Frymaster FM47 Service Manual

Service & Parts Manual

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

Price: $12.00

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

819-5384

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 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

Improper installation, adjustment, alteration, service or maintenance can cause property

damage, injury, or death. Read the installation, operating, and service instructions thoroughly

before installing or servicing this equipment.

DANGER

For your safety, do not store or use gasoline or other flammable liquids or vapors in the vicinity

of this or any other appliance.

CAUTION

Instructions explaining procedures to be followed MUST

MUST be posted in a prominent location in

MUSTMUST

the event the operator detects a gas leak. This information can be obtained from the local gas

company or gas supplier.

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.

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.

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.

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.

No structural material on the fryer should be altered or removed to accommodate placement of

the fryer under a hood. Questions? Call the Frymaster/Dean Service Hotline at 1-800-551-8633.

DANGER

WARNING

CAUTION

The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container

at the end of frying operations each day. Some food particles can spontaneously combust if left

soaking in certain shortening material. Additional information can be obtained in the filtration

manual included with the system.

DANGER

The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result

from slips or contact with the hot oil.

CAUTION

Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal

the joint between the fry vessels. Banging fry baskets on the strip to dislodge shortening will

distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be

removed for cleaning.

Frymaster fryers equipped with legs are for permanent installation. For moveable or portable

installation, Frymaster optional equipment casters MUST

QUESTIONS? CALL 1-800-551-8633.

MUST be used.

MUSTMUST

47 SERIES GAS FRYERS

TABLE OF CONTENTS

CHAPTER 1: Service Procedures..............................................................................................1-1

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

Pilot System Configuration ............................................................................................................. 1-1

Electronic Ignition Configuration.....................................................................................................1-2

Control Options...............................................................................................................................1-3

Interface Boards .............................................................................................................................1-3

Thermostats....................................................................................................................................1-8

1.2 Accessing Fryers for Servicing ..................................................................................................1-8

1.3 Cleaning the Gas Valve Vent Tube .............................................................................................1-9

1.4 Adjusting the Burner Manifold Gas Pressure............................................................................1-9

1.5 Adjusting Ceramic Burner Target Spacing and Alignment....................................................1-11

1.6 Adjusting the Pilot Flame .......................................................................................................... 1-11

1.7 Calibrating the Thermostat Control.......................................................................................... 1-12

1.8 Replacing Fryer Components...................................................................................................1-13

1.8.1 Replacing the Controller or Computer..........................................................................1-13

1.8.2 Replacing the Thermostat............................................................................................1-13

1.8.3 Replacing the Temperature Probe .............................................................................. 1-14

1.8.4 Replacing the High-Limit Thermostat in Fryers with Thermostat Controls ..................1-15

1.8.5 Replacing the High-Limit Thermostat in Fryers with Temperature Probes..................1-15

1.8.6 Replacing Control Panel Power Indicator Light in Fryers with Thermostat Controls... 1-16

1.8.7 Replacing Power or Melt Cycle Switch in Fryers with Thermostat Controls................1-16

1.8.8 Replacing Ceramic Burner Targets..............................................................................1-17

1.8.9 Replacing the Gas Valve..............................................................................................1-18

1.8.10 Replacing the Pilot Assembly.......................................................................................1-18

1.8.11 Replacing Gas Valve High-Limit Thermostat Wire Adapter......................................... 1-19

1.8.12 Replacing the Frypot....................................................................................................1-19

1.9 Troubleshooting and Problem Isolation ..................................................................................1-21

1.9.1 Ignition Failures............................................................................................................1-21

1.9.2 Improper Burner Functioning .......................................................................................1-22

1.9.3 Improper Temperature Control.....................................................................................1-24

1.9.4 Computer-Related Problem s........................................................................................1-25

1.9.5 Filtration Problems .......................................................................................................1-26

1.9.6 Leaking.........................................................................................................................1-29

1.9.7 Modular Basket Lift Malfunctions ................................................................................. 1-29

1.9.8 Interpretation of Digital Controller Lights......................................................................1-31

1.10 Troubleshooting Guides............................................................................................................1-32

1.10.1 Initial Troubleshooting..................................................................................................1-32

1.10.2 Troubleshooting the 24 VAC Circuit: Electronic Ignition..............................................1-34

1.10.3 Troubleshooting the 24 VAC Circuit: Non-Electronic Ignition ......................................1-37

1.10.4 Troubleshooting the Temperature Probe.....................................................................1-39

1.10.5 Probe Resistance Charts ............................................................................................. 1-40

1.11 Wiring Diagrams .........................................................................................................................1-40

47 SERIES GAS FRYERS

TABLE OF CONTENTS

CHAPTER 2: Parts List ..............................................................................................................2-1

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

2.2 Burner Manifold Assemblies and Component Parts.................................................................2-2

2.3 Burner Ignition System Components .........................................................................................2-3

2.4 Gas Valve Assemblies and Connection Components ..............................................................2-4

2.5 Gas Manifold Assemblies ............................................................................................................2-5

2.6 Cabinet Assemblies and Component Parts ...............................................................................2-6

2.6.1 Door Assemblies and Component Parts ........................................................................2-9

2.7 Component Box/Shield Component Parts ...............................................................................2-10

2.8 Probes, High-Limits and Basket Lift Timers ............................................................................2-12

2.9 Operating Thermostat and Related Components....................................................................2-13

2.10 Computers and Controllers........................................................................................................2-14

2.11 Filter Base Assembly- FootPrint III Series................................................................................2-15

2.12 Filter Motors, Pumps and Related Components......................................................................2-16

2.13 Filter Pan Assembly- FootPrint III Series..................................................................................2-18

2.14 Oil Return Manifolds and Related Components ......................................................................2-19

2.15 Oil Return Valve Assembly ........................................................................................................2-20

2.16 Drain Manifold Assembly and Related Components ..............................................................2-21

2.17 Filter Component Box Assemblies ...........................................................................................2-22

2.18 Flue Assemblies and Related Components.............................................................................2-23

2.19 Frypot Assemblies and Related Components.........................................................................2-25

2.19.1 Frypot Components: Full-Vat........................................................................................2-25

2.19.2 Frypot Components: Dual-Vat......................................................................................2-27

2.20 Power Shower Components......................................................................................................2-29

2.21 Drain Valve Components............................................................................................................2-30

2.21.1 Full-Vat Drain Valve Components ................................................................................2-30

2.21.1 Dual-Vat Drain Valve Components...............................................................................2-31

2.22 Modular Basket Lift Components..............................................................................................2-33

2.23 Gas Conversion Kits...................................................................................................................2-35

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

47 Series fryers contain a welded stainless steel frypot that is directly heated by gas flames that are diffused evenly over its lower surface by ceramic targets.

In full-vat configurations, the flames originate from orifices in a U-shaped burner manifold positioned beneath the frypot. In dual-vat configurations, the U-shaped manifold is replaced by a pair of J-shaped manifolds, one for each vat. The diameter of the orifices differs for natural and LP gas as indicated in the accompanying table.

47 Series Orifice Sizes

Gas Drill Size Millimeters

Natural 53 1.45

LP 65 0.86

An electromechanical gas valve regulates gas flow to the manifold(s). 47 Series fryers are equipped with a 24-volt valve system. Units with thermostat controls are equipped with a pilot ignition (millivolt) system. Units with other type controllers may be configured with either a pilot ignition (millivolt) system or an electronic ignition system.

Pilot System Configuration

The pilot system is comprised of the pilot orifice, pilot hood, and a thermopile. The pilot serves two purposes. The first is to light the burner, the second is to heat the thermopile. In operation, the thermopile is in contact with the pilot flame and generates millivolts. The millivolt output passes through a normally closed high-limit switch and 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 fryer is first placed into operation. A separate 24-volt circuit, activated by the fryer ON/OFF switch, provides voltage through the thermostat or controller to the gas valve main coil, which opens the main valve.

Controlling Thermostat

Controller

Thermopile

Pilot

ON/OFF

Switch

Main Coil

Gas Valve

Pilot Coil

The Pilot Syste m

24 VAC

Transformer

Line Voltage

High-Limit

Thermostat

1-1

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description (cont.)

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 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 pilot flame.

The module contains a 4-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.

Inside the Ignition Module

Out to Gas Valve

To Alarm

25 V +

Coil

25 V GND

Ignition Wire Flame Sensor

At start-up the ON/OFF switch is placed in the "ON" position, supplying 12 VDC to the heat control circuitry in the controller or computer and to one side of the heat relay coil on the interface board. If resistance in the temperature probe indicates the temperature in the frypot is below 180°F (82°C), the current flows through a melt cycle circuit where a timer switch alternately closes for 3 seconds and opens for 24 seconds. If the temperature is 180°F (82°C) or above, the current flows through a heat circuit, bypassing the timer switch. In either case, 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 drain safety switch. Simultaneously, the module causes the ignitor to spark for 4 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 cut, preventing the main valve from opening, and the ignition module "locks out" until the power switch is turned "OFF", then back "ON".

1-2

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description (cont.)

A temperature probe monitors the temperature in the frypot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay. This in turn cuts off the 24 VAC current to the ignition module, resulting in closure of the gas valve.

Control Options

47 Series fryers may be equipped with thermostat controls, solid-state analog controls, solid-state digital controls, basket lift timers, or Computer Magic III computers.

In fryers equipped with thermostat controls, the fryer and melt cycle are turned on and off by means of rocker switches and the temperature is set by means of a knob connected directly to the frypotmounted thermostat. These units have no interface board. In this type unit, once started, the melt cycle will continue until it is manually turned off regardless of the temperature in the frypot. Fryers equipped with other types of controllers have an interface board located in the component box (shield) behind the control panel.

Interface Boards

The interface board provides a link between the controller/computer and the fryer’s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point. Two types of interface boards may be used in 47 Series fryers; the type used depends on the fryer configuration.

In units configured for electronic ignition, P/N 806-5857 is used; the other board is P/N 106-0386 (or 806-3398 in units built before October 2002). Each type is discussed in detail in the following pages.

SOUND

PWR

GND

12 6 3 45

12 9 63

8 5

410117

RELAY

HEAT

1513

806-5857

CMP PWR 24V

12 9 63

410117

STANDING

PILOT RELAY

HEAT

RELAY

12 9 63

8 5

GND

PWR

410117

GND

V2D

PWR

AD AS

V2S

SOUND

1 2 3

3 6 9 12

2 5 8 11

1 4 7 10

GND

PWR

806-3398 and 106-0386

10741

11852

12963

12V

24V

K2 K3

F2 Ignition 2 AMP Module

3 6 9 12

2 5 8 11

1 4 7 10

Blower

Motor

2 Amp

PWR

GND

D5 GV

AIR

GND V1D PWR

ALR V1S

1-3

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

IFB 806-5857: The electronic ignition board contains two types of relays. Heat relays (K1 and K3)

operate at 12 VDC output from the controller. They switch 24 VAC to the main gas circuit when the

unit calls for heat. The middle relay (K2) switches 24 VAC to the pilot circuit when the unit is

powered up. The purpose of this relay is to allow the pilot to remain continuously lit.

SOUND

12 6 3 45

CMP PWR 24V

12 9 63

1513

410117

STANDING

PILOT

RELAY

HEAT RELAY

12 9 63

8 5

GND

PWR

410117

HEAT

8 5

RELAY

410117

PWR

GND

12 9 63

INTERFACE BOARD 806-5857

FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD P/N 806-5857

Test

12VAC Power to Controller 50VAC Scale 1 and 3 on J3 12-18 24VAC Power to Right Module 50VAC Scale 4 on J5 and GROUND 22-28 24VAC Power to Left Module 50VAC Scale 4 on J1 and GROUND 22-28 12VDC Power to Right MBL Relay 50VDC Scale 7 on J3 and 9 on J4 12-18 12VDC Power to Left MBL Relay 50VDC Scale 9 on J3 and 6 on J2 12-18 24VAC Power to Right High-Limit 50VAC Scale 12 on J4 and GROUND 22-28 24VAC Power to Left High-Limit 50VAC Scale 3 on J2 and GROUND 22-28 Probe Resistance (Right)* R x 1000 Ohms 14 on J3 and 10 on J4 ** Probe Resistance (Left)* R x 1000 Ohms 14 on J3 and 1 on J2 ** High-Limit Continuity (Right) R x 1 Ohm 12 on J4 and Wire 13C on Gas Valve 0 High-Limit Continuity (Left) R x 1 Ohm 3 on J2 and Wire 12C on Gas Valve 0

* Disconnect 15-pin harness from controller before testing probe circuit. ** See Probe Resistance Charts in this chapter.

Meter

Setting

Pins

Test

Results

1-4

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

The following table identifies the meaning associated with each of the LEDs arranged across the top of the interface board. NOTE: In full vat units, ignore the left-side LEDs.

P/N 806-5857 INTERFACE BOARD

LED DIAGNOSTIC LIGHTS

AL Indicates ignition module lockout

MV Indicates 24 VAC to main gas valve

PV Indicates 24 VAC to pilot valve

CMP Indicates 12 VAC from transformer

24V Indicates 24 VAC from transformer

PWR Indicates 24 VAC to ignition module

INTERFACE BOARD

12VAC TO CPTR

GROUND

12 VAC RETURN

COMPUTER COMPUTER COMPUTER

COMPUTER NOT USED NOT USED COMPUTER

CPTR-RT ALARM

COMPUTER

CPTR-LT ALARM

COMPUTER COMPUTER COMPUTER

1 2 3

RT HT RELAY (K3)

4 5

LT HT RELAY (K1)

6 7 8 9

SOUND DEVICE

11 12 13

J4 PIN 11 & J2 PIN 2

14 15

J4 PIN 1 GROUND

J4 PIN 3

12VDC TO

RELAYS

J4 PIN 9

J2 PIN 6

J5 PIN 1

J1 PIN 1

J4 PIN 10

J2 PIN 1

TEMP PROBE TEMP PROBE

J2 PIN 4 via HLS, DSS,

and PILOT VALVE PILOT VALVE

MAIN GAS VALVE

BASKET LIFT

NOT USED NOT USED

NOT USED

GROUND

NOT USED

MOD ALARM

MOD VALVE TERM

MOD 25V GROUND

MOD 25V TERM

J3 PIN 15

J3 PIN 14

J1 PIN 2

J3 PIN 9

NOT USED

GROUND

NOT USED

J3 PIN 12

J2 PIN 3

GROUND

J4 PIN 4 via K2

LEFT VAT FULL OR RIGHT VAT

J3 PIN 1

GROUND

J3 PIN 3

J5 PIN 4 via K2

NOT USED NOT USED NOT USED NOT USED

K3 K3

J3 PIN 7 J3 PIN 13 J3 PIN 14 J5 PIN 2

J3 PIN 10 J4 PIN 12 GROUND

J4 PIN 4 via K2

12VAC XFMR PIN 11

1 2

12VAC XFMR PIN 12

3 4 5 6 7

MAIN GAS VALVE

9 10 11

J4 PIN 7 via HLS, DSS,

and PILOT VALVE

MOD VALVE TERM

MOD 25V GROUND

MOD 25V TERM

GROUND

24V XFMR PIN 8

PILOT VALVE

BASKET LIFT TEMP PROBE TEMP PROBE

MOD ALARM

CURRENT FLOW THROUGH INTERFACE

BOARD 806-5857

1-5

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

IFBs 806-3398 and 106-0386: The 47 Series of fryers has been in production for many years. Consequently, servicers are likely to encounter three different interface board designs. Although the boards differ slightly in appearance, basic functioning and electrical connections are the same from one to another. In the earlier design 806-3398 interface board (used between June 1996 and July

1999), the diagnostic LEDs are arrayed in a row across the bottom of the board as shown in the lefthand illustration below. In later design 806-3398 interface boards (and in the 106-0396 interface boards that replaced them in current production fryers), the LEDs (labeled D1 though D7) are scattered around the board as shown in the right-hand illustration. The primary difference between the earlier design boards and the later design boards is the combining of the separate blower motor relay (K4) and the heat relays (K1 and K2) into a pair of replaceable relays (K2 and K3) in the latter. Also, the 106-0386 interface board has an additional fuse located in the upper right hand corner. Prior to June 1996, a board with replaceable relays very similar in appearance to the 106-0386 board was used. It is distinguished from the 106-0386 board by the absence of fuses. On full vat units, the relay for the left vat (K1 in early 806-3398 IFBs or K2 in later design 806-3398 and 106-0386 IFBs) is not present. On units with basket lifts, K3 and K5 (early 806-3398) or K1 and K4 are present.

NOTE: Although the printing on many boards indicates 2 Amp fuses, 3 Amp fuses (P/N 807-3843) must be used.

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

HEAT

RELAY

12 6 3 45

AL 12V

BLOWER

MOTOR

RELAY

K1 K2

AIR

10741

11852

12963

24V AL

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

V2S

GND

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

This Fuse is NOT

present on 806-3398 IFB.

HEAT

RELAY

PWR

AND

BLOWER

MOTOR

RELAY

K2 K3

10741

11852

12963

12V

HEAT

24V

RELAY

AND

BLOWER

MOTOR

RELAY

F2 Ignition 2 AMP Module

3 6 9 12

2 5 8 11

1 4 7 10

Blower Motor 2 Amp

PWR

GND

D5 GV

AIR

GND V1D PWR

ALR V1S

These standard interface boards are also used in a number of fryer types besides the 47 Series. The information contained in this section applies to 47 Series applications ONLY.

Earlier design 806-3398 boards (used from June 1996 through July 1999) contain two heat relays (K1 and K2) that switch 24VAC to the ignition and gas valve circuits when the computer/controller heat logic circuit calls for heat. Relay K4 switches 120VAC to the blower motor when either K1 or K2 closes. The relays on these boards are soldered on – if one fails, the whole board must be replaced.

The later design 806-3398 (and 106-0386 boards that replaced them in current production fryers) have only two relays. In this design, K2 and K3 are double-pole-double throw (dpdt) relays that supply 24VAC to the ignition and gas valve circuits, as well as 120VAC to the blower motor. The relays on this board plug into sockets. If a relay fails, it can be replaced.

1-6

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

FREQUENTLY USED TEST POINTS FOR INTERFACE BOARDS P/N 806-3398 and 106-0386

Test

12VAC Power to Controller 50VAC Scale 1 and 3 on J3 12-18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GROUND 22-28 24VAC Power to Left Module 50VAC Scale 8 on J1 and GROUND 22-28 12VDC Power to Right MBL Relay 50VDC Scale 7 on J2 and 7 or 10 on J3 12-18 12VDC Power to Left MBL Relay 50VDC Scale 9 on J2 and 7 or 10 on J1 12-18 24VAC Power to Right High-Limit 50VAC Scale 9 on J3 and GROUND 22-28 24VAC Power to Left High-Limit 50VAC Scale 9 on J1 and GROUND 22-28 Probe Resistance (Right)* R x 1000 Ohms 2 on J3 and 6 on J3 ** Probe Resistance (Left)* R x 1000 Ohms 2 on J1 and 6 on J1 ** High-Limit Continuity (Right) R x 1 Ohm 9 on J3 and Wire 13C on Gas Valve 0 High-Limit Continuity (Left) R x 1 Ohm 9 on J1 and Wire 12C on Gas Valve 0

* Disconnect 15-pin harness from controller before testing probe circuit. ** See Probe Resistance Charts in this chapter.

Meter

Setting

Pins

Test

Results

1-7

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

INTERFACE BOARD

12 VAC TO CPTR

GROUND

12 VAC RETURN

COMPUTER RT HT RELAY (K3) COMPUTER COMPUTER

COMPUTER K4

NOT USED NOT USED

COMPUTER K1

RT ALARM OUT**

COMPUTER SOUND DEVICE

LT ALARM OUT*

COMPUTER COMPUTER

COMPUTER J1 PIN 6

NOT USED NOT USED

NOT USED

TEMP PROBE J2 PIN 15

BASKET LIFT (DN)

24 VAC IN

MAIN GAS VALVE

via HLS

BASKET LIFT (UP)

AC COMMON AC COMMON AC COMMON

NOT USED NOT USED

MOD 25V GROUND GROUND

MOD V2D

MOD 25V TERM

DRAIN SWITCH (OPT)

NOT USED NOT USED NOT USED NOT USED

1 2 3 4

12 VDC TO RELAYS

5 6 7 8

9 10 11

13 14 15

1 2 3 4 5 6 7 8

9 10 11 12

GND V2D

PWR

V2S

LEFT

VAT

J3 PIN 1

GROUND

J3 PIN 3

LT HT RELAY (K2)

ALR (RIGHT)

AD (LEFT)

J3 PIN 6

J1 PIN 2 & J3 PIN 2

J2 PIN 14TEMP PROBE NOT USEDNOT USED NOT USED

NOT USEDNOT USED

PWR via K1

V2D

J1 PIN 9

J1 PIN 8 via K1

J2 PIN 12

configurations

* Dual Vat

configurations

** Full Vat

J2 PIN 1

J2 PIN 14 TEMP PROBE

J2 PIN 3 NOT USED NOT USED NOT USED

J2 PIN 13

PWR via K2

V1S OR V1D

NOT USED NOT USED

GROUND MOD 25V GROUND J3 PIN 9

J3 PIN 8 via K2

J3 PIN 9

1 2 3 4 5

K4 BASKET LIFT (DN)

6 7 8

9 10 11 12

GND V1D PWR ALR

V1S

FULL OR RIGHT

VAT

12 VAC XFMR PIN 11

12 VAC XFMR PIN 12

NOT USED

TEMP PROBE

24 VAC IN

MAIN GAS VALVE

via HLS

BASKET LIFT (UP)

AC COMMON

MOD V1D* MOD 25V TERM DRAIN SWITCH (OPT)J2 PIN 10

MOD V1S**

CURRENT FLOW THROUGH INTERFACE

BOARDS 806-3398 AND 106-0386

Like the 806-5857 interface board, LEDs are provided to assist in troubleshooting. NOTE: In full vat units, ignore the left-side LEDS.

P/N 806-3398 and 106-0386 INTERFACE BOARD

LED DIAGNOSTIC LIGHTS

12V Indicates 12 VAC from transformer 24V Indicates 24 VAC from transformer

GV Indicates 24 VAC to gas valve

PWR Indicates 24 VAC to PWR via K1 (L) or K2 (R or F)

Indicates

AIR Not Applicable to 47 Series Fryers

"open" Drain Safety Switch (if installed)

Thermostats

Different types of thermostats are used in 47 Series fryers, depending on the fryers’ configuration.

1-8

47 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Fryers equipped with Thermostat Controls have an adjustable controlling thermostat. The temperature at which the thermostat opens and closes is adjusted by physically changing the setting of the thermostat itself by means of an attached knob. The Fenwal controlling thermostat used in the 47 Series fryers is sensitive to one-degree changes in temperature.

CAUTION

Fenwal thermostats are used in a number of Frymaster products. The thermostat for

the 47 Series is 4 inches long. Do not use 3-inch Fenwal thermostats in 47 Series

fryers.

Fryers equipped with all other type 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 controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints). The temperatures are programmed by means of a keypad on the face of the controller.

All 47 Series fryers are equipped with a high-limit thermostat. In the event that the fryer fails to properly control the oil temperature, the high-limit thermostat prevents the fryer from overheating to the flash point. The high-limit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 425°F to 450°F (218°C to 232°C). The different types of thermostats have different part numbers for CE and Non-CE configured models, and are not interchangeable.

1.2 Accessing Fryers for Servicing

DANGER

Moving a fryer filled with cooking oil/shortening may cause spilling or splattering of

the hot liquid. Follow the draining instructions included with the fryer before

attempting to relocate a fryer for servicing.

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

supply.

2. Remove any attached restraining devices.

3. Relocate the fryer for service accessibility.

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

plug in the electrical cords.

1.3 Cleaning the Gas Valve Vent Tube

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

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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.

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

5. 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 below for location).

Non-CE Pilot Ignition Valve

Non-CE Electronic Ignition

Valve

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

CE Pilot Ignition Valve

4. Place the gas valve in the "ON" position then place the fryer 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 accompanying tables.

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Non-CE Standard

Burner Manifold Gas

Pressures

Gas Pressure

Natural

3.5" W.C.

0.8 kPa

8.25" W.C.

2.5 kPa

CE Standard

Burner Manifold Gas Pressures

Gas

Natural Gas Lacq (G20) under 20 mbar

Natural Gas Gronique (G25) under 25 mbar

Propane (G31) under 37 or 50 mbar

Pressure

(mbar)

* Belgian G25 = 7,0 mbar

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

pressure.

6. Place the fryer power switch and the gas valve in the "OFF" position. Remove the fitting from

the pressure tap hole and reinstall the pressure tap plug.

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1.5 Adjusting Ceramic Burner Target Spacing and Alignment

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

Proper spacing of the top edge of the ceramic burner targets is ¾-inch (13 mm) from the frypot side. To adjust target spacing, bend the brackets to which they are attached away or toward the frypot to the proper distance. (A length of board of the proper thickness is useful as a gauge to verify spacing and alignment.) Proper spacing of the rear ceramic burner target is 1 inch from the frypot back.

1-inch

(rear)

¾-inch

(side)

Frypot

Master Jet burner target alignment.

1.6 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.

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1.7 Calibrating the Thermostat Control

NOTE: The fryer control panel must be hinged down from the control panel mounting-frame to perform thermostat calibration. In order to hinge the control panel down, the thermostat knob must be removed from its shaft.

1. Fill the frypot to the lower OIL-LEVEL line with cooking oil/shortening. If solid shortening is

used, it must be melted before starting the calibration procedure.

2. Ensure the fryer ON/OFF Switch is in the "OFF" position, then light the pilot. (Refer to Chapter

1 for detailed lighting instructions.)

3. Insert a good grade thermometer or pyrometer into the frypot so that it touches the thermostat

guard.

4. Disconnect the solid extension shaft from the end of the flexible shaft using an appropriately

sized Allen wrench.

5. Remove the flexible shaft from the thermostat shaft screw.

6. Place the fryer ON/OFF switch in the "ON" position.

NOTE: If the burner does not light at this time, it does not mean the thermostat is defective. Recheck the wiring, and then slowly turn the thermostat adjusting screw counterclockwise until the burner lights. Turning the adjusting screw counterclockwise causes the burner to light and clockwise causes it to shut off.

7. When the cooking oil/shortening temperature reaches 325°F (162°C), turn the thermostat

adjusting screw slowly clockwise until the burner shuts off.

8. Allow the fryer to sit for a few minutes, then slowly turn the thermostat adjusting screw

counterclockwise until the burner lights.

9. Repeat steps 7 and 8 at least three times to ensure an accurate setting is obtained. The

Thermostat Control is considered to be properly calibrated if the burner lights as the cooking oil/shortening cools to 325°F (162°C)—not when the burner shuts off as the temperature rises.

10. Once the calibration point of 325°F (162°C) is determined, allow the burner to cycle on and off

at least 3 times to be sure it will light at the calibrated temperature.

11. After the calibration is complete, place the fryer power switch in the "OFF" position and

disconnect the fryer from the electrical supply.

12. Carefully install the thermostat flexible extension on the thermostat shaft, ensuring that the

setscrews are tight.

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1.7 Calibrating the Thermostat Control (cont.)

CAUTION

The thermostat adjusting screw must not be moved while installing the flexible

extension shaft.

13. Install the solid metal extension shaft on the end of the flexible shaft with the stop pin at the 12

o’clock position. Ensure the stop pin and setscrews are tight to prevent slippage.

14. Reinstall and secure the fryer control panel. Loosen the temperature dial plate screws and rotate

the dial until the 325°F (162°C)-index mark is at the 12 o’clock position, then retighten the screws.

15. Reinstall the thermostat knob with its pointer aligned with the 325°F (162°C)-index mark on the

temperature dial plate. Tighten the thermostat knob set screws to prevent slippage.

1.8 Replacing Fryer Components

1.8.1 Replacing the Controller or Computer

1. Disconnect the fryer from the electrical supply.

2. Unscrew the two control panel screws. The control panel is hinged at the bottom and will swing

open from the top.

3. Unplug the fryer wiring harness from the back of the controller/computer.

4. Remove the controller/computer by lifting it from the hinge slots in the fryer control panel frame.

5. Reverse the procedure to install a new controller/computer.

1.8.2 Replacing the Thermostat

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil/shortening below level of probe.

3. Remove thermostat knob. Remove the screws from the upper left and right corners of the control

panel. The control panel is hinged at the bottom and will swing open from the top.

4. Disconnect the wiring plug(s)from the component shield/control box.

5. Remove the control panel from the fryer by disengaging its tabs from the hinge slots in the

mounting frame.

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1.8.2 Replacing the Thermostat (cont.)

6. Remove the solid extension shaft from the end of the flexible shaft using an appropriately sized

Allen wrench. Remove the flexible shaft from the thermostat shaft screw.

7. Disconnect leads from terminal block.

8. Unscrew the thermostat from the frypot and remove.

9. Apply Loctite™ PST567 thread sealant or equivalent to the replacement thermostat threads.

10. Reverse steps 1 through 8 to install the replacement.

CAUTION

The Thermostat Control must be calibrated after installation is complete. Refer to

Section 1.7 for calibration instructions.

1.8.3 Replacing the Temperature Probe

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil/shortening below level of probe.

3. Remove the screws from the upper left and right corners of the controller panel. The controller

is hinged at the bottom and will swing open from the top.

4. Unplug the wiring harness from the back of the controller and remove the controller from the

fryer by disengaging its tabs from the hinge slots in the mounting frame.

5. Remove two screws and nuts from the base of the interface board mounting-bracket.

6. Disconnect the 12-pin plug from the back of the interface board and lay the board in the left end

of the compartment with all other wires still connected.

7. Remove the 12-volt transformer from the component shield and lay it in the left end of the

compartment with wires still connected.

8. Using a pin-pusher, remove the temperature probe wires from the 12-pin plug disconnected in

step 7.

9. Unscrew the temperature probe from the frypot and remove.

10. Apply Loctite™ PST567 thread sealant or equivalent to new probe threads.

11. Reverse steps 1 through 10 to install replacement probe.

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1.8.4 Replacing the High-Limit Thermostat in Fryers with Thermostat Controls

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil/shortening below the level of the thermostat.

3. Remove the thermostat knob. Remove the screws from the upper left and right corners of the

control panel. The control panel is hinged at the bottom and will swing open from the top.

4. Disconnect the wiring plug(s) from the component shield/control box.

5. Remove the control panel from the fryer by disengaging its tabs from the hinge slots in the

mounting frame.

6. Remove the molded high-limit thermostat wire adapter from the gas valve pilot coil.

7. Unscrew the high-limit thermostat from the frypot and remove.

8. Apply Loctite™ PST567 thread sealant or equivalent to the replacement thermostat threads.

9. Reverse steps 1 through 7 to install the replacement high-limit thermostat.

1.8.5 Replacing the High-Limit Thermostat in Fryers with Temperature Probes

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil/shortening below the level of the thermostat.

3. Remove the screws from the upper left and right corners of the controller panel. The controller

is hinged at the bottom and will swing open from the top.

4. Unplug the wiring harness from the back of the controller.

5. Remove the controller from the fryer by disengaging its tabs from the hinge slots in the mounting

frame.

6. Remove two screws and nuts from the base of the interface board mounting-bracket.

7. Disconnect the 12-pin plug from the back of the interface board and lay board in the left end of

compartment with all other wires still connected.

8. Remove the high-limit thermostat wires from the gas valve pilot coil and pull them up through

the control shield.

9. Unscrew the high-limit thermostat from the frypot and remove.

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1.8.5 Replacing the High-Limit Thermostat in Fryers with Temperature Probes (cont.)

10. Apply Loctite™ PST567 thread sealant or equivalent to new thermostat threads.

11. Reverse steps 1 through 9 to install the replacement thermostat.

1.8.6 Replacing Control Panel Power Indicator Light in Fryers with Thermostat Control

1. Disconnect the fryer from the electrical supply.

2. Remove the thermostat knob.

3. Remove the screws from the upper left and right corners of the control panel. The control panel

is hinged at the bottom and will swing open from the top.

4. Unplug the control panel wiring harness from the component shield/control box.

5. Carefully press the light out of the control panel back side. Remove one wire terminal at a time

and connect to the replacement light until all wires are transferred.

6. Carefully press the light back into the control panel back.

7. Reverse steps 1-4 to reassemble fryer.

1.8.7 Replacing Power or Melt Cycle Switch in Fryers with Thermostat Controls

1. Disconnect the fryer from the electrical supply.

2. Remove the thermostat knob.

3. Remove the screws from the upper left and right corners of the control panel. The control panel

is hinged at the bottom and will swing open from the top.

4. Unplug the control panel wiring harness from the component shield/control box.

5. Unsnap the chrome bezel from the rear of the switch and push the switch out through the rear of

the control panel.

6. Remove wires one at a time from the switch and connect to the replacement switch until all wires

are transferred.

7. Reverse steps 1-5 to reassemble fryer.

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1.8.8 Replacing Ceramic Burner Targets

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

1. Disconnect fryer from electrical and gas supplies.

2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate

reconnections.

3. Remove the high-limit thermostat wires from the gas valve pilot coil.

4. Remove the pipe union collar at the left side of the gas valve.

5. Remove the burner heat shield hanger screws at the front of the burner and remove the heat

shield.

6. Remove the burner hanger screws.

7. Lower the front of the main burner and pull it forward to clear the rear burner hanger. Lower the

burner to the floor.

8. Raise the fryer enough to slide the burner from under the fryer cabinet.

9. To replace only the ceramic targets, straighten the target locking tabs with a pair of needle nose

pliers or a screwdriver, and slide the target up and off the bracket. Slide the replacement target onto the bracket and bend the locking tabs down.

To replace the entire target assembly, using a ½-inch box end wrench, remove the two brass orifices that hold the assembly to the burner manifold, replace the assembly, and replace the orifices.

WARNING

Use extreme care to prevent cross-threading and stripping when reinstalling the

brass orifices.

10. Reverse steps 1-8 to reinstall the burner assembly. Check spacing and alignment of targets in

accordance with Section 1.5.

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1.8.9 Replacing the Gas Valve

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

1. Disconnect fryer from electrical and gas supplies.

2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate

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.

7. Reverse steps 1-5 to install the replacement gas valve.

1.8.10 Replacing the Pilot Assembly

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

1. Remove the burner assembly in accordance with Section 1.7.9.

2. Remove the pilot tubing from the bottom of the pilot assembly.

3. Bend the clip at the bottom of the pilot assembly and remove the pilot. Disconnect the pilot

fitting from the gas valve pilot coil.

4. Remove the two pilot mounting screws from the pilot mounting-bracket and remove the pilot.

5. Reverse the procedure to replace the pilot assembly.

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1.8.11 Replacing Gas Valve High-Limit Thermostat Wire Adapter

1. Remove the pilot electrical fitting from the gas valve pilot coil.

2. Lift the molded plastic wire adapter assembly and wires out of the pilot coil.

3. Cut the in-line splices from the wire adapter and high-limit thermostat wires.

4. Strip the wire insulation from the end of the high-limit thermostat wires and splice on a new

high-limit thermostat wire adapter assembly.

5. Insert the new molded plastic wire adapter into the gas valve pilot coil.

6. Screw the pilot electrical fitting into the gas valve pilot-coil finger tight, and then 1/8-turn more

with a wrench.

1.8.12 Replacing the Frypot

1. Drain cooking oil/shortening from the frypot.

2. Remove all accessories, e.g., frypot covers, basket lift arms, etc. from the fryer.

3. Disconnect the fryer from gas and electrical supplies.

4. Remove the screws from the top cap above the control panel and lift it up and off the fryer(s).

5. If the fryer is equipped with other than a Thermostat Control, skip to Step 10.

6. Remove the thermostat knob. Remove the screws from the upper left and right corners of the

control panel. Disconnect the control panel from the fryer wiring harness and remove it from the fryer.

7. Remove the thermostat flexible shaft from the thermostat shaft adjusting screw.

8. Remove the two screws and nuts from the thermostat shaft bracket and lift the thermostat

flexible shaft and bracket out of the component box.

9. Disconnect both wires from the gas valve and the 20-hole terminal block. Skip to Step 14.

10. For fryers equipped with other than thermostat controls, remove the screws from the upper left

and right corners of the control panel. Disconnect the controller from the fryer wiring harness and remove it from the fryer.

11. Remove the two screws and nuts from the base of the interface board bracket.

12. Disconnect the 12-pin plug from the back of the interface board and remove the temperature

probe and high-limit thermostat wires from the plug using a pin pusher.

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1.8.12 Replacing the Frypot (cont.)

13. Lay the interface board and bracket on top of the control shield with wires still connected.

14. Remove the louvered frame above the control panel opening.

15. Remove screws and nuts securing the component box to the fryer.

16. Disconnect wires from components in component box and mark to facilitate reconnection.

17. Remove pilot generator fitting from gas valve pilot coil and lift the high-limit thermostat wire

adapter from the slot. Pull the high-limit thermostat wires and adapter up through the grommet at the rear of the box.

18. Remove the wires from the gas valve terminal block. Mark each wire to facilitate reconnection.

19. For fryers equipped with Thermostat Controls, remove the thermostat wire from the gas valve

and pull it up through the grommet at the rear of the box. Disconnect the other thermostat wire from the 20-hole terminal block. Mark each wire to facilitate reconnection.

20. Remove the cover from the safety drain switch, disconnect the wires from the switch, and pull

them out of the switch box.

21. Pull up and forward on the component box to clear the rear-mounting stud on the front of the

frypot.

22. Remove the component box from the fryer by rotating its right side up and to the left.

23. Remove the pipe union from the right side of the gas valve.

24. Remove the section of square drain from the drain valve of the frypot to be removed.

25. Remove the frypot hold down bracket.

26. Remove the screws from the flue cap sides and back and lift it clear of the fryer(s).

27. Remove the oil return hose or line from the front of the frypot to be removed.

28. Lift the frypot complete with burner, gas valve, flue, and drain valve from the fryer cabinet.

29. Transfer burner heat shield and burner to replacement frypot.

30. Remove drain valve, thermostat or temperature probe, and high-limit thermostat and install on

replacement frypot.

31. Reverse steps 1-28 to reassemble fryer.

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CAUTION

Before installing thermostat/temperature probe, high-limit thermostat, and drain

valve on replacement frypot, clean their threads and apply Loctite™ PST567 thread

sealant or equivalent to the threads.

1.9 Troubleshooting and Problem Isolation

This section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment, and the probable causes of each. With this knowledge, the technician should be able to isolate and correct any problem encountered.

Problems you are likely to encounter can be grouped into seven broad categories:

1. Ignition failures

2. Improper burner functioning

3. Improper temperature control

4. Computer-related problems

5. Filtration problems

6. Leakage problems

7. Modular basket lift malfunctions.

The probable causes of each category are discussed in the following sections. Troubleshooting guides are included in Section 1.10 to assist in identifying some of the more common problems.

1.9.1 Ignition Failures

Ignition failure occurs when the ignition module fails to sense a flame within the 4-second time delay period and locks out. When this happens, the module sends 24 VAC through the interface board alarm circuit to the controller/computer.

Solid-state controllers indicate ignition failure by illuminating the heat light and trouble light simultaneously. Computer Magic III controls display "

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

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.

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