Frymaster MPH52-55, BIPH52-55 User Manual

SERVICE MANUAL

FRYMASTER BIPH52/55 AND MPH52/55 SERIES

GAS FRYERS

This equipment chapter is to be

installed in the Fryer Section of the

Equipment Manual.

MANUFACTURED

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

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 MAY 2006

1-800-24-FRYER

www.frymaster.com E-mail: service@frymaster.com *8196094*

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 CUST OMER 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 is installed.

NOTICE TO U.S. CUSTOMERS This equipment is to be installed in compliance with the basic plumbing code of the Building Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the 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 following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet the Class B limits.

CANADA

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

Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.

WARNING To ensure the safe and efficient operation of the fryer and hood, the electrical plug for the 120volt line, which powers the hood, must be fully engaged and locked in its 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 which 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 1-800-551-8633.

DANGER Adequate means must be provided to limit the movement of this appliance without 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 when the fryer 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 with the hot oil.

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

DANGER Instructions to be followed 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 local gas company or gas supplier.

DANGER This product contains chemicals known to the state of California to cause cancer and/or birth defects or other reproductive harm.

Operation, installation, and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne particles of glasswool or ceramic fibers is known to the State of California to cause cancer. Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm.

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

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

WARRANTY STATEMENT

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

A. WARRANTY PROVISIONS - FRYERS

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

2. All parts, with the exception of the frypot, heating elements and fuses, are warranted 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. Frymaster warrants the frypot assembly for ten years parts and labor. Components attached to the frypot, such as the high-limit, probe, gaskets, seals, ignitors and related fasteners, are also covered by the ten-year warranty if replacement is necessitated by the frypot replacement. Components that are not part of the frypot assembly, such as the blower, gas valve, micro switches, doors and cabinetry are not covered by the frypot warranty. If the frypot is found to be defective, Frymaster will replace the frypot, allowing up to the maximum time per the Frymaster time allowance chart hours of straight-time labor plus up to 100 miles/160 km of travel (50 miles/80 km each way) to change the frypot.

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

C. WARRANTY PROVISIONS – COMBUSTION CHAMBERS

(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 and labor. If the part fails the second year, warranty will cover part only. Labor is charged to the store. The third year, warranty will cover the part at a reduced cost of $90.00. No labor or handling will be covered.

2. During this warranty period, Frymaster will 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 Frymaster exchange program only carry the remaining original 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 property which is damaged), loss of

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

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

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

BIPH52/55-MPH52/55

SERIES GAS FRYERS

TABLE OF CONTENTS

CHAPTER 1: Service Procedures

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

1.1.1 The Electronic Ignition System.......................................................................... 1-1

1.1.2 Interface Board...................................................................................................1-2

1.1.3 Thermostats........................................................................................................ 1-4

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

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

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

1.5 Measuring Flame Current.................................................................................................. 1-7

1.6 Replacing Fryer Components............................................................................................ 1-7

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

1.6.2 Replacing the Temperature Probe or High-Limit Thermostat ........................... 1-8

1.6.3 Replacing the Interface Board............................................................................ 1-9

1.6.4 Replacing an Ignition Module.......................................................................... 1-10

1.6.5 Replacing an Ignitor Assembly........................................................................1-10

1.6.6 Replacing or Cleaning a Combustion Air Blower............................................1-11

1.6.8 Replacing a Burner Assembly.......................................................................... 1-15

1.6.9 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve.......1-16

1.6.10 Replacing the Frypot ........................................................................................ 1-17

1.6.11 Replacing Frypot Insulation and/or Upper Burner Rails..................................1-19

1.7 Troubleshooting and Problem Isolation..........................................................................1-25

1.7.1 Ignition Failure.................................................................................................1-25

1.7.2 Improper Burner Function................................................................................1-26

1.7.3 Improper Temperature Control ........................................................................1-28

1.7.4 Computer Malfunctions.................................................................................... 1-28

1.7.5 Filtration Malfunctions.....................................................................................1-29

1.7.6 Leakage ............................................................................................................ 1-30

1.8 Troubleshooting Guides.................................................................................................. 1-31

1.8.1 Troubleshooting the 24 VAC Circuit...............................................................1-33

1.8.2 Troubleshooting the Gas Valve........................................................................ 1-35

1.8.3 Troubleshooting the Temperature Probe.......................................................... 1-35

1.9

1.10 Principal Wiring Connections......................................................................................... 1-37

1.11 Wiring Diagrams.............................................................................................................1-38

1.11.1 Main..................................................................................................................1-38

1.11.2 Transformer / Filter Boxes...............................................................................1-39

1.11.2.1 MPH152/155................................................................................. 1-39

1.11.2.2 BIPH252/255 and 452/455 Domestic............................................1-40

1.11.2.3 BIPH252/255 and 452/455 International ...................................... 1-41

1.11.2.4 BIPH352/355 Domestic ................................................................1-42

1.11.2.5 BIPH352/355 International ...........................................................1-39

1.6.7 Replacing a Gas Valve..................................................................................... 1-14

Probe Resistance Chart.................................................................................................... 1-36

iii

BIPH52/55-MPH52/55

SERIES GAS FRYERS

TABLE OF CONTENTS

1.12 Simplified Wiring Diagrams...........................................................................................1-44

1.12.1 BIPH52/55 Series Full Vat............................................................................... 1-44

1.12.2 BIPH52/55 Series Dual Vat ............................................................................. 1-45

1.12.3 BIPH52/55 Series Full Vat (Australia and Pacific Rim).................................. 1-46

CHAPTER 2: Parts List

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

2.2 Cabinetry...........................................................................................................................2-3

2.2.1 Backs, Doors, Flue Caps, Sides, and Top Caps ................................................. 2-3

2.2.2 Filter Cabinet Bases, Casters, Framing, and Related Components.................... 2-6

2.2.3 Non-Filter Cabinet Bases, Casters, Framing, and Related Components............ 2-8

2.3 Controllers.......................................................................................................................2-10

2.4 Drain, Filtration, and Oil Return System Components...................................................2-11

2.4.1 Filtration System Components.........................................................................2-11

2.4.2 Drain Valves and Associated Components......................................................2-13

2.4.3 Rear Flush Oil Return Line Components......................................................... 2-15

2.5 Electronics and Electrical Components........................................................................... 2-17

2.5.1 Component Boxes ............................................................................................ 2-17

2.5.2 Transformer Boxes...........................................................................................2-19

2.5.3 High-Limit Thermostat and Temperature Probe.............................................. 2-22

2.7 Frypots and Associated Components.............................................................................. 2-23

2.7.1 Full-Vat Frypot Components............................................................................2-23

2.7.2 Dual-Vat Frypot Components..........................................................................2-25

2.8 Gas Supply and Combustion System Components.........................................................2-27

2.9 Gas Valves and Associated Components........................................................................2-29

2.10 Wiring Assemblies and Harnesses.................................................................................. 2-31

2.11 Miscellaneous Connectors and Terminals....................................................................... 2-35

BIPH52/55-MPH52/55 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

BIPH52/55 and MPH52/55 Series gas fryers contain a welded stainless steel frypot that is directly heated by a high efficiency infrared burner system requiring approximately 43% less energy than conventional burners to cook the same volume.

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

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

1.1.1 The Electronic Ignition System

Inside the Ignition Module

An ignition module mounted in the component box (located behind the control panel) is connected to an ignitor assembly at the burner. The ignition module performs four important functions: it provides fuse

Out to Gas Valve

To Al arm

protection for the 24-volt circuit, provides an ignition spark, supplies voltage to the gas valve, and proofs the

25 V +

burner flame. The module contains a 4-second time delay circuit and a coil that activates the gas valve. Three types are in use. A closed-box design is used in most fryers, but in some fryers built for export the module resembles an interface board. A single dual-spark module is used on

GND

Coil

current production full-vat fryers. All dual-vat fryers use two single-spark modules.

Ignition Wire Flame Sensor

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 24 VAC circuit to

1-1

provide current to the ignition module. Circuitry in the ignition module sends 24 VAC to the gas valve via a normally closed high-limit switch (and, in fryers with built-in filtration systems, 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 ignition by measuring the flow of microamps through the flame. If the burner does not light (or is extinguished), current to the ignition module is cut, the gas valve closes, and the ignition module “locks out” until the power switch is turned off and then back on. A probe monitors the temperature in the frypot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay. This in turn cuts off the 24 VAC to the ignition module, causing the gas valve to close.

1.1.2 Interface Board

All fryers in this series have an interface board located in the component box behind the control panel. The interface board provides a link between the controller/computer and the fryer’s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point. This standard interface board is also used in a number of fryer types besides the BIPH52/55 and MPH52/55 Series. The information contained in this section applies to

BIPH52/55 and MPH52/55 Series applications ONLY.

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

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

GND

V2D

PWR

AD AS

V2S

SOUND

1 2 3

3 6 9 12

2 5 8 11

1 4 7 10

GND

PWR

INTERFACE BOARD P/N 106-0386SP

HEAT

RELAY

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

PWR

GND

D5 GV

GND V1D PWR

ALR V1S

AIR

INTERFACE BOARD

LED DIAGNOSTIC LIGHTS

24 VAC to left gas valve (dual vat only)

24 VAC to left ignition module

24 VAC from transform er

24 VAC to right ignition module

24 VAC to gas valve (right valve if dual vat)

12 VAC from transform er

CE and Japanese units only: air sw itch closed

NOTE: Although the printing on some boards may indicate 2 Amp fuses, 3 Amp fuses (P/N

807-3843) must be used. In full-vat fryers, the relay for the left side (K2) may not be present. The chart on the following page illustrates current flow through the board, and the table at the top of

page 1-4 identifies frequently used test points.

1-2

INTERFACE BOARD

12 VAC TO CPTR

GROUND

COMPUTER (12 VAC)

COMPUTER RT HT RELAY

COMPUTER 12 VDC TO RELAYS

COMPUTER LT HT RELAY

COMPUTER

NOT USED NOT USED

COMPUTER LT BL RELAY

RT ALARM OUT

COMPUTER SOUND DEVICE

LT ALARM OUT

COMPUTER

COMPUTER J1 PIN 6

J3 PIN 1

GROUND

J3 PIN 3

RT BL RELAY

ALR (RIGHT)

AD (LEFT)

J3 PIN 6

J1 PIN 2 & J3 PIN 2

NOT USED NOT USED

NOT USED

TEMP PROBE J2 PIN 15

BASKET LIFT (DN) LT BL RELAY

NOT USED

MAIN GAS VALVE

via HLS

BASKET LIFT (UP)

NOT USED NOT USED

J2 PIN 14TEMP PROBE

NOT USEDNOT USED

NOT USED

NOT USEDNOT USED

NOT USED

LT BL RELAY

V2D

** Dual Vat configurations

** Full Vat configurat ions

J2 PIN 1

J2 PIN 14 TEMP PROBE

J2 PIN 3

NOT USED

NOT USED NOT USED

J2 PIN 13

RT BL RELAY BASKET LIFT (DN)

PWR via RT HT RELAY

V1S OR V1D

RT BL RELAY

BLOWER via K4 (old)

or K2/K3 (new)

BLOWER XFMR BOX

12 VAC XFMR

NOT USED

TEMP PROBE

24 VAC IN

MAIN GAS VALVE

via HLS

BASKET LIFT (UP)

120 VAC IN

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

J1 PIN 9

J2 PIN 12

LEFT VAT FULL OR RIGHT VAT

CURRENT FLOW THROUGH INTERFACE BOARD

106-0386SP (BIPH52/55 and MPH52/55 SERIES

APPLICATION)

1-3

GROUND MOD 25V GROUND

J3 PIN 9

J3 PIN 8 via RT HT RELAY

J2 PIN 10

J3 PIN 9

GND

V1D

PWR

ALR

V1S

MOD V1D *

MOD 25V TERM

DRAIN SWITCH (OPT)

MOD V1S **

FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD 106-0386SP

Meter

Test Pins Results

12VAC P ow er to Controller 50VAC S cale 1 and 3 on J3 or J2 12-18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GRO UN D 22-28 120 VAC Power 250VAC Scale 11 on J3 and GROUN D 110-125 120 VAC Power to Blowers 250VAC Scale 12 on J3 and GROU N D 110-125 24VAC Power to Full- or Right-vat High-Limit 50VAC Scale 9 on J3 and GRO UN D 22-28 24VAC Power to Left High-Limit (if present) 50VAC Scale 9 on J1 and GRO UN D 22-28 Probe Resistance (Full- or Right-vat) * R x 1000 OH M S 2 and 6 on J3 or 13 and 14 on J2 ** Probe Resistance (Left - if present) * R x 1000 OHM S 2 and 6 on J1 or 14 and 15 on J2 ** Probe Isolation R x 1000 OHM S 6 on J1 or J3 and GROUN D *** High-Limit Continuity (Full- or Right-vat) R x 1 OHM 9 on J3 and Wire 13C on Gas Valve 0 High-Limit Continuity (Left - if present) R x 1 OHM 9 on J1 and Wire 12C on Gas Valve 0

** Disconnect 15-pin harness from controller before testing probe circuit.

** See Probe Resistance Chart at end of chapter. *** 5 mega-Ohm s or greater.

Settin g

1.1.3 THERMOSTATS

BIPH52/55 and MPH52/55 Series gas fryers have temperature probes located on the front centerline of each frypot (dual-vat frypots have two probes, one in each vat). In this type of thermostat, the probe resistance varies directly with the temperature. That is, as the temperature rises, so does resistance, at a rate of approximately 2 ohms for every 1º F. Circuitry in the controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints). The temperatures are programmed by means of a keypad on the face of the controller.

BIPH52/55 and MPH52/55 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 models, and are not interchangeable.

1.2 Accessing Fryers for Servicing

DANGER

Moving a fryer filled with oil may cause spilling or splattering of the hot liquid.

Follow the draining instructions in Chapter 4 of the BIPH52/55-MPH52/55 Installation

and Operation manual (P/N 819-6087) 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.

1-4

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

3. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and plug in the electrical cords. NOTE: To ensure the safe and efficient operation of the fryer

and hood, the electrical plug for the 120-volt line, which powers the hood, must be fully engaged and locked in its pin and sleeve socket.

1.3 Cleaning the Gas Valve Vent Tube

1. Set the fryer power switch and the gas valve to the OFF position.

2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened for ease of removal.

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

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

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

1.4 Checking the Burner Manifold Gas Pressure

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

Honeywell

OFF

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

Pressure Tap Plug

Typical Non-CE Valve Assembly

1-5

Typical CE Valve

Assembly

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

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

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

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

CE Standard

Burner Manifold Gas Pressures

Pressure (mbar)

Single

Gas

Natural Gas Lacq (G20) under 20 mbar

Natural Gas Gronique * (G25) under 25 mbar

Natural Gas Gronique (G25) under 20 mbar

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

Propane (G31) under 37 or 50 mbar

* Belgian G25 = 7,0 mbar (single or dual)

Vat

10 10

17 17

20 20

Dual

Vat

Non-CE Standa rd

Burner Ma nifol d Ga s Pressures

Gas Pressure

Natural

Propane

3" W.C.

0.73 kPa

8.25" W.C.

2.5 kPa

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

correct pressure.

Non-CE

Valve

GAS VALVE REGULATOR CAP

1-6

7. 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.

1.5 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 sensing wire from one of the burner ignitors and connect it to the positive lead of the meter. Connect the negative lead of the meter to the terminal from which the sensing wire was removed.

Flame Sensor Wire

(Right Burner)

3. Place the fryer power switch in the ON position to light the burners. After the frypot temperature reaches 200°F (93°C), wait at least one minute before checking the reading. NOTE: The closer the unit is to normal operating temperature, the more accurate the reading will be.

1.6 Replacing Fryer Components

1.6.1 Replacing the Controller or the Controller Wiring Harness

1. Disconnect the fryer from the electrical power supply.

2. The controller bezel is held in place by tabs at the top and bottom. Slide the bezel up to disengage the lower tabs. Then slide the bezel down to disengage the upper tabs.

3. Remove the top two screws in the upper corners of the control panel.

4. Hinge the controller down. Allow it to rest on its hinge tabs to access the 15-pin connector on the back.

5. Disconnect the 15-pin wiring harness from the back of the controller and, if replacing the harness, disconnect it from the interface board.

6. Use a 5/16” nut driver (P/N 802-0352) to remove the nut and green ground wire from the back of the controller.

1-7

7. Remove the controller by lifting it up and out from the hinge slots in the control panel frame.

8. Re-hinge the NEW controller by inserting the tabs on the bottom into the slots on the control

panel frame and allow it to rest on the hinge tabs.

9. If replacing the 15-pin connector, do so now. Plug the new 15-pin wiring harness into the

interface board ensuring the black ferrite metal ring is on the controller-end of the wire harness.

10. Connect the 15-pin connector and the green ground wire to the new controller. When the

connector is completely engaged, the clips on either side of the connector will snap into place.

11. Move the controller into the closed position against the control panel frame and replace the

screws in the top corners.

12. Insert the top tabs on the bezel into the slots on the underside of the top cap. Slide the bezel

down to engage the lower tabs in the lower slots.

1.6.2 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. Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame.

4. Remove the top two screws in the upper corners of the control panel.

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

6. Disconnect the controller wiring harness and ground wire from the back of the controller and

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

7. If the fryer has a built-in filtration system, remove the clevis securing the oil return handle to the

oil return operating rod and separate the rod from the handle.

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

you.

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

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

11. If working on the left frypot, cut the wire tie on the wiring bundle and disconnect the main

wiring harness 15-pin connector.

12. Remove the component box mounting screws.

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13. Rotate the top of the component box out of the frame and carefully pull it out enough to disconnect the wiring harness plug from the back of the box. If the unit is equipped with built-in filtration, disconnect the wires from the filter switch. This will leave one set of wires, enclosed in spiral wrap, connected to the component box.

14. Remove the box and set it atop the fryer to expose the temperature probe and high-limit thermostat.

15. Cut the leads of the probe or thermostat, as appropriate, near the component and unscrew it from the frypot.

16. Apply Loctite® PST56765 pipe thread sealant or equivalent to the replacement part threads and screw the replacement part into the frypot, torquing to 180 inch-pounds.

17. Unscrew and remove the temperature probe (or high-limit thermostat) from the frypot.

18. Connect the wires from the new component as follows: a. If replacing the temperature probe, use a pin pusher to disconnect (one at a time) the red and

white leads from the connector and insert the corresponding leads from the new probe.

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

connector and insert the corresponding lead from the new thermostat. Disconnect the other lead from the drain safety switch and connect the remaining lead from the new thermostat.

19. Reverse steps 1 through 14 to complete the procedure.

1.6.3 Replacing the Interface Board

1. Disconnect the fryer from the electrical power supply.

2. The controller bezel is held in place by tabs at the top and bottom. Slide the bezel up to disengage the lower tabs. Then slide the bezel down to disengage the upper tabs.

3. Remove the top two screws in the upper corners of the control panel.

4. Hinge the controller down. Allow it to rest on its hinge tabs to access the 15-pin connector on the back.

5. Disconnect the 15-pin wiring harness from the back of the controller and from the interface board.

6. Use a 5/16” nut driver (P/N 802-0352) to remove the nut and green ground wire from the back of the controller.

7. Remove the controller by lifting it up and out from the hinge slots in the control panel frame.

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

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9. Remove the nuts at each corner of the interface board and carefully pull it from the studs far

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

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

11. Reverse the procedure to install the replacement board, being sure that the spacers behind the

board are in place.

1.6.4 Replacing an Ignition Module

1. Disconnect the fryer from the electrical supply.

2. Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame.

3. Remove the top two screws in the upper corners of the control panel.

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

5. Disconnect the wires from the ignition module, marking or making a note of the wires and

terminals to facilitate reconnection.

6. Remove the four ignition module screws and pull the module from the component box.

7. Move the spacers to the new module.

8. Reverse the procedure to install the replacement module.

1.6.5 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 flame sensor wire by carefully pulling its push-on terminal from the terminal

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

1-10

Flame Sensor Wire

Gas Enrichment Tube

Ignition Cable

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

4. Reverse the procedure to install the replacement ignitor.

1.6.6 Replacing or Cleaning a Combustion Air Blower

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

Wiring connection Blower assembly

mounting nuts

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

1-11

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

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

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

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

Wrap the motor and wires

with plastic wrap or a

plastic bag.

Blower Housing

Blower Wheel

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

assembly and blower housing. Reinstall the blower shield.

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

6. Light the fryer in accordance with the procedure described in Chapter 3, Section 3.1.2 of the

BIPH52/55-MPH52/55 Series Gas Fryer Installation and Operation Manual (P/N 819-6087).

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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.

Right

Viewing

Port.

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

Adjusting the Air/Gas Mixture

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

1-13

Loosen this nut and rotate shutter to open or close air intake.

1.6.7 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 drain safety and high-limit thermostat wires from the gas valve. Mark each wire

to facilitate reconnection.

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

Disconnect the flexible gas line(s).

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

A. Remove the filter pan from the unit. Remove the door adjacent to the valve being replaced. B. Remove the five screws on the front face of the pan rail assembly adjacent to the valve being

replaced. Remove the nut and bolt securing the rear end of the rail to the cabinet.

C. Remove the two nuts and bolts immediately behind the front face of the pan rail assembly. Pull

the assembly from the unit to gain access to the pipe union on the gas line.

D. Uncouple the pipe union and remove the gas valve and associated piping from the unit. E. Remove the fittings and associated piping from the failed valve and install them on the

replacement valve using Loctite® PST56765 or equivalent pipe thread sealant.

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

PST56765 or equivalent pipe thread sealant, and reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the high-limit thermostat wires and drain safety wires to the valve.

G. Reconnect the fryer to the gas supply and open the cut off valve. Apply a solution of soapy

water around each connection to check for gas leaks. Eliminate any that are found.

H. Position the pan rail assembly beneath the fryer and rest the rear end of the rail on the cabinet

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

I. Install the five screws in the front face of the rail, but do not tighten them. Install the filter pan

in the unit to make sure that all components are properly aligned; then, securely tighten the remaining bolts and screws.

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

operation has been verified, reinstall the door removed in Step A.

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ALL OTHER VALVES

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

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

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

Loctite® PST56765 or equivalent pipe thread sealant.

6. Reconnect the gas valve assembly to the fryer using Loctite® PST56765 or equivalent pipe

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

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

water around each connection to check for gas leaks. Eliminate any that are found.

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

1.6.8 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 1.6.6.

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.

NOTE: If the flexible oil return lines are blocking the plenum, carefully bend them upward enough to clear the plenum.

4. Disconnect the ignition cable from the ignitor by grasping its boot and pulling gently toward

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

5. Disconnect the flexible gas lines from the burner orifice and the enrichment tube from the ignitor

assembly.

6. Remove the four ¼-inch 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.

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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 1.6.10 for procedure.

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

Refer to Section 1.6.11 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.

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

1. Disconnect the unit from the electrical power supply.

2. Remove the filter pan from the unit and drain the frypots into a Shortening Disposal Unit (SDU) or other appropriate metal container.

1-16

DANGER

DO NOT attempt to drain more than one full frypot or two split frypots into the SDU

at one time.

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

flexible oil line from the fitting, allowing any residual oil to drain into the container.

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

transformer box. Using a pin pusher, push the pump solenoid valve wires from Pins 7 and 9.

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

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

motor wires.

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

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

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

mount to slide forward and off the rear motor mount support.

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

from beneath the fryer and the failed component can be removed and replaced.

10. Position the new/repaired motor and pump assembly beneath the fryer and reconnect the oil

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

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

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

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

support. Reconnect the solenoid valve wires to Pins 7 and 9 of the 9-pin connector (polarity does not matter) and reconnect the plug.

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

Reconnect the motor power wires and reinstall the wiring cover plate.

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

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

operation.

1.6.10 Replacing the Frypot

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

1-17

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

DANGER

DO NOT attempt to drain more than one full frypot or two split frypots into the SDU

at one time.

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

4. Remove the bezels by lifting them up to disengage the tabs along the lower edges from the slots in the control panel frame. Remove the top two screws in the upper corners of the control panel.

5. Grasp the upper edge of each controller and swing the controller downward. Unplug the controller wiring harness and grounding wire from the back of each controller.

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

7. Remove the clevis that secures the oil return rod to the oil return handle and separate the rod and handle. NOTE: On split-vat units, there are two oil return handles.

8. Disconnect the sound device wire from the interface board and disconnect the oil return switch wires from the switch terminals.

9. Disconnect the flame sensor wires by carefully pulling the push-on terminals from the terminal strips on the ignitors. Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you.

10. Remove the two mounting screws on each side of the component box and rotate the top of the box out of the frame. Carefully pull it out enough to disconnect the wiring harness connector from the back of the box. Cut any ties that prevent the box from being pulled out of the control panel frame.

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

12. Using a pin pusher, remove the temperature probe and high-limit thermostat wires from the plugs or terminals, marking each wire to facilitate re-assembly.

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

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

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

16. Remove the frypot hold down bracket.

1-18

17. Remove the screws in the back panel and inside the flue cap at each end that secure the flue cap

to the fryer and lift it clear of the fryer.

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

19. Carefully lift the frypot from the fryer cabinet.

20. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), and ignitor

assemblies. Inspect each of these components carefully and install them in the replacement frypot if they are in serviceable condition. Use Loctite® PST56765 sealant or equivalent on component threads.

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

21. Reverse steps 1-19 to reassemble fryer.

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

22. Perform steps 14 through 18 of Section 1.6.8 to ensure that there are no leaks in the burner

insulation.

CAUTION

Before installing temperature probe, high-limit thermostat, and drain valve on

replacement frypot, clean the threads and apply Loctite® PST56765 thread sealant or

equivalent.

1.6.11 Replacing Frypot Insulation and/or Upper Burner Rails NOTE: Replacing the burner rails requires completely tearing down the frypot and installing new

frypot insulation. Refer to the frypot exploded view on page 1-21 for component identification.

1. Remove the frypot per Section 1.6.10.

2. Remove the burner assemblies (1).

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

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

5. Remove the plenum (4).

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

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

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

1-19

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

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

10. Remove the flue assembly (10).

See Page 1-22 for Reassembly

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