Frymaster FPC128-236S Service Manual

2836 Series Electric Fryers

Service and Parts Manual

This manual is for fryers starting with series AD manufactured starting Fall

2006. This manual makes no references to previous models with rounded elements and float switches. For parts associated with those fryers, refer to 2836 Series Service and Parts Manual part number 819-6049.

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

www.frymaster.com Email: service@frymaster.com

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

*8196114*

MAY 2006

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

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

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 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 Communications du Canada.

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.

DANGER Copper wire suitable for at least 167ºF (75ºC) must be used for power connections.

DANGER The electrical power supply for this appliance must be the same as indicated on the rating and serial number plate located on the inside of the fryer door.

DANGER This appliance must be connected to the voltage and phase as specified on the ratings and serial number plate located on the inside of the fryer door.

WARNING Do not attach accessories to this fryer unless the fryer is secured from tipping. Personal injury may result.

WARNING Do not use water jets to clean this equipment.

WARNING This equipment is intended for indoor use only. Do not install or operated this equipment in outdoor areas.

DANGER Adequate means must be provided to limit the movement of this appliance without depending on or transmitting stress to the electrical conduit. A restraint kit is provided with the fryer. If the restraint kit is missing contact your local Frymaster Dean Factory Authorized Service Center (FASC) for part number 826-0900.

DANGER Prior to movement, testing, maintenance and any repair on your Frymaster fryer, disconnect all electrical power from the fryer.

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

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

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

WARNING 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.

WARNING

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

joint between the frypot. 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.

2836 Series Electric Fryers

Service & Parts Manual

TABLE OF CONTENTS

Page #

1. SERVICE PROCEDURES 1-1

1.1 General 1-1

1.2 Replace Computer/Controller 1-1

1.3 Replace Interface Board 1-2

1.4 Replace Transformer 1-3

1.5 Replace Temperature Probe 1-3

1.6 Replace Heating Element 1-4

1.7 Replace High-Limit 1-6

1.8 Replace Frypot 1-6

1.9 Replace Contactor (Latching or Heating) 1-7

1.10 Built-in Filter System Service Procedures 1-7

1.11 Basket Lift Service Procedures 1-9

1.12 Electric Interface Board Diagnostic Chart 1-12

1.13 Probe Resistance Chart 1-13

1.14.1 Wiring Diagrams, Main 208/240V 1-14

1.14.2 Wiring Diagrams, Main 480V (120V Controls) 1-15

1.14.3 Wiring Diagrams, Main FP28DV/36 480V (120V Controls) 1-16

1.15 Wiring Diagrams, Modular Basket Lifts 1-17

1.16 Wiring Diagrams, 208/240V Systems With Built-in Filtration 1-18

1.16.1 Wiring Diagrams, 480V Systems With Built-in Filtration 1-19

2836 Series Electric Fryers

Service & Parts Manual

TABLE OF CONTENTS (CONT.)

Page #

2. PARTS LIST 2-1

2.1 Accessories 2-1

2.2 Basket Lift Assembly (Modular) and Related Components 2-2

2.3 Cabinetry and Related Components 2-5

2.3.1.1 F228 Cabinetry 2-5

2.3.1.2 F128/136 Cabinetry 2-7

2.3.1.3 F128/236 Cabinetry 2-9

2.3.2 Door Components 2-11

2.3.3 Dump Station Components 2-12

2.4 Computer and Related Components 2-13

2.5 Contactor and Power Cord Box Assembly 2-14

2.6 Terminal Block Mount Assembly 2-16

2.7 Component Box Assembly 2-17

2.8 Filter Pan and Related Components 2-19

2.9 Frypot and Related Components 2-20

2.9.1.1 Frypot and Drain Valve Components 2-20

2.9.1.2 Drain Components 2-21

2.10 Elements and Related Components 2-22

2.11 Oil Disposal Wand 2-24

2.12 Oil Return Assembly 2-25

2.13 Filter Pump Assembly 2-27

2.14 Wiring Harnesses and Cables 2-28

2836 SERIES ELECTRIC FRYERS

CHAPTER 1: SERVICE PROCEDURES

FINDING YOUR WAY AROUND THE 2836 SERIES FRYER

Left

Contactor

Box

Fuse

Left Drain

Handle

Transformers

Under Fryer

Filtration

Filter

Control

Handles

Right Drain

Handle

Right

Contactor

Box

Interface

Board

Wire

Harness

Component

Box

Terminal

Mercury

Contactor

Block

Controller

Mechanical

Contactor

Contactor Box

1-1

1.1 General

Before performing any maintenance on your Frymaster Dean 2836 Series Electric fryer, you must disconnect the electrical power supply.

When electrical wires are disconnected, it is recommended that they be marked in such a way as to facilitate reassembly.

DANGER

Hot oil will cause severe burns. Never attempt to move this appliance when filled with hot

oil, or to transfer hot oil from one container to another.

DANGER

This equipment should be unplugged when servicing, except when electrical circuit tests are

required. Use extreme care when performing such tests.

This appliance may have more than one electrical power supply connection point.

Disconnect all power cords before servicing.

Inspection, testing and repair of electrical components should be performed by an

authorized service agent only.

1.2 Replace Computer/Controller

1. Unscrew and remove two control panel screws on control panel front. Swing the panel open

from the top.

2. Unplug wiring harness at plug on back of controller. Unplug controller ground wire from

controller.

3. Remove the control panel/controller by lifting the assembly from the hinged slots in the control-

panel frame.

4. Reverse procedures to install new controller.

1.3 Replace Interface Board

1. Unplug all power cords. Perform Procedure 1.2, Steps 1-4, Replace Computer/Controller.

2. Unplug wire harness from the interface board. Remove all wiring from the terminals of the

interface board, ensuring that each wire is marked for reattachment.

3. Remove the nuts from each corner of the interface board and slide the board from the studs.

Unplug connectors J1 and J2, mark and unplug all other wiring on rear of the interface board. Ensure that standoffs remain in place on studs prior to installing new interface board. Install the new interface board by reversing the previous procedures.

1-2

4. Ensure that wire harnesses are connected to back of interface board prior to securing interface

board. Also, ensure that wiring and wire harnesses are connected to the proper terminals.

1.4 Replace Transformer

1. Unplug all power cords. Perform Procedure 1.2, Steps 1-4, Replace Computer/Controller.

2. Hold new transformer up to old transformer to be replaced and disconnect one wire at a time

from old and connect to new.

3. Remove the screws that secure the transformer to the component box.

4. Install the new transformer by reversing the preceding procedures. Make sure you reconnect the

wiring to the proper terminals and the harnesses to the correct connectors.

1.5 Replace Temperature Probe

1. Unplug fryer from the electrical source.

2. Drain the cooking oil from the frypot.

3. Remove the fryer from the exhaust hood to gain access to the rear of the fryer.

4. If unit is equipped with modular basket lift, remove basket lift assembly and set aside.

5. Remove the screws from the top cap and back cover(s). Set the cover(s), top cap and screws

aside.

6. Disconnect the wire harness containing the probe wiring. It may be necessary to remove the

wire ties.

7. Use a pin-pusher (P/N 806-4855 or P/N 807-

0928) to remove the red and white probe wires from the connector. Note probe pin location in plug. Pull the probe wires out of the insulation.

8. Remove the screw(s) securing the probe

bracket to the element. Remove the metal wraps securing the probe to the element.

Use a pin-pusher to remove probe wires from

connector (arrows).

1-3

9. Remove the probe bracket and the securing components from the probe bulb and element.

Thread the probe wire through the hole in the tilt plate assembly and remove the probe.

10. Thread the new probe wire through the hole in tilt plate. Place the new temperature probe

assembly onto the element and secure with the bracket and screws removed earlier. Clip the probe onto the rear of the element in two places. The temperature probe assembly should be oriented in the same manner as the probe being replaced.

11. Thread the probe wires into the harness insulation. Note the pin positions and insert pins in the

connector. Reconnect the harness and secure with a wire-tie.

12. Lower the element into the frypot with the lift handle.

13. Install the back covers, basket lift assembly, and top cap and secure with screws.

1.6 Replace Heating Element

1. Perform Procedure 1.5, Replace Temperature Probe, Steps 1-7.

2. Unplug the element connectors for the

element being removed (right element- 6-pin harness connector; left element- 9-pin harness

Harness

Connector

Closed

Top Portion

Harness

Connector

Open

connector). Remove the element wires from the connector. Press down on either side of the connector while pulling up on the top portion. The connector will open from the top. Note wiring configuration in connector before removing element wire pins. Pull all wires from the connector.

3. Loosen conduit connector and pull element

Push in on tabs to release

top portion

wires through conduit.

4. Remove the screws securing the temperature

probe bracket from the element. Remove the probe clamp (metal wire-wrap). Set the temperature probe and probe-securing components aside.

NOTE: Temperature probe removal is not

required if the left element is being replaced.

Loosen connector here.

5. Disconnect the element springs from the tilt brackets.

6. Remove the element clamps and hardware before removing mounting-screws and nuts on the

defective element. Remove all wire-ties securing element wiring, and then remove element from frypot.

1-4

7. Install the replacement element in the frypot and secure with the mounting hardware.

8. Reinstall the temperature probe and probe-bracket components onto the replacement element.

9. Route the element leads (terminals) to the rear of the fryer

10. Secure element wiring with wire-ties.

11. Route the element wires through the conduit

and tighten conduit connector.

11. When replacing the left element (as viewed

from the rear of the fryer), use the 9-pin connector, inserting the leads from the replacement element. Ensure the pin numbers match the numbers of the defective

Ensure that the wires are properly routed and

secured.

element wires. When all pin terminals have been fully inserted, close the connector by sliding the halves together until the tabs snap back into place (reverse procedure in this section, Step 2). Check wire numbers to ensure correct wiring of the replacement element.

When replacing the right element (as viewed from the rear of the fryer), follow the above procedure, inserting pin terminals into the corresponding holes in the 6-pin connector.

Left Element— 9-Pin Connector

Right Element— 6-Pin Connector

12. Connect the connectors, ensuring the latches

lock in place.

13. Install the temperature probe wires (marked for re-assembly) in the corresponding pin locations.

14. Reconnect the element springs to the tilt brackets

15. Install the back covers, basket lift assembly, and top cap and secure with screws.

16. Position fryer under exhaust hood.

1-5

1.7 Replace High-Limit

1. Perform Procedure 1.5, Replace Temperature

Probe, Steps 1-4.

2. Disconnect the wire harness containing the

high-limit wires.

3. Use a pin-pusher (P/N 806-4855 or P/N 807-

0928) to remove the two high-limit wires from the wire harness connector (arrows). Note pin location in connector before removing wires.

4. Remove the high-limit from the frypot using

an open-end wrench or other suitable tool.

5. Apply Loc-Tite PST 567 sealant to the

replacement high-limit threads.

6. Screw the replacement high-limit into the

frypot and tighten to 170-180 inch-pounds

Using a pin-pusher, remove two high-limit wires (arrows) from connector.

torque. DO NOT OVERTIGHTEN.

7. Insert the replacement high-limit wires into

the connector, ensuring each wire is in the correct hole..

8. Reconnect the high-limit wire-harness

connector.

9. Install and secure the back cover(s).

10. Return fryer to operation.

Place wrench here when removing and installing

high-limit.

1.8 Replace Frypot

1. Perform Procedure 1.5, Replace Temperature Probe, Steps 1-7.

2. Perform Procedure 1.2, Replace Computer/Controller, Steps 1-3.

3. Perform Procedure 1.7, Replace High-Limit, Steps 1-4.

4. Disconnect the element wire harnesses.

5. If the fryer has a built-in filtration system, remove all the plumbing from the frypot, including

oil-return and drain plumbing.

1-6

6. Remove the screws securing the frypot to the front frame of the fryer.

7. Carefully lift the frypot from the cabinet.

8. Remove the drain valve from the old frypot and install on the new frypot.

9. Apply Loc-Tite Sealant PST 567 to the high-limit threads. Install high-limit into the new frypot.

10. Disconnect the tilt plate springs from the old frypot.

11. Remove the securing screws from the tilt plate. Lift the tilt plate/heating element assembly from

the old frypot and install on the new frypot.

12. Follow the preceding steps in reverse to install the new frypot into the fryer.

13. NOTE: Apply Loc-Tite Sealant PST 567 to all pipefittings prior to installation.

1.9 Replace Contactor (Latching or Heating)

1. Remove filter pan.

2. Remove cover to contactor box.

3. Identify faulty contactor. Remove all wiring connected to the contactor terminals inside the

component box. Tape wire-pairs together and mark each wire-set or wire for reassembly.

4. Remove contactor-mounting screws and remove the contactor.

5. Install the new contactor and connect the wiring removed in Step 3.

1.10 Built-in Filter System Service Procedures

Troubleshooting Built-In Filtration Systems

One of the most common errors is placing the filter paper on the bottom of the filter pan rather than over the filter screen.

CAUTION Ensure that the paper support screen is in place prior to filter paper placement and filter pump operation. Improper screen placement is the major cause of filter system malfunction.

Whenever the complaint is "the pump is running, but no oil is being filtered", check the installation of the filter paper, and ensure that the correct size is being used.

1-7

If the pump motor overheats, a circuit breaker will trip and the motor will not start until the breaker is reset. If the pump motor does not start, press the white reset button located under the component box, inside the cabinet.

If the pump starts after resetting the breaker, then something is causing the motor to overheat. A major cause of overheating is when several frypots are filtered sequentially, thus overheating the pump and motor. Allow the pump motor to cool at least 30 minutes before resuming operation, and allow time for the motor to cool between sequential frypot filtering.

Pump overheating can be caused by:

• Solidified shortening in the pan or filter lines,

• Attempting to filter unheated oil or shortening.

Cold oil and shortening are more viscous, causing the pump motor to overheat. Always filter with the oil or shortening at operating temperature [350°F (177°C)].

If the motor runs but the pump does not,

Sediment Particle

there is a blockage in the pump. Incorrectly sized or installed paper/pads will allow food particles and sediment to pass through the filter pan and into the pump. When sediment

Oil Flow

enters the pump, the gears bind, causing the motor to overload, again tripping the thermal overload. Solidified shortening in the pump will also cause it to seize, with the same problem.

A pump seized by debris or hard shortening can usually be freed by manually moving the

Sediment Particle

Up for reverse

gears with a screwdriver or other instrument.

Disconnect power to the filter system, remove the input plumbing from the pump, and use a screwdriver to manually turn the

Down for forward

gears.

● Turning the pump gears in reverse will

release a hard particle.

● Turning the pump gears forward will push softer objects and solid shortening through the

pump and allow free movement of the gears.

Incorrectly sized or installed paper/pads allows food particles and sediment to pass through and clog the suction tube on the bottom of the filter pan. Particles large enough to block the suction tube may indicate that the crumb tray is not being used. Pan blockage can also occur if shortening is left in the pan and allowed to solidify. Blockage removal can be accomplished by forcing the item out with an

1-8

auger or drain snake. Compressed air or other pressurized gases should not be used to force out the blockage

1.11 Basket Lift Service Procedures

2836 Series Electric fryers may optionally be equipped with automatic basket lifts to ensure uniform cooking times. Electric fryers can be equipped with "modular" or "bell-crank" basket lifts.

A modular basket lift (illustrated) consists

of a toothed rod to which the basket lift arm is attached, a reversible-drive gear motor and a pair of roller-activated microswitches. The gear motor engages the teeth of the rods, moving them up or down, depending upon the motors’ direction. The microswitches at the upper and lower limits of movement stop the motor when the basket is in the full up or full down position.

Timing circuitry in the controller initiates and stops basket lift operation depending upon the variables programmed by the operator. When the product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power to the lower microswitch. The microswitches stop the motor at the lift’s upper and lower travel limits and reverse the direction of current flow, thus reversing the motor direction.

Modular Basket Lift Assembly (Typical).

1-9

Simplified Schematic

1 or 4

To computer/controller via

interface board

Basket Lift

Relay

Normally Open Upper-limit

Microswitch

Normally Closed Lo wer-limit

Microswitch

When the product button is pushed on the computer/controller, current flows through a coil in the basket lift relay, causing the lower circuit to be activated. The basket lift lowers, closing the normally open upper-microswitch. When the lower normally closed microswitch is opened by the downward moving lift rod, power to the motor ceases to flow. When the computer/controller timesout, the current to the relay coil is interrupted, allowing the upper circuit to be activated. The basket lift then raises and closes the lower microswitch. When the basket lift rod clears the upper microswitch, the microswitch opens, and power to the circuit is interrupted, stopping the motor. Pushing the product button or activating the manual control (if equipped) restarts the cycle.

Problems with the modular basket lift design can be grouped into three categories:

● Binding/jamming problems

● Motor and gear problems

● Electronics problems

1-10

BINDING/JAMMING PROBLEMS

Noisy, jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and their bushings. Apply a light coat of Lubriplate or similar lightweight white grease to the rod and bushings to correct the problem.

With the modular basket lift, another possible cause of binding is improper positioning of the motor, which prevents the gear from correctly engaging the teeth in the rod. To correct the problem, loosen the screws that hold the motor in place and move it forward or backward until the rod has just enough slack to be rotated slightly.

MOTOR AND GEAR PROBLEMS

With the modular basket lift, the most likely problem to be encountered in this category is erratic motion of the lift due to a worn drive gear. Failure to keep the lift rod and bushings properly lubricated will cause unnecessary wear of the gear. The problem is corrected by replacing the worn gear.

If the lift cycles correctly but fails to remain in the up position (i.e., goes up, but then slowly settles back down into the frypot), the problem is a failed motor brake. The motor must be replaced.

If power is reaching the motor but the motor fails to run, the motor is burned out and must be replaced.

ELECTRONICS PROBLEMS

Within this category are problems associated with the relays, microswitches, capacitors, resistors, interface board, wiring, and controls. The most common problem in this category is a lift that continuously travels up and down. This is usually caused by a microswitch that is out of adjustment.

Troubleshooting the electronics of a modular-type basket lift is simply a process of verifying current flow through the individual components up to and including the motor. Using a multimeter set to the 250 VAC range, check the connections on both sides of the component for the presence of the applied line voltage. The accompanying simplified wiring diagrams identify the components and wiring connection points.

1-11

1.12 Electric Interface Board Diagnostic Chart

The following diagram and charts provide ten quick system checks that can be performed using only a multimeter.

Note: The sealed relays are replaceable. If a relay fails, the replacement part number is 807-3932.

11 12

10 13

CMP indicates power from 12V transformer

K3 K4

24 indicates power from 24V transformer

HI (RH) indicates output (closed) from right latch

HI (LH) not applicable to Ultimate Electric fryers

HT (RH) indicates output from right heat relay

HT (LH) not applicable to Ultimate Electric fryers

AL (RH) indicates output (open) from right latch

AL (LH) not applicable to Ultimate Electric fryers

Diagnostic LED Legend

relay

Meter Setting Test Pin Pin Results

12 VAC Power 50 VAC Scale 1 of J2 3 of J2 12-16 VAC 24 VAC Power 50 VAC Scale 2 of J2 Chassis 24-30 VAC *Probe Resistance R X 1000 OHMS 11 of J2 12 of J2 See Chart Hi-Limit Continuity R X 1 OHMS 7 of J2 4 of J2 0 - OHMS Latch Contactor Coil R X 1 OHMS 8 of J2 Chassis 3-10 OHMS Heat Contactor Coil R X 1 OHMS 9 of J2 Chassis 18-25 OHMS

*Disconnect 15-Pin harness from the computer/controller before testing the probe circuit.

1-12

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