Frymaster BIH152 Service Manual

SERVICE MANUAL
FRYMASTER MH52 AND BIH52 SERIES
GAS FRYERS
This equipment chapter is to be
installed in the Fryer Sect i on of the
Equipment Manual.
MANUFACTURED
BY
FRYMASTER, L.L.C.
P.O. BOX 51000
SHREVEPORT, LOUISIANA 71135-1000
PHONE: 1-318-865-1711
TOLL FREE: 1-800-551-8633
1-800-24 FRYER
FAX: 1-318-219-7135
FOR YOUR SAFETY
Do Not Store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
TABLE OF CONTENTS
WARRANTY STATEMENT ..................................................................................................Page i
INTRODUCTION ..................................................................................................................Page 1-1
INSTALLATION INSTRUCTIONS ........................................................................................ Page 2-1
SERVICE PROCEDURES, TROUBLESHOOTING, AND WIRING DIAGRAMS.................Page 3-1
Frymaster, L.L.C. 8700 Line Avenue 71106, 5489 Campus Drive 71129
P.O. Box 51000, Shreveport, Louisiana 71135-1000
TEL 318-865-1711 FAX (Parts) 318-219-7140 (Tech Support) 318-219-7135
PRINTED IN THE UNITED STATES SERVICE HOTLINE 819-5423 02/01
1-800-24-FRYER U.S. $10.00
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
WARNING
FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
COMPUTERS
FCC
This device complies with Part 15 of the FCC rules. Operation is subject to the f ollowing two conditions: 1)This device may not cause harmful interference, and 2) This devic e m ust ac cept any interference r eceived, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet the Class B limits
CANADA
This digital apparatus do es not exceed the Class A or B limits for radio noise emissions as set o ut by the ICES-003 standard of the Canadian Department of Communications.
Cet appareil numerique n'emet pas de bruits radioelectriques depassany les limites de classe a et b prescrites dans la norme NMB-003 edictee par le ministre des communications du Canada.
WARNING
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND/OR
BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
Operation, installation and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne particles of glasswool or ceramic fibers is known to the State of California to cause cancer. Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm.
FRYMASTER FRYERS ARE MANUFACTURED FOR USE WITH THE TYPE VOLTAGE AND GAS SPECIFIED ON THE FRYER RATING PLATE LOCATED ON THE FRYER DOOR. FOR PROPER ELECTRICAL INSTALLATION PROCEDURES IN THE UNITED STATES, REFER TO THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE ANSI/N.F.P.A. NO. 70; IN CANADA, CANADIAN ELECTRICAL CODE PART 1, CSA-22.1. FOR INSTALLATION IN COUNTRIES OTHER THAN THE UNITED STATES AND CANADA, REFER TO THE NATIONAL CODE APPROPRIATE FOR THE COUNTRY IN WHICH THE EQUIPMENT IS BEING INSTALLED. FOR GAS COMPONENTS, INSTALLATION IS TO COMPLY WITH THE BASIC PLUMBING CODE OF THE BUILDING OFFICIALS AND CODE ADMINISTRATORS INTERNATIONAL, INC. (BOCA) AND THE FOOD SERVICE SANITATION MANUAL OF THE U.S. FOOD AND DRUG ADMINISTRATION (US FDA) OR THE APPLICABLE NATIONAL AND LOCAL REGULATIONS OF THE COUNTRY IN WHICH THE EQUIPMENT IS BEING INSTALLED.
INFORMATION ON THE CONSTRUCTION AND INSTALLATION OF VENTILATING HOODS MAY BE OBTAINED FROM THE LATEST EDITION OF THE "STANDARD FOR THE INSTALLATION OF EQUIPMENT FOR THE REMOVAL OF SMOKE AND GREASE LADEN VAPORS FROM COMMERCIAL COOKING EQUIPMENT,” N.F.P.A. NO. 96. COPIES OF THESE ELECTRICAL STANDARDS ARE AVAILABLE FROM THE NATIONAL FIRE PROTECTION ASSOCIATION, BATTERY MARCH PARK, QUINCY, MASS. 02269

WARRANTY STATEMENT

The following applies to equipment sold to domestic (U.S.) markets. International warranty provisions will vary depending upon the country in which the equipment is sold. See your dealer for specific warranty provisions applicable to your location. For all international warranties, the customer is responsible for freight and duty charges.
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. The Frymaster Corporation warrants all components against defects in material and workmanship for a period of one year.
2. All parts, with the exception of fuses and filter O-rings, are warranted for one year after installation date of fryer. (See Sections B and C for frypot and combustion chamber warranty duration.)
3. If any parts, except fuses and filter O-rings, become defective during the first year after installation date, Frymaster will also pay straight-time labor costs to replace the part, plus up to 100 miles/160 km of travel (50 miles/80 km each way).

B. WARRANTY PROVISIONS - FRYPOTS

(Applies to fryers installed on or after November 1, 1994, only.)
1. If a frypot develops a leak within seven years after installation, Fr ymaster will replace the frypot, allowing up to the maximum time per the Frymaster time allowance chart of straight­time labor plus up to 100 miles/160 km of travel (50 miles/80 km each wa y) 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

(Applies to fryers installed on or after November 1, 1994, only.)
1. The Frymaster Corporation warrants the combustion chambers against defective material or workmanship for a period of seven 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 ignitor, blower, high-limit thermostat, and temperature probe.
3. This warranty is limited to fryers operating on natural or propane (LP) gas.
i

D. WARRANTY PROVISIONS - COOKING COMPUTER

1. The Frymaster Corporation warrants the M-100B Cooking Computer against defective material or workmanship for a period of one year from the original installation date, parts and labor. Replacements for defective units during the second and third year are available at a reduced rate.
2. During this warranty period, Frymaster will, at its option, repair or replace defective cooking computer returned with new or factory rebuilt and functionally operative units.
3. For replacement of defective computers under warranty, call your local Frymaster Factory Authorized Service Center. All computers replaced under the Fr ymaster exchange pro gram are covered by a one-year (parts only) warranty.

E. PARTS RETURN

All defective in-warranty parts must be returned to a Frymaster Authorized Factory Service Center 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 seven-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.
ii

CHAPTER 1: INTRODUCTION

1.1 General

Read the instructions in this manual thoroughly before attempting to service this equipment. This manual covers all configurations of models MH52 and BIH52 fryers built since December 1995. Models designated MH52 do not have built-in filtration systems. Models designated BIH52 are equipped with FootPrint III built-in filtration systems.
H52 Series fryers feature deep cold-zones and easy to clean open frypots. The fryers are controlled by multi-product cooking computers or optional thermostat controllers. Fryers in this series come in full or split-pot arrangements, and can be purchased as single units or grouped in batteries of up to five fryers.

1.2 Safety Information

Before attempting to service this equipment, read the instructions in this manual thoroughly.
Throughout this manual, you will find notations enclosed in double-bordered boxes similar to the ones below.
CAUTION boxes contain information about actions or conditions that may cause or result in a malfunction of the system.
CAUTION
Example of a CAUTION box.
WARNING boxes contain information about actions or conditions that may cause or result in damage to the system, and which may cause the system to malfunction.
WARNING
Example of a WARNING box.
DANGER boxes contain information about actions or conditions that may cause or result in injury to personnel, and which may cause damage to your system and/or cause the system to malfunction.
DANGER
Hot cooking oil causes severe burns. Never attempt to move a fryer containing hot
cooking oil or to transfer hot cooking oil from one container to another.
Fryers in this series are equipped with automatic safety features:
1. A high-limit thermostat causes the gas valve to close should the controlling thermostat fail or computer temperature probe fail.
2. In BIH52 fryers, a safety switch built into the drain valve prevents the gas valve from opening with the drain valve even partially open.
1-1

1.3 Computer Information

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. While this device is a verified Class A device, it has been shown to meet the Class B limits. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of the equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
The user is cautioned that any changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.
If necessary, the user should consult the dealer or an experienced radio and television technician for additional suggestions.
The user may find the following booklet prepared by the Federal Communications Commission helpful: "How to Identify and Resolve Radio-TV Interference Problems". This booklet is available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-000-00345-4.

1.4 European Community (CE) Specific Information

The European Community (CE) has established certain specific standards rega rding equipment of this type. Whenever a difference exists between CE and non-CE standards, the information or instructions concerned are identified by means of shadowed boxes similar to the one below.
CE Standard
Example of box used to distinguish CE and
Non-CE specific information.
1-2
CHAPTER 2: INSTALLATION INSTRUCTIONS

2.1 General Installation Requirements

NOTE: PROPER INSTALLATION IS ESSENTIAL FOR EFFICIENT, TROUBLE-FREE OPERATION OF YOUR FRYER. ANY UNAUTHORIZED ALTERATIONS MADE TO THIS EQUIPMENT WILL VOID THE FRYMASTER WA RRANTY.
Upon arrival, inspect the fryer carefully for visible or concealed damage. (See Shipping Damage Claim Procedure in Chapter 1.)
CLEARANCE AND VENTILATION
The fryer(s) must be installed with a 6” (150 mm) clearance at both sides and back when installed adjacent to combustible construction; no clearance is required when installed adjacent to noncom­bustible construction. A minimum of 24” (600 mm) clearance should be provided at the front of the fryer.
One of the most important considerations of efficient fryer operation is ventilation. Make sure the fryer is installed so that products of combustion are removed efficiently, and that the kitchen ventila­tion system does not produce drafts that interfere with proper burner operation.
The fryer flue opening must not be placed close to the intake of the exhaust fan, and the fryer must never have its flue extended in a “chimney” fashion. An extended flue will change the combustion characteristics of the fryer, causing longer recovery time. It also frequently causes delayed ignition. To provide the airflow necessary for good combustion and burner operation, the areas surrounding the fryer front, sides, and rear must be kept clear and unobstructed.
Fryers must be installed in an area with an adequate air supply and adequate ventilation. Adequate distances must be maintained from the flue outlet of the fryer to the lower edge of the ventilation filter bank. Filters should be installed at an angle of 45º. Place a drip tray beneath the lowest edge of the filter. For U.S. installation, NFPA standard No. 96 states, “A minimum distance of 18 in. (450 mm) should be maintained between the flue outlet and the lower edge of the grease filter.”
Frymaster recommends that the minimum distance be 24 in. (600 mm) from the flue outlet to the bottom edge of the filter when the appliance consumes more than 120,000 BTU per hour.
For installations in the United States, information on construction and installation of ventilating hoods can be found in the NFPA standard cited above. A copy of the standard may be obtained from the National Fire Protection Association, Battery March Park, Quincy, MA 02269.
DANGER
Do not attach an apron drainboard to a single fryer. The fryer may become unstable,
tip over, and cause injury. The appliance area must be kept free and clear of com-
bustible material at all times.
2-1
NATIONAL CODE REQUIREMENTS
The type of gas for which the fryer is equipped is stamped on the data plate attached to the inside of the fryer door. Connect a fryer stamped “NAT” only to natural gas, those stamped “PRO” only to propane gas, and those stamped “MFG” only to manufactured gas.
Installation shall be made with a gas connector that complies with national and local codes, and, where applicable, CE codes. Quick-disconnect devices, if used, shall likewise comply with national, local, and, if applicable, CE codes.
ELECTRICAL GROUNDING REQUIREMENTS
All electrically operated appliances must be grounded in accordance with all applicable national and local codes, and, where applicable, CE codes. A wiring diagram is located on the inside of the fryer door. Refer to the rating plate on the inside of the fryer door for proper voltages.
DANGER
If this appliance is equipped with a three-prong (grounding) plug, it must be plugged
directly into a properly grounded receptacle.
Do not cut or remove the grounding prong from the plug.
DANGER
This equipment requires electrical power for operation.
Place the gas control valve in the OFF position in case of a prolonged power outage.
Do not attempt to use the equipment during a power outage.
FCC COMPLIANCE
The user is cautioned that any changes or modifications to Frymaster computers not expressly ap­proved by the party responsible for compliance could void the user’s authority to operate the equip­ment.
Frymaster computers have been tested and found to comply with the limits for a Class A digital de­vice, pursuant to Part 15 of the FCC rules. Whil e these devices are verified as C lass A devices, t hey have been shown to meet the Class B limits. These limits are designed to provide reasonable protec­tion against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of the equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
If necessary, the user should consult the dealer or an experienced radio and television technician for additional suggestions.
2-2
The user may find the booklet “How to Identify and Resolve Radio-TV Interference Problems” help­ful. It is prepared by the Federal Communications Commission and is available from the U.S. Gov­ernment Printing Office, Washington, DC 20402, Stock No. 004-000-00345-4.

2.2 Caster/Leg Installation

Depending upon the specific configuration ordered, your fryer may have been shipped without in­stalled casters or legs. If casters or legs are installed, you may skip this section and proceed to sec­tion 2.3, Pre-Connection Preparations.
If your fryer requires the installation of casters/legs, install them in accordance with the in­structions included in your accessory package.

2.3 Pre-Connection Preparations

DANGER
Do not connect fryer to gas supply before completing each step
in this section.
After the fryer has been positioned under the fry station exhaust hood, ensure the following has been accomplished:
1. Adequate means must be provided to limit the movement of fryers without depending upon the gas line connections. If a flexible gas hose is used, a restraining cable must be connected at all times when the fryer is in use. The restraining cable and installation instructions are packed with the flexible hose in the accessories box that was shipped with your unit.
2. Single unit fryers must be stabilized by installing restraining chains on fryers equipped with casters or anchor straps on fryers equipped with legs. Follow the instructions shipped with the casters/legs to properly install the chains or straps.
3. Level the fryer, if necessary, by loosening the locking screw on the caster legs and rotating the leg to increase or decrease the exposed length. Verify that the fryer is at the proper height in the exhaust hood. Frymaster recommends that the minimum distance from the flue outlet to the bottom edge of the hood be 24 in. (600 mm) when the appliance consumes more than 120,000 BTU per hour.
4. Test the fryer electrical system: a. Plug the fryer electrical cord(s) into a grounded electrical receptacle.
b. Place the power switch in the ON position.
For fryers equipped with thermostat controls, note the illumination of the power light and
the heat light.
For fryers having computers, note that the display reads LO-TEMP
comes on.
If the store is equipped with a hood interlock system, the hood exhaust fan should be on.
If not, the store hood interlock system is improperly wired and must be corrected.
c. Place the fryer power switch in the OFF position. Verify that the power and heat lights are
out, or that the display is blank.
LO-TEMP and the heat light
LO-TEMPLO-TEMP
2-3
5. Refer to the data plate on the inside of the fryer door to determine if the fryer burner is config-
ured for the proper type of gas before connecting the fryer quick-disconnect device or piping from the gas supply line.
6. Verify the minimum and maximum gas supply pressures for the type of gas to be used in accor-
dance with the accompanying tables.
CE Standard
for Incoming Gas Pressures
for Fryers Manufactured After April 1999
Orifice Diameter
Pressure
Gas
G20 20 2 x 3.40 2 x 3.40 7 mbar 6.5 mbar G25 20 or 25 2 x 3.40 2 x 3.40 10 mbar 9 mbar G30 28/30 or 50 2 x 2.05 2 x 2.05 17 mbar 17 mbar G31 37 or 50 2 x 2.05 2 x 2.05 20 mbar 18.5 mbar
(mbar)
Single
(1)
Vat
Dual
Vat
Regulator Pressure
Single
Vat
(1) mbar = 10.2 mm H2O
CE Standard
for Incoming Gas Pressures
for Fryers Manufactured Through April 1999
Orifice Diameter
Pressure
Gas
G20 20 2 x 3.40 2 x 3.40 7 mbar 6.5 mbar G25 20 - 25 2 x 3.40 2 x 3.40 10 mbar 9 mbar G31 37 - 50 2 x 2.05 2 x 2.05 20.2 mbar 18.5 mbar
(mbar)
Single
(1)
Vat
Dual
Vat
(1) mbar = 10.2 mm H2O
Regulator Pressure
Single
Vat
Dual
Vat
Dual
Vat
Non-CE Standard
for Incoming Gas Pressures
Gas Minimum Maximum
Natural
LP
6" W.C.
1.49 kPa
14.93 mbar 11" W.C.
2.74 kPa
27.37 mbar
14" W.C.
3.48 kPa
34.84 mbar 14" W.C.
3.48 kPa
34.84 mbar
7. For fryers equi pped w ith a Foot Pri nt III sys tem ( BIH52 m odel s), p lug t he el ectr ical cord i nto a
power receptacle behind the fryer.
2-4

2.4 Connection to Gas Line

The H52 Series has received the CE mark for the countries and gas categories indicated in the accompanying table. NOTE: The nominal heat input (Qn) is 21kW except for AT, DE, LU, and for category 3B/P under 50 mbar, which is 23kW.
CE Approved Gas Categories by Country*
COUNTRIES CATEGORIES GAS PRESSURE (mbar)
AUSTRIA (AT)
BELGIUM (BE)
DENMARK (DK)
FRANCE (FR)
FINLAND (FI)
GERMANY (DE)
GREECE (GR)
ITALY (IT)
IRELAND (IE)
LUXEMBOURG (LU)
NETHERLANDS (NL)
NORWAY (NO) PORTUGAL (PT)
SPAIN (ES)
SWEDEN (SE)
UNITED KINGDOM (GB)
II
2H3B/P
I
2E(R)B
I
II
2H3B/P
II
2Esi3+
II
2Esi3P
II
2H3B/P
II
2ELL3B/P
I
II
2H3+
II
2H3+
II
2H3+
II
2E3B/P
II
2L3P
II
2L3B/P
I
3B/P
II
2H3+
II
2H3+
II
2H3P
II
2H3B/P
II
2H3+
3+
3P
G20 20
G30, G31 50 G20, G25 20, 25
G30, G31 28-30, 37
G20 20 G30, G31 30 G20, G25 20, 25 G30, G31 28-30, 37 G20, G25 20, 25
G31 50
G20 20 G30, G31 30 G20, G25 20 G30, G31 50
G31 50
G20 20 G30, G31 28-30, 37
G20 20 G30, G31 28-30, 37
G20 20 G30, G31 28-30, 37
G20 20 G30, G31 50
G25 25
G31 50
G25 25 G30, G31 30
G30, G31 30
G20 20 G30, G31 28-30, 37
G20 20 G30, G31 28-30, 37
G20 20
G31 37, 50
G20 20 G30, G31 30
G20 20 G30, G31 28-30, 37
* H152-2 units are not approved for G30 (Butane) gas.
The size of the gas line used for installation is very important. If the line is too small, the gas pres­sure at the burner manifold will be low. This may cause slow recovery and delayed ignition. Fry­master recommends the incoming gas supply line be a minimum of 1½” (38 mm) in diameter. Refer to the chart on the following page for the minimum sizes of connection piping.
2-5
Gas Connection Pipe Sizes
(Minimum incoming pipe size should be 1 1/2" (38 mm))
4 or more
Gas Single Unit 2 - 3 Units
Natural Propane 1/2" (13 mm) 3/4" (19 mm) 1" (25 mm) Manufactured 1" (25 mm) 1 1/4" (33 mm) 1 1/2" (38 mm)
3/4" (19 mm)
1" (25 mm) 1 1/4" (33 mm)
units*
* For distances of more than 20 feet (6 m) and/or more than 4 fittings or elbows, increase the con­nection by one pipe size.
Before connecting new pipe to your unit, the pipe must be thoroughly blown out to remove any for­eign particles. If these foreign particles get into the burner and controls, they will cause improper and sometimes dangerous operation.
CE Standard
Required airflow for the combustion air supply is 2m3/h per kW.
1. Connect the quick-disconnect hose to the fryer quick-disconnect fitting under the front of the fryer and to the building gas line.
NOTE: Some fryers are configured for a rigid connection to the gas supply line. These units are connected to the gas supply line at the rear of the unit.
When using thread compound, use very small amounts on male threads only. Use a pipe thread compound that is not affected by the chemical action of LP gases (Loctite™ PST56765 Sealant is one such compound). DO NOT apply compound to the first two threads. This will ensure that the burner orifices and control valve do not become clogged.
2. Open the gas supply to the fryer and check all piping, fittings, and gas connections for leaks. A soap solution should be used for this purpose.
DANGER
Never use matches, candles, or any other ignition source to check for leaks.
If gas odors are detected, shut off the gas supply to the fryer
at the main shut-off valve and contact the local gas company or an authorized
service agency for service.
3. Close the fryer drain valve and fill the frypot with water and boil-out solution to the bottom OIL­LEVEL line at the rear of the frypot. Light the fryer and perform the boil-out procedures that are described in the “Lighting Instructions” and “Boiling Out the Frypot” topics found in Chapter 3 of this manual.
2-6
WARNING “Dry-firing” your unit will cause damage to the frypot. Always ensure that melted shortening, cooking oil, or water and boil-out solution is in the frypot before firing
your unit for any extended period.
4. It is suggested that the burner manifold pressure be checked at this time by the local gas company
or an authorized service agent. Refer to “Check Burner Manifold Pressure” in Chapt er 5 of this manual for the proper procedure. The accompanying tables list the burner manifold gas pressures for the various gas types that can be used with this equipment.
CE Standard
Burner Manifold Gas Pressures
for Fryers Manufactured After April 1999
Pressure (mbar)
Single
Natural Gas Lacq
Gas
(G20) under 20 mbar Natural Gas Groningue *
(G25) under 25 mbar Natural Gas Groningue
(G25) under 20 mbar Butane
(G30) at 28/30 or 50 mbar Propane
(G31) under 37 or 50 mbar
* Belgian G25 = 7,0 mbar (single or dual)
Vat
77
10 10
10 10
17 17
20 20
Burner Manifold Gas Pressures
for Fryers Manufactured Through April 1999
Dual
Vat
Natural Gas Lacq (G20) under 20 mbar
Natural Gas Gronigue * (G25) under 25 mbar
Natural Gas Gronigue (G25) under 20 mbar
Butane (G30) at 28/30 or 50 mbar
Propane (G31) under 37 or 50 mbar
* Belgian G25 = 7,0 mbar (single) or 6,5 (dual)
Gas
Non-CE Standard
Burner Manifold Gas Pressures
Gas Pressure
Natural
Propane
3" W.C.
0.73 kPa
8.25" W.C.
2.5 kPa
CE Standard
Pressure (mbar)
Single
Vat
76,5
10 9
10 9
17 16,5
20,2 18,5
Dual
Vat
5. Check the programmed temperature or analog controller thermostat setting. (Refer to Chapter 3,
Operating Instructions, for the setpoint programming instructions for your particular controller.)
2.5 Converting to Another Gas Type
Your fryer is configured at the factory for either natural gas or propane (LP) gas. If you desire to switch from one type of gas to another, a gas conversion kit must be installed by a Factory Authorized Service Center technician.
DANGER
Switching to a different type of gas without installing the proper conversion kit may
result in fire or explosion! NEVER attach your fryer to a gas supply for which it is
not configured.
2-7
H52 Series Fryers manufactured for Non-CE countries use different burners for each type gas. The burners in fryers built for Propane gas have a special gray-colored coating on the burner tiles to en­able them to withstand the higher caloric value of the Propane gas. Burners designed for use in Pro­pane units may be used in natural gas applications, but not vice versa.
Non-CE Gas Conversion Kits
Natural Gas to Propane (LP) Gas Propane (LP) Gas to Natural Gas
Full Vat: Part Number 826-1145 Full Vat: Part Number 826-1146 Dual Vat: Part Number 826-1147 Dual Vat: Part Number 826-1148
Units manufactured for export to CE countries are equipped with “universal” burners that may be used with either natural (G20, G25) gas or Butane (G30) and Propane (G31) gasses.
CE Gas Conversion Kits for Units with Gas Valve 810-1011
G20 or G25 (Natural) to G30 or G31 Gas: G30 or G31 to G20 or G25 (Natural) Gas:
Part Number 826-1196 Part Number 826-1197
CE GAS CONVERSION INSTRUCTIONS
1. Between G20- and G25-type Natural Gas, adjust the gas pressure at the regulator. (Refer to the CE Standard Burner Manifold Gas Pressure Chart.) Do not change the orifice.
2. Between a 2nd family (G20 or G25) and a 3rd family gas (G30 Butane or G31 Propane): a. Change the orifices. b. Change the gas valve spring (units with valve part number 810-1011only) c. Adjust the manifold pressure.
3. Remove the rating plate and install a new one. Call your local service agency or KES for a new rating plate.
4. If the destination language changes, replace the labels. Call your local service agency or KES for a label kit. The language of reference will be on the corner of the label.

2.6 Frypot Boil-Out

Before the fryer is first used for cooking product, it should be boiled out to ensure that any residue from the manufacturing process has been eliminated.
In addition, after the fryer has been in use for a period of time, a hard film of caramelized vegetable oil will form on the inside of the frypot. This film should be periodically removed by following the boil-out procedure.
Refer to Fryers Maintenance Requirement Card (MRC) 14A for the boil-out procedure.
2-8
CHAPTER 3: SERVICE PROCEDURES,
TROUBLESHOOTING, AND WIRING DIAGRAMS

3.1 Functional Description

H52 Series 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 their heat to the frypot by means of infrared radiation, providing much more constant and uniform heat dispersion over the surface of the frypot than do conventional burners. Because relatively less heat is lost to the atmos­phere in the process, compared to “open-burner” designs, less fuel is required to achieve and main­tain a given frypot temperature.
In full-vat units, gas flow to both of the burners is regulated by one electromechanical gas valve. In dual-vat units, each burner has its own valve. All fryers in this series are equipped with 24VAC gas valve systems, and all are configured with electronic ignition.
THE ELECTRONIC IGNITION SYSTEM
An ignition module mounted in the component box or “shield” (located behind the control panel) is connected to an ignitor assembly at the burner. The ignition module performs three important functions: it provides an ignition spark, supplies voltage to the gas valve, and proofs the
Inside the Ignition Module
Out to Gas Valve
To Alarm
burner flame. The module contains a 4-second time delay circuit and a coil that activates the gas valve. Three designs
25 V +
are in use. The module used in Australian export units resembles an interface board. A closed-box design is used in units built for the U.S. and other export markets. Before mid-2001, fryers (other than Australian) were equipped with two 807-1006 modules. Fryers built after mid-2001
HV
GND
Coil
TD
late-2000 are equipped with one 807-3365 (dual vat) or one 807-3366 (full vat) module. Fryers built between late-2000 and mid-2001 may have either configuration. Australian
Ignition Wire Flame Sensor
units continue to use two 807-2971 modules.
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 or computer 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 6 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 then close electronic switches in the 24VAC circuit to
3-1
provide current to the ignition module. Circuitry in the ignition module sends 24VAC to the gas valve via a normally closed high-limit switch (and, in BIH52 fryers, a normally closed drain safety switch). Simultaneously, the module causes the ignitor to spark for 4 seconds to light the burner. A flame sensor verifies the burner is lit by measuring the flow of microamps through the flame. If the burner does not light (or is extinguished), current to the ignition module is cut, the gas valve closes, and the ignition module “locks-out” until the power switch is turned off and then back on.
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 24VAC to the ignition module, causing the gas valve to close.
H52 Series fryers may be equipped with solid-state analog controls, M100B computers, or M2000 computers.
All fryers in this series have an interface board located in the component box located behind the
control panel.
INTERFACE BOARDS
The interface board provides a link between the controller/computer and the fryer’s individual com­ponents without requiring excessive wiring, and allows the controller to execute commands from one central point. The H52 Series of fryers has been in production since 1983. Consequently, servicers are likely to encounter several different interface board designs. Although the boards differ in ap­pearance, basic functioning and electrical connections are the same from one to another. In mid­2000, a new, unfused, ignition module design was introduced. Consequently, an additional fuse was added to the design of interface board 806-3398 to compensate. The new, two-fuse board is P/N 106-0386. With the exception of manufactured gas units, no matter what generation board is in the fryer now, if it becomes necessary to replace the board, either P/N 806-3398 or 106-0386 will be the
replacement part installed. If unit being serviced is equipped with two P/N 807-1006 or 807-2971 ignition modules, either interface board may be used. If the unit is equipped with one P/N 807-3365
or 807-3366 ignition module, interface board 106-0386 should be used. The two boards most likely to be seen (i.e., the two latest designs) are illustrated below.
GND
J1
GND
V2D
PWR
AD AS
V2S
3 6 9 12
2 5 8 11
1 4 7 10
SOUND
1 2 3
GND GVPWR
EARLIER DESIGN INTERFACE BOARD P/N 806-3398
J2
K4
K3 K5
BLOWER
MOTOR
RELAY
HEAT
RELAY
K1 K2
12 6 3 45
AL 12V
AIR
13
10741
11852
14
15
12963
RELAY
24V AL
HEAT
PWR
J3
GV
GND
3 6 9 12
2 5 8 11
1 4 7 10
GND
GND V1D PWR ALR V1S
SOUND
1 2
GND
3
3 6 9 12
2 5 8 11
J1
1 4 7 10
D1
GND
V2D
PWR
AD AS
D2
V2S
GND
LATER DESIGN INTERFACE BOARDS P/N 806-3398 and 106-0386
J2
This Fuse is NOT
present on 806-3398 IFB.
GV
HEAT
RELAY
PWR
AND
BLOWER
MOTOR
RELAY
K2 K3
13
10741
11852
14
15
12963
12V
K1
K4
D3
HEAT
24V
RELAY
AND
BLOWER
MOTOR
RELAY
D6
F2 Ignition 2 AMP Module
3 6 9 12
2 5 8 11
1 4 7 10
Blower Motor 2 Amp
D4
GND
PWR
GND
D5 GV
D7
AIR
J3
GND V1D PWR ALR V1S
3-2
FREQU E NT LY U SED TEST POINTS FOR INTERFACE BOARDS 806-3398 AN D 10 6-0386
Meter
Test Setting Pins Results
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 GROU N D 22-28 24VAC Power to Left Module 50VAC Scale 8 on J1 and GRO U N D 22-28 120 VAC Po w er 250VAC Scale 11 on J3 and GRO U N D 110-125 120 VAC Po w er to Blowers 250VA C Scale 12 on J3 and GRO U N D 110-125 24VAC Power to Right High-Limit 50VAC Scale 9 on J3 and GROU ND 22-28 24VAC Power to Left High-Limit 50VAC Scale 9 on J1 and GROUN D 22-28 Probe Resistance (Right) * Probe Resistance (Left) * R x 1000 O H MS 2 and 6 on J1 or 14 and 15 on J2 ** Probe Isolation R x 1000 O H M S 6 on J1 or J3 and GROUND *** High-Limit Continuity (Right) R x 1 OHM 9 on J3 and Wire 13C on Gas Valve 0 High-Limit Continuity (Left) 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 at end of chapter. *** 5 mega-Ohms or greater.
R x 1000 O H M S 2 and 6 on J3 or 13 and 14 on J2 **
These standard interface boards are also used in a number of fryer types besides the H52 Series. The information contained in this section applies to H52 Series applications ONLY.
The earlier design 806-3398 board contains two heat relays (K1 and K2) that switch 24VAC to the ignition and gas valve circuits when the computer/controller heat logic circuit calls for heat. Relay K4 switches 120VAC to the blower motor when either K1 or K2 closes. The relays on this board are soldered on – if one fails, the whole board must be replaced.
The newer design 806-3398 and 106-0386 boards have only two relays. In this design, 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.
All three interface boards have LEDs to assist in troubleshooting. On the earlier design 806-3398 board, nine LEDs are arranged along the bottom. Later versions of the 806-3398 board, and the 106­0386 board have seven LEDs placed at various locations. The tables below identify the LEDs and their meaning.
LATER DESIGN INTERFACE BOARD
EARLIER DESIGN INTERFACE BOARD
LED DIAGNOSTIC LIGHTS
12V Indic at es 12 VAC from transf ormer 24V Indic at es 24 VAC from transf ormer
GV Indicates 24 VAC to gas valve (left or ri ght)
PWR Indic ates 24 VAC to module (lef t or right)
AL Indicates module lock-out (left or right)
AIR CE and Japanese uni ts only: air switch closed
1 24 VAC to left gas valve (dual vat only) 2 24 VAC to left i gni t i on module 3 24 VAC from transformer 4 24 VAC to right igni tion module 5 24 VAC to gas valve (right valve if dual vat) 6 12 VAC from transformer
7 CE and Japanese units only: air switc h closed
LED DIAGNOSTIC LIGHTS
3-3
INTERFACE BOARD
12 VAC TO CPTR
GROUND
COMPUTER (12 VAC)
COMPUTER RT HT RELAY
COMPUTER 12 VDC TO RELAYS
COMPUTER LT HT RELAY
NOT USED
NOT USED NOT USED
NOT USED NOT USED
**
RT ALARM OUT
COMPUTER SOUND DEVICE
*
LT ALARM OUT
COMPUTER
COMPUTER
COMPUTER J1 PIN 6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
J1
NOT USED NOT USED
NOT USED
TEMP PROBE J2 PIN 15
NOT USED
24 VAC IN
MAIN GAS VALVE
via HLS via HLS
NOT USED
NOT USED NOT USED
NOT USED NOT USED
1
2
3
4
5
6
7
8
9
10
11
12
J3 PIN 1
GROUND
J3 PIN 3
NOT USED
ALR (RIGHT)
AD (LEFT)
J3 PIN 6
J1 PIN 2 & J3 PIN 2
J2 PIN 14TEMP PROBE
NOT USEDNOT USED
NOT USED
NOT USEDNOT USED
NOT USED
PWR via LT HT RELAY
V2D
NOT USED
*
** Dual Vat configurations
** Full Vat configurations
J2 PIN 1
J2 PIN 14 TEMP PROBE
J2 PIN 3
NOT USED
J2 PIN 5 HOOD RELAY
J2 PIN 13
NOT USED NOT USED
PWR via RT HT RELAY
V1S OR V1D
NOT USED
BLOWER via K4 (old)
or K2/K3 (new)
BLOWER XFMR BOX
J3
1
2
3
4
5
6
7
8
9
10
11
12
J2
12 VAC XFMR
12 VAC XFMR
NOT USED
TEMP PROBE
24 VAC IN
MAIN GAS VALVE
NOT USED
120 VAC IN
MOD 25V GROUND GROUND
MOD V2D
MOD 25V TERM
DRAIN SWITCH (OPT)
NOT USED NOT USED
NOT USED NOT USED
GND
V2D
J1 PIN 8 via LT HT RELAY
PWR
AD
AS
V2S
J1 PIN 9
J2 PIN 12
LEFT VAT FULL OR RIGHT VAT
INTERFACE BOARDS 806-3398 AND 106-0386
GROUND MOD 25V GROUND
J3 PIN 9
J3 PIN 8 via RT HT RELAY
J2 PIN 10
J3 PIN 9
CURRENT FLOW THROUGH
(H52 APPLICATION)
3-4
GND
V1D
PWR
ALR
V1S
MOD V1D *
MOD 25V TERM
DRAIN SWITCH (OPT)
MOD V1S **
THERMOSTATS
All fryers in the H52 Series have temperature probes located on the front centerline of each the fry-
pot. (Dual vat frypots have a probe in each vat.) In this type 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). The temperatures are programmed by means of a keypad or knob on the face of the control­ler.
H52 Series 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 high-limit 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 configured models, and are not interchangeable.

3.2 Accessing Fryers for Servicing

DANGER
Moving a fryer filled with cooking oil/shortening may cause spilling or splattering of
the hot liquid. Follow the draining instructions in Chapter 4 of this 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.
3. Relocate the fryer for service accessibility.
4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and
plug in the electrical cords.
3.3 Cleaning the Gas Valve Vent Tube
NOTE: This procedure is not required for fryers configured for export to CE countries.
1. Set the fryer power switch and the gas valve to the OFF position.
2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be
straightened for ease in removal.
3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any
obstruction.
3-5
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.
3.4 Checking the Burner Manifold Gas Pressure
DANGER
Frymaster recommends that ONLY qualified service personnel perform this task.
1. On non-CE fryers, ensure that the gas valve knob is in the OFF position.
Honeywell
ON
OFF
2. Remove the pressure tap plug from the gas valve assembly.
Pressure Tap Plug
Typical Non-CE Valve Assembly
Typical CE Valve
Assembly
2. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.
3. On non-CE fryers only, place the gas valve in the ON position.
4. 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 found on the following page.
3-6
CE Standard
B urn e r M a n if o ld G a s Pre s s u res
fo r F ry ers M a n u fac tu re d A fte r A p ril 19 99
Pressure (mb ar)
Single
Gas
Natural G as Lacq (G20) at 20 mbar
Natural Gas Gronique * (G25) at 25 mbar
Natural Gas Gronique (G25) at 20 mbar
Butane/Propane (G30) at 28/30 or 50 mbar
Propane (G31) at 37 or 50 m bar
* B e lg ian G2 5 = 7.0 m b ar (s in g le o r d u a l)
Vat
77
10 10
10 10
17 17
20 20
Dual
Vat
CE Standard
Bu rner Manifold Gas P ressures
for Fryers Manufactured T hrough Ap ril 1999
Pressure (m b ar)
Gas
Natural Gas Lacq (G20) under 20 mbar
Natural Gas G ronique (G25) under 25 mbar
Natural Gas Gronique (G25) under 20 mbar
Propane (G31) under 37 or 50 m bar
*
Single
Vat
76.5
10 9
10 9
20.2 18.5
Dual
Vat
* Belgian G 25 = 7.0 mb ar (single) or 6.5 (dual)
Non-C E Standard
B urner M anifold G as Pressures
Gas Pressure
Natural
LP
3" W .C .
0.73 kPa
8.25" W .C .
2.5 kPa
3-7
5. To adjust the burner gas pressure, remove the cap from the gas valve regulator and adjust to cor-
rect pressure.
Non-CE
Valve
Earlier Model CE Valve
GAS VALVE REGULATOR CAP
Later Model
CE Valve
6. Place the fryer 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.

3.5 Measuring Flame Current

When the burner flame is properly adjusted, it will produce a current between 3.5 µA and 6.5 µA. Flame current is measured by placing a microamp (not milliamp) meter in series with the white
sensing wire on the ignitor. This is accomplished as follows:
1. Place the fryer power switch in the OFF position.
2. Disconnect the white 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.
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.

3.6 Replacing Fryer Components

3.6.1 Replacing the Controller or the Controller Wiring Harness

1. Disconnect the fryer from the electrical supply.
2. Remove the two screws in the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
3. Disconnect the wiring harness from the back of the controller and, if replacing the harness, dis-
connect it from the interface board.
4. Disconnect the ground wire from the controller, and remove the controller by lifting it from the
hinge slots in the control panel frame.
3-8
5. Reverse the procedure to install a new controller or wiring harness.
3.6.2 Replacing the Temperature Probe or 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 from the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
4. Unplug the controller wiring harness from the back of the controller.
5. Disconnect the ground wire from the controller, and remove the controller by lifting it from the
hinge slots in the control panel frame.
6. Remove the screws securing the topcap to the fryer and lift the topcap up and off the fryer.
7. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward
you.
8. Remove the screws securing the control panel frame in place and remove the frame.
9. Remove the component box mounting screws and rotate the top of the component box out of the
cabinet. Carefully pull it out far enough to disconnect the wiring harness plug(s) from the back of the box. Remove the box and set it aside.
10. On CE fryers with a blower shield assembly installed, remove the screws securing the shield in
place and remove it from the cabinet.
11. Make a note of the location of the existing wires. Using a pin-pusher, disconnect the temperature
probe wires (or high-limit thermostat wires) from the connector plug.
12. Unscrew and remove the temperature probe (or high limit thermostat) from the frypot.
13. Apply Loctite
®
PST56765 pipe thread sealant or equivalent to the replacement part threads.
14. Screw the replacement part into the frypot.
15. Connect the wires from the new component to the connector plug, referring to the note made in
step 11.
16. Reverse steps 1 through 10 to complete the procedure.
3-9

3.6.3 Replacing the Interface Board

1. Remove the component box per steps 1 through 9 of Section 3.6.2.
2. Unplug the controller wiring harness from the interface board.
3. Disconnect the wires attached to the interface board, marking or making a note of the wires and
terminals to facilitate reconnection.
4. Remove the nuts at each corner of the interface board and pull it from the studs.
5. Reverse the procedure to install the replacement board, being sure to reinstall the spacers behind
the interface board.

3.6.4 Replacing an Ignition Module

1. Disconnect the fryer from the electrical supply.
2. Remove the screws from the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
3. Disconnect the wires from the ignition module, marking or making a note of the wires and termi-
nals to facilitate reconnection.
4. Remove the four ignition module screws and pull the module from the component box.
5. Reverse the procedure to install the replacement module.

3.6.5 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 ignition cable from the ignitor by grasping the boot and gently pulling toward
you.
3. Remove the two 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.
3-10

3.6.6 Cleaning or Replacing a Combustion Air Blower

A sheet metal shield or shield assembly prevents inadvertent access to the blower assembly. The specific design varies depending upon the particular configuration of the fryer and the country for which manufactured, but in all cases, the shield is attached to the cabinet framing by sheet metal screws. Remove the screws that secure the shield or shield assembly to the cabinet framing and pull the shield out of the fryer to expose the combustion air blower assembly.
1. Disconnect the blower wiring harness and remove the blower assembly mounting nuts.
Blower
Wiring connection
assembly mounting
nuts
2. Remove the three fasteners that secure the blower motor assembly to the blower housing, and
separate the two components.
Remove these fasteners. (On black-colored FASCO blowers there are three nuts. On silver-colored KOOLTRONICS blowers there are three screws.)
3-11
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.
Wrap the mot or 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 assembly in the fryer.
5. Reinstall the blower shield or shield assembly.
6. Light the fryer in accordance with the procedure described in Chapter 3, Section 3.1.
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.
Left Viewing
Port is Behind
Motor
(NOTE: Blower
shield omitted
for clarity.)
Right
Viewing
Port
The air/gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable table on page 3-7 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.
3-12
Adjusting Air/Gas Mixture
Non-CE Units and CE Units Built After April 1999
On the side of the blower housing opposite the motor is a plate with one or two locking nuts. Loosen the nut(s) enough to allow the plate to be moved, then adjust the position of the plate to open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold the plate in position and tighten the locking nut(s).
TYPICAL NON-CE BLOWER ASSEMBLY TYPICAL CE BLOWER ASSEMBLY
ON UNITS BUILT AFTER APRIL 1999
Adjusting Air/Gas Mixture
CE Units Built Through April 1999
CE units built through April 1999 are equipped with a shield assembly in front of the blowers. An air shutter plate on the face of the shield assembly regulates the amount of airflow to the blower in­take. To adjust the shutter plate, loosen the locking screws and slide the shutter to the left or right as necessary to obtain a bright orange-red glow. Carefully hold the shutter plate in position and tighten the locking screws.
TYPICAL CE BLOWER SHIELD ASSEMBLY
ON UNITS BUILT THROUGH APRIL 1999
3-13

3.6.7 Replacing a Gas Valve

DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1. Disconnect fryer from electrical and gas supplies.
2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate recon­nection.
3. Remove the vent tube and the enrichment tube fitting from the valve.
4. Disconnect the flexible gas line(s).
5. Carefully unscrew the valve from the manifold. NOTE: Some models may have the valve at-
tached to the manifold by means of a pipe union. In such cases, remove the valve by uncoupling the union.
6. Remove all fittings from the old gas valve and install them on the replacement valve, using Loc-
tite® PST56765 or equivalent pipe thread sealant.
7. Apply Loctite
®
PST 56765 or equivalent pipe thread sealant to the threads of the manifold (or the
union). Reverse steps 1-5 to install the replacement gas valve.

3.6.8 Replacing a Burner Assembly

DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1. Disconnect the unit from the electrical and gas supplies.
2. Remove the combustion air blower per the procedure found in Section 3.6.6.
3. Remove the four nuts from the air plenum assembly and pull the assembly straight out toward
you until it clears the burner tubes.
NOTE: On a dual vat fryer, it will be necessary to remove the drain valve handles before the
plenum can be removed.
4. Disconnect the ignition cables from the ignitors by grasping their boots and pulling toward you.
5. Disconnect the gas lines and enrichment tubes from the burner orifices and ignitor assemblies.
6. Remove the four ¼” (6mm) nuts securing the outer front covers to the frypot assembly.
7. Remove the sheet metal screws at the top of the outer front covers and pull the covers straight out
toward you until clear of the mounting studs.
3-14
8. Remove the washers and tubular spacers from the mounting studs, then pull the inner covers
straight out toward you until clear of the mounting studs.
9. Grasp the burner firmly and pull it toward you until it clears the burner channels, taking care not
to damage the ceramic tiles in the process.
10. Clean all debris from the burner channels and combustion area.
11. 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 3.6.9 for procedure.
b. If the welds in the upper rail are cracked or burned out, the upper rail must be replaced. Re-
fer to Section 3.6.10 for procedure.
12. Place a new insulating strip along the top, rear, and bottom edge of the burner and carefully slide
it straight into the rails.
NOTE: Use P/N 826-0931 for full vat frypots and P/N 826-0932 for dual vat frypots.
13. Reverse steps 1 through 9 to reassemble the components.
14. 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.
15. Visually examine the burner flame. The color and intensity on both sides should be the same.
16. Use an inspection mirror to check for leaks in areas that cannot be directly observed.
17. If a leak is detected, tighten all the lower insulation retainer nuts, allow the frypot to run for five
additional minutes, and repeat steps 15 and 16.
18. If the 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 15 through 17. Repeat this step
until no leakage is detected.

3.6.9 Replacing the Frypot

1. Drain cooking oil/shortening from the frypot.
2. Remove all accessories, e.g., frypot covers, basket lift arms, etc. from the fryer.
4. Disconnect the fryer from gas and electrical supplies.
5. Remove the screws from the topcap above the control panel and lift it up and off the fryer(s).
3-15
6. Remove the screws from the upper left and right corners of the control panel. Open the panel,
disconnect the controller wiring harness and ground wire. Remove the controller from the fryer.
7. Disconnect the ignition wires from the ignitor plugs by grasping their boots and pulling toward
you.
8. Remove the screws securing the component box to the frame, and then rotate the top of the box
forward and out of the fryer enough to disconnect the wiring harness connector plug(s) on the rear of the box. Set the component box aside.
9. Using a pin pusher, remove the temperature probe and high-limit thermostat wires from the
plug(s), marking each wire to facilitate re-assembly.
10. On BIH52 units, remove the cover from the safety drain switch, disconnect the wires from the
switch, and pull them out of the switch box.
11. On BIH52 units, remove the section(s) of square drain from the drain valve(s) of the frypot to be
removed.
12. Disconnect the gas lines and enrichment tubes from the burner orifices and ignitor assemblies.
13. Remove the frypot hold down bracket.
14. Remove the screws from the flue cap sides and back and lift it clear of the fryer(s).
15. On BIH52 units, disconnect the oil return line(s) from the frypot to be removed.
16. Carefully lift the frypot from the fryer cabinet.
17. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), and ignitor assem-
blies. 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, but this remains the customer’s decision.
18. Reverse steps 1-16 to reassemble fryer.
19. Perform steps 14 through 18 of Section 3.6.8 to ensure that there are no leaks in the burner insu-
lation.
CAUTION
Before installing the temperature probe, high-limit thermostat, and drain valve on the
replacement frypot, clean their threads and apply Loctite® PST56765 thread sealant
or equivalent.
3-16
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