryer power switch in the ON position. When the burner has lit and burned steadily for at least one

minute, compare the gas pressure reading to the pressure for the corresponding gas in the appropriate table on the following page. The tables list the burner manifold gas pressures for each of the gas types that can be used with this equipment.

1-5

CE Standard

Burner Manifold Gas Pressures

Pressure

(mb a r ) Single

Gas

Natural Gas Lacq (G20) under 20 mbar

Natural Gas Gronique (G25) under 25 mbar

Natural Gas Gronique (G25) under 20 mbar

Butane/Propane (G30) at 28/30 or 50 mbar

Propane (G31) under 37 or 50 mbar

* Belgian G25 = 7,0 mbar

Vat

Non-CE Standard

Bur ner Ma nifold G as Pr e ssures

Gas Pressure

Natural

Propane

3" W.C.

0.73 kPa

8.25" W.C.

2.5 kPa

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

Non-CE

Valve

GAS VALVE REGULATOR CAP

7. Place the fry er power switch (and the gas valve in non-CE fryers) in the OFF position. Remove the fitting from

the pressure tap hole and reinstall the pressure tap plug.

1.8 Measuring Flame Current

When the burner flame is properly adjusted, it will produce a current between 2.5 A and 3.5 A. Flame current is measured by placing a microamp (not milliamp) meter in series with the sensing wire on the ignitor. This is accomplished as follows:

1. Place the fryer power switch in the OFF position.

1-6

2. Disconnect the sensing wire from one of the burner ignitors and connect it to the positive lead of the meter.

Connect the negative lead of the meter to the terminal from which the sensing wire was removed.

Flame Sensor Wire

3. Place the fryer power switch in the ON position to light the burners. After the frypot temperature reaches 200F

(93C), wait at least one minute before checking the reading. NOTE: The closer the unit is to normal operating temperature, the more accurate the reading will be.

1.9 Replacing Fryer Components

1.9.1 Replacing the Controller or the Controller Wiring Harnesses

1. Disconnect the fryer from the electrical power supply.

2. Open the control panel by removing the screws on the bottom of the bezel. Carefully lower the bezel.

3. Remove the two screws from the upper corners of the controller. The controller is hinged at the bottom and will

swing open from the top.

4. Unplug the wiring harnesses from the connectors on the back of the controller marking their position for

reassembly and disconnect the grounding wires from the terminals. Remove the controller by lifting it from the hinged slots in the control panel frame.

Ground Wire Terminal

Communication Wires

Drain Switch

Manual M3000 controller.

Ground Wire Terminal

20-Pin Connecto

Locator Wire

5. Install the replacement controller. Reverse steps 1 thru 4.

6. Setup the manual M3000 controller following the instructions in the Installation and Operation manual. Setup

MUST be performed after replacement.

7. Once setup is complete on all replaced controllers, reset all control power following the instructions in section

1.13.6 to readdress the new controller. Check software version and if necessary update the software. If a software update was necessary, follow the instructions to update the software in section 1.15 on page 1-34.

1.9.2 Replacing the Temperature Probe, High-Limit Thermostat

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil below the level of the probe or thermostat.

3. Remove the screws on the bottom of the bezel. Carefully lower the bezel.

4. Remove the top two screws in the upper corners of the controller.

5. Swing the controller out from the top and allow it to rest on its hinge tabs.

6. Disconnect the controller wiring harness(es) and ground wire from the back of the controller and remove the

controller by lifting it from the hinge slots in the control panel frame.

7. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you.

8. Disconnect the flame sensor wires from the flame sensors.

9. Disconnect the sound device lead from the interface board.

1-7

10. If working on the left frypot, cut the wire tie on the wiring bundle and disconnect the main wiring harness 15-pin

connector.

11. Remove the spark module boxes.

12. Remove the component box mounting screws.

13. Lower the component box far enough to expose the probes and carefully disconnect the wiring harness plug from

the back of the box. This will leave one set of wires, enclosed in spiral wrap, connected to the component box.

14. Unscrew the probe or thermostat from the frypot.

15. Apply Loctite

PST56765 pipe thread sealant or equivalent to the replacement part threads and screw the

replacement part into the frypot, torquing to 180 inch-pounds.

16. Connect the wires from the new component as follows:

a. If replacing the temperature probe, use a pin pusher to disconnect (one at a time) the red and white leads from

the connector and insert the corresponding leads from the new probe into the plug..

b. If replacing the high-limit thermostat, use a pin pusher to disconnect the lead running to the connector and

insert the corresponding lead from the new thermostat.

c. Disconnect the other lead from the drain safety switch and connect the remaining lead from the new

thermostat.

17. Reverse steps 1 through 13 to complete the procedure.

1.9.3 Replacing the Interface Board

1. Perform steps 1 through 4 from section 1.9.1.

2. Disconnect the wires attached to the interface board, marking or making a note of the wires and terminals to

facilitate reconnection.

3. Remove the nuts at each corner of the interface board and carefully pull it from the studs far enough to allow the

connector on the back of the board to be disconnected, then remove the board from the box. When removing the board, be careful not to lose the spacers that fit over the studs behind the board.

4. Recover the relay(s) from the failed interface board and install on the replacement board.

5. Reverse the procedure to install the replacement board, being sure that the spacers behind the board are in place

and the computer locator ground wire is attached to a stud.

1.9.4 Replacing an Ignition Module

1. Disconnect the fryer from the electrical supply.

2. Remove the screws on the bottom of the bezel. Carefully lower the bezel.

3. Remove the top two screws in the upper corners of the controller.

4. Swing the controller out from the top and allow it to rest on its hinge tabs.

5. Loosen the nuts attached to the screws of the module. Slide the module towards the rear of the component box

until the nuts drop through the keyholes.

6. Carefully rotate the module and pull forward. On some units it may be necessary to remove the blower.

7. Disconnect the wires from the ignition module, marking or making a note of the wires and terminals to facilitate

reconnection.

8. Remove the screws from the module.

9. Move the screws and spacers to the new module.

10. Reverse the procedure to install the replacement module.

1.9.5 Replacing an Ignitor Assembly

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

1. Disconnect the fryer from the electrical supply.

2. Disconnect the flame sensor wire by carefully pulling its push-on terminal from the terminal strip on the ignitor.

Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition cable from the ignitor by grasping its boot and gently pulling toward you. (See photo below)

1-8

Flame Sensor Wire

Gas Enrichment Tube

Ignition Cable

3. Remove the sheet metal screws securing the ignitor to the mounting plate and pull the ignitor from the fryer.

4. Reverse the procedure to install the replacement ignitor.

1.9.6 Replacing or Cleaning a Combustion Air Blower

Disconnect the blower wiring harness, remove the blower assembly mounting nuts, and remove the blower assembly from the fryer. If cleaning the motor, continue with Step 2; otherwise, install the replacement blower, reconnect the wiring harness, and then go to Step 6.

Blower assembly

mounting nuts

Wiring connection

2. Remove the blower motor shield and separate the blower motor from the housing as shown in the illustration

below.

Remove these screws to remove the shield from the blower assembly.

Remove these nuts to separate the blower motor from the housing.

3. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreaser or detergent on the blower

wheel and the blower housing. Allow it to soak for five minutes. Rinse the wheel and housing with hot tap water, then dry with a clean cloth.

NOTICE- Australia Only The air pressure switch on the combustion blower should read: Full Vat units-122pa (0.5 inches W.C.) and for Split Vat units-180pa (0.72 inches W.C.).

1-9

Wrap the motor and wires

with plastic wrap or a

plastic bag.

Blower Housing

Blower Wheel

4. Remove the plastic wrap from the blower motor assembly. Reassemble the blower motor assembly and blower

housing. Reinstall the blower shield.

5. Reinstall the blower assembly in the fryer and reconnect the wiring disconnected in Step 1.

6. Light the fry er in accordance with the procedure described in Chapter 3, Section 3.2.2 of the BIGL30 Series Gas

Fryer Installation and Operation Manual.

7. After the burners have been lit for at least 90 seconds, observe the flames through the burner viewing ports

located on each side of the combustion air blower.

Right

Viewing Port is

behind motor.

Left Viewing

Port.

The air/gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable table on page 1-6 and the burners display a bright orange-red glow. If a blue flame is observed or if there are dark spots on a burner face, the air/gas mixture requires adjustment.

result in whistling. It should not be more than 1/3 open.

NOTE: Opening the air shutter too much may

1.9.7 Adjusting the Air/Gas Mixture

On the side of the blower housing opposite the motor is a shutter plate with a locking nut. Loosen the nut enough to allow the shutter to be moved, then adjust the position of the shutter to open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold the shutter in position and tighten the locking nut (see illustration on the following page).

1-10

On non-CE blowers, loosen this nut and rotate shutter to open or close air intake.

On CE blowers, loosen both wing nuts and slide the shutter to adjust the air intake.

1.9.8 Replacing a Gas Valve

1. Disconnect fryer from electrical and gas supplies.

2. Disconnect the drain safety and high-limit thermostat wires from the gas valve. Mark each wire to facilitate

reconnection.

3. Remove the vent tube (on non-CE fryers) and the enrichment tube fitting from the valve. Disconnect the flexible

gas line(s).

If replacing the left-most valve on any configuration, or the right valve on a two-fryer battery, follow the instructions below. If replacing valves in other positions, skip to “ALL OTHER VALVES.”

A. Remove the filter pan from the unit. Remove the door adjacent to the valve being replaced. B. Remove the screws that attach the pan rails adjacent to the valve being replaced. C. Uncouple the pipe union and remove the gas valve and associated piping from the unit. D. Remove the fittings and associated piping from the failed valve and install them on the replacement valve using

Loctite

E. Reconnect the gas valve assembly to the fryer using Loctite

reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the highlimit thermostat wires and drain safety wires to the valve.

F. Reconnect the fryer to the gas supply and open the cut off valve. Apply a thick soapy solution of water around

each connection to check for gas leaks and ensure there are no bubbles. Eliminate any that are found. There should be no smell of gas.

G. Position the pan rail assembly beneath the fryer and rest the rear end of the rail on the cabinet frame. Install the

two nuts and bolts behind the front face of the rail, but do not tighten them. Install the nut and bolt at the rear end of the filter rail and tighten securely.

H. Reattach the screws for the pan rails. Install the filter pan in the unit to make sure that all components are properly

aligned.

I. Reconnect the fryer to the electrical power supply and check for proper operation. When proper operation has

been verified, reinstall the door removed in Step A.

ALL OTHER VALVES

4. Carefully unscrew the valve from the manifold. NOTE: Some models may have the valve attached to the

manifold by means of a pipe union. In such cases, remove the valve by uncoupling the union.

5. Remove all fittings from the old gas valve and install them on the replacement valve, using Loctite

equivalent pipe thread sealant.

6. Reconnect the gas valve assembly to the fry er using Loctite

reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the highlimit thermostat wires and drain safety wires to the valve.

7. Reconnect the fryer to the gas supply and open the cut off valve. Apply a thick soapy solution of water around

each connection to check for gas leaks and ensure there are no bubbles. Eliminate any that are found. There should be no smell of gas.

8. Reconnect the fryer to the electrical power supply and check for proper operation.

PST56765 or equivalent pipe thread sealant.

PST56765 or equivalent pipe thread sealant, and

PST56765 or

PST56765 or equivalent pipe thread sealant, and

1-11

1.9.9 Replacing a Burner Assembly

1. Disconnect the unit from the electrical and gas supplies.

2. Remove the gas line and enrichment tube using a 7/16” and 5/8” wrench from the front of the burner.

3. Remove the elbow and tee off the bottom of the burner to ensure easier

removal of the burner.

4. Remove the fryer back.

5. Remove the screws attaching the flue cap to the brace.

6. Remove the top cross brace in the back.

7. Remove the flue by removing the two screws in the rear and one screw in

the front of the flue.

Figure 1

8. Remove all the screws on the flue collector and bend back the tabs and remove the

collector.

9. Remove four screws on the collector insulation plate (see Figure 1).

10. Remove the four nuts and cover of the lower insulation retaining cover (see Figure

2).

11. Carefully remove the insulation.

12. Grasp the burner firmly and slide the burner out the rear of the fryer. Pull it toward

you until it clears the burner channels, taking care not to damage the ceramic tiles in the process.

Figure 2

13. Slide the burner out the rear of the fryer.

14. Clean all debris from the burner channels and combustion area.

15. Inspect the upper and lower burner rails for cracked or burned out welds. a. If the welds in the lower rail are cracked or burned out, the frypot must be

replaced. Refer to Section 1.9.11 for procedure.

b. If the welds in the upper rail are cracked or burned out, the upper rail must be

replaced. Refer to Section 1.9.12 for procedure.

16. Wrap a new insulating strip along the edges of the burner. NOTE: Use P/N 8260931 for full-vat frypots and P/N 826-0932 for dual-vat frypots.

17. Carefully slide the replacement burner into the rails starting at the top and lifting slightly up on the bottom (see Figure 3). Ensure that the insulation is not torn or damaged.

Figure 3

18. In reverse order, reassemble insulation and holding plates.

19. Install flue collector.

20. Install the flue.

21. Install the cross brace, ensuring the flue cap is secured to the brace.

22. Replace the fryer back.

23. Reattach the elbow, gas line and enrichment tubes to the front of the burner.

24. Fill the frypot with oil. Turn the fryer on; turn off or bypass the melt cycle and operate the unit for at least 10 minutes.

25. Examine the burner flame. The color and intensity on both sides should be the same. Use an inspection mirror to check for leaks in areas that cannot be directly

26.

observed.

27. If a leak is detected, tighten all the lower insulation retainer nuts, allow the frypot to heat for five additional minutes, and repeat steps 25 and 26.

28. If a leak persists, use a rubber hammer and a small block of wood to tap the corners of the lower combustion chamber insulation retainers. Repeat steps 25 through 27. Repeat this step until no leakage is detected.

1-12

1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve

1. Disconnect the unit from the electrical power supply.

2. Remove the filter pan from the unit.

3. Position a container beneath the oil return fitting at the front of the cabinet. Disconnect the flexible oil lines from

the fittings, allowing any residual oil to drain into the container.

4. At the rear of the fryer, unplug the left connector (as viewed from the rear of the fryer) from the transformer box.

5. Remove the four nuts and bolts attaching the motor mount to the rear motor mount support.

6. At the front of the fryer, remove the cover plate from the front of the motor and disconnect the motor wires.

7. Place a 1-foot (30.5-cm) length of wood (or similar support) beneath the motor mount near the front of the unit

and remove the two remaining nuts and bolts attaching the motor mount to the front cabinet cross-brace.

8. Carefully remove the support and lower the motor mount to the floor, allowing the rear of the mount to slide

forward and off the rear motor mount support.

9. Disconnect the return flexline from the pump. The motor and pump assembly can now be pulled from beneath the

fryer and the failed component can be removed and replaced.

10. Position the replacement motor and pump assembly beneath the fryer and reconnect the oil return flexline to the

pump. Lift the rear of the motor mount up and onto the rear motor mount support.

11. Lift the front of the motor mount up and support it with a 1-foot (30.5-cm) piece of wood or a similar support.

Install but do not tighten the two nuts and bolts that attach the motor mount to the front cabinet cross-brace.

12. Install and tighten the four nuts and bolts that secure the motor mount to the rear motor mount support.

13. At the front of the fryer, tighten the two nuts and bolts at the front of the motor mount. Reconnect the motor

power wires and reinstall the wiring cover plate.

14. Reconnect the oil return flexline and reinstall the filter pan.

15. Reconnect the unit to the electrical power supply, fill the frypots with oil and check for proper operation.

1.9.11 Replacing the Frypot

1. Disconnect the fryer from the electrical and gas supplies.

2. Remove the filter pan from the unit and drain one frypot at a time into a Shortening Disposal Unit (SDU) or other

appropriate metal container.

DANGER

DO NOT attempt to drain more than one full frypot into the SDU at one time.

3. Open the control panel by removing the two screws on the bottom of the bezel. Carefully lower the bezel.

4. Remove the top screws in the upper corners of the controller.

5. Grasp the upper edge of each controller and swing the controller downward. Unplug the controller wiring harness

and grounding wire from the back of each controller.

6. Remove the controllers by lifting them from the hinge slots in the control panel frame.

7. Disconnect the sound device wire from the interface board.

8. Disconnect the flame sensor wires by carefully pulling the push-on terminals from the terminal strips on the

ignitors. Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you.

9. Dismount the topcap by removing the screws on the bottom of each front corner and lifting the topcap straight up.

10. Remove the two mounting screws on each side of the component box and rotate the top of the box out of the

frame. Carefully pull it out enough to disconnect the wiring harness connector from the back of the box. Cut any ties that prevent the box from being pulled out of the control panel frame.

11. Carefully pull the box clear of the frame and rest it on top of the fryer.

12. Using a pin pusher, remove the temperature probe, high-limit thermostat wires and RTD probe wires from the

plugs or terminals, marking each wire to facilitate re-assembly.

13. Remove the cover from the safety drain switch. Disconnect the wires from the switch.

14. Disconnect any auto top-off sensors if equipped and wiring.

15. Remove the section(s) of drain from the drain valve(s) of the frypot to be removed.

1-13

16. Disconnect the gas lines from the burner orifices and ignitor assemblies.

17. Remove the frypot hold down bracket.

18. Remove the screws in the back panel and inside the flue cap at each end that secure the flue cap to the fryer and lift it clear of the fryer.

19. Disconnect the oil return line(s) from the frypot to be removed.

20. Carefully lift the frypot from the fryer cabinet.

21. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), RTD probes and igniter assemblies. Inspect each of these components carefully and install them in the replacement frypot if they are in serviceable condition. Use Loctite

PST56765 sealant or equivalent on component threads.

NOTE: Some servicers, based upon their experience, recommend that probes and thermostats be replaced whenever a frypot is replaced; however, this remains the customer’s decision.

20. Reverse steps 1-19 to reassemble fryer. NOTE: Care should be taken not to over-torque nuts on frypots made of 400-series stainless steel, as this could tear the material. One turn past hand-tight is sufficient torque.

21. Perform steps 14 through 18 of Section 1.9.9 to ensure that there are no leaks in the burner insulation.

CAUTION Before installing temperature probe, high-limit thermostat, RTD probe and drain valve on replacement frypot, clean the threads and apply Loctite® PST56765 thread sealant or equivalent.

1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails

NOTE: Replacing the burner rails requires completely tearing down the frypot and installing new frypot insulation.

Refer to the frypot exploded view (on next page) for component identification.

1. Remove the frypot per Section 1.9.11.

2. Remove the burner assemblies (1).

3. Remove insulation retainers and blanket insulation (2).

4. Remove the upper oil zone insulation bracket and upper oil zone insulation (3).

5. Remove the plenum (4).

6. Remove the front lower combustion chamber insulation retainer and insulation (5) and the front lower combustion

chamber inner insulation retainer and insulation (6). NOTE: Full-vat units have two-piece insulation retainer and insulation components. Dual-vat units have one-piece components.

7. Remove the upper combustion chamber insulation retainer and insulation (7).

8. Remove the inner upper combustion chamber insulation retainer and insulation (8).

9. Remove the rear lower combustion chamber retainers, back, and insulation (9). NOTE: Full-vat units have two-

piece backs and four retainers. Dual-vat units have one-piece backs and two retainers.

10. Remove the flue assembly (10).

1-14

Spacer

Disassembling A Frypot

(Full Vat Illustrated)

See page 1-17 for reassembly illustration.

11. Remove the upper burner rails (11). NOTE: For the following steps, refer to the frypot exploded view on page 1-

15 for component identification.

12. Remove any residual insulation, sealant, and/or oil from the exterior of the frypot.

13. Place the “L” shaped pieces of the combustion chamber insulation (1) in the front and rear corners of both upper

rail-retaining slots. (See page 1-17).

14. Using a mallet and short piece of wood, tap the corner tabs of the combustion chamber over the insulation to

ensure a solid seal of the burner.

15. Install the upper burner rails (2) with the heat deflectors slanting toward the rear of the frypot. The rails will

cover the “L” shaped pieces of combustion chamber insulation previously installed.

16. Place the upper inner combustion chamber insulation and insulation retainers (3) on the top two studs on each side

of the front of the frypot and secure with ¼”-20 washer-nuts. It is normal for the retainers to slice off the overhanging insulation.

17. Place the lower rear combustion chamber insulation (4) on the lower four studs at the rear of the frypot.

18. Place one 1.625-inch tubular spacer (5) on each of the flue assembly (upper) studs at the rear of the frypot.

NOTE: There are three different sizes of spacers. Verify the size to ensure the correct spacers are installed.

19. Press the flue assembly (6) over the burner rails. It may be necessary to use a rubber mallet or screwdriver to

align the components. Use four ¼”-20 washer nuts to secure the flue assembly. Do not tighten the retainer nuts at this point. They should be finger-tight only. NOTE: The flue edge will cover one to two inches of the lower insulation.

20. Install the lower rear combustion chamber back(s) and retainer(s) (7) with the flanged edge(s) against the flue.

Secure with ¼”-20 washer nuts. NOTE: Full-vat units have two-piece backs and four retainers. Dual-vat units come with one-piece backs and only two retainers.

1-15

21. Insert the burners (9) into the rails to ensure the rail spacing and alignments are correct. The burner should slide

freely into and out of the rails. The upper rail can be bent slightly to increase or decrease tension on the burner and the edges of the slot can be closed or opened slightly to best fit the burner frame.

22. Carefully wrap a strip of burner insulation (8) tightly around the rear and sides of the burner frame (9), with the

glass-tape side of the strip on the outside. Do not use duct tape or adhesive to secure the strip to the burner frame.

23. Align the burner to the burner rails while maintaining tension on the insulation strip. Insert the burner at a slight

angle and begin pushing the burner slowly into the rails until it contacts the rear combustion chamber. The fit should be snug, but not excessively tight.

24. Verify that the burners are flush with the front edge of the burner rails. Remove the excess burner insulation by

cutting with a knife or diagonal pliers. Do not try to tear the insulation!

25. Insert the upper front insulation (10) into its retainer (11), making sure that the holes in each piece are aligned

with one another. Install the assembly with the insulation side toward the frypot and secure with ¼”-20 washernuts. Do not over tighten.

26. Place a washer on each of the four lower studs on the front of the frypot. Install the lower inner front insulation

(12) with the rectangular openings toward the drain valve nipple. Install the lower inner front insulation retainer(s) (13). NOTE: Full-vat units have a two-piece insulation retainer. Dual-vat units have a one-piece retainer.

27. If necessary, replace the sight-glasses and insulation (14).

28. Place one washer and one 1.888-inch spacer (15) on each stud. NOTE: There are three different sizes of spacers.

Verify the size to ensure the correct spacers are installed.

29. Insert the front lower insulation (16) into the front lower insulation retainer(s) (17) and install assembly on

frypot. Secure with ¼”-20 washer-nuts. If frypot uses two retainers, connect them together with two ¼” selftapping screws. NOTE: Full-vat units have a two-piece insulation retainer and two pieces of insulation. Dual-vat units have one-piece components.

30. Return to the rear of the frypot and fully tighten all washer-nuts.

31. Remove and replace the plenum gaskets (18).

32. Place a 0.938-inch spacer (19) on the plenum-mounting studs, and mount the plenum (20). Ensure the gaskets

are clear of the burner tubes by pulling the plenum back slightly. Place a washer on each stud and secure plenum with ¼”-20 lock-nuts.

33. Install the upper oil-zone insulation (21) by pressing it under the upper combustion chamber metalwork. Secure

the insulation with the bracket (22) and ¼” self-tapping screws.

34. Install the upper burner rail blanket insulation (23). Position any excess insulation toward the top of the frypot.

Avoid overhang past the bottom of the upper burner rail. Overhang in this area will make future burner replacement more difficult.

35. Cover the insulation with the insulation retainer (24), and secure with ¼” self-tapping screws.

36. Reinstall probes, drain valves, high-limit thermostats, and other pipe fittings using Loctite® PST56765 sealant or

equivalent on the threads.

1-16

Re-assembling A Frypot

(Full-Vat Illustrated)

1.10 Troubleshooting and Problem Isolation

Because it is not feasible to attempt to include in this manual every conceivable problem or trouble condition that might be encountered, this section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment, and the probable causes of each. With this knowledge, the technician should be able to isolate and correct any problem encountered.

Problems you are likely to encounter can be grouped into six categories:

1. Ignition failure

2. Improper burner function

3. Improper temperature control

4. Controller malfunctions

5. Filtration malfunctions

6. Leakage

The probable causes of each category are discussed in the following sections. A series of Troubleshooting Guides is also included at the end of the chapter to assist in solving some of the more common problems.

1-17

1.10.1 Heating (Ignition) Failure

Heating (ignition) failure occurs when the ignition module fails to sense a flame within the 4-second time delay period and locks out. When this happens, the module sends 24 VAC through the interface board alarm circuit to the controller.

M3000 controllers display “HEATING FAILURE.” The three primary reasons for ignition failure, listed in order of probability, are problems related to:

1. Gas and/or electrical power supplies

2. Electronic circuits

3. 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 and/or there are no indicator lights illuminated on the fryer experiencing ignition failure. Verify that the quick disconnect fitting is properly connected, the fryer is plugged in with connector twisted and locked, the main gas supply valve is open, and the circuit breaker for the fryer electrical supply is not tripped.

PROBLEMS RELATED TO THE ELECTRONIC CIRCUITS

If gas and electrical power are being supplied to the fryer, the next most likely cause of ignition failure is a problem in the 24 VAC circuit. Verify that the drain valve is fully closed. The valve is attached to a microswitch that must be closed for power to reach the gas valve (often, although the valve handle appears to be in the closed position, the microswitch is still open). If the valve is fully closed, refer to Section 1.11.1, TROUBLESHOOTING THE 24 VAC

CIRCUIT.

Some typical causes of heating failure in this category include a defective sensing wire in the ignitor assembly, a defective module, a defective ignition wire, and a defective ignitor.

Occasionally, a heating failure occurs in which all components appear to be serviceable and the microamp reading is within specification, but the unit nevertheless goes into ignition failure. The probable cause in this case is an intermittent failure of an ignition module. When the unit is opened up for troubleshooting, the module cools down enough to operate correctly; however, when the unit is again closed up and placed back into service the module heats up and fails.

PROBLEMS RELATED TO THE GAS VALVE

If the problem is not in the 24 VAC circuit, it is most likely in the gas valve, itself. Before replacing the gas valve, refer to Section 1.11.2

1.10.2 Improper Burner Function

TROUBLESHOOTING THE GAS VALVE.

With problems in this category, the burner ignites but exhibits abnormal characteristics such as “popping,” dark spots on the burner ceramics, fluctuating flame intensity, and flames shooting out of the flue.

“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  Defective or incorrectly adjusted

combustion air blower

 Inadequate make-up air  Heat-damaged computer or ignition module

1-18

 Cracked ignitor or broken ignition wire  Defective ignition module  Cracked burner tile (typically causes a very

loud pop).

If popping occurs only during peak operating hours, the problem may be incorrect or fluctuating gas pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the appropriate CE or Non-CE Standard found in Section 2.3 page 2-4 of the BIGL30 Series Gas Fryer Installation and Operation Manual, and that the pressure remains constant throughout all hours of usage. Refer to Section 1.7, Checking the Burner Manifold Gas Pressure in this manual for the procedure for checking the pressure of gas supplied to the burner.

If popping is consistent during all hours of operation, the most likely cause is an insufficient air supply. Check for “negative pressure” conditions in the kitchen area. If air is flowing into the kitchen area, this indicates that more air is being exhausted than is being replenished and the burners may be starved for air.

If the fryer’s gas and air supplies are correct, the problem is most likely with one of the electrical components. Examine the ignition module and controller for signs of melting, distortion, and/or discoloration due to excessive heat build-up in the fryer (this condition usually indicates improper flue performance). A melted or distorted ignition module is automatically suspect and should be replaced; however, unless the condition causing excessive heat is corrected, the problem is likely to recur.

Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage. Again, if damage is due to excessive heat in the fryer, that problem must also be corrected. Check for proper operation by disconnecting the wire from the ignitor (spark plug), inserting the tip of a screw driver into the terminal. With the insulated handle of the screwdriver, hold the shaft 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 four seconds.

DANGER

Make sure you are holding the insulated handle of the screwdriver and not the blade. The sparking charge is approximately 25,000 volts.

Examine the ignitor (spark plug) for any signs of cracking. A cracked ignitor must be replaced. If all other causes have been ruled out, examine the burner tiles for any signs of cracking. If cracking is

found, the burner must be replaced. Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure, but

may also be the result of variations in the kitchen atmosphere. Verify incoming gas pressure in the same way as for “popping,” discussed in the preceding paragraphs. Variations in the kitchen atmosphere are usually caused by air conditioning and/or ventilation units starting and stopping during the day. As they start and stop, the pressure in the kitchen may change from positive or neutral to negative, or vice versa. They may also cause changes in airflow patterns that may affect flame intensity.

Dark spots on the burner tiles are the result of an improper air/gas mixture. Adjust the combustion air blower to reduce the amount of air in the mixture to correct this problem

Flames shooting out of the flue are usually an indication of negative pressure in the kitchen. Air is being sucked out of the burner 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 1.7.

An excessively noisy burner, especially with flames visible above the flue opening, may indicate that the gas pressure is too high, or it may simply be that the gas valve vent tube is blocked. If the incoming gas pressure is correct and the vent tube is unobstructed, the gas valve regulator is probably defective.

Occasionally a burner may apparently be operating correctly, but nevertheless the fryer has a slow recovery rate (the length of time required for the fryer to increase the oil temperature from 250ºF to 300ºF (121ºC to 149ºC)). The primary causes of this include an over-filled frypot, a dirty or out-of-adjustment combustion air blower, low burner manifold pressure, and/or damaged burner tiles. Adding oil to the frypot during the recovery process will also cause a slow recovery rate.

If these causes are ruled out, the probable cause is a misadjusted gas valve regulator. Refer to Section 1.7, Checking the Burner Manifold Gas Pressure, for the gas valve adjustment procedure.

1-19

1.10.3 Improper Temperature Control

Temperature control, including the melt cycle, is a function of several interrelated components, each of which must operate correctly. The principle component is the temperature probe. Other components include the interface board, the controller itself, and the ignition module.

Improper temperature control problems can be categorized into melt cycle problems and failure to control at setpoint problems.

MELT CYCLE PROBLEMS

Initiation of the melt cycle with manual M3000 controllers is automatic. Problems may originate from the

controller itself, the temperature probe, or a malfunctioning heat relay on the interface board.

FAILURE TO CONTROL AT SETPOINT

Problems in this category may be caused by the temperature probe, the interface board, or the controller.

1.10.4 Controller Malfunctions

RECOVERY TIME

Recovery time – is a method of measuring a fryer’s performance. Put simply, it is the time required for the fryer to increase the oil temperature from 250ºF to 300ºF (121ºC to 149ºC). This range is used as a standard since ambient kitchen temperatures can affect the test if lower ranges are used.

The controller performs the recovery test each time the fryer warms up. An operator can view the results of the test any time the fryer is above the 325ºF (163ºC) point by pressing the INFO button once when the fryer is on. The test results will be displayed in the controller’s LED panel in minutes and seconds. The maximum acceptable recovery time for BIGL30 series gas fryers is two minutes and twenty-five seconds (2:25).

1.10.5 Filtration Malfunctions

The majority of filtration problems arise from operator error. One of the most common errors is placing the filter pad on the bottom of the filter pan rather than over the filter screen.

Whenever the complaint is “the pump is running, but no oil is being filtered,” check the installation of the filter pad, including that the correct size is being used. While you are checking the filter paper/pad, verify that the O-rings on the filter pan suction tube are present and in good condition. Missing or worn O-rings will allow the pump to suck air and decrease its efficiency.

If the pump motor overheats, its thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch located on the front of the motor. If the pump then starts, something caused the motor to overheat. It may be that several frypots in a large battery of fryers were being filtered one after the other and the pump became hot. Letting the pump cool down for at least a halfhour is all that is required in this case. More often, the pump overheated for one of the following reasons:

 Shortening that remained in the pan, after

previous filtering, solidified in the suction tube recess in the bottom of the pan or the suction tube, itself. Adding hot oil to the pan and waiting a few minutes will usually correct this problem. A flexible wire can be used to clean out the suction tube and the recess in the bottom of the pan. NEVER use compressed air to blow solidified shortening out of the suction tube!

FLOW

FREEING A SEIZED PUM P

Sediment Particle

Up fo r re v e rse

Down for forward

1-20

 Room temperature oil was filtered. Cold oil is thicker and causes the pump motor to work harder and

overheat.

If the motor hums but the pump does not rotate, there is a blockage in the pump. Incorrectly sized or installed paper will allow food particles and sediment to pass through the filter pan and into the pump. When sediment enters the pump, the gears can bind up and cause the motor to overload, tripping the thermal overload. Solidified shortening in the pump will also cause it to seize, with similar results.

A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a screwdriver or other instrument as illustrated on the previous page. Make sure power to the pump motor is

off before trying this.

1. Disconnect power to the filter system.

2. Remove the input plumbing from the pump.

3. Use a screwdriver to manually turn the gears.

 Turning the pump gears backwards will release a hard particle and allow its removal.  Turning the pump gears forward will push softer objects and solid shortening through the pump and

allow free movement of the gears.

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

1.10.6 Leakage

Leakage of the frypot is usually due to improperly sealed high-limit thermostats, RTD’s, temperature probes, and drain fittings. When installed or replaced, each of these components must be sealed with Loctite

PST56765 sealant or equivalent to prevent leakage. In very rare cases, a leak may develop along one of the welded edges of the frypot. When this occurs, the frypot must be replaced.

If the sides or ends of the frypot are coated with oil, the most likely cause is spillage over the top of the frypot rather than leakage.

The clamps on the rubber boots that hold the drain tube sections together may loosen over time as the tubes expand and contract with heating and cooling during use. Also, the boot itself may be damaged. If the section of drain tube connected to the drain valve is removed for any reason, ensure that its rubber and clamps are in good condition and properly fitted around the drain tube when it is reinstalled. Also, check to ensure that the drain tube runs downward from the drain along its whole length and has no low points where oil may accumulate.

1.11 Troubleshooting Guides

The troubleshooting guides on the following pages are intended to assist service technicians in isolating the probable causes of equipment malfunctions by following a logical, systematic process. An additional set of operator troubleshooting guides are contained in Chapter 7 of the BIGL30 Series Installation and Operation Manual. It is suggested that service technicians thoroughly familiarize themselves with both sets.

1-21

1.11.1 Troubleshooting the 24 VAC Circuit

Prior to checking for problems associated with the 24 VAC circuit, ensure that the unit is connected to a power supply, the drain valve is fully closed, and the controller is on and is calling for heat (green dot appears under heat indicator and display toggles between LOW TEMP).

NOTE: All voltage measurements must be made within 4 seconds of the unit calling for heat. If unit does not fire within 4 seconds, ignition modules will lock out and controller must be turned off, then on to reset.

The following processes will assist you in troubleshooting the 24 VAC circuit and ruling it out as a probable cause:

 24 VAC is not present on the interface board J3 pin 9 (LED 5 (GV)).

1. If LED 3 is not continually lit, the probable causes are a failed 24 VAC transformer or failed wiring

between the transformer and interface board.

2. If LED 3 is continually lit, check the right PWR terminal (LED 4) for 24 VAC.

check the left PWR terminal (LED 2) for 24 VAC.

Verify that the F2 fuse is not blown.

a. If 24 VAC is not present, the probable cause is a failed interface board, blown fuse or a defective

heat relay.

b. If 24 VAC is present, check for 24 VAC on V1S

(or V1D and V2D, if dual unit)..

i. If 24 VAC is not present, check the fuses. If they are good, the probable causes are failed

ignition module(s) or a failed interface board. Replace the questionable ignition module with one known to be good to isolate the cause.

ii. If 24 VAC is present, the probable cause is a failed interface board.

 24 VAC is present on interface board J3 pin 9 (LED 5 (GV))

(GV)).

and, on dual units, on J1 pin 9 (LED 1

1. If 24 VAC is not present across the gas valve main coil (MV terminals), probable causes are an open

high-limit thermostat or a failed wire between the interface board and gas valve. Be sure to check both valves on dual units. Check continuity of high-limit thermostat. If reading is zero, problem is in wiring.

2. If 24 VAC is present across the gas valve main coil (MV terminals), the 24 VAC circuit is working

and the problem may be with the gas valve. Be sure to check both valves on dual vat units.

 Ensure drain valve is closed and that it has continuity. If reading is zero, problem is in wiring.

On dual units, also

1-22

1-23

1.11.2 Troubleshooting the Gas Valve

Prior to checking for problems associated with the gas valve, ensure that the unit is calling for heat. Also, for non-CE units, verify that the gas valve is in the ON position.

The following processes will assist you in troubleshooting the gas valve and ruling it out as a probable cause:  If 24 VAC is not present across gas valve main coil, the probable cause is the 24 VAC circuit. Refer to

the 24 VAC circuit troubleshooting guide.

 If 24 VAC is present across gas valve main coil, check the incoming gas pressure and compare to the

tables on page 2-4 of the Installation and Operation manual.

1-24

1. If incoming gas pressure is not correct, the probable cause is the gas supply to fryer.

2. If incoming gas pressure is correct, check the burner manifold gas pressure and compare it to the

tables on page 2-7 of the Installation and Operation manual. a. If burner manifold gas pressure is not correct, the probable cause is an improperly adjusted or

failed gas valve. Adjust the valve by following the procedure “Check Burner Manifold Pressure” in Section 1.7 of this manual. If the valve cannot be adjusted, replace it.

b. If outgoing gas pressure is correct, the gas valve is okay.

1.11.3 Troubleshooting the Temperature Probe CAUTION

Disconnect the controller before testing temperature probe resistances to avoid invalid readings

Prior to checking for problems associated with the temperature probe, inspect the probe body for damage while it is still in the frypot. Remove and replace the probe if it is bent, dented, or cracked. Also, inspect leads for fraying, burning, breaks, and/or kinks. If found, replace the probe.

The following processes will assist you in troubleshooting the temperature probe and ruling it out as a probable cause:

Before testing the probe, determine the temperature of the cooking oil using another thermometer or pyrometer placed at the tip of the questionable probe.

 If resistance through J3 pins 2 and 6 (J1 pins 2 and 6 for left side of dual unit) is not approximately

equal to that given in the Probe Resistance Chart for the corresponding temperature, the probe has failed and must be replaced.

 If resistance through J3 pins 2 and 6 (J1 pins 2 and 6 for left side of dual unit) is approximately

equal to that given in the Probe Resistance Chart for the corresponding temperature, measure the resistance through each of the previously tested pins to ground.

1. If resistance is not 5 mega-Ohms or greater in each pin, the probe has failed and must be replaced.

2. If resistance is 5 mega-Ohms or greater in each pin, the probe is okay.

1.11.4 Replacing the Transformer, Reset Switch or Filter Relay

Disconnect the fryer from the electrical power supply. Remove the cover from the transformer box in the rear of the fryer to expose the interior of the transformer box. Replace the transformer or filter relay marking the wires to ease reassembly. Once replaced, reconnect the power. When replacing a filter relay in the transformer, ensure the 24VAC relay (8070012) is used.

1-25

1.12 Probe Resistance Chart

Probe Resistance Chart

For use with BIGL30 Series fryers manufactured with Minco Thermistor probes only.

F OHMS C F OHMS C F OHMS C F OHMS C F OHMS C

60 1059 16 130 1204 54 200 1350 93 270 1493 132 340 1634 171 65 1070 18 135 1216 57 205 1361 96 275 1503 135 345 1644 174 70 1080 21 140 1226 60 210 1371 99 280 1514 138 350 1654 177 75 1091 24 145 1237 63 215 1381 102 285 1524 141 355 1664 179 80 1101 27 150 1247 66 220 1391 104 290 1534 143 360 1674 182 85 1112 29 155 1258 68 225 1402 107 295 1544 146 365 1684 185 90 1122 32 160 1268 71 230 1412 110 300 1554 149 370 1694 188

95 1133 35 165 1278 74 235 1422 113 305 1564 152 375 1704 191 100 1143 38 170 1289 77 240 1432 116 310 1574 154 380 1714 193 105 1154 41 175 1299 79 245 1442 118 315 1584 157 385 1724 196 110 1164 43 180 1309 82 250 1453 121 320 1594 160 390 1734 199 115 1174 46 185 1320 85 255 1463 124 325 1604 163 395 1744 202 120 1185 49 190 1330 88 260 1473 127 330 1614 166 400 1754 204 125 1195 52 195 1340 91 265 1483 129 335 1624 168 405 1764 207

1.13.6 Control Power Reset Switch

The control power reset switch, is a momentary rocker switch located below the left control box (see Figures 6), that resets all power to all the controllers and boards in the fryer. It is necessary to reset all power after replacing any controller or board. Press and hold the switch for at least ten seconds when resetting the control power to ensure power has sufficiently drained from boards.

Figure 6

1-26

1.14 Controller Service Procedures

1.14.1 Controller Troubleshooting Problem Probable Causes Corrective Action

A. No power to the fryer. B. Power switch turned off. C. Loose fuse holder.

No Display on

Controller.

M3000 display shows

filter busy.

D. Controller has failed. E. Damaged controller wiring harness. F. Power supply component or interface board has failed.

A. Another filtration cycle is still in

process.

A. Verify controller power cord is

plugged in and that circuit breaker is not tripped.

B. Some fryers have a rocker power

switch inside the cabinet below the controller. Ensure the switch is turned on.

C. Ensure fuse holder is screwed in

properly.

D. Swap the controller with a

controller known to be good. If controller functions, replace the controller.

E. Swap with a harness known to be

good. If controller functions, replace the harness.

F. If any component in the power

supply system (including the transformer and interface board) fail, power will not be supplied to the controller and it will not function.

A. Wait until the previous filtration

cycle ends to start another filtration cycle. This may take up to one minute. If filter busy is still displayed with no activity, remove and restore ALL power to the fryer.

M3000 display shows

RECOVERY

FAULT.

M3000 display is in

wrong temperature

scale (Fahrenheit or

Celsius).

Recovery time exceeded maximum time limit for two or more cycles.

Incorrect display option programmed.

Silence the alarm by pressing the  button. Check that fryer is heating properly. Maximum recovery for electric is 1:40.

Fryers using the M3000 controller can toggle between F° to C° by pressing and

holding the

and simultaneously

for TEN seconds; three chirps sound. The computer displays TECH MODE.

displays OFF. Turn the controller on to check temperature. If the desired

scale is not displayed, repeat.

Enter 1658. The controller

1-27

Problem Probable Causes Corrective Action

M3000 displays

SERVICE

REQUIRED followed

by the error.

M3000 display shows

hot-hi-1.

M3000 display shows

HI-LIMIT.

Controller displays

LOw temp with an

alarm.

M3000 display shows

low temp,

indicator cycles on and

off normally but fryer

M3000 display shows

TEMP PROBE

M3000 display shows

PROBE FAILURE

with alarm sounding.

Controller will not go

into program mode or

some buttons do not

M3000 display shows

FAILURE with

alarm sounding.

Heating indicator is

on, but fryer is not

heating

does not heat.

FAILURE.

actuate.

HI 2 BAD.

HEATING

heating.

Press YES to silence alarm. The error is displayed three times. See list of issues in section 1.14.3. Fix issue. The computer displays SYSTEM

An error has occurred.

Frypot temperature is more than 410ºF (210ºC) or, in CE countries, 395ºF (202ºC).

Controller in high-limit test mode.

Frypot temperature has dropped more than 40°F (17°C) for M3000 controllers below setpoint in idle mode or 45°F (25°C) in cook mode.

A. Failed controller. B. Damaged controller wiring harness.

Problem with the temperature measuring circuitry including the probe.

Damaged controller wiring harness or connector.

Failed controller. Replace controller

ERROR FIXED? YES/NO. Press YES. Computer displays

ENTER CODE. Enter 1111 to clear error code. Pressing NO will allow the

fryer to cook but the error will be redisplayed every 15 minutes. This in an indication of a malfunction in the temperature control circuitry, including a failure of the high-limit thermostat. This is displayed only during a test of the high-limit circuit and indicates that the high-limit has opened properly. This display is normal for a short while if a large batch of frozen product is added to the frypot or if the fryer is not heating properly.

A. Replace controller.

B. Replace controller wiring harness.

This indicates a problem within the temperature probe circuitry. Check resistance of probe, if faulty replace probe.

Swap the controller wiring harness with one known to be good. If problem is corrected replace harness.

This is displayed only during a test of

Controller in high-limit test mode.

Failed controller, failed interface board, open high limit thermostat, gas valve or gas is turned off.

the high-limit circuit and indicates that the high-limit has failed.

Check high limit thermostat, interface board, controller, gas valve. Ensure the gas valve is on.

1-28

Problem Probable Causes Corrective Action

M3000 display shows

HEATING

FAILURE and alarm

sounds, but fryer

operates normally

(false alarm).

M3000 display shows

CLOSE DRAIN

VALVE.

M3000 display shows

ERROR RM

SDCRD

M3000 display shows

CALL TECH

Failed controller.

Drain valve is open or switch is out of adjustment or failed.

Defective SD Card. Shown only during software updates.

Typically shown during software update. Also may be that parameter data has been corrupted or lost.

Replace controller.

Ensure all drain valves are completely closed and that microswitches are adjusted and working.

Replace card with another card.

Press the FILTER button to bypass and

continue.

1-29

1.14.2 M3000 Controller Useful Codes

To enter any of the following codes: Press and hold and simultaneously for TEN seconds; three chirps sound. The computer displays TECH MODE. Enter the codes below to perform the function.

 1658 – Change from F° to C° The computer displays off. Turn the computer on and check

temperature to see the temperature scale. If the desired scale is not displayed, repeat.

 3322 – Reset Factory Menu The computer displays COMPLETE and then off. (NOTE:

This will delete any hand-entered menu items).

 1650 – Enter Tech Mode. See page 1-36 to reset passwords and change filter pad time.  1212 – Switch between Domestic Menu and International Menu. The computer displays

COMPLETE and then off. (NOTE: This will delete any hand-entered menu items).

 0469 – Reset FILTER STAT DATA

 1000 – Reset CALL TECH Message - Disconnect board locator plug (J3). Reinsert plug.

Enter 1000. Computer display switches to off. Remove and then restore power to the computer using the 20-pin plug

 9988 – Reset BADCRC Message - Disconnect board locator plug (J3). Reinsert plug. Enter

9988. Computer display switches to off. Remove and then restore power to the computer

using the 20-pin plug.

The following codes are entered when prompted to do so or from an energy misconfigured exception error.

 1111 – Reset SERVICE REQUIRED Message – Enter when the issue is fixed and

prompted to enter.

 1234 – Enter SETUP MODE (This usually can be done without pressing the filter buttons if an

error is displayed.)

PASSWORDS

To enter level one, level two passwords: Press and hold the TEMP and INFO buttons simultaneously until level 1 or level 2 is displayed. Release the buttons and ENTER Code appears.

 1234 – Fryer Setup, Level One and Level Two  4321 – Usage Password (resets usage statistics).

1.14.3 Service Required Errors

A SERVICE REQUIRED error alternating with YES displays on the computer. After YES is pressed the alarm is silenced. The computer displays an error message from the list below three times with the location of the error. Then the computer displays SYSTEM ERROR FIXED? YES/NO. If yes is chosen, enter code 1111. If NO is chosen the system returns to cook mode for 15 minutes then redisplays error until issue is fixed.

1-30

1.14.4 Error Log Codes

Code ERROR MESSAGE

E03 ERROR TEMP PROBE FAILURE TEMP Probe reading out of range E04 HI 2 BAD High limit reading is out of range. E05 HOT HI 1

E06 HEATING FAILURE A component has failed in the high limit circuit

E08 ERROR ATO BOARD ATO board connection lost; ATO board failure E17 ERROR ATO PROBE ATO RTD reading out of range E20 INVALID CODE LOCATION SD card removed during update E21 FILTER PAPER PROCEDURE ERROR

(Change Filter Paper)

E22 OIL IN PAN ERROR Oil may be present in the filter pan. E25 RECOVERY FAULT Recovery time exceeded maximum time limit.

E27 LOW TEMP ALARM Oil temperature has dropped 40°F (17°C) below

High limit temperature is past 410°F (210°C), or in CE countries, 395°F (202°C)

such as controller, interface board, contactor, gas valve, failure to light, open-high limit or gas is off.

25-hour or customer-set timer has expired and the user has pressed “NO” twice at the “CHANGE FILTER PAPER” prompt.

Recovery time should not exceed 1:40 for electric.

setpoint temperature in idle mode or 45°F (25°C) in cook mode. (This message may appear if a product is dropped and the start cook button is not pressed immediately or if too large of cook loads are dropped.)

EXPLANATION

1-31

1.14.5 M3000 Controller Menu Summary Tree

Reflected below are the major programming sections in the M3000 and the order in which submenu headings will be found under the sections in the Installation and Operation Manual.

Adding New Product Menu Items See section 2.10.2 in the M3000 Controller manual

1-32

1.14.6 M3000 Controller Pin Positions and Harnesses

Connector From/To Harness PN

8075165

J4 Drain Switch

J7 Next M3000 J6

Interface Board

to Controller

Locator

Harness

Interface Board

Ground to Controller

M3000 J7 or

Network Resistor

SMT Controller to

Interface Board

Harness

1080485 1080486 1080487 1080488 1080489

8075159 (FV) 8075160 (DV)

8074546

Controller

Communication

Harness

8074646

Controller

Communication

Harness

# Function Voltage Wire Color

1 12VAC In 12VAC 2 Ground 3 12VAC In 12VAC 4 FV Heat Demand 5 V Relay 12VDC 6 DV Heat Demand 7 R/H B/L 12VDC 8 Analog Ground

9 L/H B/L 12VDC 10 ALARM 11 Sound Device 5VDC 12 ALARM 13 FV Probe 14 Common Probes 15 DV Probe 16 17 18

Blower Relay 12VDC Orange

19 20

1 Vat #1 2 Vat #2 3 Vat #3 4 Vat #4 5 Vat #5 6

1 FV Drain Black

2 FV Drain Red

3 DV Drain Black

4 DV Drain Red

1 Ground Black

2 CAN Lo Red

3CAN Hi White

1 Ground Black

2 CAN Lo Red

3CAN Hi White

Orange

Black

1-33

1.15 Loading and Updating Software Procedures

Updating the software takes approximately 30 minutes. The software only needs to be loaded in ONE controller, typically the far left controller in a battery and it will replicate to all the controllers and boards in the system. Press the TEMP button to check current M3000 software version. Remove the bezel by removing the screws under the bottom of the bezel. Remove the two screws securing the controller allow it to swing down. Remove the two screws on the left side cover plate of the M3000 controller or far left controller in a battery.

To update the software, follow these steps carefully:

Left Display Right Display Action

OFF OFF

UPGRADE IN

WAIT

PROGRESS

UPDATING

BOOT

PERCENTAGE

COMPLETE

BLANK

CALL TECH

UPGRADE IN

WAIT

PROGRESS

IF_COOK

HEXand

PERCENTAGE

COMPLETE

IF_aTO HEX

REMOVE SD

100

CARD

CYCLE

BLANK Cycle the control power using the hidden reset switch under the far left control

POWER.

BOARD ID

Zero or a number

from 1-4

System

BIGL30

type

System

BIGL30 Press . Ensure correct fryer type is displayed.

type TYPE

TYPE

GL30 Press the or  to select proper fryer model. One of several fryer models may

GL30 Once proper fryer model is displayed, press .

With the controller folded down, insert the SD card, with the contacts facing down and the notch on the bottom right (see Figure 7 and 8), into the slot on the left side of the M3000 controller. ENSURE THE CARD IS FULLY

INSERTED INTO THE SD CARD SLOT.

None required.

None required. If this message is displayed, press the FILTER button and the software load will

continue. None required.

None required.

Remove the SD card using the fingernail slot on the top of the SD card.

box. ENSURE THE SWITCH IS HELD FOR 10 SECONDS. Press the IO (Power) button.

Press the or  to choose correct fryer type. BIGL30 (Frymaster)

be displayed.

EXIT EXIT

OFF OFF

Press the

With the controller displaying OFF, VERIFY software update by pressing the TEMP button to check updated M3000 version on each controller.

M3000 should display software version shown on SD card on all controllers .

OFF OFF

Once the software has been updated and the versions are correct, replace the cover and screws covering the SD card slot. Replace the screws attaching the controller and replace the bezel and screws.

OFF OFF

Using the menu on page 1-31, perform fryer setup under Level 1.

 (check) button.

Figure 7 Figure 8

1-34

1.16 Principal Wiring Connections

1-35

1.17 Wiring Diagrams

1.17.1 BIGL230/430 Wiring

1-36

1.17.2 BIGL330 Wiring

1-37

1.17.3 BIGL430 Extra Transformer Box Wiring

1-38

1.18 Simplified Wiring Diagrams

1.18.1 BIGL30 Series Full Vat Single Spark Module

LINE

VOLTAGE

RIGHT IGNITION

MODULE

GND

25V+

ALAR

TEMP

PROBE

BLOWER

24V

12V

621291185431

HIGH

LIMIT

AIR

SWITCH

OPTIONAL

LED 5

R-GV

FUSE

12V

LED 3

LED 6

24V

PWR

R-

HEAT

LED 4

VALVE

BNR

GND

V1S

ALARM

HEAT

RELAY

AIR

HEAT

LED 2

ALARM

PWR

V2S

IGNITOR

RIGHT

47K

1/50

LINE VOLTAGE

HEAT

12 VDC

POWER

24 VAC

12 VAC

PROBE CIRCUIT

SOUND DEVICE CIRCUIT

TROUBLE

ON/

OFF

BIGL30 SERIES – FULL-VAT – SINGLE SPARK MODULES

AIR SWITCH ONLY ON CE

AND SOME EXPORT UNITS

LEFT IGNITION

MODULE

ALARM

25V+

VALVE

GND

BNR

IGNITOR

LEFT

1-39

1.18.2 BIGL30 Series Dual Vat Single Spark Module

N O

I T

T A V

L A U D

– S

I R

I N G

I R

E B

R E

W O L B

L A

V G

E S

2 1

V 4

3 2 1

V G

A L A

W P

E L

5 D

E L

V 2 1

t o n

D E L

I A

D E L

D T

D N G

r u

A V

1 V

A L A

E S

3 L

E G A T

E B

S T

I N U

T R O P X E

W P

M R A L

N O

I T

I N G

I T

F E L

E L U D

O M

5 2

D 2 V

E V

D T

R O

I N

D S

2 J

K 1

M R A L A

R O T

I U C

O V

E N

I L

T A E H

D D

N U O S

I U C R

B O R P

‘

E L B U O R T

R E

W O P

R E

W O P

T A E H

F F O

/ N O

F F O

/ N O

E L B U O R T

1-40

1.18.3 BIGL30 Series Data Network Flowchart

Left M3000

120 O Pins 2 & 3

NOTE: Pins 2 & 3 can be tested on any plug throughout the system and should read 120O. Unplug one end of the harness and meter for 120O.

The data network plugs on the boards can be swapped. (ie. J6 and J7 on the M3000)

Right M3000

3-wire harness

Middle M3000

3-wire harness

J203

3-wire harness

Turn each computer to OFF. Press the TEMP button on each computer and verify ALL software versions are present (M3000 and optional LON). A missing version may indicate an open connection.

Harness

Function

Pin#

1 Ground Black 2 CAN Lo Red 3 CAN Hi White 4 5

Voltage

NOT USED

WireColor

LON Board

(Optional)

120 O Pins 2 & 3

J202

1-41

1.18.3 BIGL30 Series Data Network Flowchart without LON

1-42

MANUAL LOV SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1 Accessories

ITEM PART # COMPONENT

1 810-2793 Hanger, Basket

* 809-0171 Thumbscrew, ¼-20 X 1⅜-inch Universal Hood (use 809-0921 for Spacer)

* 809-0402 Thumbscrew, ¼ -20 X ½-inch Cap-N-Splash Hood 2 803-0197 Cleanout Rod, 27-inch 3 803-0430 Brush, Frypot Ecolab 4 106-8930 * 826-0993SP Handle Kit, Frypot Cover (includes handle and screws) 5 803-0375 6 810-0478 Gas Line, 1-Inch Dormont Flexible 7 108-6156 Connecting Strip, Frypot

* Not illustrated.

Cover, Full-Vat Frypot (use 106-8931 for Dual-Vat Cover)

Rack, Full-Vat Basket Support (use 803-0372 for Dual-Vat Basket Support)

2.2 Doors, Sides, Flue Caps, Top Caps and Casters

2-1

2.2 Doors, Sides, Flue Caps, Top Caps and Casters cont.

ITEM PART # COMPONENT

1 2317908 Side, Standard Cabinet Left SS 2 2327908 Side, Standard Cabinet Right SS 3 8101105 Magnet, Door (vertical) (use 8102346 for horizontal over filter pan)

4 1064397

5 2304960 Handle, Eurolook Door 6 1064067 Pin Assy, Door * 8100275 Spring, Door Pin * 2307192 Hinge, Door Lower * 2108288 Panel, Universal Door * 2206097 Holder, Manual 7 8100327 Caster 4” without Brake 8 8100944 Caster 3” with Brake 9

8237656 8238926 8237657 8238927 8237658 8238928 8238064 8238930

10 Top Cap

1081522 1086158 1081523 1086159 1081524 1086160 1083030 1086161

* Cap-N-Splash Assemblies

8237659 Two Station Fryer 8237660 Three Station Fryer 8237661 Four Station Fryer 8238101 Five Station Fryer

* Not illustrated.

Door, Left or Right (Left shown – move handle to bottom for right) (use 1080915 for Door w/ Manual Holder)

Flue Cap-Stainless Steel (Use Aluminized steel with Cap-N-Splash)

Two Station (8236666 for Alz Steel)(2302635 for Hood Strip) Two Station (8236666 for Alz Steel)(2302635 for Hood Strip) Three Station (8236681 for Alz Steel) (2302405 for Hood Strip) Three Station (8239032 for Alz Steel)(Use 2302405 for Hood Strip) after 06/2014 Four Station (8236680 for Alz Steel) (Use 2302636 for Hood Strip) prior to 07/2014 Four Station (8239033 for Alz Steel)(Use 2302636 for Hood Strip) after 06/2014 Five Station (8238100 for Alz Steel) (Use 2302637 for Hood Strip) prior to 07/2014 Five Station(8239034 for Alz Steel)(Use 2302637 for Hood Strip) after 06/2014

Two Station Fryer prior to 07/2014 Two Station Fryer after 06/2014 Three Station Fryer prior to 07/2014 Three Station Fryer after 06/2014 Four Station Fryer prior to 07/2014 Four Station Fryer after 06/2014 Five Station Fryer prior to 07/2014 Five Station Fryer after 06/2014

prior to 07/2014 after 06/2014

2-2

2.3 Drain System Components

2.3.1 Drain Valves and Associated Parts

ITEM PART # COMPONENT

108-2509 Valve, Assy Drain FV or DV Left

108-2510 Valve, Assy Drain DV Right 1 809-0540 Nut, ½-13 2-Way Hex Lock 2 900-2936 Retainer, Nut Drain Valve 3 230-9433 Handle, Drain Valve FV or DV Left

230-9434 Handle, Drain Valve DV Right 4 814-0047 Cap, Vinyl Red 5 901-2348 Cover, Safety Switch 6 807-4936 Switch, Micro Gold Plated 7 816-0220 Insulation, RF Switch 8 200-6496 Support, Drain Tube 9 108-2506 Bracket Assy, Drain Switch FV and DV Left

108-2537 Bracket Assy, Drain Switch DV Right

10 816-0135PK O-Ring, Round Drain Seal 11 810-1018 Valve, 1¼-inch Drain with Filter

* 807-5159 * 807-5160

Harness, Drain FV (connects from drain switch to rear of M3000 controller only) Harness, Drain DV(connects from drain switch to rear of M3000 controller only)

2-3

2.3.2 Drain Tube Sections and Associated Parts

2-4

2.3.2 Drain Tube Sections and Associated Parts cont.

ITEM PART # COMPONENT

1 823-8135 Drain Tube, Dump Full-Vat Left Closed/Right End Open 2 823-8136 Drain Tube, Dump Dual-Vat Left Closed/Right End Open 3 823-8137 Drain Tube, Dump Full-Vat Left Closed Both Ends 4 823-8138 Drain Tube, Dump Dual-Vat Left Closed Both Ends 5 823-8139 Drain Tube, Dump Full-Vat Left Closed Both Ends * 823-8130 Drain Tube, Dump Full-Vat Left Closed/Right End Open 6 823-7943 Drain Tube, Dump Dual-Vat Left Closed Both Ends * 823-8131 Drain Tube, Dump Dual-Vat Left Closed/Right End Open 7 823-4643 Drain Tube, Full-Vat, Short, Open Both Ends 8 823-7905 Drain Tube, Dual-Vat, Short, Open Both Ends

9 810-3550 Drain Tube, Short, Open Both Ends 10 810-3551 Drain Tube, Long, Open Both Ends 11 823-4625 Drain Tube, Short Full-Vat Left Open/Right End Closed 12 823-7906 Drain Tube, Short Dual-Vat Left Open/Right End Closed 13 823-4639 Drain Tube, Long Full-Vat Left Open/Right End Closed 14 823-7908 Drain Tube, Long Dual-Vat Left Open/Right End Closed 15 823-4641 Drain Tube, Long Full-Vat Open Both Ends 16 823-7907 Drain Tube, Long Dual-Vat Open Both Ends 17 816-0772 Sleeve 18 809-0969 Clamp

* 816-0630 Vinyl Cap

* 811-1071 Tubing, ¼-inch OD Teflon Vent (sold by the foot) 19 823-7915 Guard, Filter Lid Splash

* Not illustrated.

2.4 Electronics and Electrical Components

2.4.1 Controllers and Associated Components

ITEM PART # COMPONENT

√ 1 108-5589 Replacement Manual LOV M3000 Controller Gas

807-4403 Speaker SMT

√ Recommended parts.

2-5

2.4.2 Control Box

2-6

2.4.2 Control Box cont.

ITEM PART # COMPONENT

1 810-1164 Block, One-Piece Screwless Terminal 2 816-0217 Insulation, Terminal Block Paper

√ 3 807-3843 Fuse 3A 250V

√ 4 807-5008 Cable, Ignition 19” (CE)

5 807-4199 Cable, 20-pin Computer to 15-pin Interface Board - SMT 6 806-6085SP Wire Assembly, Ignitor 7 108-2353 Wire Assembly, Ignition Module CE FV * 108-1260 Wire Assembly, Ignition Module CE DV

√ 8 807-1006 Ignition Module, CE

9 106-0531SP Fuse Assembly, Inline (not used on all models)

10 108-1094 Plate, Ignition Module 11 824-2091 Cover, Ignition Module CE

√ 12 807-0833 Relay, DPDT 5A 12VDC Latch

13 810-2243 Spring, Relay Retaining

* 807-2659 Switch, Momentary (Control Power Reset, only used in far left component box)

* 807-1683 Relay, 12VDC Reset Switch

√ 14 826-2264 Interface Board

* 807-4343 Wire Harness, SMT Interface Board to Ignition Module 15 807-2469 Bushing, Heyco 1"I.D. 16 810-0045 Bushing, .875 * Not illustrated. √ Recommended parts.

2-7

2.4.3 Transformer Boxes

ITEM PART # COMPONENT

A 108-1765 BIGL230 and 430 CE and Export (430 has added cordset 108-1770) B 108-1764 BIGL330 CE and Export C 108-1768 BIGL430 CE and Export

√ √ √

√

2 3

4 5 6 7 8

9 10 11 12 13

15 16

18 19

807-5129 807-2180 Transformer 208-240V/24VAC 50/60HZ, 50VA Filter 807-1597

Transformer V&F Dual

Fuse, 3 Amp Slo-Blow

108-0994 Cable Assembly, Transformer Box #1 BIGL230 and 330 CE Export

108-0995 108-0996

108-1728 106-8170

Cable Assembly, Transformer Box #2 BIGL230 and 330 CE Export Cable Assembly, Transformer Box #3 BIGL 330 CE Export Cable Assembly, Transformer Box Filter Pump 230 CE Export

Cable Assembly, Transformer Box Filter Pump 230 and 330 CE Export 108-3433 Harness, Bulk Oil Jumper 108-3432 Harness, T-Box Gas OCF 108-1778 Harness Assembly, Vat # 4 108-1777 Harness Assembly, Vat # 3 108-1789 Harness Assembly, 4 Batt Cordset

807-4770 Relay, Power Reset DPDT 20A 240V

810-1164 Block,1 PLC Screwless Terminal

816-0217 Insulation, Terminal Block Paper

807-0012 Relay Filter 18 AMP 1/3 HP 24V Coil

807-1973 Terminal, Post 807-0070 Terminal, Ground Lug

208/222/230/240V -12V (20VA) / 24V (50VA) Control Box

2-8

ITEM PART # COMPONENT

20 21 22 23

* * * *

* Not illustrated. √ Recommended parts.

220-3191 Cover, Large Transformer Box

823-6324 Box, Large Transformer/Filter

823-7638 Box, Transformer/Filter GL30 4-Battery

220-6514 Cover, GL30 Small Transformer Box WIR 0100 Wire Assembly, 430 (used in Items C) WIR 0799 Wire Assembly, GL230 Transformer/Filter Box (used in Item A) WIR 0798 Wire Assembly, GL330 Transformer/Filter Box (used in Item B) WIR 0957 Wire Assembly, GL230/430 (used in Items A and B)

2.5 Wiring

2.5.1 Main Wiring Harnesses

ITEM PART # COMPONENT

807-1978 Main Wiring Harness 230/430 807-4014 Main Wiring Harness 330

2-9

2.5.2 M3000 Communication Wiring Harnesses (Refer to wiring diagram on page 1-41.)

ITEM PART # COMPONENT

* 807-4546 Controller Communication (used from controller to controller)

* 807-4573

* 807-4552

√ * 807-4660PK SMT Pin Service Repair Kit √ * 230-2345 SMT Pin Extractor

* Not illustrated. √ Recommended parts. See page 1-33 for Pin Positions.

Controller Locator Wire (used from controller to interface board) See wiring dia-

gram on page 1-41 for locator pin positions. Communications Terminator (used on controller pin J6and J7 to terminate network)

2-10

2.6 Frypots and Associated Components

2.6.1 Full-Vat Frypot Components

2-11

2.6.1 Full-Vat Frypot Components cont.

ITEM PART # COMPONENT

√

1 2 3 4 5 6 7 8

9 10 11

* 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29 30 31 32

108-4156 Frypot Assembly, Manual LOV Full-Vat 108-2897 Flue assembly, FV Frypot 108-4423 Cover assembly, GL30 FV Front Combustion

220-2851 Brace, H30 FV Rear 220-2920 Brace, GL30 Foam Deck

220-6529 Cover,GL30 FV Upper Insulation 220-7831 Retainer FV Insulation

230-6960 Plate, GL30 FV Collector 930-0818 Bracket Flue to Pot 824-2165 GL30 FV RH Upper Seal 824-2164 GL30 FV LH Upper Seal

810-0476 Spacer .250 x 1 187

810-3435 Burner, HE30, Universal

823-8590

Plenum, Full-Vat (use 823-6660 for Non-CE units)

810-3743 Fitting, 1/8 NPT x 3/16 Barb (used on plenum)

826-2592 Insulation Kit, Burner Full-Vat 826-2595 Insulation Kit, Complete Full-Vat 812-0706 Insulation, Upper Burner Rail 812-1029 Insulation, Burner Side 816-0731 Insulation, Front, L/R 816-0733 Insulation, Front 816-0746 Insulation, Foam Deck 816-0837 Insulation, FV Rear Lower 816-0900 Insulation, Burner 816-0976 Insulation, Lower Front 816-0978 Insulation, Outer Front 823-8175 Cover GL30 FV Rear Combustion 823-8193 Retainer GL30 FV LH Burner 823-8194 Retainer GL30 FV RH Burner

823-8470 823-8981

Frypot FV prior to 07/2014 Frypot FV after 06/2014

823-8575 Cover GL30 FV Lower Outer 900-1049 Retainer, Plenum Gasket 816-0057 Gasket, Plenum 900-1031 Retainer, Burner Sight Glass 812-0356 Insulation, Burner Sight Glass

814-0048SP Glass, Burner Sight

* Not illustrated √ Recommended parts.

2-12

2.6.2 Dual-Vat Frypot Components

2-13

2.6.2 Dual-Vat Frypot Components cont.

ITEM PART # COMPONENT

√

9 10 11

* 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 33 34

108-4157 Frypot Assembly, Manual LOV Dual-Vat 106-7690 Plate Assy, DV Collector 108-2898 Flue assembly, DV Frypot 108-4424 Cover assembly, GL30 DV Front Combustion

220-2920 Brace, GL30 Foam Deck

220-2972 Brace, Dual-Vat Rear Insulation

220-6530 Retainer, Dual-Vat Upper Insulation

220-7916 Retainer, Dual-Vat Outer Frypot 824-2167 Seal Weldment, DV RH Upper 824-2166 Seal Weldment, DV LH Upper

930-0818 Bracket Flue to Pot

810-0476 Spacer .250 x 1 187

810-3435 Burner, HE30, Universal

823-8589

Plenum, Dual-Vat (use 823-7582 for Non-CE units)

810-3743 Fitting, 1/8 NPT x 3/16 Barb (used on plenum)

826-2596 Insulation Kit, Complete Dual-Vat 826-2593 Insulation Kit, Burner Dual-Vat 812-0688 Insulation, Flue Collection 812-0706 Insulation, Upper Burner Rail 812-1029 Insulation, Burner Side 816-0741 Insulation, Dual-Vat LH/RH Front Seal 816-0743 Insulation, Dual-Vat Front Upper 816-0746 Insulation, Foam Deck 816-0838 Insulation, Dual-Vat Rear Lower 816-0900 Burner, Insulation 816-0977 Insulation, DV Lower Inner Front 816-0979 Insulation, DV Outer Front 823-8176 Cover GL30 DV Rear Combustion 823-8195 Retainer GL30 DV LH Burner 823-8196 Retainer GL30 DV RH Burner

823-8476 823-8977

Frypot DV prior to 07/2014 Frypot DV after 06/2014

823-8576 Cover GL30 DV Lower Outer 824-1796 Riser Weldment, DV 900-1049 Retainer, Plenum Gasket 816-0057 Gasket, Plenum 900-1031 Retainer, Burner Sight Glass 812-0356 Insulation, Burner Sight Glass

814-0048SP Glass, Burner Sight

* Not illustrated √ Recommended parts.

2-14

2.6.3 Frypot Probes and Thermostats

See page 2-3 for Drain Valve Assemblies and page 2-11 through 2-14 for Frypot Assemblies

ITEM PART # COMPONENT

√

√ Recommended parts.

826-2900 Probe, Temperature Cooking 826-1177

Thermostat, High-Limit 425F/218C

2-15

2.7 Gas Valves, Supply and Combustion System Components

BIGL30 Full Vat Gas Manifold

The example illustrated is typical of

(Typical)

BIGL Series Fryer Gas Manifolds. Each manifold is assembled from

standard 1/2-, 3/4-, and 1-inch NPT black iron pipe nipples, elbows, tees, plugs, and unions, which may be locally acquired.

Non-CE Gas Valve Assembly

(Typical)

NOTE: The gas tube and enrichment tube fittings are assembled in varying configurations depending

upon the location of the valve and whether the associated frypot is a full- or dual-vat pot.

ITEM PART # COMPONENT

√ 1 Ignitor

826-3053 Natural Gas (G20, G25) (includes gasket 816-0059) 826-2994

Propane (G30, G31) (includes gasket 816-0981)

√ 2 Blower Assembly, Combustion Air (includes harness and Item 3)

108-1960 230V 50HZ RH CE (Dual Vat) 108-1959 230V 50HZ RH CE (Full Vat) 3 816-0554 Cover, Blower Motor (component of all blowers listed above) * 807-1067 Harness Assembly, Blower Motor

2-16

2.7 Gas Valves, Supply and Combustion System Components cont.

ITEM PART # COMPONENT

4 Orifice, Burner 810-3861 3.26 mm Natural Gas (G20, G25) (0-4999 Ft, 0-1524 M) 810-3865 1.95 mm Propane/Butane (G30, G31) (0-4999 Ft, 0-1524 M)

√ 5 108-3346 Switch, Air Pressure Assembly Full Vat (812-2226 switch alone)

108-1455 Switch, Air Pressure Assembly Dual Vat (812-2141 switch alone)

√ 6 Valve, Non-CE Gas

826-1122 Natural Gas (G20, G25) 826-1120 Kit Natural Gas w/ flexlines and hardware 826-1123 Propane Gas (G30, G31) 826-1121 Kit, Propane Gas w/ flexlines and hardware 9 810-0691 Tube, ⅛-inch Vent 10 806-9678SP Plug Assy, CE Gas Valve 11 813-0304 Bushing, ½-inch NPT to ¼-inch NPT Flush Reducing 12 813-0700 Nipple, ¼-inch NPT x 3-inch 13 813-0302 Elbow, ¼-inch Male NPT to ⅜-inch Tube 90° (used on DV valve) 14 813-0449 Tee, ¼ -inch NPT Brass 15 810-3147 Bushing, ¾-inch OD x ½ -inch ID NPT Flush 16 813-0340 Adapter, ⅛-inch NPT to ⅛-inch Tube 17 810-3807 Tube, ⅛-inch OD X 6.5-inch Enrichment 18 813-0301 Tee, ¼-inch Male NPT to ⅜-inch Tube 19 810-1353 Gas Line, ⅜-inch OD X 9-inch SS Flexible (Used on some split pots) 20 810-1355 Gas Line, ⅜-inch OD X 15-inch SS Flexible 21 810-3435 Burner, HE30, Universal * 826-2965 Conversion Kit, Natural Gas FV (G20, G25) to Propane/Butane(G30,G31) * 826-2966 Conversion Kit, Natural Gas DV (G20, G25) to Propane/Butane(G30,G31) * 826-2967 Conversion Kit, Propane/Butane FV(G30, G31) to Natural Gas (G20,G25) * 826-2968 Conversion Kit, Propane/Butane DV(G30, G31) to Natural Gas (G20,G25) * 826-2969 Conversion Kit, Natural Gas FV (G20, G25) to Prop/Butane(G30,G31) Aust /CE * 826-2970 Conversion Kit, Natural Gas DV (G20, G25) to Prop/Butane(G30,G31) Aust/CE * 826-2971 Conversion Kit, Prop/Butane FV(G30, G31) to Natural Gas (G20,G25) Aust /CE * 826-2972 Conversion Kit, Prop/Butane DV(G30, G31) to Natural Gas (G20,G25) Aust/CE

* Not illustrated. √ Recommended parts.

2-17

2.8 Filtration System Components

ITEM PART # COMPONENT

1 823-8028 Lid, Filter Pan 2 810-3276 Crumb Tray 3 810-3268 Hold-Down Ring 11.20 x 19.10, 4 812-2025 Sana Grid Filter Screen 5 108-3999 Pan, Filter

813-0568 Plug, ⅛-inch Socket Head Pipe (used with Item 5; two required)

√ * 826-1392 O-Ring (Pkg. of 5; used with Item 5)

6 823-6458 Suction Tube Assembly 7 810-1067 Flexline, 8.50-inch Oil Return 8 230-8373 Rail, Upper Filter Pan Left/Right

9 230-8372 Rail, Lower Filter Pan Left/Right 10 823-8030 Support, Left Filter Pan 11 220-8368 Support, Right Filter Pan 3,4 and 5 battery

* Not illustrated. √ Recommended parts.

2-18

2.9 Filter Pump, Motor and Associated Components

ITEM PART # COMPONENT

1 Motor and Gasket Kit

826-1785 100V 50/60 Hz

826-1712 115V 50/60 Hz

826-1756 208V 50/60 Hz

√ 826-1270 220-240V 50/60 Hz

826-1755 250V 50/60 Hz

2 826-3191 Pump and Gasket Kit, Viking 4 GPM (includes gasket and cap screws below)

816-0093 Gasket, Pump/Motor

3 809-1062 Cap Screw, 5/16-inch-18 4.00” NC Hex (Connects pump to motor, use 8090194 wash-

er)

* 108-0649 Heater Strip Assembly, 100-120V 25W 18” * 106-5912 Heater Strip Assembly, 208-250V 25W 18” 4 106-3470 Valve, Solenoid ¼-inch” NPT 5 813-0265 Nipple, ½-inch x 2.50-inch NPT BM 6 810-1057 Flexline, 13-inch Oil Return 7 810-1067 Flexline, 8.5-inch Oil Return 8 810-1668 Adapter, ⅝-inch to ½-inch NPT Male 9 810-1669 Adaptor, Female ⅞-inch OD x ½-inch

10 813-0165 Elbow, ST ½-inch x ½-inch NPT 90° BM 11 813-0304 Bushing, ½-inch x ¼-inch BM Flush 12 813-0530 Tee, Reducing ½-inch x ¼-inch x½-inch 13 813-0838 Nipple, ¼-inch NPT BM Close 14 220-6191 Brace

* 106-1020 Wiring, Pump

* Not illustrated. √ Recommended parts.

2-19

2.10 Frypot Assemblies and Associated Parts

To Return

Manifold

Full VatDual Vat

See Page 2-3 for Drain Valve Assemblies.

ITEM PART # COMPONENT

1 823-8470 Frypot, Full-Vat 2 823-8476 Frypot, Dual-Vat * 824-1796 Riser, DV Frypot 3 813-0022 Elbow, St ½” x ½” NPT 90° BM 4 901-2772 Handle, Valve Rear Flush LT 5 902-2772 Handle, Valve Rear Flush RT * 900-2935 Retainer, Nut Oil Return Valve 6 810-2201 Valve, Return ½” Ball LT 7 810-1067 Flexline, ⅝” OD x 8.50” Long Return Oil 8 810-1668 Adaptor, Male ⅝” OD x ½”

10 813-0062 Elbow, ½” BM x 90° 11 813-0298 Nipple, ½” x 2.00” NPT BM Pipe 12 813-0908 Adapter, ½” NPT 90° 13 824-2223 Cover, Oil Return Microswitch 14 816-0220 Insulation, RF Switch 15 807-4101 Switch, Micro 16 813-0087 Nipple, ½” x 1.50” NPT BM Pipe

* Not illustrated.

2-20

2.11 Oil Return System Components

ITEM PART # COMPONENT

1 809-0601 Clip, Clevis 2 816-0643 Grip, Oil Return Valve Handle 3 813-0907 Cap, 15/16-inch Valve Safety 4 811-1071 Tube, ¼-inch OD Teflon Manifold Vent 5 106-3470 Valve, ¼-inch NPT Solenoid 6 810-2493 Elbow, 90° ⅛-inch NPT x ¼-inch Quick Connect 7 813-0807 Bushing, ¼-inch NPT x ⅛-inch 8 813-0700 Nipple, ¼-inch NPT x 3.00-inch 9 Manifolds * 810-3958 Manifold, Two-Station Fryer * 810-3959 Manifold, Three-Station Fryer * 810-3960 Manifold, Four-Station Fryer * 810-3961 Manifold, Five-Station Fryer

* Not illustrated.

2-21

2.12 Wiring Connectors, Pin Terminals and Tools

ITEM PART # COMPONENT

1 2 3 5 5 6 7 8

9 10 11 12 13 14 15 16

* Not illustrated.

807-1068 807-0158 807-0156 807-0159 807-0875 807-1067 807-0157 807-0155 807-0160 807-0804 826-1341 826-1342 807-2518 807-0928 806-4855 230-2345

2-Pin Female 6-Pin Female 9-Pin Female 12-Pin Female 15-Pin Female 2-Pin Male 6-Pin Male 9-Pin Male 12-Pin Male 15-Pin Male Terminal, Female Split Pin (Pkg of 25) Terminal, Male Split Pin (Pkg of 25) Plug, Mate-N-Lock (Dummy Pin) Extract Tool Pin Pusher Pin Pusher Screwdriver Assy SMT Pin Extractor

2-22

2.13 Fasteners

ITEM PART # COMPONENT

* 809-0429 Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap * 809-0131 Bolt, ¼-inch -20 x ¾-inch Hex * 809-0953 Bolt, ¼-20 x ¾-inch Hex Head * 807-1926 Bushing, .875-inch Split * 809-0514 Capscrew, 5/16-inch-18 NC Hex * 809-0448 Clip, Tinnerman * 826-1351 Nut Retainer, ¼-20 (Pkg. of 10 – for basket hanger thumbscrew) Std. Fluecap * 809-0171 Thumbscrew, ¼-20 x 1⅜-inch (for use on Standard Fluecap) * 826-1366 Nut, 4-40 Keps Hex (Pkg. of 25) (809-0237) * 826-1358 Nut, 6-32 Keps Hex (Pkg. of 25) (809-0049) * 809-0247 Nut, 8-32 Keps Hex * 809-0052 Nut, 10-24 Hex * 826-1376 Nut, 10-32 Keps Hex (Pkg. of 10) (809-0256) * 809-0766 Nut, 10-32 Keps Hex SS * 809-0581 Nut, ½ NPT Locking * 809-0020 Nut Cap 10-24 NP * 826-1372 Nut Grip ¼-inch ¼-20 Hex NP (Pkg. of 10) (809-0059) * 809-0417 Nut Flange ¼-inch ¼-20 Serr * 809-0535 Nut, "T" ¼-inch-20 x 7/16 SS * 809-0495 Nut, ¼-inch - 20 Press

809-0804 Nut, ¼- inch - 20 Keps Hex * 826-1362 Nut, ¼-20 Hex (Pkg. of 10) (809-0071) * 809-0540 Nut, Lock ½-inch-13 Hex 2-Way ZP * 809-0656 Screw, 4-40 X 3/8-inch Slotted Round Head * 826-1359 Screw, 4-40 x ¾-inch Slotted Round Head (Pkg. of 25) (809-0354) * 826-1365 Screw, 6-32 x ⅜-inch Slot Head (Pkg. of 25) (809-0095) * 809-0098 Screw, 6-32 x 1¼-inch Slotted Round Head * 809-0357 Screw, 6 x ⅜-inch Phillips Head NP * 809-0359 Screw, 8 x ¼-inch Hex Washer Head * 809-0360 Screw, 8 x ⅜-inch Hex Washer Slot Head * 826-1371 Screw, 8 x ½-inch Hex Head ZP (Pkg. of 25) (809-0361) * 809-0364 Screw, 8 x ⅝-inch Hex Washer Head ZP * 809-0441 Screw, 8 x 1½-inch Hex Washer Head * 809-0362 Screw, 8 x 1¼-inch Hex Washer Head Drill Point * 809-0518 Screw, 8-32 x ⅜-inch Hex Washer Slotted Head SS * 809-0104 Screw, 8-32 x ½-inch Slotted Head ZP * 826-1363 Screw, 8-32 x ½-inch NP (Pkg. of 25) (809-0103) * 826-1360 Screw, 10-24 x 5/16-inch Round Slot Head ZP (Pkg. of 25) (809-0024) * 809-0123 Screw, 10-24 x 3/4-inch Slotted Truss Head * 826-1330 Screw, 10-32 x ⅜-inch Slot Head SS (Pkg. of 25) (809-0117) * 809-1003 Screw, 10-32 x ⅜-inch Hex Trim Head SS * 809-0938 Screw, 10-32 x ⅝-inch Philips Truss Head * 826-1375 Screw, 10-32 x ¾-inch Hex Trim Head SS (Pkg. of 5) (809-0401) * 809-1000 Screw, 10-32 x 1¼-inch Hex Sck C/S * 826-1374 Screw, 10 x ½-inch Hex Head (Pkg. of 25) (809-0412) * 809-0266 Screw, 10 x ½-inch Phillips Head ZP

continued on the following page

2-23

2.13 Fasteners cont.

ITEM PART # COMPONENT

* 809-0500 Screw, 10 x ½-inch Hex Washer Head 410 SS *

* 809-0123 Screw, 10 x ¾-inch Slot Head * 826-1389 Screw, ¼-20 x ¾-inch Hex Head ZP (Pkg. of 10) (809-0131) * 826-1346 Spacer, Ignition Module (Pkg. of 10) * 810-2763 Spacer, Interface Board * 826-1340 Spacer, .25-inch x 1.187-inch (Pkg. of 10)

* 810-0500 Spacer, .25-inch x .9375-inch

810-2023 Spacer, .25-inch x .110-inch (Used on drain valves.) * 200-6721 Plate, Strain Relief * 826-1337 Tab, ¼-inch Terminal (Pkg. of 5) * 807-0070 Terminal, Ground Lug * 807-1948 Ty-Wrap

* 807-1359 Mount, Ty-Wrap * 826-1383 Washer, ¾-inch O.D. x ¼-inch I.D. ZP (Pkg. of 5) (809-0435) * 809-0582 Washer ½ NPT Locking *

* * * * * 809-0196 * 810-1165

809-0434 Screw, 10 x ⅜-inch Hex Washer Head NP

809-0184 Washer, #10 LK ZP 809-0190 Washer, .625 X .275 X 40 Flat SS 809-0191 Washer, Lock ¼ Spring ZP 809-0193 Washer, Flat ¼ Nylon 809-0194 Washer, Flat 5/16 ZP

Washer, ⅜-inch Flat Washer, ⅜-inch Teflon

2-24

THIS PAGE INTENTIONALLY LEFT BLANK

Frymaster, L.L.C., 8700 Line Avenue, Shreveport, Louisiana 71106

TEL 1-318-865-1711 FAX (Tech Support) 1-318-219-7135

PRINTED IN THE UNITED STATES

SERVICE HOTLINE

1-800-551-8633

8196968

03/2016

Frymaster BIGL30 Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual