Frymaster FPEL14 User Manual

PROTECTOR

ELECTRIC FRYERS

Service & Parts Manual

SERIES

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

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

*8196344*

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

APRIL 2008

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 ORIGI NAL CONFIGUR ATION, THI S WARRANTY WI LL BE VOID. FURTHER, FRYMASTER DEA N 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

Copper wire suitable for at least 167°F (75°C) 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 rating and serial number plate located on the inside of the fryer door.

DANGER All wiring connections for this appliance must be made in accordance with the wiring diagrams furnished with the equipment. Wiring diagrams are located on the inside of the fryer door.

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

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

WARNING Frymaster fryers equipped with legs are for permanent installations. Fryers fitted with legs must be lifted during movement to avoid damage and possible bodily injury. For a moveable or portable installation, Frymaster optional equipment casters must be used. Questions? Call 1-800-551-8633 or email at service@frymaster.com.

WARNING

Do not use water jets to clean this equipment.

WARNING This equipment is intended for indoor use only. Do not install or operate 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 KES.

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

ELECTRICAL POWER SPECIFICATIONS

Three (3) Phase Requirements

WIRE

kW VOLTAGE PHASE

14 208 3 3 6 16 39 39 39 14 240 3 3 6 16 34 34 34 14 480 3 3 8 10 17 17 17 14 220/380 3 4 6 16 21 21 21 14 240/415 3 4 6 16 20 20 21 14 230/400 3 4 6 16 21 21 21

ALL

EPRI 14kW

(SOLID STATE)

17 208 3 3 6 16 48 48 48 17 240 3 3 6 16 41 41 41 17 480 3 3 6 16 21 21 21 17 220/380 3 4 6 16 26 26 26 17 240/415 3 4 6 16 24 24 24 17 230/400 3 4 6 16 25 25 25

ALL

EPRI 17kW

(SOLID STATE)

22 208 3 3 4 25 61 61 61 22 240 3 3 4 25 53 53 53 22 480 3 3 6 16 27 27 27 22 220/380 3 4 6 16 34 34 34 22 240/415 3 4 6 16 31 31 31 22 230/400 3 4 6 16 32 32 32

208 3 3 6 16 39 39 39

240 3 3 6 16 34 34 34 220/380 3 4 6 16 21 21 21 240/415 3 4 6 16 20 20 20

208 3 3 6 16 48 48 48

240 3 3 6 16 41 41 41 220/380 3 4 6 16 26 26 26 240/415 3 4 6 16 24 24 24

SERVICE

MINIMUM SIZE AMPS PER LEG

AWG mm2 L1 L2 L3

Single Phase Requirements

WIRE

kW VOLTAGE PHASE

14 208 1 2 3 34 68 14 240 1 2 4 25 59 14 480 1 2 8 10 30

SERVICE

MINIMUM SIZE

AWG mm2

AMPS

PROTECTOR® SERIES ELECTRIC FRYERS

TABLE OF CONTENTS

CAUTIONARY STATEMENTS...............................................................................................................i

ELECTRICAL POWER SPECIFICATIONS........................................................................................ii

CHAPTER 1: Service Procedures

1.1 General.....................................................................................................................................1-1

1.2 Replacing a Controller.............................................................................................................1-1

1.3 Replacing Component Box Components.................................................................................1-1

1.4 Replacing a High-Limit Thermostat........................................................................................1-3

1.5 Replacing a Temperature Probe...............................................................................................1-3

1.6 Replacing a Heating Element...................................................................................................1-5

1.7 Replacing Contactor Box Components....................................................................................1-6

1.8 Replacing a Frypot...................................................................................................................1-7

1.9 Built-In Filtration System Service Procedures.........................................................................1-9

1.9.1 Filtration System Problem Resolution .....................................................................1-9

1.9.2 Replacing the Filter Motor, Filter Pump and Related Components.......................1-10

1.9.3 Replacing the Filter Transformer or Filter Relay...................................................1-12

1.10 Basket Lift Service Procedures..............................................................................................1-12

1.11 ATO (Automatic Top-Off) Service Procedures.....................................................................1-14

1.11.1 ATO (Automatic Top-Off) Troubleshooting).........................................................1-15

1.11.2 ATO (Automatic Top-Off) Board Pin Positions and Harnesses.............................1-16

1.11.3 Replacing the ATO board or Transformer..............................................................1-17

1.11.4 Replacing the ATO Pump or Solenoid ...................................................................1-17

1.12 CM7 Computer Service Procedures.......................................................................................1-18

1.12.1 CM7 Computer Troubleshooting............................................................................1-18

1.12.2 CM7 Useful Codes..................................................................................................1-21

1.12.3 CM7 Menu Summary Tree.....................................................................................1-22

1.12.4 CM7 Pin Positions and Harnesses ..........................................................................1-23

1.13 Loading and Updating Software............................................................................................1-24

1.14 Interface Board Diagnostic Chart ..........................................................................................1-25

1.15 Probe Resistance Chart ..........................................................................................................1-26

1.16 Wiring Diagrams....................................................................................................................1-27

1.16.1 Basket Lift Wiring 208-250V.................................................................................1-27

1.16.2 Basket Lift Wiring 100-120V.................................................................................1-28

1.16.3 FPEL Component Wiring Domestic.......................................................................1-29

1.16.4 FPEL Component Wiring Domestic 120V.............................................................1-30

1.16.5 FPEL Component Wiring CE.................................................................................1-31

1.16.6 Tilt Switch Wiring..................................................................................................1-32

1.16.7 Contactor Box-Delta Configuration.......................................................................1-33

1.16.8 Contactor Box-WYE Configuration.......................................................................1-34

1.16.9 Terminal Block Wiring ..........................................................................................1-35

1.16.10 Simplified FPEL14/17/22 Full-Vat Delta Wiring..................................................1-36

1.16.11 Simplified FPEL14/17/22 Full-Vat Export WYE Wiring......................................1-37

1.16.12 Simplified FPEL14/17/22 Full-Vat EPRI Wiring..................................................1-38

1.16.13 Simplified FPEL14/17/22 Full-Vat EPRI Export WYE Wiring............................1-39

1.16.14 FPEL Simplified Wiring ........................................................................................1-40

iii

PROTECTOR® SERIES ELECTRIC FRYERS

TABLE OF CONTENTS cont.

CHAPTER 2: Parts List

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

2.2 Basket Lift Assembly and Associated Parts ............................................................................2-2

2.3 Doors, Sides and Casters..........................................................................................................2-4

2.4 Drain System Components.......................................................................................................2-5

2.4.1 Drain Tube Sections and Associated Parts...............................................................2-5

2.4.2 Drain Valves and Associated Parts (Units with Built-In Filtration).........................2-6

2.5 Electronics and Wiring Components .......................................................................................2-7

2.5.1 Component Boxes ....................................................................................................2-7

2.5.2 Contactor Boxes.......................................................................................................2-9

2.5.3 Fuse Boxes .............................................................................................................2-11

2.5.4 Terminal Blocks.....................................................................................................2-12

2.5.5 Heating Element Assemblies and Associated Parts ...............................................2-13

2.5.6 Element Tube Assemblies......................................................................................2-15

2.5.7 Computers ..............................................................................................................2-15

2.5.8 Wiring.....................................................................................................................2-16

2.5.8.1 Contactor Box Wiring Assemblies 12-Pin Full Vat...............................2-16

2.5.8.2 Contactor Box Wiring Assemblies 6-Pin Left Element.........................2-17

2.5.8.3 Contactor Box Wiring Assemblies 9-Pin Right Element.......................2-17

2.5.8.4 Main Wiring Harnesses..........................................................................2-18

2.5.8.5 Component Box, Filter Pump and Basket Lift Wiring Harnesses..........2-19

2.5.8.6 Component Box to Filter Pump Harness................................................2-19

2.5.8.7 Basket Lift Harness................................................................................2-19

2.5.8.8 Interface Board to Controller Wiring Harness 15-Pin............................2-20

2.5.8.9 CM7 and ATO Wiring Harnesses..........................................................2-20

2.6 Filtration System Components...............................................................................................2-21

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

2.8 Oil Return System Components.............................................................................................2-24

2.9 Auto Top-Off Components....................................................................................................2-25

2.9.1 JIB Indicator Light and Basket ................................................................................2-25

2.9.2 Automatic Top-Off Board Assembly.......................................................................2-25

2.9.3 Solenoid and Pump Assemblies...............................................................................2-26

2.9.4 JIB Cap and Pick-up Assembly ...............................................................................2-27

2.9.5 BIB Cap snd Pick-up Assembly...............................................................................2-27

2.10 Wiring Connectors, Pin Terminals and Power Cords............................................................2-28

2.11 Fasteners ...............................................................................................................................2-29

PROTECTOR® SERIES ELECTRIC FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 General

Before performing any maintenance on your Frymaster fryer, disconnect the fryer from the electrical power supply.

To ensure the safe and efficient operation of the fryer and hood, the electrical plug must be fully engaged and locked in its pin and sleeve socket.

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

1.2 Replacing a Computer

1. Disconnect the fryer from the electrical power supply.

2. The controller bezel is held in place by tabs at the top and bottom. Slide the metal bezel up to

disengage the lower tabs. Then slide the bezel down to disengage the upper tabs.

3. Remove the two screws from the upper corners of the control panel. The control panel is hinged at

the bottom and will swing open from the top.

4. Unplug the wiring harnesses from the connectors on the back of the computer, marking their

position for reassembly, and disconnect the grounding wires from the terminals. Remove the control panel assembly by lifting it from the hinged slots in the control panel frame.

WARNING

Ground Wire Terminal

Communication Wires

Ground Wire Terminal

20-Pin Connecto

Locator Wire

5. Remove the controller from the control panel assembly and install the replacement computer.

Reinstall the control panel assembly by reversing steps 1 thru 4.

1.3 Replacing Component Box Components

1. Disconnect the fryer from the electrical power supply.

2. The controller bezel is held in place by tabs at the top and bottom. Slide the metal bezel up to

disengage the lower tabs. Then slide the bezel down to disengage the upper tabs.

3. Remove the two screws from the upper corners of the control panel and allow the control panel to

swing down.

1-1

4. Unplug the wiring harnesses and disconnect the grounding wires from the terminals on the back of

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

5. Disconnect the wiring from the component to be replaced, being sure to make a note of where each

wire was connected.

6. Dismount the component to be replaced and install the new component, being sure that any

required spacers, insulation, washers, etc. are in place.

NOTE: If more room to work is required, the control panel frame assembly may be removed by

removing the hex-head screws, which secure it to the fryer cabinet (see illustration below). If this option is chosen, all control panel assemblies must be removed per steps 1 and 2 above. The cover plate, on the lower front of the component box, may also be removed to allow additional access if

desired. Removing the component box itself from the fryer is not recommended due to the difficulty

involved in disconnecting and reconnecting the oil-return valve rods, which pass through openings in the component box.

Remove these three screws at each end.

Remove these two screws from the center supports.

Removing the Control Panel Frame and Top Cap Assembly

7. Reconnect the wiring disconnected in step 5, referring to your notes and the wiring diagrams on

the fryer door to ensure that the connections are properly made. Also, verify that no other wiring was disconnected accidentally during the replacement process.

8. Reverse steps 1 through 4 to complete the replacement and return the fryer to service.

1-2

1.4 Replacing a High-Limit Thermostat

1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit

(SDU) or other appropriate METAL container.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to the rear of

the fryer.

3. Remove the screws from the bottom of the lower back panel attaching the contactor plug guards.

4. Remove each of the guards.

5. Remove the four screws from both the left and right sides of the lower back panel.

6. Locate the high-limit that is being replaced and follow the two-black wires to the 12-pin connector

C-6. Note where the leads are connected prior to removing them from the connector. Unplug the 12-pin connector C-6 and using a pin-pusher push the pins of the high-limit out of the connector.

7. Carefully unscrew the high-limit thermostat to be replaced.

8. Apply Loctite™ PST 567 or equivalent sealant to the threads of the replacement and screw it

securely into the frypot.

9. Insert the leads into the 12-pin connector C-6 (see illustration below). For full-vats the leads go

into positions 1 and 2 of the connector. Polarity does not matter.

10. Reconnect the 12-pin connecting plug C-6. Use wire ties to secure any loose wires.

11. Reinstall the back panels, contactor plug guards, reposition the fryer under the exhaust hood, and

reconnect it to the electrical power supply to return the fryer to service.

1.5 Replacing a Temperature Probe

1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit

(SDU) or other appropriate METAL container.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

1-3

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to the rear of

the fryer.

3. Remove the screws from the bottom of the lower panel attaching the contactor plug guards.

4. Remove each of the guards.

5. Remove the four screws from both sides of the lower back panel. Then remove the two screws on

both the left and right sides of the back of the tilt housing. Lift the tilt housing straight up to remove from the fryer.

6. Locate the red and white wires of the temperature probe to be replaced. Note where the leads are

connected prior to removing them from the connector. Unplug the 12-pin connector C-6 and using a pin-pusher push the pins of the temperature probe out of the connector.

7. Raise the element and remove the securing probe bracket and metal tie wraps that secure the probe

to the element (see illustration below).

8. Gently pull on the temperature probe and grommet, pulling the wires up the rear of the fryer and

through the element tube assembly.

9. Insert the replacement temperature probe (wires first) into the tube assembly ensuring that the

grommet is in place. Secure the probe to the elements using the bracket which was removed in Step 7 and the metal tie wraps which were included in the replacement kit.

10. Route the probe wires out of the tube assembly following the element wires down the back of the

fryer through the Heyco bushings to the 12-pin connector C-6. Secure the wires to the sheathing with wire ties.

11. Insert the temperature probe leads into the 12-pin connector C-6 (see illustration below). For full-

vat units, the red lead goes into position 3 and the white lead into position 4 of the connector.

1-4

12. Secure any loose wires with wire ties, making sure there is no interference with the movement of

the springs. Rotate the elements up and down, making sure movement is not restricted and that the wires are not pinched.

13. Reinstall the tilt housing, back panels and contactor plug guards. Reposition the fryer under the

exhaust hood, and reconnect it to the electrical power supply to return the fryer to service.

1.6 Replacing a Heating Element

1. Perform steps 1-5 of section 1.5, Replacing a Temperature Probe.

2. Disconnect the wire harness containing the probe wiring. Using a pin pusher, disconnect the probe

wires from the 12-pin connector C-6.

3. In the rear of the fryer, disconnect the 6-pin connector for the left element (as viewed from the

front of the fryer) or the 9-pin connector for the right element from the contactor box. Press in on the tabs on each side of the connector while pulling outward on the free end to extend the connector and release the element leads (see photo below). Pull the leads out of the connector and out of the wire sleeving.

4. Raise the element to the full up position and support the elements.

5. Remove the hex head screws and nuts that secure the element to the tube assembly and pull the

element out of the frypot. NOTE: Full-vat elements consist of two dual-vat elements clamped

together. For full-vat units, remove the element clamps before removing the nuts and screws that secure the element to the tube assembly.

6. If applicable, recover the probe bracket and probe from the element being replaced and install

them on the replacement element. Install the replacement element in the frypot, securing it with the nuts and screws removed in Step 5 to the tube assembly. Ensure the gasket is between the tube and element assembly.

7. Route the element leads through the element tube assembly and into the wire sleeving to prevent

chafing. Ensure that the wire sleeving is routed back through the Heyco bushings, keeping it clear from the lift springs. Also ensure that the wire sleeving extends into the tube assembly, protecting the wires. Press the pins into the connector in accordance with the diagram on the following page,

and then close the connector to lock the leads in place. NOTE: It is critical that the wires be

routed through the sleeving to prevent chafing.

1-5

Index Marker marks Position 1

14253

5L 4L6L 1L2L3L

789

8. Reconnect the element connector ensuring that the latches lock.

9. Insert the temperature probe leads into the 12-pin wiring harness connector C-6 (see illustration

below). For full-vat units the red lead goes into position 3 and the white into position 4.

10. Reconnect the 12-pin connector C-6 of the wiring harness disconnected in Step 2.

11. Lower the element down onto the basket rack.

12. Reinstall the tilt housing, back panels and contactor plug guard. Reposition the fryer under the

exhaust hood, and reconnect it to the electrical power supply.

1.7 Replacing Contactor Box Components

1. If replacing a contactor box component, remove the filter pan and lid from the unit.

2. Disconnect the fryer from the electrical power supply.

3. Remove the two screws securing the cover of the contactor box. The contactor boxes above the

filter pan are accessed by sliding under the fryer. They are located to the left and right above the guide rails (see photo on following page).

1-6

Remove two screws to access contactor box components above the filter pan

4. The contactors and relays are held on by threaded pin studs so that only removal of the nut is

required to replace the component.

5. After performing necessary service, reverse steps 1-4 to return the fryer to operation.

Left and right views of mechanical contactor box components.

1.8 Replacing a Frypot

1. Drain the frypot into the filter pan or, if replacing a frypot over the filter system, into a Shortening

Disposal Unit (SDU) or other appropriate METAL container. If replacing a frypot over the filter system, remove the filter pan and lid from the unit.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to both the

front and rear.

3. Slide the metal bezel up to release the bottom tabs, then slide the bezel down to disengage the

upper tabs.

4. Remove the two screws from the upper corners of the control panels and allow them to swing

down (see photo on page 1-1).

1-7

5. Unplug the wiring harnesses and ground wires from the backs of the controllers. Remove the

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

6. Remove the screws from the bottom of the lower back panel attaching the contactor plug guards.

7. Remove each of the guards

8. Remove the tilt housing and back panels from the fryer. The tilt housing must be removed first in

order to remove the upper back panel.

9. To remove the tilt housing, remove the hex head screws from the rear edge of the housing. The

housing can be lifted straight up and off the fryer.

10. Remove the control panel by removing the screws on both sides.

11. Loosen the component boxes by removing the screws, which secure them in the cabinet.

12. Remove the top cap by removing the nuts at each end that secure it to the cabinetry.

13. Remove the hex head screw that secures the front of the frypot to the cabinet cross brace.

14. Remove the top-connecting strip that covers the joint with the adjacent frypot.

15. Unscrew the nut located on the front of each section of drain tube, and remove the tube assembly

from the fryer.

16. Remove the covers from the drain safety switch(es) and disconnect the wiring at the switch(es).

17. Disconnect any auto top-off sensors and wiring.

18. At the rear of the fryer, unplug the 12-pin connector C-6 and, using a pin pusher, disconnect the

high-limit thermostat leads.

19. Disconnect the oil return and top off flexline(s).

20. Raise the elements to the “up” position and disconnect the element springs.

21. Remove the machine screws and nuts that secure the element tube assembly to the frypot.

Carefully lift the element assembly from the frypot and secure it to the cross brace on the rear of the fryer with wire ties or tape.

22. Carefully lift the frypot from the fryer and place it upside down on a stable work surface.

23. Recover the drain valve(s), oil return flexline connection fitting(s), auto top-off sensors and high-

limit thermostat(s) from the frypot. Clean the threads and apply Loctite

™

PST 567 or equivalent

sealant to the threads of the recovered parts and install them in the replacement frypot.

24. Carefully lower the replacement frypot into the fryer. Reinstall the hex head screw removed in step 9 to attach the frypot to the fryer.

25. Position the element tube assembly in the frypot and reinstall the machine screws and nuts removed in step 21.

1-8

26. Reconnect the oil return and auto top off flexlines to the frypot, and replace aluminum tape, if necessary, to secure heater strips to the flexlines.

27. Insert the high-limit thermostat leads disconnected in step 18 (see illustration on page 1-3 for pin positions).

28. Reconnect the auto top-off sensors.

29. Reconnect the drain safety switch wiring to the switch(es) in accordance with the diagram below then reinstall the switch covers.

30. Reinstall the drain tube assembly.

31. Reinstall the top connecting strips, top cap, tilt housing, back panels and contactor plug guards.

32. Reinstall controllers in the control panel frame and reconnect the wiring harnesses and ground wires.

33. Reposition the fryer under the exhaust hood and reconnect it to the electrical power supply.

1.9 Built-in Filtration System Service Procedures

1.9.1 Filtration System Problem Resolution

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

CAUTION Ensure that filter screen is in place prior to filter paper placement and filter pump operation. Improper screen placement is the primary cause of filtration 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. While you are checking the filter paper, verify that the O-rings on the pick-up tube of the filter pan are in good condition. A missing or worn O-ring allows the pump to take in air and decrease its efficiency.

If the pump motor overheats, the thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch (button) located on the rear of the motor.

If the pump starts after resetting the thermal overload switch, then something is causing the motor to overheat. A major cause of overheating is when several frypots are filtered sequentially, overheating the pump and motor. Allow the pump motor to cool at least 30 minutes before resuming operation. Pump overheating can be caused by:

1-9

• Solidified shortening in the pan or filter

Sediment Particle

lines, or

• Attempting to filter unheated oil or

shortening (cold oil and shortening are

Oil Flow

more viscous, overloading the pump motor and causing it to overheat).

If the motor runs but the pump does not return oil, there is a blockage in the pump. Incorrectly sized or installed paper will allow food particles and sediment to pass through the filter pan and

Sediment Particle

Up for reverse

into the pump. When sediment enters the pump, the gears bind, causing the motor to overload, again tripping the thermal overload. Shortening that has solidified in the pump will also cause it to seize, with the same result.

Down for forward

A pump seized by debris or hard shortening can usually be freed by manually moving the 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 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 will also allow 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 auger or drain snake. Compressed air or other pressurized gases should not be used to force out the blockage.

1.9.2 Replacing the Filter Motor, Filter Pump, and Related Components

1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit

(SDU) or other appropriate metal container.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to both the

front and rear.

1-10

3. Disconnect the flexline running to the oil-return manifold at the rear of the fryer as well as the

pump suction flexline at the end of the filter pan connection (see photo below).

Disconnect flexlines indicated by the arrows.

4. Loosen the nut and bolt that secures the bridge to the oil-return manifold.

5. Remove the cover plate from the front of the motor and disconnect the motor wires.

6. Unplug the pump motor assembly 6-pin connector C-2.

7. Remove the two nuts and bolts which secure the front of the bridge to the cross brace and carefully

slide the bridge rearward off the cross brace until its front end can be lowered to the floor. Undo the single nut holding it in place in back. Be careful not to let the rear of the bridge slip off the manifold at this point.

8. Get a good grip on the bridge, carefully pull it forward off the oil-return manifold, and lower the

entire assembly to the floor. Once on the floor, pull the assembly out the front of the fryer.

9. When required service has been completed, reverse steps 3-8 to reinstall the bridge. NOTE: The

black motor wires go on the top terminal, the white on the bottom. The red/black heater tape wires go into position 3 and the violet/white wires go into position 6 (see illustration below).

10. Reconnect the unit to the electrical power supply, and verify that the pump is functioning correctly

(i.e., when a filter handle is placed in the ON position, the motor should start and there should be strong suction at the intake fitting and outflow at the rear flush port.)

1-11

11. When proper operation has been verified, reinstall the back panels and the filter pan and lid.

12. Reposition the fryer under the exhaust hood and reconnect it to the electrical power supply, if

necessary to return the fryer to service.

1.9.3 Replacing the Transformer or Filter Relay

Disconnect the fryer from the electrical power supply. Remove the left controller from the fryer to expose the interior of the left component box. The transformer and relay on the left are located as shown in the illustration below. Once replaced, reconnect the power.

When replacing a filter relay in the left component box, ensure the 24VAC relay (8070670) is used on 208-240V units and 8070012 is used on 120V units. This relay is the same relay used in the RE fryers.

1.10 Basket Lift Service Procedures

Protector® Series electric fryers may be equipped with automatic basket lifts. Basket lifts always come in pairs, although each operates independently.

A modular basket lift (illustrated on the following page) is a self-contained sub-assembly consisting

of a pair of toothed rods, which support removable basket lift arms, a pair of reversible-drive gear motors, and four microswitches. The gear motors engage the teeth of the rods, moving them up or down depending upon the motors’ direction of rotation. The microswitches at the upper and lower limits of movement stop the motors 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.

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-micro-switch. When the downward-moving rod opens the lower normally closed microswitch, the power to the motor ceases to flow. When the computer times out, the current to the relay coil is cut, allowing the upper circuit to be activated. The basket lift rises and re-closes the lower

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microswitch. When the basket lift rod clears the upper microswitch, the microswitch reopens, power to the circuit is cut, and the motor stops. Pushing the product button restarts the cycle.

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

● Binding/jamming problems

● Motor and gear problems

● Electronic problems

100-120V Configuration

208-250V Configuration

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. A failed motor brake cannot be repaired and requires replacement of the motor itself.

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

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ELECTRONIC 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 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 schematic below and the wiring diagram on page 1-27 and 1-28 can identify the components and wiring connection points.

1.11 ATO (Automatic Top-off) Service Procedures

The automatic top-off system is activated when the oil level falls below a sensor in the rear of the frypot. The signal is sent to the ATO board to engage the solenoid to the frypot and turn on the ATO pump. The pump draws oil from the JIB (Jug In Box) to a port in the rear of the frypot. Once the oil level has satisfied the sensor, the pump and solenoid turn off.

The ATO board is located inside the box, behind the JIB (see Figure 1). The power for the ATO board is supplied from the right hand component box. The power passes through the transformer inside the ATO box to the board.

Figure 1

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1.11.1 ATO (Automatic Top-off) Troubleshooting

Problem Probable Causes Corrective Action

A. Check to see that fryer is

heating. Fryer temperature must be at least 300°F (149°C). Check probe resistance. If probe is bad, replace the probe.

B. Ensure oil is above 70°F

Frypots won’t top

off.

The yellow JIB low

light won’t illuminate.

One vat tops off but

other vats fail to top

off.

Incorrect vat tops

off.

A. Probe temperature lower than

setpoint.

B. Temperature in supply line or JIB

is too low.

C. ATO board power loss

D. Failed solenoid.

E. ATO pump failed or over

tightened.

F. Failed transformer/harness.

G. Failed ATO board.

A. No power in the component box.

B. Failed transformer.

C. Loose wire connection

A. Failed solenoid

B. Loose wire connection.

A. Wired incorrectly. B. Flexlines connected to wrong vat.

(21°C).

C. Power to the ATO board has

been cut off. Restore power to the board and switch all computers off and on again to readdress system.

D. Check solenoid to see if

functioning properly.

E. If the solenoid is working,

ensure that the screws on the bottom of the pump are not too tight. Loosen the screws. If loosening the screws doesn’t fix the problem, replace the pump.

F. Ensure transformer in ATO box

is functioning properly. Check power from transformer to ATO board. Ensure all harnesses are plugged securely into place.

G. Check for proper voltages using

the pin position chart found on page 1-16. If ATO found defective, replace ATO board.

A. Ensure power is present in the

component box.

B. If power is present in

component box, check the transformer for correct voltage.

C. Ensure the yellow LED is

securely attached to plug J6 on the ATO board.

A. Check power to the pump. If

the pump is hot, the solenoid has probably failed.

B. Ensure all wiring harnesses are

securely connected to ATO board and solenoids.

A. Ensure wires are wired

correctly.

B. Switch flexlines to correct vat.

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1.11.2 ATO (Automatic Top-Off) Board Pin Positions and Harnesses

Connector From/To Harness #

Solenoids

Top Off Pump

J4 (Rear) /

J5 (Front)

J3 - Vat #3 J2 - Vat #2 J1 - Vat #1

J6 Orange LED 8074555

J10

J9 CM7 J7 8074646

JIB Low Reset Switch

Solenoids

Top Off Pump & JIB

Low Reset Switch

Transformer 8074553

ATO RTD

Network Resistor

(pins 2 & 3)

or to next ATO Board (4

& 5 vat units)

8074572 x1 (FV) 8074572 x2 (DV)

8074627

8074572 x1 (FV) 8074572 x2 (DV)

8074627

8074655 - Vat #1

8074654 - Vat #2 8074621 - Vat #3

8074552

# Function

1 Output DV - Vat #1 2 Output FV - Vat #1 3 Output DV - Vat #2 4 Output FV - Vat #2 5 Output DV - Vat #3 6 Output FV - Vat #3 7 Top Off Pump Black 8 JIB Low Reset

9 24VAC DV - Vat #1 10 24VAC FV - Vat #1 11 24VAC DV - Vat #2 12 24VAC FV - Vat #2 13 24VAC DV - Vat #3 14 24VAC FV - Vat #3 15 Ground Red 16 Ground

1 24VAC Ret Orange

2 24VAC

5 12VAC Ret Red

6 12VAC

1 DV - Probe Ground White

2 DV - Probe Red

3 FV - Probe Ground White

4 FV - Probe

1 16VDC Black

2 16VDC Ret

3 Ground

4 RB7/DATA

5 RB6/CLOCK

1 Ground Black

2 CAN Lo Red

3 CAN Hi White

1 Ground Black

2 CAN Lo Red

3 CAN Hi White

Voltag

Ground Orange

16VDC

24VAC Orange

16VDC

24VAC

12VAC

Ohm

16VDC

Wire

Color

Black

Red

Blue

Brown

Red

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1.11.3 Replacing the ATO board or Transformer

Disconnect the fryer from the electrical power supply. Locate the ATO box (see Figure 1 on page 14), behind the JIB (Jug In Box). Remove the cover to expose the transformer and ATO board (see Figure 2). Mark and unplug any wires or harnesses. Replace the defective component and reattach all wires or harnesses. Replace the cover. Once replaced, reconnect the

power. Remove and restore power to ALL

computers after power has been restored to the

Figure 2

ATO board.

1.11.4 Replacing the ATO Pump or Solenoid

Disconnect the fryer from the electrical power supply. Locate the ATO pump and solenoid tree (see Figure 3), behind the ATO box. Mark and unplug any wires or harnesses. Replace the defective component and reattach all wires or harnesses. Once replaced, reconnect the power.

Figure 3

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1.12 CM7 Computer Service Procedures

1.12.1 CM7 Computer Troubleshooting

Problem Probable Causes Corrective Action

A. Press the ON/OFF switch to turn

the computer on.

B. Verify fryer is plugged in and

that the circuit breaker is not tripped.

C. Swap the computer with a

computer known to be good. If computer functions, replace the computer.

D. Swap with a harness known to

e good. If computer functions,

replace the harness.

E. If any component in the power

supply system (including the transformer and interface board) fail, power will not be supplied to the computer and it will not function.

Remove and restore power to the computer.

See section 1.12.2 on page 1-21 to change temperature scale.

This in an indication of a malfunction in the temperature control circuitry, including a failure of the high-limit thermostat.

This is displayed only during a test of the high-limit circuit and indicates that the high-limit has opened properly.

No Display on

Computer.

Computer locks up.

CM7 display is in

wrong temperature

scale (Fahrenheit or

Celsius).

CM7 display shows

hot-hi-1.

CM7 display shows

HI-LIMIT.

A. Computer not turned on.

B. No power to the fryer.

C. Computer has failed.

D. Damaged computer wiring harness.

E. Power supply component or

interface board has failed.

Computer error.

Incorrect display option programmed.

Frypot temperature is more than 410ºF (210ºC) or, in CE countries, 395ºF (202ºC).

Computer in high-limit test mode.

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