Frymaster FGP55 Service Manual
FGP55 Rethermalizer
Service & Parts Manual
NON-CE &
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline
1-800-551-8633
www.frymaster.com
Email: service@frymaster.com
OCTOBER 2006
*8196250*
Please read all sections of this manual and retain for future reference.
This product has been certified as commercial cooking equipment and MUST be installed by
professional personnel as specified. Installation, maintenance and repairs should be performed
by your FRYMASTER FACTORY AUTHORIZED SERVICE CENTER.
DANGER
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other cooking appliance.
DANGER
Instructions explaining procedures to be followed MUST be posted in a prominent location in
the event the operator detects a gas leak. This information can be obtained from the local gas
company or gas supplier.
DANGER
Safe and satisfactory operation of your equipment depends on proper installation. Installation
MUST conform with local codes, or in absence of local codes, with the National Fuel Gas Code,
ANSI Z223.1; The Natural Gas Installation Code, CAN/CGA-B149.1; The Propane Installation
Code, CAN/CGA-B149.2; or The latest edition of the National Electric Code, N.F.P.A. 70.
NOTICE
If, during the warranty period, the customer uses a part for this Enodis equipment other than an
unmodified new or recycled part purchased directly from Frymaster Dean, or any of its
authorized service centers, and/or the part being used is modified from its original
configuration, this warranty will be void. Further, Frymaster Dean and its affiliates will not be
liable for any claims, damages or expenses incurred by the customer which arise directly or
indirectly, in whole or in part, due to the installation of any modified part and/or part received
from an unauthorized service center.
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.
WARNING
Drawings and photos used in this manual are intended to illustrate operational, cleaning and
technical procedures and may not conform to on-site management operational procedures.
WARNING
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.
NOTICE
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 Food and Drug Administration.
NOTICE
The Commonwealth of Massachusetts requires any and all gas products to be installed by a
licensed plumber or pipe fitter.
COMPUTERS
FCC
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.
DANGER
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALI FORNIA 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.
WARNING
Do not bang rethermalizer baskets or other utensils on the rethermalizer’s joiner strip. The strip
is present to seal the joint between the cookpot vessels. Banging rethermalizer baskets on the
strip will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only
be removed for cleaning.
DANGER
Improper installation, adjustment, maintenance or service, and unauthorized alterations or
modifications can cause property damage, injury, or death. Read the installation, operating and
service instructions thoroughly before installing or servicing this equipment. Only qualified
service personnel may convert this appliance to use a gas other than that for which it was
originally configured.
DANGER
Adequate means must be provided to limit the movement of this appliance without depending
upon the gas line connection or transmitting stress to the electrical conduit. 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.
FGP55 Series Rethermalizers
Service & Parts Manual
TABLE OF CONTENTS
Page #
1. SERVICE PROCEDURES 1-1
1.1 Functional Description 1-1
1.2 Accessing Fryers for Service 1-3
1.3 Cleaning the Gas Valve Vent Tube (if applicable) 1-3
1.4 Adjusting Burner Manifold Gas Pressure 1-3
1.5 Adjusting the Pilot Flame 1-4
1.6 Replacing Rethermalizer Components 1-5
1.7 Troubleshooting and Problem Isolation 1-20
1.8 Troubleshooting Guides 1-26
1.8 Probe Resistance Chart 1-29
1.10 Wiring Diagrams 1-30
2. PARTS LIST 2-1
2.1 FGP55 Primary Components 2-2
2.2 Components and Controllers 2-4
2.3 Float Switch Assemblies 2-6
2.4 Control Boxes 2-7
2.5 Incoming Water Plumbing 2-9
2.6 Drain and Associated Parts 2-10
2.7 Gas Plumbing 2-11
2.8 Fasteners 2-12
)
)
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.1 Functional Description
FGP55 Series gas rethermalizers contain a welded stainless steel cookpot that is heated by gas
flames diffused evenly through tubes built into the cookpot.
Flames originate from orifices in a burner manifold positioned beneath the burners. The burners are
positioned in the tube openings, at the front of the cookpot. The diameter of the orifices differs for
natural (CE:G20/G25) and LP (CE:G31) gas as indicated in the accompanying table.
NON-CE (Altitudes of 2000 feet or less
MODEL
FGP55 90
INPUT
(BTU)
GAS
TYPE
NAT
LP
ORIFICE
MM
(INCH)
2.53(#38)
1.51(#53)
ORIFICE
PART NO.
810-2048
810-2059
QTY
4
4
EQUIPMENT
PRESSURE
MBAR INCH W.C.
10
27.5
4
11
CE ONLY (Altitudes of 2000 feet or less
MODEL
FGP55 26.4
INPUT
(kW)
GAS
TYPE
G20
G25
G31
ORIFICE
MM
(INCH)
2,53
2,53
1,51
ORIFICE
PART NO.
810-2048
810-2048
810-2059
QTY/
COLOR
4/BLUE
4/BLUE
4/RED
EQUIPMENT
PRESSURE
MBAR INCH W.C.
10,0
15,0
27,0
4,0
6,0
10,8
An electromechanical gas valve regulates gas flow to the manifold. FGP55 Series gas rethermalizers
are equipped with a 24-volt valve system. Current units are configured with an electronic standing
pilot system.
Pilot System Configuration
In older units a pilot system comprised of the pilot orifice, pilot hood, and a thermopile were used.
The pilot serves two purposes. The first is to light the burner, the second is to heat the thermocouple
(some systems incorporate a thermopile). In operation, the thermocouple is in contact with the pilot
flame and generates millivolts. The millivolt output energizes the gas valve pilot coil, which in turn
opens the pilot valve. If the pilot flame is extinguished, voltage is lost to the gas valve pilot coil and
the pilot valve closes. The gas valve is constructed so that the main valve will not open if the pilot
valve is not open. The pilot flame must be manually lit when the rethermalizer is first placed into
operation. A separate 120-volt circuit, activated by the rethermalizer power switch, provides voltage
through the electronic thermostat controller to the gas valve main coil, which opens the main valve.
Electronic Ignition Configuration
In units configured for electronic ignition, an ignition module connected to an ignitor assembly
replaces the pilot system. The ignition module performs three important functions: it provides an
ignition spark, supplies voltage to the gas valve, and proofs the pilot flame.
1-1
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
Electronic Ignition Configuration (cont.)
The module contains a 60-second time delay circuit and a coil that activates the gas valve. The
ignitor assembly consists of a spark plug, a pilot, and a flame sensor element.
At start-up the power switch is placed in the "ON" position, supplying 12 VDC to the heat control
circuitry in the computer. Current 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 current to the gas valve via a normally closed highlimit switch and a float switch. Simultaneously, the module causes the ignitor to spark for up to 60
seconds to light the pilot flame. A flame sensor verifies that the pilot is lit by measuring the flow of
microamps through the flame. If the pilot does not light (or is extinguished), current to the ignition
module is interrupted, preventing the main valve from opening, and the ignition module "locks out"
until the power switch is turned "OFF", then back "ON".
A temperature 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
interrupt current flow through the heat relay. This in turn interrupts the 24 VAC current to the
ignition module, resulting in closure of the gas valve.
Control Options
FGP55 Series gas rethermalizers are equipped with computers. These are unique in that the
components are wired directly to the computer and do not require an interface board.
Temperature Probe
FGP55 rethermalizers equipped with computer controls have a temperature probe. In this
configuration, the probe resistance varies directly with the temperature. That is, as the temperature
rises, so does resistance at a rate of approximately 2 ohms for every 1° (°F or °C). Circuitry in the
computer monitors the probe resistance and controls burner firing when the resistance exceeds or
falls below programmed temperatures (setpoints). The temperatures are programmed by means of a
keypad on the face of the computer.
All FGP55 Series gas rethermalizers are equipped with a high-limit thermostat. In the event that the
rethermalizer fails to properly control the water temperature, the high-limit thermostat prevents the
rethermalizer from overheating. The high-limit thermostat acts as a normally closed power switch
that opens when exposed to temperatures above 250°F (121°C).
1-2
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.2 Accessing Rethermalizers for Servicing
DANGER
Moving a rethermalizer filled with water may cause spilling or splattering of the hot
liquid. Follow the draining instructions included with the rethermalizer before
attempting to relocate a rethermalizer for servicing.
1. Shut off the gas supply to the unit. Unplug the power cords. Remove any attached restraining
devices.
2. Disconnect the unit from the gas supply.
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 cords.
1.3 Cleaning the Gas Valve Vent Tube (if applicable)
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.
3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any
obstruction. Remove the wire and blow through the tube to ensure it is clear.
4. Reinstall tube and bend so that the opening is pointing downward.
1.4 Adjusting Burner Manifold Gas Pressure
WARNING
This task should be performed by qualified service personnel only.
1. Ensure that the gas valve knob is in the "OFF" position.
2. Remove the pressure tap plug from the gas valve (see arrows in photos on the following page for
location).
1-3
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.4 Adjusting Burner Manifold Gas Pressure (cont.)
3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.
4. Place the gas valve in the "ON" position then place the rethermalizer power switch in the "ON"
position. When the burner lights and continues to burn, note gas pressure reading for correct
pressure in accordance with the table on page 1-1.
5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct
pressure.
6. Place the rethermalizer power switch and the gas valve in the "OFF" position. Remove the
pressure-measuring device fitting from the pressure tap hole and reinstall the pressure tap plug.
1.5 Adjusting the Pilot Flame
1. Remove the cap from the pilot adjustment screw hole on the gas valve.
2. Using a small, flat-tipped screwdriver, turn the pilot adjusting screw counterclockwise to
increase length of flame or clockwise to decrease length of flame. Adjust to obtain a flame from
1 inch to 1½ inches long.
3. Reinstall the pilot adjustment screw cap.
1-4
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6 Replacing Rethermalizer Components
1.6.1 Replacing the Computer or Solid State Relays
1. Disconnect the rethermalizer from the electrical supply.
2. Unscrew the two computer panel screws.
The computer panel is hinged at the bottom
and will swing open from the top.
3. Unplug the rethermalizer wiring harness and
ground wire from the back of the computer.
If replacing the solid-state relays disconnect
the wires and replace the faulty relay.
4. Remove the computer by lifting it from the
hinge slots in the rethermalizer control panel
frame.
5. Reverse the procedure to install a new
computer.
Computer panel in “down” position.
Disconnect the 15-pin connector and ground
wire (arrows) from the computer.
Control panel frame with computer removed.
1-5
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6.2 Replacing the Temperature Probe
1. Disconnect the rethermalizer from the electrical supply.
2. Drain the water from the cookpot. Allow the cookpot to cool completely before proceeding.
3. Remove the rethermalizer door for easier
access to the temperature probe. Lift door up,
disengage rod from lower door bracket, and
then remove door.
Remove door for easier access to temperature
probe.
4. Disconnect the probe harness connector
(arrow). Use a pin pusher to remove plug
from probe wires (probe side only). Retain
the plug for re-assembly on new probe.
Disconnect the two-pin probe harness connector
(arrow).
5. Remove the appropriate burners to gain
access to the temperature probe (see Steps
13-14 on page 1-15 for more detail).
Remove burners to gain access to temperature
probe.
1-6
)
p
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6.2 Replacing the Temperature Probe (cont.)
6. Loosen and unscrew completely the
compression nut, then the pass-through nut
from the cookpot. Proceed to the next step
before removing probe from cookpot.
Note: The temperature probe can be
removed through the top of the cookpot as
follows: Ensure the two-pin connector has
been removed from the probe wiring harness
(step 4, this section). Remove the harness
insulation. The probe can be pulled through
the cookpot from the top (complete step 7 in
this section, prior to removing probe).
7. Remove probe bracket and probe spring from
Loosen and unscrew completely the compression
nut (bottom arrow), then the pass-through nut (top
arrow
probe inside cookpot (bracket location and
configuration will vary according to
rethermalizer model). Retain mounting
hardware for installation of new temperature
probe.
First remove the probe bracket (two screws), then
First remove the probe bracket (two screws), then
the probe spring. Retain mounting hardware for
the probe spring. Retain mounting hardware for
installation of new
installation of new probe.
8. Carefully remove the probe from the cookpot.
As the probe is removed, tilt the probe at an
angle to facilitate removal (curved probes
only).
9. Reverse steps for installation of new probe.
IMPORTANT: When installing new probe,
ensure probe is positioned properly with the
mounting hardware installed prior to tightening
the compression nut. Once tightened, the probe
cannot be repositioned.
Removing old probe from cookpot. (Cookpot
removed from rethermalizer for clarity).
.
robe.
1-7
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6.3 Replacing the High-Limit Thermostat
1. Turn rethermalizer off and drain water from the cookpot. Allow the cookpot to cool completely
before proceeding.
2. Perform steps 1-4 in Section 1.6.1, Replacing the Computer.
3. Remove rethermalizer door for easier access (see Section 1.6.3, Step #3 for more detail).
4. Remove two screws securing the high-limit
mounting-bracket. Do not disconnect wires
from high-limit at this time.
Remove screws (arrows) securing high-limit to
rethermalizer.
5. Loosen and completely unscrew the
compression nut, then the pass-through nut
on the cookpot bottom. Proceed to the next
step before removing high-limit from
cookpot.
Compression nut unscrewed. Unscrew the passthrough nut (arrow)
1-8
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6.3 Replacing the High-Limit Thermostat (cont.)
6. Remove high-limit mounting bracket and
high-limit spring inside cookpot. Retain
mounting hardware for installation of new
high-limit.
Remove high-limit mounting hardware. Retain
mounting hardware for installation of new highlimit. (Mounting hardware and location will vary
according to rethermalizer model.)
7. Carefully pull high-limit capillary tube and
bulb out of the cookpot from the bottom.
Remove high-limit capillary tube and bulb from the
bottom of the cookpot.
1-9
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6.3 Replacing the High-Limit Thermostat (cont.)
8. Mark and disconnect wires at the high-limit
in the component box.
Mark and disconnect high-limit wiring (arrows).
(Reconnect wires to the same terminals on the
replacement high-limit.)
9. Remove high-limit from rethermalizer by
pulling the capillary tube and bulb through
the component box opening (arrow). (This
may require removal of the control panel
frame.)
10. Reverse the above steps for high-limit
installation.
IMPORTANT: When installing new high-limit
or backup thermostat, ensure the capillary tube
and bulb are positioned properly with the
mounting hardware installed prior to tightening
the compression nut. Once tightened, the
capillary tube cannot be repositioned.
Pull the capillary tube and bulb up and through the
component box opening to remove old high-limit.
Removing the control panel frame will facilitate
high-limit removal. Replace control panel frame
after new high-limit has been installed.
1-10
FGP55 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.6.4 Replacing Float Switches
1. Disconnect the rethermalizer from the
electrical power supply.
2. Drain the water from the cookpot. Allow
the cookpot to cool completely before
proceeding.
3. Unplug the float switch connector.
4. Remove the clip and float from float
switch shaft. (See photo)
5. Loosen and completely unscrew the compression nut from the
cookpot.
6. Carefully pull the float switch shaft out of the cookpot.
7. Reverse the above steps for float switch installation.
1.6.5 Replacing the Gas Valve
DANGER
Drain the cookpot or remove the handle from the drain valve before proceeding
further.
1. Disconnect rethermalizer from electrical and gas supplies.
2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate
reconnections.
3. Remove the high-limit thermostat wire from the gas valve pilot coil.
4. Remove the pilot gas line fitting from the gas valve.
5. Remove the pipe union collars to the left and right of the gas valve and remove the valve.
6. Remove the pipefitting from the old gas valve and install on the replacement valve, using
Loctite™ PST567 or equivalent pipe thread sealant on threads. Do not apply sealant to the first
two pipe threads. Doing so will clog and damage the gas valve.
7. Reverse steps 1-5 to install the replacement gas valve.
1-11
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