Frymaster BIMH52 User 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

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.

Frymaster, L.L.C. 8700 Line Avenue 71106, 5489 Campus Drive 71129

TEL 318-865-1711 FAX (Parts) 318-219-7140 (Tech Support) 318-219-7135

PRINTED IN THE UNITED STATES

P.O. Box 51000, Shreveport, Louisiana 71135-1000

SERVICE HOTLINE

1-800-24-FRYER

*8195423*

JUNE 2005

NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER.

NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster/DEAN Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty.

NOTICE This equipment must be installed in accordance with the appropriate national and local codes of the country and/or region in which the appliance i s installed.

NOTICE TO U.S. CUSTOMERS This equipment is to be installed in compliance with the basic plumbi ng 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.

NOTICE Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to onsite management operational procedures.

NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS

U.S.

This device complies with Part 15 of the FCC rules. Operation is subject to the follow ing tw o conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet the Class B limits.

CANADA

This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES-003 standard of the Canadian Department of Communicat i ons.

Cet appareil numerique n’emet pas de bruits radioelect riques depassany les li mit es de cl asse A et B prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.

WARNING To ensure the safe and efficient operation of the fryer and hood, the electrical plug for the 120-volt line, whi ch powers the hood, must be fully engaged and locked in i ts pin and sleeve socket.

DANGER Improper installation, adjustment, maintenance or service, and unauthorized alterations or modifications can cause property damage, injury, or death. Read the installation, operating, and service instructions thoroughly before installing or servicing this equipment. Only qualified service personnel may convert this appliance to use a gas other than that for w hich it was originally configured.

DANGER No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the Frymaster Dean Service Hotline at 1-800551-8633.

DANGER Adequate means must be provided to limit the movement of this appliance wi thout depending upon the gas line connection. Single fryers equipped with legs must be stabilized by installing anchor straps. All fryers equipped with casters must be stabilized by installing restraining chains. If a flexible gas line is used, an additional restraining cable must be connected at all times w hen the f r yer is in use.

DANGER The front ledge of the fryer is not a step! Do not stand on the fryer. Serious injury can result from slips or contact wi t h t he hot oi l .

DANGER Do not store or use gasoline or other flammable li quids or vapors in the vicini ty of this or any other appliance.

DANGER Instructions to be follow ed in the event the operator smells gas or otherwise detects a gas leak must be posted in a prominent location. This information can be obtained from the l ocal gas company or gas supplier.

DANGER This product contains chemicals known to the st ate of Cal if ornia to cause cancer and/or bi rth 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 know n to the State of Californi a to cause cancer. Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm.

DANGER The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shorteni ng mat eri al .

WARNING Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip i s present to seal the joint between the fry vessels. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning.

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. Frymaster L.L.C. warrants all components against defects in material and workmanship for a period of one year.

2. All parts, with the exception of the frypot, heating elements and fuses, are wa rranted for one year after installation date of fryer.

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 manufactured after December 1, 2003, only.)

1. If a frypot develops a leak within ten years after installation, Frymaster will, at its option, either replace the complete battery or 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

(Applies to fryers installed on or after November 1, 1994, only.)

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.

D. WARRANTY PROVISIONS - COOKING COMPUTER

1. Frymaster L.L.C. warrants the M-2000 Cooking Computer against defective material or workmanship for a period of three years from the original installation date. If the unit fails within the first year, warranty will cover part, labor and handling. If the part fails the second year, warranty will cover part and handling only. Labor is charged to the store. The third year, warranty will cover the part only. No labor or handling will be covered.

2. During this warranty period, Frymaster will, at its option, repair or replace a returned defective cooking computer with a new or factory rebuilt and functionally operative units.

3. For replacement of defective computers under warranty, call your local Frymaster 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 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 propert y 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.

BIH52 / MH52

SERIES GAS FRYERS

TABLE OF CONTENTS

CHAPTER 1: Introduction

1.1 General ..............................................................................................................................1-1

1.2 Safety Information............................................................................................................. 1-1

1.3 Computer Information....................................................................................................... 1-2

1.4 European Community (CE) Specific Information............................................................. 1-2

CHAPTER 2: Installation Instrucitons

2.1 General Installation Requirements....................................................................................2-1

2.2 Caster/Leg Installation ......................................................................................................2-3

2.3 Pre-Connection Preparations............................................................................................. 2-3

2.4 Connections to Gas Line ...................................................................................................2-5

2.5 Converting to Another Gas Type ......................................................................................2-7

2.6 Frypot Boil-Out.................................................................................................................2-8

CHAPTER 3: Service Procedures, Troubleshooting and Wire Diagrams

3.1 Functional Description...................................................................................................... 3-1

3.2 Accessing Fryers for Servicing .........................................................................................3-5

3.3 Cleaning the Gas Valve Vent Tube................................................................................... 3-5

3.4 Checking the Burner Manifold Gas Pressure....................................................................3-6

3.5 Measuring Flame Current..................................................................................................3-8

3.6 Replacing Fryer Components............................................................................................ 3-8

3.6.1 Replacing the Controller or the Controller Wiring Harness............................... 3-8

3.6.2 Replacing the Temperature Probe or High-Limit Thermostat ........................... 3-9

3.6.3 Replacing the Interface Board..........................................................................3-10

3.6.4 Replacing an Ignition Module .......................................................................... 3-10

3.6.5 Replacing an Ignitor Assembly........................................................................3-10

3.6.6 Replacing or Cleaning a Combustion Air Blower............................................ 3-11

3.6.7 Replacing a Gas Valve..................................................................................... 3-14

3.6.8 Replacing a Burner Assembly.......................................................................... 3-14

3.6.9 Replacing the Frypot........................................................................................ 3-15

3.6.10 Replacing Frypot Insulation and/or Upper Burner Rails..................................3-17

3.7 Troubleshooting and Problem Isolation.......................................................................... 3-21

3.7.1 Ignition Failure.................................................................................................3-22

3.7.2 Improper Burner Function ................................................................................ 3-23

3.7.3 Improper Temperature Control ........................................................................ 3-24

3.7.4 Recovery Time and the M100B “Rec Loc” Condition ....................................3-25

3.7.5 Filtration Malfunctions.....................................................................................3-26

3.7.6 Leakage ............................................................................................................ 3-29

3.8 Troubleshooting Guides.................................................................................................. 3-29

3.8.1 Troubleshooting the 24 VAC Circuit...............................................................3-30

3.8.2 Troubleshooting the Gas Valve........................................................................ 3-33

3.8.3 Troubleshooting the Temperature Probe.......................................................... 3-34

iii

BIH52 / MH52

SERIES GAS FRYERS

TABLE OF CONTENTS

3.9 Probe Resistance Chart.................................................................................................... 3-35

3.10 Simplified Wiring Diagrams........................................................................................... 3-37

3.11 Principle Wiring Connections......................................................................................... 3-42

3.12 Main Wiring Diagrams.................................................................................................... 3-43

CHAPTER 4: Parts List

4.1 Accessories........................................................................................................................4-1

4.2 Cabinetry Components......................................................................................................4-2

4.2.1 BIH152 and MH152 Cabinet Components........................................................ 4-2

4.2.2 BIH52 Cabinet Components ..............................................................................4-4

4.2.3 MH52 Cabinet Components............................................................................... 4-6

4.2.4 BIH52/MH52 Cap N Splash, Fluecaps, Standoffs and Related Parts................4-9

4.2.5 BIH52/MH52 Control Panel Frames and Topcaps ..........................................4-11

4.2.6 BIH52/MH52 Door Components.....................................................................4-12

4.3 Combustion System, Frypot and Gas System Components............................................ 4-13

4.3.1 Blowers and Associated Parts ..........................................................................4-13

4.3.2 Ignition Sub-System Components.................................................................... 4-14

4.3.3 Frypot Assembly Components.........................................................................4-15

4.3.3.1 Full Vat Frypot Assembly Components ..........................................4-15

4.3.3.2 Dual Vat Frypot Assembly Components.........................................4-17

4.3.4 Service Frypot Kits........................................................................................... 4-19

4.3.5 Gas Manifolds – Single BIH52/MH52 Units...................................................4-20

4.3.6 Gas Manifolds – BIH52/MH52 Multi-Fryer Units ..........................................4-21

4.3.7 Gas Valves, Gas Lines and Fittings.................................................................. 4-23

4.4 Electronics.......................................................................................................................4-25

4.4.1 Computers, Controllers and Associated Components...................................... 4-25

4.4.2 Component Boxes ............................................................................................ 4-27

4.4.3 Filter Box Components .................................................................................... 4-28

4.4.4 Transformer Box Components.........................................................................4-29

4.4.5 Wiring............................................................................................................... 4-31

4.5 Oil Handling System Components..................................................................................4-34

4.5.1 Drain System Components............................................................................... 4-34

4.5.1.1 Square Drain Sections and Components..........................................4-34

4.5.1.2 Drain Valve Assemblies .................................................................. 4-35

4.5.2 Filtration System Components.........................................................................4-37

4.5.2.1 Filter Base Assemblies..................................................................... 4-37

4.5.2.2 Filter Motor and Pump Plumbing....................................................4-39

4.5.2.3 Filter Pan Assemblies and Associated Components........................ 4-41

4.5.2.4 Rear Flush Oil Return Components................................................. 4-43

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 regarding 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 UNAUTHORIZE D 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. While these devices are verified as Class A devices, they 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 cabl e 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 and the heat light

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.

2-3

c. Place the fryer power switch in the OFF position. Verify that the power and heat lights are

out, or that the display shows “OFF”.

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 M aximum

Natural

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

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)

2H3B/P

2E(R)B

2H3B/P

2Esi3+

2Esi3P

2H3B/P

2ELL3B/P

2H3+

2E3B/P

2L3P

2L3B/P

3B/P

2H3+

2H3P

2H3B/P

2H3+

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 50

G25 25

G31 50

G25 25 G30, G31 30

G30, G31 30

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” on 3.4 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

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

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 frye r 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 hi gh 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 valv e. 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 late 2000 to

GND

Coil

mid-2001 are equipped with two 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 th e 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 late2000, 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

V2D

PWR

AD AS

V2S

3 6 9 12

2 5 8 11

1 4 7 10

SOUND

1 2 3

GND GV PWR

EARLIER DESIGN INTERFACE BOARD P/N 806-3398

K3 K5

BLOWER

MOTOR

RELAY

HEAT

RELAY

K1 K2

12 6 3 45

AL 12V

AIR

10741

11852

12963

RELAY

24V AL

HEAT

PWR

GND

3 6 9 12

2 5 8 11

1 4 7 10

GND

GND V1D PWR ALR V1S

SOUND

1 2

GND

3 6 9 12

2 5 8 11

1 4 7 10

GND

V2D

PWR

AD AS

V2S

GND

LATER DESIGN INTERFACE BOARDS P/N 806-3398 and 106-0386

This Fuse is NOT

present on 806-3398 IFB.

HEAT

RELAY

PWR

AND

BLOWER

MOTOR

RELAY

K2 K3

10741

11852

12963

12V

HEAT

24V

RELAY

AND

BLOWER

MOTOR

RELAY

F2 Ignition 2 AMP Module

3 6 9 12

2 5 8 11

1 4 7 10

Blower Motor 2 Amp

GND

PWR

GND

D5 GV

AIR

GND V1D PWR ALR V1S

3-2

FREQU E NT LY U SED TEST POINTS FOR INTERFACE BOARDS 806-3398 AN D 106-0386

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 250V AC Scale 12 on J3 and GRO U N D 110-125 24VAC Power to Right High-Limit 50VAC Scale 9 on J3 and GRO U N D 22-28 24VAC Power to Left High-Limit 50VAC Scale 9 on J1 and GROU N 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 OH M 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 one or 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 Indicates 12 VAC from transformer 24V Indicates 24 VAC from transformer

GV Indicates 24 VAC t o gas valve (left or right)

PWR Indicates 24 VAC to module (left or right)

AL Indicates module lock-out (l eft or right)

AIR CE and Japanese units only: ai r switch closed

1 24 VAC to left gas valve (dual vat only) 2 24 VAC to left i gni tion module 3 24 VAC from t rans former 4 24 VAC to right ignition module 5 24 VAC to gas valve (right val ve if dual vat) 6 12 VAC from t rans former

7 CE and Japanese units only: air switch 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

RT ALARM OUT

COMPUTER SOUND DEVICE

LT ALARM OUT

COMPUTER

COMPUTER J1 PIN 6

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

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

12 VAC XFMR

NOT USED

TEMP PROBE

24 VAC IN

MAIN GAS VALVE via

HIGH LIMIT

NOT USED

120 VAC IN

BLOWER FAN

AND XFMR BOX

MOD 25V GROUND GROUND

MOD V2D

MOD 25V TERM

DRAIN SWITCH (OPT)

NOT USED NOT USED

GND

V2D

J1 PIN 8 via LT HT RELAY

PWR

V2S

J2 PIN 12

LEFT VAT FULL OR RIGHT VAT

INTERFACE BOARDS 806-3398 AND 106-0386

GROUND MOD 25V GROUND

J1 PIN 9

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 VALVE used on

Dual Vat Only

MOD 25V TERM

MOD ALARM

MOD VALVE

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

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 er M a nifo ld Ga s P r e s s u r e s

fo r F ry ers M a n u fa c tu red A fte r A p ril 19 9 9

Pressure (mb ar)

Single

Gas

Natural Gas 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 ia n G 2 5 = 7 .0 mba r (s in g le o r d u al)

Vat

10 10

17 17

20 20

Dual

Vat

CE Standard

Bu rner Manifold Gas P ressures

for Fryers Manufactu red Through April 1999

Pressure (m b ar)

Gas

Natural Gas Lacq (G20) under 20 m bar

Natural Gas G ronique (G25) under 25 m bar

Natural Gas Gronique (G25) under 20 m bar

Propane (G31) under 37 or 50 m bar

Single

Vat

76.5

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 anifo ld G as Pressures

Gas Pressure

Natural

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 the

correct 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 2.5 µA and 3.5 µA.

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.

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.

5. Reverse the procedure to install a new controller or wiring harness.

3-8

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 plast ic 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

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