Frymaster FBR18 User Manual

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Installation, Operation, Service, and Parts Manual

FBR18 & FBRA18 Series

Gas Rethermalizers

Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.

24-Hour Service Hotline 1-800-551-8633

819-5278

May 2003

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 AFFILIAT ES 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. See Chapter 1 of this manual for definitions of qualified personnel.

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. See NATIONAL CODE REQUIREMENTS in Chapter 2 of this manual for specifics.

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.

CAUTION Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

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. See Chapter 1 of this manual for definition of qualified service personnel.

DANGER No structural material on the rethermalizer should be altered or removed to accommodate placement of the rethermalizer 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 rethermalizers equipped with legs must be stabilized by installing anchor straps. All rethermalizers 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 rethermalizer is in use.

DANGER The front ledge of the rethermalizer is not a step! Do not stand on the rethermalizer. Serious injury can result from slips or contact with the hot water.

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.

NOTICE The Commonwealth of Massachusetts requires any and all gas products to be installed by a licensed plumber or pipe fitter.

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

TABLE OF CONTENTS

CHAPTER 1: General Information

1.1 Parts Ordering and Service Information ............................................................................1-1

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

1.3 Equipment Description ......................................................................................................1-2

1.4 Installation, Operating, and Service Personnel ..................................................................1-2

1.5 Definitions..........................................................................................................................1-2

1.6 Shipping Damage Claim Procedure...................................................................................1-3

CHAPTER 2: Installation Instructions

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

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

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

2.4 Connecting to the Gas Supply............................................................................................2-4

2.5 Converting to Another Gas Type.......................................................................................2-5

CHAPTER 3: Operating Instructions

3.1 Introduction........................................................................................................................3-1

3.2 FBR18/FBRA18 Digital Controller...................................................................................3-1

Operating the FBR18/FBRA18 Digital Controller ............................................................3-1

Operating the FBR18/FBRA18 Timers .............................................................................3-2

3.3 Start-Up Procedure.............................................................................................................3-2

3.4 Boiling Out the Cookpot....................................................................................................3-3

3.5 Shutting the Rethermalizer Down......................................................................................3-4

CHAPTER 4: Preventive Maintenance

4.1 Daily Checks and Services.................................................................................................4-1

4.2 Quarterly Checks and Services ..........................................................................................4-1

4.3 Semi-Annual Checks and Services ....................................................................................4-2

Clean Combustion Air Blower...........................................................................................4-2

Clean Gas Valve Vent Tube ..............................................................................................4-2

Check Burner Manifold Pressure.......................................................................................4-3

CHAPTER 5: Operator Troubleshooting

5.1 Introduction........................................................................................................................5-1

5.2 Operator Troubleshooting Guides......................................................................................5-2

5.3 Replacing the Computer or Computer Wiring Harness.....................................................5-6

CHAPTER 6: Service Procedures

6.1 Functional Description.......................................................................................................6-1

The Electronic Ignition System .........................................................................................6-1

Controller and Mechanical Timers ....................................................................................6-2

Interface Boards .................................................................................................................6-2

Temperature Probe ............................................................................................................ 6-3

Water Level Sensors (FBRA18 Only)............................................................................... 6-3

6.2 Accessing the Rethermalizer for Servicing ....................................................................... 6-4

6.3 Cleaning the Gas Valve Vent Tube................................................................................... 6-4

6.4 Checking the Burner Manifold Gas Pressure .................................................................... 6-4

6.5 Measuring Flame Current.................................................................................................. 6-4

6.6 Replacing Components...................................................................................................... 6-5

6.6.1 Replacing the Controller or Controller Wiring Harness ................................................... 6-5

6.6.2 Replacing the Temperature Probe ..................................................................................... 6-5

6.6.3 Replacing the Interface Board........................................................................................... 6-5

6.6.4 Replacing an Ignition Module........................................................................................... 6-6

6.6.5 Replacing an Ignitor Assembly ......................................................................................... 6-6

6.6.6 Replacing the Combustion Air Blower ............................................................................. 6-7

6.6.7 Replacing the Gas Valve ...................................................................................................6-7

6.6.8 Replacing a Burner Assembly........................................................................................... 6-7

6.6.9 Replacing the Cookpot ...................................................................................................... 6-8

6.7 Troubleshooting and Problem Isolation ............................................................................ 6-8

6.7.1 Ignition Failures ................................................................................................................ 6-9

6.7.2 Improper Burner Functioning.......................................................................................... 6-10

6.7.3 Improper Temperature Control ....................................................................................... 6-12

6.8 Troubleshooting Guides .................................................................................................. 6-12

6.8.1 Troubleshooting the Gas Valve....................................................................................... 6-13

6.8.2 Troubleshooting the 24 VAC Circuit in FBR18 Units.................................................... 6-14

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units................................................. 6-16

6.8.4 Troubleshooting the Temperature Probe......................................................................... 6-21

Probe Resistance Chart.................................................................................................... 6-22

6.9 Wiring Diagram for FBR18 Units................................................................................... 6-23

6.10 Wiring Diagram for FBRA18 Units................................................................................ 6-24

CHAPTER 7: Parts List

7.1 Burner System Components.............................................................................................. 7-1

7.2 Cabinetry and Associated Components............................................................................. 7-2

7.3 Control Box Assembly and Associated Parts, FBR18/FBRA18....................................... 7-3

7.4 Controller and Component Box Assemblies..................................................................... 7-4

7.5 Cooking Timer Control Panel Components ...................................................................... 7-5

7.6 Cookpot, FBR18................................................................................................................ 7-6

7.7 Cookpot, FBRA18.............................................................................................................7-7

7.8 Gas Supply Components ................................................................................................... 7-8

7.9 Plumbing Components ...................................................................................................... 7-9

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 1: GENERAL INFORMATION

1.1 Parts Ordering and Service Information

In order to assist you as quickly as possible, the Frymaster Factory Authorized Service Center (FASC) or Service Department representative requires certain information about your equipment. Most of this information is printed on a data plate affixed to the inside of the door.

Parts orders may be placed directly with your local FASC or distributor. Included with the unit when shipped from the factory is a list of FASCs. If you do not have access to this list, contact the Frymaster Technical Service Department at 1-800-551-8633 or 1-318-865-1711.

When ordering parts, the following information is required:

Model Number: Serial Number: Gas Type: Item Part Number: Quantity Needed:

Service information may be obtained by contacting your local FASC/Distributor. Information may also be obtained by calling the Frymaster Technical Service Department at 1-800-551-8633 or 1-318-865-1711. When requesting service, please have the following information ready:

Model Number: Serial Number: Gas Type:

In addition to the model number, serial number, and gas type, please be prepared to describe the nature of the problem and have ready any other information that you think may be helpful in solving your problem.

RETAIN AND STORE THIS MANUAL IN A SAFE PLACE FOR FUTURE USE.

1.2 Safety Information

Before attempting to operate your unit, read the instructions in this manual thoroughly. Throughout this manual, you will find safety notations enclosed in double-bordered boxes similar to

the ones illustrated on the following page.

1-1

CAUTION

CAUTION boxes contain information about actions or conditions that may cause or result in a malfunction of your system.

WARNING WARNING boxes contain information about actions or conditions that may cause or result in damage to your system, and which may cause your system to malfunction.

DANGER 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 your system to malfunction.

1.3 Equipment Description

The FBR18 and FBRA18 Series Gas Rethermalizers are specifically designed to rethermalize meats, sauces, and other vacuum packaged foods at a safe temperature range that prevents overcooking. They can be configured for either natural or LP (Propane) gas, and their efficient infrared burners deliver 90,000 BTUs (94.9 MJ – 26.4 kW).

The two models are identical except that the FBRA18 has an automatic filling (AutoFill) feature. Both models feature digital temperature controls with continuous temperature display and individual color-coded timer controls with corresponding color-coded baskets. Each unit can rethermalize up to 15 lbs. (7 kg) of food an hour in large capacity 2-5 lb. (0.9-2.3 kg) baskets.

The rethermalizers are safeguarded against boil-over by a standpipe overflow drain, and come with a 1¼” cookpot drain for fast, clog-free emptying. The unit has a rethermalizing area of 18” x 24” (457mm x 609mm) and holds 25 gallons (94.6 liters) of water.

1.4 Installation, Operating, and Service Personnel

Operating information for Frymaster equipment has been prepared for use by qualified and/or authorized personnel only, as defined in Section 1.5.

All installation and service on Frymaster equipment must be performed by qualified, certified, licensed, and or/authorized installation or service personnel, as defined in Section 1.5.

1.5 Definitions

QUALIFIED AND/OR AUTHORIZED OPERATING PERSONNEL

Qualified/authorized operating personnel are those who have carefully read the information in this manual and have familiarized themselves with the equipment functions, or who have had previous experience with the operation of the equipment covered in this manual.

1-2

QUALIFIED INSTALLATION PERSONNEL

Qualified installation personnel are individuals, or firms, corporations, or companies which, either in person or through a representative, are engaged in and are responsible for the installation of electrical and gas appliances. Qualified personnel must be experienced in such work, be familiar with all electrical precautions involved, and have complied with all requirements of applicable national and local codes.

QUALIFIED SERVICE PERSONNEL

Qualified service personnel are those that are familiar with Frymaster equipment and who have been authorized by sonnel are required to be equipped with a complete set of service and parts manuals, and to stock a prescribed minimum amount of Frymaster equipment parts.

A list of Frymaster Factory Authorized Service Centers (FASC) was included with the unit when it was shipped from the factory. Failure to use qualified service personnel will void the Frymaster Warranty on your equipment.

1.6 Shipping Damage Claim Procedure

Your Frymaster equipment was carefully inspected and packed before leaving the factory. The transportation company assumes full responsibility for safe delivery upon acceptance of the equipment for transport.

What to do if your equipment arrives damaged:

Frymaster

to perform service on Frymaster equipment. All authorized service per-

1. File a claim for damages immediately, regardless of the extent of damages.

2. Inspect for and record all visible loss or damage and ensure that this information is noted on

the freight bill or express receipt and is signed by the person making the delivery.

3. Concealed loss or damage that was unnoticed until the equipment was unpacked should be re-

corded and reported to the freight company or carrier immediately upon discovery. A concealed damage claim must be submitted within 15 days of the date of delivery. Ensure that the shipping container is retained for inspection.

Frymaster

DOES NOT ASSUME RESPONSIBILITY

FOR DAMAGE OR LOSS INCURRED IN TRANSIT.

1-3

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 2: INSTALLATION INSTRUCTIONS

2.1 General Installation Requirements

PROPER INSTALLATION IS ESSENTIAL FOR EFFICIENT, TROUBLE-FREE OPERATION OF YOUR RETHERMALIZER. ANY UNAUTHORIZED ALTERATIONS MADE TO THIS EQUIPMENT WILL VOID

Frymaster WARRANTY.

THE

Upon arrival, inspect the rethermalizer carefully for visible or concealed damage. (See Shipping Damage Claim Procedure in Chapter 1.)

CLEARANCE AND VENTILATION

This equipment must be installed with a 6” (150mm) 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” (600mm) clearance should be provided at the front of the unit.

One of the most important considerations of efficient operation is ventilation. Make sure the equipment 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 equipment flue opening must not be placed close to the intake of the exhaust fan, and the flue must never be extended in a “chimney” fashion. An extended flue will change the combustion characteristics of the equipment, causing longer recovery times. It also frequently causes delayed ignition. To provide the airflow necessary for good combustion and burner operation, the areas surrounding the front, sides, and rear of the unit must be kept clear and unobstructed.

This equipment must be installed in an area with an adequate air supply and adequate ventilation. For U.S installations, information on construction and installation of ventilating hoods can be found in NFPA Standard 96. This document can be ordered from the National Fire Protection Association, Battery March Park, Quincy, MA 02269. For installations in countries other than the U.S., the appropriate regulating authority should be contacted for information related to hood construction and installation.

DANGER Do not attach an apron drain to a single rethermalizer. The rethermalizer may become unstable, tip over, and cause injury to personnel.

NATIONAL CODE REQUIREMENTS

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.

2-1

This equipment is manufactured to use the type of gas specified on the rating plate attached to the door. Connect equipment stamped “NAT” only to natural gas and that stamped “PRO” only to LP (Propane) gas.

Installation shall be made with a gas connector that complies with national and local codes. Quick disconnect devices, if used, shall likewise comply with national and local codes.

ELECTRICAL GROUNDING REQUIREMENTS

All electrically operated appliances must be grounded in accordance with all applicable national and local codes. A wiring diagram is located on the inside of the door. In the United States and Canada, the electrical supply must be 120VAC, 60 Hz. In other countries, refer to the rating plate on the inside of the door for proper voltages.

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.

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

Your unit requires casters or legs to be installed. IT MAY NOT BE CURB MOUNTED!

If casters or legs are not already installed, install them in accordance the instructions included in your accessory package. FAILURE TO INSTALL CASTERS OR LEGS WILL RESULT IN IMPROPER OPERATION OF YOUR UNIT.

2.3 Pre-Connection Preparations

DANGER Do not connect this equipment to the gas supply before completing each step in this section.

2-2

After the unit has been positioned in the area where it will be used, ensure the following has been accomplished before connecting the unit to the gas supply:

1. Adequate means must be provided to limit the movement of this equipment without depending

upon the gas line connections. If a flexible gas hose is used, a restraining cable must be connected at all times when the equipment is in use.

2. The rethermalizer must be stabilized by installing restraining chains on units equipped with cast-

ers or anchor straps on units equipped with legs. Follow the instructions shipped with the casters/legs to properly install the chains or straps.

3. Level rethermalizers equipped with legs by screwing out the legs approximately 1 inch then ad-

justing them so that the rethermalizer is level.

4. For rethermalizers equipped with casters, there are no built-in leveling devices. The floor where

the rethermalizer is to be installed must be level.

5. Connect the water hose to the fitting at the rear of the unit.

NOTE 1: The hose comes with a quick-disconnect coupling. The quick disconnect may be attached to the rethermalizer or to the water supply line, or it may be left off entirely, whichever you prefer. Whichever of the options is chosen, Teflon thread-seal tape or Loctite™ PST56765 or equivalent thread sealer must be used when installing the fittings.

NOTE 2: Either hot or cold water may be connected to the unit. Connecting to hot water will minimize the amount of time required to bring the unit to boil when filling with fresh water.

NOTE 3: In order for the water level sensors to work properly, a certain amount of mineral content in necessary in the water. For that reason, purified, deionized, or highly filtered water should not be used.

4. Connect the desired drain plumbing to the 1¼” drain valve.

5. Test the equipment electrical system by plugging the power cord into a grounded 120VAC outlet

and pressing the controller’s ON/OFF button. After four (4) seconds, the last programmed setpoint temperature will display constantly.

6. Turn the controller off. Verify that the display is blank.

7. Verify th at t h e mi ni mu m a n d ma x i mu m i nc o mi n g g a s pressures for the type of gas to be used are

in accordance with the accompanying table.

Incoming Gas Pressures

Gas Minimum Maximum

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

2-3

2.4 Connecting to the Gas Supply

GAS CONNECTIONS AND PIPE SIZES

The size of the gas supply pipe is very important. If the pipe is too small, the gas pressure at the burner manifold will be low. This will cause slow recovery and delayed ignition. The incoming gas supply line should be a minimum of 1½ inches (38mm) ID.

When configured for natural gas, this equipment requires a standard gas pipe size of ¾ inch (19mm) ID for connections within 20 feet (6m) of the supply line, provided no more than 4 fittings or elbows are used in the run. For a pipe run over 20 feet (6m), increase the pipe size to 1 inch (25.4mm). For use with LP (Propane) gas, the next smaller pipe size may be used.

IF IN DOUBT ABOUT THE PIPE SIZE TO BE USED, CONSULT YOUR LOCAL GAS COMPANY.

DANGER Before connecting new pipe to this equipment, the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls may cause improper and dangerous operation.

1. Connect the equipment to the gas supply line.

When making connections, apply a small amount of Loctitite® PST 56765 or equivalent thread compound to the male threads only. DO NOT apply the compound to the first two threads. This will prevent clogging of the burner orifices and control valve.

2. Open the gas supply to the fryer and check all piping, fittings, and gas connections for leaks. A

soap and water 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.

The rethermalizer and any shut-off valves installed between the rethermalizer and the gas supply line must be disconnected from the gas supply line during any pressure testing of the supply line at pressures equal to or greater than ½ PSIG (3.45kPa, 13.84 inches W.C.).

3. Close the drain valve and fill the cookpot with water and boil-out solution to the overflow. Light

the burners and perform the boil-out procedures that are described in the “Start-Up Procedure” and “Boiling Out the Cookpot” sections in Chapter 3 of this manual.

2-4

WARNING “Dry-firing” this equipment will cause damage to the cookpot. Always ensure that the cookpot is filled with water before firing your unit.

4. It is suggested that the burner manifold pressure be checked at this time by the local gas com-

pany or an authorized service agent. Refer to “Check Burner Manifold Pressure” in Chapter 4 of this manual for the proper procedure.

2.5 Converting to Another Gas Type

This equipment is configured at the factory for either natural gas or LP (Propane) gas.

If you desire to switch from one type of gas to the other, a gas conversion kit must be installed by a Factory Authorized Service Center technician.

DANGER Switching to a different type of gas without installing the proper conversion kit may result in fire or explosion! NEVER attach your fryer to a gas supply for which it is not configured.

2-5

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 3: OPERATING INSTRUCTIONS

3.1 Introduction

Mechanically, the FBR18 and FBRA18 rethermalizers are virtually identical, the only difference being that the FBRA18 units have an automatic filling (AutoFill) feature. Both units use the same digital temperature controller and mechanical timers.

In operation, a setpoint is programmed into the controller which then regulates burner firing to maintain the water in the cookpot at the desired temperature. Six individual color-coded mechanical timers allow different types or quantities of product to be rethermalized simultaneously. The timers are equipped with an alarm to notify the operator that rethermalizing is complete. The product baskets have color-coded handles that correspond to the timers to eliminate confusion.

3.2 FBR18/FBRA18 Digital Controller

Celsius or Power Switch

Digital

Display

Fahrenheit

Display Switch

9 . 9 9 9

Frymaster

Temperature

or Setpoint

Display Switch

OPERATING THE FBR18/FBRA18 DIGITAL CONTROLLER

Setpoint

Adjustment

Arrows

Melt

Cycle

Switch

WARNING Ensure the cookpot is filled with water before turning the controller on. “Dry firing” will cause damage to the cookpot!

1. Turn the controller on by pressing the Power

switch. The controller software version num-

ber will display for 4 seconds in the digital display then change to the last programmed setpoint temperature.

Heating

Mode

Indicator

3-1

NOTE: The unit comes from the factory configured to display in degrees Fahrenheit. To toggle back and forth between Fahrenheit and Celsius, press the Celsius/Fahrenheit display switch.

2. The controller will automatically cycle the burners on and off seven times or until the tempera-

ture in the cookpot reaches 160°F (71°C), whichever comes first. At that time, it will enter the continuous heat mode. When in the continuous heat mode the Heat Mode indicator (a decimal point between the first two digits of the temperature display) will appear. When the setpoint is reached, the Heat Mode indicator will go out, indicating the rethermalizer is ready for use.

3. To enter or change the setpoint temperature, press the up arrow key to raise the setpoint or

the down arrow keys to lower the setpoint. The display will change at a rate of about 1 degree per second for approximately the first 12 degrees, then change at a faster rate if the arrow is continuously pressed.

4. Pressing the Temperature/Setpoint display switch toggles the display back and forth be-

tween constant temperature display and constant setpoint display. Use this feature if you want to check the actual cookpot temperature.

5. To turn the controller (and burners) off, press the Power

switch.

OPERATING THE FBR18/FBRA18 TIMERS

1. Place a packet of product in one of the rethermalizing baskets and note the handle color of the

basket.

2. Place the basket into the water and rotate the correspondingly colored timer knob to the desired

rethermalizing time, up to 60 minutes.

3. An alarm will sound when the rethermalizing time has elapsed.

3.3 Start-Up Procedure

CAUTION If this is the first time the unit is being used after installation, refer to Section 3.4, Boiling-Out the Cookpot.

Before turning the rethermalizer on, ensure that:

• the unit is connected to the water supply

• the water supply is turned on

• the unit is plugged into a 120VAC outlet

• the electrical power supply to the rethermalizer is turned on

• the gas supply to the rethermalizer is turned on.

3-2

1. Turn the gas valve to the ON position (see illustration below).

OFF

Hone yw ell

2. Press the controller Power switch.

On FBR18 models, the burners will light for several seconds then go out. A few seconds later they will light again. This cycle will repeat seven times or until the water in the cookpot reaches 160°F (71°C), whichever comes first, at which time the burners will remain lit until the setpoint is reached.

On FBRA18 models, if the cookpot is not already full of water, the AutoFill feature will immediately begin adding water. When the water level reaches the upper water level sensor, the AutoFill solenoid valve will cut off the water flow. (If the water level drops below the upper water level sensor during operation, the AutoFill solenoid valve will open and add water to the cookpot). When the water level is above the lower water level sensor, the burners will light for several seconds then go out. A few seconds later they will light again. This cycle will repeat seven times or until the water in the cookpot reaches 160°F (71°C), whichever comes first, at which time the burners will remain lit until the setpoint is reached.

3. When the burners have been lit continuously for at least 90 seconds, observe the burners

through the burner viewing ports. The burners should 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. Refer to Chapter 4, Section 4.4, Clean Combustion Air Blower for ad- justment procedures.

3.4 Boiling-Out the Cookpot

CAUTION Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

To ensure that the cookpot is free of any contamination resulting from its manufacture, shipping, and handling during installation, the cookpot must be boiled out before first use.

1. Close the drain valve and fill the cookpot with a solution of cold water and 1 cup of Frymaster

FRYER ‘N’ GRIDDLE cleaner or detergent. NOTE: Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

2. Place the unit into operation in accordance with Section 3.3.

3. Program the setpoint for 200°F (93°C). When the Heat Mode indicator (decimal between the

first two digits of the display) goes out, set one of the product timers for 60 minutes.

3-3

4. After the solution simmers for an hour, turn the unit off, allow the solution to cool, then add 2

gallons (7.75 liters) of cold water and stir. Drain the solution and clean the cookpot thoroughly.

5. Rinse the cookpot at least twice by filling with clean water and draining.

6. Reprogram the setpoint to the appropriate temperature.

3.5 Shutting Down the Rethermalizer

1. Turn the unit off by pressing the Power switch.

2. If shutting down at the end of the day, turn the gas valve to the OFF position (see illustration

below).

OFF

Honey w ell

3. Drain and clean the cookpot. NOTE: Do not use deliming solution to clean these units. Use of

deliming solution will damage all stainless steel parts.

CAUTION Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

CAUTION The electronic circuitry in your controller can be adversely affected by current fluctuations and electrical storms. Should it fail to function or program properly for no apparent reason, unplug the controller and plug it back in to reset it. This could prevent a service call.

3-4

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 4: PREVENTIVE MAINTENANCE

4.1 Daily Checks and Services

Inspect Rethermalizer and Accessories for Damage Look for loose or frayed wires and cords, leaks, foreign material in cookpot or inside cabinet, and

any other indications that the rethermalizer and accessories are not ready and safe for operation. Clean Cabinet Inside and Out Clean inside the cabinet with a dry, clean cloth. Wipe all accessible metal surfaces and components

to remove accumulations of oil, dust, or cooking residue. Clean the outside of the cabinet with a clean cloth dampened with dishwashing detergent, removing

oil, dust, or cooking residue.

DANGER Never attempt to clean rethermalizer during the rethermalizing process or when the cookpot is filled with hot water and/or food products.

CAUTION Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

Clean Water-Level Sensors, Temperature Probe, and Cookpot

NOTE: Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

Press the controller power switch to the OFF position. FBRA18 Units: Remove the cap nut at the top of the shield (located on the left front of the cook-

pot) and remove the shield by lifting up until it can be removed from the stud that holds it at the bottom. Clean the exposed screw heads with a solution of detergent and water. A Scotchbrite™ or equivalent nylon pad may be used to scrub away any accumulated mineral deposits.

FBR18 & FBRA18 Units: Clean the temperature probe, located on the lower front centerline of the cookpot, using a small bottlebrush wet with a solution of detergent and water.

Using a Scotchbrite™ or similar abrasive pad and a solution of detergent and water, clean the inside of the cookpot.

Rinse the cookpot thoroughly with clean water at least twice.

4-1

4.2 Quarterly Checks and Services

Check Digital Controller Set Point Accuracy

1. Fill the cookpot with water. Press the controller power switch. When the Heat Mode indicator

(decimal between the first and second digits of the display) goes out, insert a good-grade thermometer or pyrometer probe into the cookpot, with the end touching the temperature probe at the lower front centerline of the cookpot and wait one minute.

2. Press the Temperature Display switch once to display the temperature of the water as sensed

by the temperature probe. Press the Temperature Display switch again to display the set point. The displayed water temperature should be within ±10°F (5°C) of the setpoint and the temperature shown on the thermometer or pyrometer should be within ± 5ºF (2ºC) of the displayed water temperature. If either set of readings is outside its range, contact a Factory Authorized Service Center for assistance.

4.3 Semi-Annual Checks and Services Clean Combustion Air Blower

1. Unplug the rethermalizer.

2. There are 4 wires (2 orange, 1 white, and 1 black) running from the motor. Remove the wire

nuts and disconnect these wires from the rethermalizer wiring harness, marking each to ensure proper reconnection.

3. Remove the 4 nuts and bolts securing the blower to its mounting bracket and remove the blower

from beneath the rethermalizer.

4. Remove the 3 motor flange nuts from the side of the blower housing and remove the motor and

blower wheel from the housing.

5. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreasing detergent

on the blower wheel and blower housing. Wait 5 minutes, then rinse under hot water, being careful not to get water into the motor. Dry with a clean cloth.

6. Reverse steps 1-5 to reinstall the blower.

7. Light the rethermalizer in accordance with the procedure described in Chapter 3, Section 3.1.

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

viewing ports. The air/gas mixture is properly adjusted when the burner manifold gas pressure is in accordance with the table on page 4-3 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 mix requires adjustment.

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

4-2

open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold the plate in position and retighten the nut(s).

Clean Gas Valve Vent Tube

1. Set the rethermalizer 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.

Vent Tube

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

obstruction.

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

5. Reinstall tube and bend so that the opening is pointing downward. Check Burner Manifold Pressure

WARNING

Frymaster recommends that this task be performed by the local gas company or an

authorized service technician only.

1. Ensure that the gas valve knob is in the OFF position.

2. Remove the pressure tap plug from the gas valve assembly and attach the fitting for a gas

pressure-measuring device to the tap.

Pressure Tap Plug

Regulator Cap

4-3

3. Place the gas valve in the ON position. Place the controller power switch in the ON position.

When the burner lights and continues to burn, compare the indicated pressure to the table below.

Burner Manifold Gas

Pressures

Gas Pressure

Natural

3.5" W.C.

0.8 kPa

8.25" W.C.

2.5 kPa

4. If necessary, adjust the burner gas pressure by removing the cap from the gas valve regulator

and turning the regulator screw to obtain the correct pressure. When the correct pressure is obtained, reinstall the cap.

5. Place the controller power switch and the gas valve in the OFF position. Remove the fitting

from the pressure tap hole and reinstall the pressure tap plug.

4-4

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 5: OPERATOR TROUBLESHOOTING

5.1 Introduction

This chapter provides an easy reference guide to the more common problems that may occur during the operation of your equipment. The troubleshooting guides in this chapter are intended to help you correct, or at least accurately diagnose, problems with your equipment. Although the chapter covers the most common problems reported, you may very well encounter a problem not covered. In such instances, the Frymaster Technical Service Department will make every effort to help you identify and resolve the problem.

When troubleshooting a problem, always use a process of elimination starting with the simplest solution and working through to the most complex. Never overlook the obvious. Anyone can forget to plug a cord into a receptacle or open the valve on the water supply line. Don’t assume that you are exempt from such occurrences.

Always try to establish a clear idea of why a problem has occurred. Part of your corrective action involves taking steps to ensure that it doesn’t happen again. If a controller malfunctions because of a poor connection, check all other connections while you’re at it. If a fuse continues to blow, find the cause. Keep in mind that failure of a small component may often be indicative of potential failure or incorrect functioning of a more important component or system.

Each guide begins with a description of a common problem in a six-sided figure. Simply follow the arrows and answer the questions to determine the corrective action to take. If you have doubts as to the proper action to take, do not hesitate to call the Frymaster Technical Service Department or your local Frymaster Factory Authorized Service Center for assistance.

DANGER

Hot water can cause severe burns. Never attempt to move a rethermalizer containing hot water or to transfer hot water from one container to another.

DANGER

Use extreme care when performing electrical circuit tests. Live circuits will be exposed.

WARNING Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The equipment should be unplugged when servicing, except when electrical tests are required.

5-1

5.2 Troubleshooting Guides

NOTE: This guide applies

to FBRA18 units only.

COOKPOT DID NOT FILL

WHEN UNIT WAS TURNED ON.

WATER SUPPLY TO UNIT

VERIFIED TO BE ON.

Controller is not functioning.

Probable causes are failed 12V

transformer, failed interface

board, or failed controller.

Probable causes are a failed

interface board or

failed/loose high-level water

sensor wiring.

Did anything appear

in controller display when unit

was turned on?

Open control panel by

removing screws in

each upper corner.

LED on interface board

Use bottlebrush to

clean water level

Yes

Is WATER

illuminated?

sensors.

Did LED

illuminate?

Yes

Call FASC.

Problem resolved.

5-2

Did unit begin

to fill?

NoYes

Probable causes are a failed

water solenoid or a failed

interface board.

WATER DID NOT SHUT

OFF WHEN COOKPOT

WAS FULL.

NOTE: This guide applies

to FBRA18 units only.

Use bottlebrush to clean

water level sensors.

Problem resolved.

Mineral content of water is

insufficient for water sensor to

detect it. Whenever cookpot is

refilled, add 1/8 cup of salt.

Remove the cover over the

water sensors and thoroughly

clean the sensors with a

Scotchbrite or similar pad.

Yes

Yes No

Did water

stop?

Add 1/8 cup of salt to

water in cookpot and

stir.

Did water

stop?

Open control panel by

removing screws in each

upper corner.

Is WATER

LED on interface board

illuminated?

Probable cause is failed

water solenoid.

If water still does not stop,

probable cause is

failed/loose high water

sensor wiring.

Call FASC.

5-3

WATER NOT HEATING.

AUTOFILL (IF INSTALLED)

WORKED PROPERLY.

Press the Temperature

Check button twice to

display setpoint.

Has the correct setpoint

been programmed?

Yes

Did burners

light?

Yes

Did water reach

setpoint temperature?

Yes

Problem

resolved.

Insert a good grade thermometer into

the Temperature Check button once to

Program setpoint in

accordance with instructions

in Chapter 3.

Refer to troubleshooting

guide "BURNERS DO NOT

LIGHT".

cookpot with tip near temperature

probe and wait two minutes. Press

display cookpot temperature.

Is temperature

displayed reasonably close to thermometer

reading?

There is a problem in

temperature probe circuit. Call FASC.

Yes

Temperature control

features are working properly.

If water still fails to reach

setpoint, call FASC.

5-4

BURNERS DO

NOT LIGHT.

Verify that correct setpoint has

been programmed, that main gas

supply valve is open, and that

equipment gas valve is set to ON.

Press ON/OFF button.

Did burners

light?

Use bottlebrush to clean low water sensor. If burners still do not light,

remove the cover over the water

sensors and thoroughly clean them

with a Scotchbrite or similar nylon pad.

Did burners

light?

Open control panel by

removing screws in

each upper corner.

Yes

Problem

resolved.

Problem

resolved.

Is HEAT LED

on interface board

illuminated?

Problem is with a failed interface board or a malfunctioning computer.

Call FASC.

Yes

5-5

Problem is with the gas

supply or ignition system.

Call FASC.

5.3 Replacing the Controller or Controller Wiring Harness

1. Disconnect the rethermalizer 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. If replacing the harness, discon-

nect it from the interface board, install the new harness, and then reverse steps 1 and 2 to complete the process.

4. Disconnect the ground wire from the controller. Remove the control panel by lifting it from the

hinge slots in the frame.

If substituting one complete control panel for another, reverse steps 1-4 to complete the procedure.

If replacing the controller, remove the nuts securing the controller to the control panel and install the replacement controller on the control panel. Reverse steps 1-4 to complete the procedure.

Wiring Harness

Connection

Ground Wire

5-6

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 6: SERVICE PROCEDURES

6.1 Functional Description

These rethermalizers contain a welded stainless steel cookpot that is directly heated by a high efficiency burner system requiring approximately 43% less energy than conventional burner systems to heat the same volume of water.

Two self-contained combustion chambers (referred to as “burners”) are located beneath the cookpot. 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 cookpot by means of infrared radiation, providing much more constant and uniform heat dispersion over the surface of the cookpot than do conventional burners. Because relatively less heat is lost to the atmosphere in the process, compared to “open-burner” designs, less fuel is required to achieve and maintain a given cookpot temperature.

Gas flow to both of the burners is regulated by one electromechanical gas valve.

THE ELECTRONIC IGNITION SYSTEM

Ignition modules, located in the component box, are connected to ignitor assemblies at each burner. An ignition module performs four important functions: it provides fuse protection for the 24-volt circuit, provides an ignition spark, supplies voltage to the gas valve, and proofs the burner flame. The module contains a 4second time delay circuit and a coil that activates the gas valve.

The ignitor assembly consists of a spark plug, an enrichment tube, and a flame sensor.

At start-up, the power switch is placed in the ON position, supplying approximately 12-volts DC to the heat control circuitry in the controller and to one side of the heat relay coil on the interface board. If resistance in the temperature probe indicates the temperature in the cookpot is below 160ºF (71ºC), the current flows through a warm-up circuit containing a timer switch that alternately closes for 4 seconds and opens for 24 seconds. If the temperature is 160ºF (71ºC) 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 coil, which then closes an electronic switch in the 24 VAC circuit to provide current to the ignition module.

Circuitry in the ignition module sends 24 VAC to the gas valve. Simultaneously, the module causes the ignitor to spark for 4 seconds to light the burner. A flame sensor verifies that the burner is lit by measuring the flow of microamps through the flame. If the burner does not light (or is extin-

Inside the Ignition Module

Out to Gas Valve

To Alarm

25 V +

Coil

25 V GND

Ignition Wire Flame Sensor

6-1

guished), current to the ignition module is cut, preventing the main valve from opening, and the ignition module “locks out” until the power switch is turned off and then back on. A probe monitors the temperature in the cookpot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay. This in turn cuts off the 24 VAC to the ignition module, causing the gas valve to close.

CONTROLLER AND MECHANICAL TIMERS

FBR18 and FBRA18 Series rethermalizers are equipped with a digital controller that allows the operator to enter or adjust a specific rethermalizing temperature for the cookpot. The controller does not control rethermalizing times. Rethermalizing times for up to six different products are specified by means of 60-minute mechanical timers arrayed across the front of the unit.

INTERFACE BOARDS

An interface board is located in the component box directly behind the control panel. The interface board provides a link between the controller and the rethermalizer’s individual components without requiring excessive wiring, and it allows the controller to execute commands from one central point. FBR18 and FBRA18 models use different interface boards. The boards are not interchangeable.

FBR18 rethermalizers have been manufactured with two different interface boards, similar in appearance to the ones illustrated below. Regardless of the board used when manufactured, the uni- versal replacement part is 806-3398. Earlier design boards may be replaced with later design boards and vice versa.

SOUND

1 2

GND

3 6 9 12

2 5 8 11

1 4 7 10

GND

V2D

PWR

AD AS

V2S

GND GV PWR

EARLIER DESIGN INTERFACE BOARD P/N 806-3398

K3 K5

NOT

USED

NOT

USED

12 6 3 45

AL 12V AIR 24V AL

BLOWER

MOTOR

RELAY

K1 K2

10741

11852

12963

NOT

USED

HEAT

RELAY

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 BOARD P/N 806-3398

PWR

NOT

USED

NOT

USED

24V

K2 K3

10741

11852

12963

12V

NOT

USED

HEAT

RELAY

AND

BLOWER

MOTOR

RELAY

3 6 9 12

2 5 8 11

1 4 7 10

Blower

Motor 2 Amp

PWR

GND

AIR

GND V1D PWR ALR

V1S

In earlier versions, nine diagnostic LEDs are arrayed along the bottom edge of the board. Each of the LEDs is labeled with two or three letters indicating its function, and six of them are numbered. In later versions, there are seven LEDs scattered around the board. All of these LEDs are labeled and numbered. The diagnostic purposes of LEDs 1 through 6 on one board correspond directly to those of LEDs 1 through 6 on the other board. When lit, LED 3 indicates the 24VAC is being received from the transformer. LEDs 2 and 4, when lit, indicate that 24VAC is being supplied to the left and right ignition modules respectively. LED 5, when lit, indicates that 24VAC is being supplied to the gas valve. A lit LED 6 indicates that 12VAC is being received from the transformer. All other LEDs have no diagnostic purpose in rethermalizer applications.

6-2

The relays in earlier design boards are soldered on and cannot be replaced. Later design boards feature replaceable plug-in relays. In earlier designs boards, a heat relay (K2) switches 24VAC to the ignition and gas valve circuits when the controller heat logic circuit calls for heat. Simultaneously, a blower motor relay (K4) switches 120VAC to the blower motor. In later design boards, relay K3 serves as both the heat relay and blower motor relay.

FBRA18 rethermalizers use interface board 806-9592, often referred to as a water board.

HEAT

INTERFACE BOARD P/N 806-9592

WATER

CYCLE WATER BLOWER

BLOWER

POWER

On interface board 806-9592, the heat (or cycle) relay (K1) switches 24VAC to the ignition and gas valve circuits when the controller’s heat logic circuit calls for heat and the lower water level sensor is grounded (i.e., the water level in the cookpot is above the lower water level sensor). If the water level in the cookpot is below the upper water level sensor, the water relay (K2) closes, switching power to the normally closed water solenoid valve, causing it to open. When the water level reaches the upper sensor, the relay opens, cutting power to the valve, causing it to close. The blower relay (K3) closes and switches 120VAC to the blower motor only when the heat relay (K1) is closed. The board has four LEDs to assist in troubleshooting. Three of the LEDs (CYCLE, WATER, and BLOWER) are arrayed along the lower edge of the board. The fourth LED (POWER) is located at the right edge of the board. When the cycle, water, and blower LEDs are illuminated, they indicate that the associated relay is closed. The power LED indicates that 24VAC is being supplied to the interface board by the transformer.

TEMPERATURE PROBE A temperature probe is located on the front centerline of the cookpot. The probe is a type of thermo-

stat in which the resistance varies directly with the temperature. That is, as the temperature changes, so does resistance, at a rate of approximately 2 ohms for every 1° of rise or fall. Circuitry in the controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below a programmed temperature (setpoint). The temperature is programmed by means of up or down arrow buttons on the face of the controller.

WATER LEVEL SENSORS (FBRA18 Only) A pair of water level sensors is arranged one above the other on the left front of the FBRA18 cook-

pot. When water contacts the sensors they are grounded. The lower sensor acts as a safety device to keep the burner from firing when there is no water in the cookpot. When the sensor is grounded by contact with water, a transistor on the interface board is biased and the heat relay (K1) pulls in, supplying power to the blower via relay K3 and to the gas valve via the ignition modules. Grounding the upper water level sensor causes the water relay (K2) to open. This cuts power to the water solenoid valve, which closes, cutting off water flow into the cookpot.

6-3

6.2 Accessing the Rethermalizer for Servicing

DANGER Moving a rethermalizer filled with hot water may cause spilling or splattering of the hot water. Always drain the cookpot before attempting to relocate the unit for servicing.

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

the gas supply.

2. Remove any attached restraining devices.

3. Relocate the rethermalizer for service accessibility.

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

plug in the electrical power cord.

6.3 Cleaning the Gas Valve Vent Tube

Refer to Semi-Annual Checks and Services in Chapter 4, Preventive Maintenance.

6.4 Checking the Burner Manifold Gas Pressure

Refer to Semi-Annual Checks and Services in Chapter 4, Preventive Maintenance.

6.5 Measuring Flame Current

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

1. Turn the unit OFF (press the

2. Disconnect the white flame sensor wire

button).

Ignitor Wire

Flame Sensor

Wire

from one of the burner ignitor assemblies 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. Turn the unit ON (press the

button). When a cold unit is first turned on, the burner will cycle on and off repeatedly until the temperature in the cookpot reaches 180°F (82°C). When the water in the unit exceeds that temperature, the burner will stay on until the setpoint is reached. Check the reading when the burner has been on continuously for at least one minute.

6-4

6.6 Replacing Components

6.6.1 Replacing the Controller or Controller Wiring Harness

Refer to Chapter 5, Section 5.3 for this procedure.

6.6.2 Replacing the Temperature Probe

1. Unplug the rethermalizer and drain the cookpot.

2. Remove the screws from the upper corners of the timer panel and swing the panel open from the

top, allowing it to rest on its hinge tabs. Cut the probe leads off at the rear of the probe. NOTE: Once the probe leads have been cut, the probe cannot be reused. Work the Tinnerman retaining clip rearward off the probe.

3. Remove the two screws securing the probe cover to the probe block and remove the cover. Slip

the failed probe out of the block from the cookpot side and replace with a new probe. Carefully remove the Tinnerman retaining clip from the replacement probe to allow the leads and short end of the probe to be inserted through the probe block from cookpot side. When the replacement probe has been inserted, work the retaining clip onto the probe until the probe is held securely in place. Reinstall the probe cover and timer panel.

4. 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. Remove the two upper screws securing the component box to the rethermalizer. Rotate the box forward and outward to expose the 12-pin connector on the rear of the interface board.

5. Unplug the 12-pin connector from the interface board. Using a pin pusher, remove the cut off

pieces of wire from the connector one at a time, and insert the corresponding wire from the new probe.

6. Reattach the 12-pin connector to the interface board, rotate the component box back into posi-

tion, and replace and tighten the mounting screws. Close the control panel and replace the screws in each upper corner.

6.6.3 Replacing the Interface Board

1. Unplug the rethermalizer and drain the cookpot.

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. Detach the grounding wire from the controller, unplug the 15-pin connector from the interface

board, and remove the control panel from the unit by lifting it up and out of the hinge slots in the control panel frame.

4. Remove the two upper screws securing the component box to the rethermalizer. Rotate the box

forward and outward to expose the 12-pin connector on the rear of the interface board, and unplug it from the board.

6-5

5. On FBRA18 models only, mark the water level sensor wires and disconnect them from terminals

J1-1 (upper sensor) and J1-2 (lower sensor).

6. Remove the nuts in each corner of the interface board and carefully pull the board off the mount-

ing studs, being careful not to dislodge the spacers on the studs.

7. Position the replacement board on the studs and replace the four nuts.

8. Reconnect the water level sensor wires (FBRA18 models only) and the 12-pin connector to the

interface board.

9. Rotate the component box back into position and replace and tighten the mounting screws. Re-

mount the control panel to the component box and reattach the grounding wire.

10. Reattach the 15-pin connector to the interface board.

11. Close and secure the control panel.

6.6.4 Replacing an Ignition Module

1. Unplug the rethermalizer and drain the cookpot.

2. Disconnect the ignitor wire and flame sensor wire from the right burner assembly.

3. Remove the five screws from the rear of the transformer box and pull the box out of the unit suf-

ficiently to allow the removal of the five screws in the cover of the box. Remove the cover.

4. Unplug the ignitor wire and flame sensor wire from the module to be replaced. Disconnect the

remaining wires from the ignition module one at a time and mark them to facilitate reconnection.

5. Remove the four screws securing the module in place and lift the module out of the box. Re-

move the four spacers from the back of the failed module and insert them into the holes on the replacement module, tapered end in.

6. Reverse steps 1 through 5 to complete the procedure.

6.6.5 Replacing an Ignitor Assembly

1. Unplug the rethermalizer and drain the cookpot.

2. Remove the ignitor wire and flame sensor wire from the ignitor assembly. Disconnect the gas

enrichment tube from the assembly.

3. Remove the two mounting screws and pull the ignitor assembly out of the burner.

4. Install the replacement ignitor assembly.

5. Reconnect the ignitor wire, flame sensor wire, and gas enrichment tube.

6-6

6.6.6 Replacing the Combustion Air Blower

Refer to Chapter 4, Section 4.4, Clean Combustion Air Blower, for instructions on removing and reinstalling the combustion air blower.

6.6.7 Replacing the Gas Valve

1. Turn off the gas supply to the rethermalizer, unplug the unit, and drain the cookpot.

2. Disconnect the unit from the gas supply line and remove any fitting that may be attached to the

gas manifold at the rear of the unit.

3. Disconnect the gas lines at each burner orifice.

4. Disconnect the gas enrichment tubes at the gas valve cross fitting.

5. Disconnect the wires from the gas valve terminal, marking each wire to facilitate reconnection.

6. Remove the two nuts securing the gas manifold bracket to the base frame.

7. Pull the gas manifold assembly out the front of the unit.

8. Remove the gas valve from the manifold assembly and remove all fittings from the old valve.

9. Install the fittings removed from the old valve on the new valve, using Loctite® PST56765 or

equivalent pipe thread sealant.

10. Apply Loctite® PST56765 pipe thread sealant or equivalent to the threads of the manifold and

install the new gas valve.

11. Position the gas manifold system in the unit and replace the two nuts removed in step 6.

12. Reverse steps 1-5 to complete installation.

13. Check burner manifold gas pressure in accordance with procedure given in Chapter 4.

6.6.8 Replacing a Burner Assembly

NOTE: If space permits, it is recommended that the unit be disconnected from the gas line and laid

( on its back when performing this procedure. Be sure to place blocks under the unit to protect the end of the gas line.)

1. Unplug the rethermalizer.

2. Disconnect the flexible gas line at the burner orifice.

3. Remove both air hoses from the blower assembly and the burner assemblies.

6-7

4. Remove the four screws from the blower stabilizing bracket attached to the blower assembly and

to each burner. Remove the stabilizing bracket from the unit.

5. Remove the screw securing the blower support bracket to the cookpot assembly and lower the

blower assembly out of the way. It is not necessary to disconnect the blower wiring.

6. Remove the two screws at the front of the burner assembly to be replaced, then pull the assembly

toward the front of the unit slightly to free it from its rear support. Remove the assembly through the bottom of the unit.

7. Reverse steps 1-6 to install replacement burner assembly, being careful to get the insulation strip

running along the top of the blower support bracket back in place.

6.6.9 Replacing the Cookpot

1. Remove the cookpot insert.

2. Remove the top cap by removing the two screws on the front and the screw on each end.

3. Remove the flue cap and lid assembly by removing the two screws on each side and the two out-

ermost screws on the back. Rotate the bottom of the flue cap forward slightly to allow the top of the flue cap to slip out from under the back panel.

4. Remove the four screws securing the upper flue assembly to the back panel.

5. Remove the blower motor by removing the four nuts securing it to blower mounting bracket.

6. Disconnect the flexible gas lines, gas enrichment tubes, ignitor wires, and flame sensor wires

from the burner assemblies.

7. Remove the temperature probe from the cookpot. Leave wires attached.

8. Disconnect the water fill line at the cookpot and at the solenoid valve inlet.

9. Disconnect the wires from the water level sensors, marking them to facilitate reconnection.

10. Lift the cookpot assembly out of the cabinet and set it, top down, on a suitable work surface.

11. Remove all other hardware from the old cookpot and install the components on the replacement

cookpot, using Loctite

PST56765 on the drain valve threads. (NOTE: Install any replacement

insulation that might be required before installing components.)

12. Reverse steps 1-10 to install the replacement cookpot.

6.7 Troubleshooting and Problem Isolation

Because it is not feasible to attempt to include in this manual every conceivable problem or trouble condition that might be encountered, this section is intended to provide technicians with a general

6-8

knowledge of possible problems, and the probable causes of each. With this knowledge, the technician should be able to isolate and correct any problem encountered.

Problems that are likely to be encountered can be grouped into five broad categories:

1. Ignition failures

2. Improper burner functioning

3. Improper temperature control

4. Controller-related problems

5. Autofill system problems.

The probable causes of each category are discussed in the following sections. A series of troubleshooting guides (decision trees) is also included at the end of the chapter to assist in identifying some of the more common problems.

6.7.1 Ignition Failures

Ignition failure occurs when the ignition module fails to sense a flame within 4 seconds and locks out. When this happens, the module sends 24 VAC through the interface board alarm circuit to the controller and the trouble light on the timer control panel lights.

The three primary reasons for ignition failure, listed in order of probability, are:

1. Problems related to the gas and/or electrical power supplies.

2. Problems related to the electronic circuits.

3. Problems related to the gas valve.

PROBLEMS RELATED TO THE GAS AND/OR ELECTRICAL POWER SUPPLIES

The main indicator of a problem with the electrical power supply is that there are no indicator lights illuminated on the unit. The main indication of a problem with the gas supply is failure of the unit to fire. Verify that the gas line quick-disconnect fitting (if used) is properly connected, the unit is plugged in, the main gas supply valve is open, and the circuit breaker for the unit’s electrical supply is not tripped.

PROBLEMS RELATED TO THE ELECTRONIC CIRCUITS

If gas and electrical power are being supplied to the rethermalizer, the next most likely cause of ignition failure is a problem in the 24 VAC circuit. First, verify that the drain valve is fully closed. (The drain valve assembly includes a microswitch that must be closed for power to reach the gas valve. Often, although the valve handle appears to be in the closed position, the microswitch is still open.) If the drain valve is fully closed, refer to the troubleshooting guide

CIRCUIT

TROUBLESHOOTING THE 24 VAC

Some typical causes of ignition failure in this category include a defective sensing wire in the ignitor assembly, a defective module, a defective ignition wire, or a defective ignitor. Occasionally an igni-

6-9

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

PROBLEMS RELATED TO THE GAS VALVE

If the problem is not in the 24 VAC circuit, it is most likely in the gas valve itself, but before replacing the gas valve, refer to the troubleshooting guide

TROUBLESHOOTING THE GAS VALVE.

6.7.2 Improper Burner Functioning

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

“Popping” indicates delayed ignition. In this condition, the main gas valve is opening but the burner is not immediately lighting. When ignition does take place, the excess gas “explodes” into flame, rather than smoothly igniting.

The primary causes of popping are:

z Incorrect or fluctuating gas pressure z A defective, dirty, or incorrectly adjusted combustion air blower z Inadequate make-up air z Heat damage to the controller or ignition module z A cracked ignitor or broken/loose ignition wire z A defective ignition module z A cracked burner tile.

If popping occurs only during peak operating hours, the problem is most likely incorrect or fluctuating gas pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the following table, and that the pressure remains constant throughout all hours of usage.

Incoming Gas Pressures

Gas Minimum Maximum

6" W.C.

Natural

1.49 kPa

14.93 mbar 11" W.C.

2.74 kPa

27.37 mbar

Refer to Check Burner Manifold Pressure in the Semi-Annual Checks and Services section of Chapter 4 for the procedure for checking the gas pressure supplied to the burner.

14" W.C.

3.48 kPa

34.84 mbar 14" W.C.

3.48 kPa

34.84 mbar

6-10

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

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

Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage. Again, if damage is due to excessive heat in the equipment, that problem must also be corrected. Check for proper operation by disconnecting the wire from the ignitor, inserting the tip of a screw driver into the terminal, and holding it near the frame of the unit as the power switch is placed in the on position. A strong blue spark should be generated for at least 4 seconds.

DANGER

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

Examine the ignitor for any signs of cracking. A cracked ignitor must be replaced.

If all other causes have been ruled out, examine the burner tiles for any signs of cracking. If found, the burner must be replaced.

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

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

Flames shooting out of the flue are usually an indication of negative pressure in the kitchen. Air is being sucked out of the burner enclosure and the flames are literally following the air. If negative pressure is not the cause, check for high burner manifold gas pressure in accordance with the procedures in Chapter 4.

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

6-11

6.7.3 Improper Temperature Control

Temperature control is a function of several interrelated components, each of which must operate correctly. The principle component is the temperature probe. Other components include the interface board, the water level sensors (on FBRA18 units), the controller, and the ignition module. Whatever the cause, the symptom is failure of the unit to attain or maintain setpoint temperature.

On FBR18A models, the unit will not call for heat unless the controller senses that the unit is full of water. Sensing is accomplished when the water level in the cookpot contacts the upper water level sensor, grounding it. If the mineral content of the water is unusually low, such as with distilled, purified, or highly filtered water, the water will not ground the sensor. If this is the cause, adding approximately ⅛-cup of salt to the water will usually solve the problem.

Similarly, if the upper water level sensor becomes encrusted with lime, starch, or some other buildup, it will not ground properly. The solution is to clean the water level sensors thoroughly with a Scotchbrite™ or similar nylon scouring pad. NOTE: Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

CAUTION Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.

6.8 Troubleshooting Guides

The troubleshooting guides found in the pages that follow are intended to assist service technicians in quickly isolating the probable causes of equipment malfunctions by following a logical, step-bystep process. An additional set of operator troubleshooting guides is contained in Chapter 5. It is suggested that service technicians thoroughly familiarize themselves with both sets.

6-12

6.8.1 Troubleshooting the Gas Valve

VALVE VERIFIED TO BE

OPEN AND EQUIPMENT GAS

VALVE IN ON POSITION.

MAIN GAS SUPPLY

NOTE: All voltage measurements

must be made within 4 seconds of

unit calling for heat. If unit does

not fire within 4 seconds, ignition

modules will lock out and

controller must be turned off then

back on to reset.

Natual Gas

Is incoming

gas pressure 6-14"

W.C. (1.49-3.49

kPa)?

Yes

Is there 24VAC

on gas valve main coil (PV

terminal)?

Yes

What gas is the

unit configured for?

Problem is with gas

supply to fryer.

Problem is with

24VAC circuit. Refer to

Troubleshooting the

24VAC Circuit.

LP (Propane)

Gas

Is incoming

gas pressure 11-14"

W.C. (2.74-3.49

kPa)?

Yes

Is burner manifold

gas pressure 3.5" W.C.

(0.8 kPa)?

Yes

Is gas valve vent tube

obstructed?

Yes

Adjust pressure to

specification. If gas valve

will not adjust, replace gas

valve.

Clear obstruction.

Problem is not with

gas valve.

6-13

Yes

Is burner manifold

gas pressure 8.25" W.C.

(2.5 kPa)?

Yes

Is gas Valve vent tube

obstructed?

6.8.2 Troubleshooting the 24 VAC Circuit in FBR18 Units

UNIT IS CONNECTED TO

POWER SUPPLY, DRAIN VALVE

IS FULLY CLOSED, CONTROLLER

IS ON AND IS CALLING FOR HEAT

(decimal appears between first two digits in controller display).

Is 24VAC present on

interface board J3 pin 9

(LED 5 (GV) lit)?

Is LED 3 (24V) lit

continuously?

Yes

Is LED 4

(PWR) lit?

Yes

NOTE: All voltage measurements must

be made within 4 seconds of unit

calling for heat. If unit does not fire

within 4 seconds, ignition modules will

lock out and controller must be turned

off then back on to reset.

Yes

Is 24VAC

present across the gas

valve main coil (PV

terminal)?

Probable cause is

failed wire between

interface board and gas

valve.

Probable causes are failed

24V transformer or failed

wiring between transformer

and interface board.

Is LED 2

(PWR) lit?

Yes

24V circuit is

OK.

Is 24VAC

present on 25V terminal

of LEFT ignition

module?

Yes

Check for 12VDC across interface

board J2 pins 4 & 5 when controller is calling

for heat. If 12VDC is not present, probable

causes are failed controller or failed relay on

interface board. On later design boards, relay K3

may be replaced. On earlier design boards,

the entire interface board must be

replaced..

Is 24VAC

present on 25V terminal

of RIGHT ignition

module?

Probable causes are failed

wiring between blower centrifugal

switch and module, failed centrifugal

switch, or failed wiring harness.

Yes

Is 24VAC present on VALVE terminal of ignition

module?

If fuse is not blown,

module has failed.

Probable cause is

Yes

failed wiring harness.

6-14

THE 24 VAC CIRCUIT IN FBR18 UNITS

24V

TRANSFORMER

J3 PIN 8

LED

3 (24V)

RIGHT PWR TERMINAL

J2 PIN 7

BLOWER

CENTRIFUGAL

SWITCH

RIGHT IGNITION MODULE

J2 PIN 5

V1S TERMINAL

RELAY K2 ON EARLY DESIGN BOARDS RELAY K3 ON LATER DESIGN BOARDS

LED

4 (PWR)

LED

2 (PWR)

LEFT PWR TERMINAL

J2 PIN 2

LEFT IGNITION MODULE

J2 PIN 4

V2S TERMINAL

LED

J3 PIN 9

GAS

VALVE

5 (GV)

6-15

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units

UNIT IS CONNECTED TO

POWER SUPPLY, DRAIN

VALVE IS FULLY CLOSED,

NO WATER IS IN POT,

CONTROLLER IS ON.

Is POWER

LED lit?

Yes

Is WATER

LED lit?

Yes

Is unit filling with water?

Yes

Once water

reaches upper water

level sensor, does filling stop

and WATER LED

go out?

Yes

Go to

"A".

Ensure upper water level

sensor is not grounded (i.e., 24VAC

present across sensor and cabinet). If

sensor is not grounded, most

probable cause is failed

interface board.

Most probable cause is

a failed solenoid, but may

also be a failed water relay on

interface board or failed

interface board.

Most probable cause

Is WATER

LED lit?

is failed solenoid, but may

also be a failed water relay

on interface board.

Yes

Water leg of 24V

circuit is OK.

Most probable cause is dirty upper

water level sensor, but could also be a

loose connection between sensor and

interface board, or a failed interface

board.

6-16

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued)

NOTE: All voltage measurements involving the

gas valve leg of the 24V circuit must be made

within 4 seconds of unit calling for heat. If unit

does not fire within 4 seconds, ignition modules

will lock out and controller must be turned off

then back on to reset.

Is 24VAC

present on N/O

terminal of latch

relay?

Yes

Is 24VAC

present on COM

terminal of latch

relay?

Yes

Is 24VAC

present on J1 pin

Yes

When water level

is above lower water level

sensor, is CYCLE LED lit?

Probable causes are failed

24V transformer or failed wiring

between transformer box and

component box.

If 12VDC is applied across coil,

probable cause is failed relay. If not,

probable cause is failed wiring between

controller and latch relay or failed

controller.

Probable causes are failed

wiring between terminal block

and computer, or failed

computer.

Go to

"C".

Yes

Go to

"B".

6-17

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued)

Is 24VAC

present across the gas

valve main coil (PV)

terminal?

24VAC present on

VALVE terminal of LEFT

ignition module?

Is 24VAC present

on 25V terminal of LEFT

ignition module?

NOTE: All voltage measurements involving the

gas valve leg of the 24V circuit must be made

within 4 seconds of unit calling for heat. If unit

does not fire within 4 seconds, ignition

modules will lock out and controller must be

turned off then back on to reset.

Yes

Gas valve leg

of 24V circuit is

OK.

Probable cause is

Yes

failed wiring between

module and gas valve.

Yes

If fuse is not

blown, module

has failed.

Is 24VAC

present on J2

pin 4?

Is 24VAC

present on J2

pin 3?

Probable cause is

failed wiring between

terminal block and J2

pin 3.

Yes

Is 24VAC present

on 25V terminal of RIGHT

ignition module?

Probable causes are failed

wiring between blower centrifugal

switch and module, failed

centrifugal switch, or failed

wiring harness.

Probable cause is failed CYCLE

relay.

Yes

24VAC present on

VALVE terminal of RIGHT

ignition module?

Yes

Probable cause

is failed wiring

harness.

6-18

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued)

Is 24VAC

present on J1 pin 5

when unit calls for

heat?

Yes

NOTE: All voltage measurements must be

made within 4 seconds of unit calling for

heat. If unit does not fire within 4 seconds,

ignition modules will lock out and controller

must be turned off then back on to reset.

Is J1 pin 2

grounded?

Yes

Probable cause

is failed interface

Clean lower water

level sensor and

ground it.

Does

CYCLE LED light

when unit calls for

heat?

Yes

board.

Is 24VAC

present on N/O

terminal of 12VDC

relay?

Probable cause is

failed wiring between

latch relay and 12VDC

relay.

Yes

Go to

"B".

Is 24VAC

present on COM

terminal of 12VDC relay

when unit calls for

heat?

12VDC present

across coil of 12VDC relay

when unit calls for

heat?

Probable cause is

failed controller wiring

harness or failed

controller.

Yes

Probable cause is

failed wiring between

relay and interface

board.

Probable cause is failed 12VDC

relay.

6-19

THE 24VAC CIRCUIT IN FBRA18 UNITS

CONTROLLER

12VDC RELAY

J1 PIN 5

WATER

RELAY

WATER

24V

TRANSFORMER

LATCH RELAY

INTERFACE BOARD

LOGIC CIRCUITRY

LED

POWER

LED

CYCLE

CYCLE RELAY

J2 PIN 3J2 PIN 2 J1 PIN 3

J2 PIN 1

WATER

SOLENOID

VALVE

INTERFACE BOARD

BLOWER

CENTRIFUGAL

SWITCH

IGNITION MODULE

J2 PIN 4

RIGHT

WIRING HARNESS PIN 5

WIRING HARNESS PIN 2

LEFT IGNITION MODULE

WIRING HARNESS PIN 4

GAS

VALVE

6-20

6.8.4 Troubleshooting the Temperature Probe

WHILE IT IS STILL IN

THE COOKPOT,

INSPECT THE PROBE

BODY FOR DAMAGE.

REPLACE IF BENT,

DENTED, OR CRACKED.

Inspect leads for

fraying, burning,

breaks, and/or kinks. If

found, replace probe.

Determine temperature

of water in cookpot

using a thermometer or

pyrometer placed at tip

of probe.

Is resistance

approximately equal to that

given in the Probe Resistance

Chart for the corresp on di ng

temperature?

Yes

Measure resista nce through each of the

previously tested pins

to ground.

Is resistance

5 megaohms or greater

in each pin?

Yes

Probe has failed.

Probe is good.

6-21

Probe Resistance Chart

FOHMSC FOHMSC FOHMSC FOHMSC FOHMSC

32 1000 0 83 1107 28 134 1214 57 185 1320 85 236 1424 113 33 1002 1 84 1110 29 135 1216 57 186 1322 86 237 1426 114 34 1004 1 85 1112 29 136 1218 58 187 1324 86 238 1428 114 35 1006 2 86 1114 30 137 1220 58 188 1326 87 239 1430 115 36 1008 2 87 1116 31 138 1222 59 189 1328 87 240 1432 116 37 1011 3 88 1118 31 139 1224 59 190 1330 88 241 1434 116 38 1013 3 89 1120 32 140 1226 60 191 1332 88 242 1436 117 39 1015 4 90 1122 32 141 1229 61 192 1334 89 243 1438 117 40 1017 4 91 1124 33 142 1231 61 193 1336 89 244 1440 118 41 1019 5 92 1126 33 143 1233 62 194 1338 90 245 1442 118 42 1021 6 93 1128 34 144 1235 62 195 1340 91 246 1444 119 43 1023 6 94 1131 34 145 1237 63 196 1342 91 247 1447 119 44 1025 7 95 1133 35 146 1239 63 197 1344 92 248 1449 120 45 1030 7 96 1135 36 147 1241 64 198 1346 92 249 1451 121 46 1032 8 97 1137 36 148 1243 64 199 1348 93 250 1453 121 47 1034 8 98 1139 37 149 1245 65 200 1350 93 251 1455 122 48 1036 9 99 1141 37 150 1247 66 201 1352 94 252 1457 122 49 1038 9 100 1143 38 151 1249 66 202 1354 94 253 1459 123 50 1040 10 101 1145 38 152 1251 67 203 1357 95 254 1461 123 51 1042 11 102 1147 39 153 1253 67 204 1359 96 255 1463 124 52 1044 11 103 1149 39 154 1255 68 205 1361 96 256 1465 124 53 1046 12 104 1151 40 155 1258 68 206 1363 97 257 1467 125 54 1049 12 105 1154 41 156 1260 69 207 1365 97 258 1469 126 55 1051 13 106 1156 41 157 1262 69 208 1367 98 259 1471 126 56 1053 13 107 1158 42 158 1264 70 209 1369 98 260 1473 127 57 1055 14 108 1160 42 159 1266 71 210 1371 99 261 1475 127 58 1057 14 109 1162 43 160 1268 71 211 1373 99 262 1477 128 59 1059 15 110 1164 43 161 1270 72 212 1375 100 263 1479 128 60 1061 16 111 1166 44 162 1272 72 213 1377 101 264 1481 129 61 1063 16 112 1168 44 163 1274 73 214 1379 101 265 1483 129 62 1065 17 113 1170 45 164 1276 73 215 1381 102 266 1485 130 63 1067 17 114 1172 46 165 1278 74 216 1383 102 267 1487 131 64 1068 18 115 1174 46 166 1280 74 217 1385 103 268 1489 131 65 1070 18 116 1176 47 167 1282 75 218 1387 103 269 1491 132 66 1072 19 117 1179 47 168 1284 76 219 1389 104 270 1493 132 67 1074 19 118 1181 48 169 1287 76 220 1391 104 271 1495 133 68 1076 20 119 1183 48 170 1289 77 221 1393 105 272 1497 133 69 1078 21 120 1185 49 171 1291 77 222 1395 106 273 1499 134 70 1080 21 121 1187 49 172 1293 78 223 1398 106 274 1501 134 71 1082 22 122 1189 50 173 1295 78 224 1400 107 275 1503 135 72 1084 22 123 1191 51 174 1297 79 225 1402 107 276 1505 136 73 1086 23 124 1193 51 175 1299 79 226 1404 108 277 1507 136 74 1089 23 125 1195 52 176 1301 80 227 1406 108 278 1509 137 75 1091 24 126 1197 52 177 1303 81 228 1408 109 279 1512 137 76 1093 24 127 1199 53 178 1305 81 229 1410 109 280 1514 138 77 1095 25 128 1201 53 179 1307 82 230 1412 110 281 1516 138 78 1097 26 129 1204 54 180 1309 82 231 1414 111 282 1518 139 79 1099 26 130 1206 54 181 1311 83 232 1416 111 283 1520 139 80 1101 27 131 1208 55 182 1313 83 233 1418 112 284 1522 140 81 1103 27 132 1210 56 183 1315 84 234 1420 112 285 1524 141 82 1105 28 133 1212 56 184 1317 84 235 1422 113 286 1526 141

6-22

6.9 Wiring Diagram for FBR18 Units

GAS

VALVE

IGNITER

HIGH TEMP. WIRE

NOTE: FLAME SENSOR WIRE

MUST BE CONNECTED TO THE

SAME IGNITOR AS ITS MATCHING

HIGH VOLTAGE LEAD.

IGNITER

SWITCH

23C

101C

(ORN)

SAFETY DRAIN

36C

(ORN)

CABLE HIGH VOLTAGE

13C

(ORN)

12C

CENT.

(WHT)

111C

SWITCH

BLOWER

8050417D

(BLK)

120

LINE

LOAD

120

LINE

LOAD

51C

10C

MODULE IGNITION

(BURNER)

25V

GND

VALVE

(GND)

ALARM

25V

111C

49C

3 2

6 5

SPARK MODULE RT.

MODULE IGNITION

(BURNER)

25V

GND

VALVE

(GND)

ALARM

25V

SPARK MODULE LT.

11C

WHITE

BLACK

GREEN

43C

12C

14C

19C

18C

120 VAC

CORDSET

44C

123456789

60C

53C

42C

GND

879

16C

V1S

V1D

PWR

GND

ALRM

GND

55C

129

811

4 1

SOUND

GND

6 3

GND

V2S

A S

A D

PWR

V2D

21C

22C

17C

10 11 12

987654321

LIGHT

TROUBLE

TEMP.

PROBE

CONTROLLER

1C 3C 8C 56C 5C

6-23

6.10 Wiring Diagram for FBRA18 Units

LOW PROBE

TEMP PROBE

25C

24C

HIGH PROBE

42C

N/O

22C

COMPUTER

27C

26C

46C

1 2345678 9 10 11 12 13 14 15

28C

30C

49C

LINE

LOAD

12V

LINE

LOAD

24V

11C

51C

49C

32C

31C

20C

34C

47C

35C

50C

COM

RELAY

37C

35C

21C

26C

4132 65 987 1110 12

33C

COM

48C

8051017B

SOLENOID

37C

COM N/O

12C

27C

18C

44C

12C

13C

RIGHT IGNITION

14C

19C

43C

GND

(BURNER)

VALVE

ALARM

GND

25V

18C

RED

4132 65 987

38C39C

16C

41C

29C

LIGHT

15C

IGNITION MODULE

17C

WIRE

HIGH

TEMP

45C

40C

GAS VALVE

IGNITOR

10C

BLACK

SWITCH

43C

GND

(BURNER)

VALVE

ALARM

HIGH

WIRE

TEMP

NOTE:

WHITE

111C

BLACK

WHITE

ORANGE

LEFT IGNITION

GND

25V

BLOWER

44C

IGNITION MODULE

25V

HIGH VOLTAGE LEAD.

AS ITS MATCHING

TO THE SAME IGNITOR

MUST BE CONNECTED

FLAME SENSOR WIRE

IGNITOR

120 V

6-24

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 7: PARTS LIST

7.1 Burner System Components

ITEM PART # COMPONENT

Burner Assemblies 806-5563 Natural Gas, Complete

806-5564SP Propane Gas, Complete 1 810-1382 Burner, Reverse Plenum, Universal 2 Orifice

810-0916 Natural Gas, 3.26mm

810-0917 Propane Gas, 2.00mm 3 Ignitor

810-0521 Natural Gas

810-0608 Propane Gas 4 807-1564 Blower, Combustion Air 5 823-2528 Mount, Combustion Air Blower 6 900-5525 Bracket, Combustion Air Blower Stabilizer * 816-0055 Insulation, Burner Support, ½” x 17.38” * 810-0507 Spacer, Combustion Air Blower Mount, .23” x .75” * 807-1878 Ignitor Wire, 19” (See illustration on Page 7-3) * 816-0165 Insulation, Ignitor * 806-5541 Flame Sensor Wire (See illustration on Page 7-3) * 816-0278 Hose, Air, ⅝” ID * 823-2526 Bracket, Air Hose Connection, Left * 823-2685 Bracket, Air Hose Connection, Right * 900-1789 Enrichment Tube

* Not illustrated

7-1

7.2 Cabinetry and Associated Components

)

(

)

(

)

ITEM PART # COMPONENT

1 910-1181 Retainer, Flue Cap Insulation 2 816-0157 Insulation, Flue 3 900-4603 Flue Guard 4 823-2107 Flue Cap 5 810-2263 Hanger, Basket (replaced extruded aluminum hanger, no longer available 6 910-7434 Top Cap 7 900-7379 Back, Cabinet 8 900-7377 Side, Cabinet, CRS, Left or Righ

9 900-4521 Retainer, Cabinet Back Insulation 10 812-1141 Insulation, Cabinet Bac 11 900-1552 Gusset 12 900-4505 Top Brace 13 900-1759 Bracket, Pot Hold Down 14 900-7376 Channel, Base Side, Left or Righ 15 900-4504 Channel, Base Front or Rea 16 806-3853 Door Assembly 17 826-3811 Leg Assembly (set of four 18 810-0356 Caster, 5-inch Wheel, w/o Brake 19 810-0357 Caster, 5-inch Wheel, w/Brake 20 826-0900 Chain Restraint Ki

* 806-5209 Leg Pad Assembl

* 812-1142 Insulation, Cabinet Back, 2” x 17.5” 21 810-1422 22 210-9214

Handle, Wireform Door Handle, Eurolook Door

cannotreplace 210-9214

cannotreplace 810-1402

* Not illustrated

7-2

7.3 Control Box Assembly and Associated Parts, FBR18/ FBRA18

120

LINE

LOAD

120

LINE

LOAD

84 7

3 2

WHITE

GREEN

BLACK

(BURNER)

GND

VALVE

(GND)

ALARM

25V

(BURNER)

25V 25V

GND

VALVE

(GND)

ALARM

25V

RIGHTLEFT

LEFT IGNITOR RIGHT IGNITOR

ITEM PART # COMPONENT

1 900-4509 Control Box Mounting Base 2 807-1006 Ignition Module, 4-Second Honeywell 3 809-0446 Spacer, .26-inch x .50-inch 4 807-1706 Cable, Ignition, 36-inch 5 806-5541 Wire, Flame Sensor 6 807-0855 Transformer, 120V-12V, 20VA, 50/60 Hz 7 807-0800 Transformer, 120V-24V, 50VA, 50/60 Hz 8 807-0067 Block, 8-pin Terminal 9 810-0045 Bushing, .875-inch

10 806-5332 Cord, Electrical Power

* 900-4508 Control Box Heat Shield * 900-4510 Control Box Side * 806-9334 Harness, 12-pin Wiring * 806-9335 Harness, 9-pin Wiring

* Not illustrated.

7-3

7.4 Controller and Component Box Assemblies

SOUND

GND

2 3

Frymaster

- - - -

346

118

912

GND V2D PWR A D

GND GND A S V2S

GND

4 5

GND

V1D

PWR

ALRM

V1S

FBR18

Component Box

Controller

FBRA18

Component Box

ITEM PART # COMPONENT

1 824-0396 Control Box (used on FBR18 only) 2 806-3398 Interface Board (used on FBR18 only) * 809-0394 Spacer, Interface Board Standoff, 4mm x 6mm (used on FBR18 only) 3 810-0045 Bushing, .875-inch (used on FBR18 and FBRA18) 4 806-5303 Controller, Digital (used on FBR18 and FBRA18) 5 806-9414 Control Box Assembly (used on FBRA18 only) 6 806-9592 Interface Board (used on FBRA18 only) 7 807-1683 Relay, 12VDC (used on FBRA18 only) 8 807-0067 Block, 8-pin Terminal * 807-1241 Spacer, Interface Board Standoff, ⅝-inch (used on FBRA18 only)

* Not illustrated.

7-4

7.5 Cooking Timer Control Panel Components

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ITEM PART # COMPONENT

1 910-4496 Cooking Timer Control Panel 2 Knob Assembly

810-1287 Black 806-5339 Gray 806-5340 Red 806-5341 Brown 806-5342 Blue

806-5343 Green 3 810-0808 Faceplate, Timer Dial 4 810-0807 Timer, Springwound, 60-Minute 5 807-1547 Lamp, Red Lens, 24V Trouble 6 806-5260SP Frame, Cooking Timer Control Panel

7-5

7.6 Cookpot, FBR18

ITEM PART # COMPONENT

1 900-1762 Retainer, Insulation 2 900-7431 Cover, Cookpot Front Insulation 3 816-0143 Insulation, Cookpot Front 4 823-1891SP Cookpot 5 816-0144 Insulation, Cookpot Side 6 806-5251SP Probe Assembly, Temperature 7 824-0395 Guard, Probe 8 900-1031 Retainer, Sight Glass 9 816-0053 Insulation, Sight Glass

10 814-0048 Sight Glass

* 810-0809 Block, Probe Mounting * 816-0157 Insulation, Upper Flue, 8.5” x 18.0” * 816-0158 Insulation, Lower Flue, 10.5” x 19.0” * 816-0055 Insulation, Burner Support, ½” x 17.38” * 816-0145 Insulation, Bottom Front, 3.0” x 14.5” * 816-0166 Insulation, Bottom Rear, 3.5” x 17.0” * 809-0204 Washer, Teflon, ⅝” x 1”

* Not illustrated.

7-6

7.7 Cookpot, FBRA18

This washer must be seated in hole before

nut is tightened.

Inside face of

cookpot.

Torque nut to

30 in-lb ± 5.

Enlarged View of Water Level Sensor Assembly

ITEM PART # COMPONENT

1 900-1762 Retainer, Insulation 2 900-7431 Cover, Cookpot Front Insulation 3 816-0143 Insulation, Cookpot Front 4 823-4094SP Cookpot 5 813-0557 Elbow, Plastic, 1” NPT to 1” Barb 6 816-0144 Insulation, Cookpot Side 7 806-7552SP Sensor Assembly, Upper or Lower Water Level 8 910-5196 Cover, Water Level Sensors 9 806-5251 Probe Assembly, Temperature

10 824-0395 Guard, Probe 11 900-1031 Retainer, Sight Glass 12 816-0053 Insulation, Sight Glass 13 814-0048 Sight Glass

* 810-0809 Block, Teflon, Probe Mounting * 816-0157 Insulation, Upper Flue, 8.5” x 18.0” * 816-0158 Insulation, Lower Flue, 10.5” x 19.0” * 816-0145 Insulation, Bottom Front, 3.0” x 14.5” * 816-0166 Insulation, Bottom Rear, 3.5” x 17.0” * 809-0204 Washer, Teflon, ⅝” x 1” * 816-0055 Insulation, Burner Support, ½” x 17.38”

* Not illustrated.

7-7

7.8 Gas Supply Components

ITEM PART # COMPONENT

1 Gas Valve

810-0786 Natural Gas

810-0787 LP (Propane) Gas 2 813-0378 Fitting, Cross, ⅛” NPT, Brass 3 813-0154 Plug, Pipe, ⅛” Hex Head 4 813-0340 Adapter, ⅛” NPT x ⅛” Tube, Brass 5 813-0016 Nipple, ⅛” x ¾” NPT, BM 6 813-0004

Elbow, ⅛” NPT x 90°, BM 7 813-0433 Nipple, ⅛” NPT x 2 ½”, BM 8 813-0304 Bushing, ½” x ¼” Flush, BM 9 813-0301 Tee, Male, ⅜” x ¼” NPT x ⅜”, Brass

10 813-0022 Nipple, ½” NPT Close, BM 11 813-0062

Elbow, ½” x 90°, BM 12 813-0265 Nipple, ½” NPT x 2 ½”, BM 13 823-2766 Mounting Bracket, Gas Line 14 813-0257 Nipple, ¾” NPT x 24 ½”, BM 15 823-1893 Bracket, Rear Manifold

* 810-0816 Plug, Honeywell Gas Valve

* Not illustrated.

7-8

7.9 Plumbing Components

ITEM PART # COMPONENT

1 806-9067 Valve Assembly, Solenoid (FBRA18 only) 2 810-1208 Valve, Water Pressure Regulator (FBRA18 only) 3 900-2916 Bracket, Water Pressure Regulator Valve (FBRA18 only) 4 813-0448 Elbow, Pipe Fitting, Brass, ¼” (FBRA18 only) 5 813-0302 Elbow, Compression, ¼” NPT x ⅜” Tubing (FBRA18 only) 6 910-8027 Tubing, SS, Solenoid to Cookpot (FBRA18 only) 7 810-1025 Compression Fitting, Straight, ¼” (FBRA18 only) 8 813-0022 Nipple, ½” x Close, BM NPT (FBRA18 only)

9 910-8026 Tubing, SS, Water Line (FBRA18 only) 10 813-0471 Nipple, ¼” x 1½” Brass NPT (FBRA18 only) 11 806-8467SP Valve Assembly, Drain w/Microswitch, Complete (FBR18 only) 12 807-2103 Microswitch (FBR18 and FBRA18) 13 813-0379 Elbow, Street, 1 ¼” BM NPT (FBR18 only) 14 810-1020 Valve, Drain (FBRA18 only) 15 823-2047 Handle, Drain Valve (FBRA18 only) 16 816-0371 Hose, Drain (FBRA18 only) 17 813-0314 Tee, 1” BM NPT (FBRA18 only) 18 813-0138 Nipple, 1” BM NPT (FBRA18 only) 19 813-0202

Elbow, 1” x 90° BM NPT (FBRA18 only)

20 813-0525 Fitting, Barbed, 1” NPT to Hose (FBRA18 only)

7-9

7-10

Frymaster, L.L.C., 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000

Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106

TEL 1-318-865-1711 FAX (Parts) 1-318-219-7140 FAX (Tech Support) 1-318-219-7135

PRINTED IN THE UNITED STATES

SERVICE HOTLINE

1-800-551-8633

Price: $10.00

819-5278

May 2003

Frymaster FBR18 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual