Frymaster FPGL130-2C Service Manual
Oil Conserving Fryer (OCF30)
Service & Parts Manual
GAS FRYERS
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline 1-800-551-8633 FEB 2015
www.frymaster.com
E-mail: service@frymaster.com
*8196688*
™
NOTICE
IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS MANITOWOC
FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART
PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS FACTORY AUTHORIZED
SERVICERS, 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 EXP ENSES INCUR RED B Y
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 Factory Authorized Servicer (FAS) or other qualified professional
should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by
unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for
definitions of qualified personnel.
NOTICE
This equipment must be installed in accordance with the appropriate national and local codes of
the country and/or region in which the appliance is installed. See NATIONAL CODE
REQUIREMENTS in Chapter 2 of this manual for specifics.
NOTICE TO U.S. CUSTOMERS
This equipment is to be installed in compliance with the basic plumbing code of the Building
Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation
Manual of the U.S. Food and Drug Administration.
NOTICE
Drawings and photos used in this manual are intended to illustrate operational, cleaning and
technical procedures and may not conform to onsite management operational procedures.
NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS
U.S.
This device complies with Part 15 of the FCC rules. Operation is subject to the following two
conditions: 1) This device may not cause harmful interference, and 2) This device must accept
any interference received, including interference that may cause undesired operation. While
this device is a verified Class A device, it has been shown to meet the Class B limits.
CANADA
This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set
out by the ICES-003 standard of the Canadian Department of Communications.
Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A
et B prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.
DANGER
Improper installation, adjustment, maintenance or service, and unauthorized alterations or
modifications can cause property damage, injury, or death. Read the installation, operating,
and service instructions thoroughly before installing or servicing this equipment. Only qualified
service personnel may convert this appliance to use a gas other than that for which it was
originally configured.
ii
DANGER
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
Adequate means must be provided to limit the movement of this appliance without depending
upon the gas line connection. Single fryers equipped with legs must be stabilized by installing
anchor straps. All fryers equipped with casters must be stabilized by installing restraining
chains. If a flexible gas line is used, an additional restraining cable must be connected at all
times when the fryer is in use.
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 liquids or vapors in the vicinity of this or any
other appliance.
DANGER
Instructions to be followed in the event the operator smells gas or otherwise detects a gas leak
must be posted in a prominent location. This information can be obtained from the local gas
company or gas supplier.
DANGER
This product contains chemicals known to the state of California to cause cancer and/or birth
defects or other reproductive harm.
Operation, installation, and servicing of this product could expose you to airborne particles of
glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne
particles of glasswool or ceramic fibers is known to the State of California to cause cancer.
Inhalation of carbon monoxide is known to the State of California to cause birth defects or other
reproductive harm.
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.
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 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.
NOTICE
The Commonwealth of Massachusetts requires any and all gas products to be installed by a
licensed plumber or pipe fitter.
iii
OCF30™ SERIES GAS FRYERS
TABLE OF CONTENTS
CAUTIONARY STATEMENTS ...................................................................................................................... i
CHAPTER 1: Service Procedures
1.1 Functional Description ................................................................................................................... 1-1
1.2 The Electronic Ignition System ...................................................................................................... 1-1
1.3 Interface Board ............................................................................................................................... 1-2
1.4 Thermostats .................................................................................................................................... 1-4
1.5 Accessing Fryers for Servicing ....................................................................................................... 1-4
1.6 Cleaning the Gas Valve Vent Tube ................................................................................................ 1-5
1.7 Checking the Burner Manifold Gas Pressure ................................................................................. 1-5
1.8 Measuring Flame Current ............................................................................................................... 1-6
1.9 Replacing Fryer Components ......................................................................................................... 1-7
1.9.1 Replacing the Controller or the Controller Wiring Harness ........................................... 1-7
1.9.2 Replacing the Temperature Probe or High-Limit Thermostat ....................................... 1-7
1.9.3 Replacing the Interface Board ........................................................................................ 1-8
1.9.4 Replacing an Ignition Module ........................................................................................ 1-8
1.9.5 Replacing an Ignitor Assembly ...................................................................................... 1-8
1.9.6 Replacing or Cleaning a Combustion Air Blower .......................................................... 1-9
1.9.7 Adjusting the Air/Gas Mixture ..................................................................................... 1-10
1.9.8 Replacing a Gas Valve ................................................................................................. 1-11
1.9.9 Replacing a Burner Assembly ...................................................................................... 1-12
1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve ................... 1-13
1.9.11 Replacing the Frypot .................................................................................................... 1-13
1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails .............................................. 1-14
1.10 Troubleshooting and Problem Isolation ....................................................................................... 1-17
1.10.1 Ignition Failure ............................................................................................................. 1-18
1.10.2 Improper Burner Function ............................................................................................ 1-18
1.10.3 Improper Temperature Control .................................................................................... 1-20
1.10.4 Computer Malfunction ................................................................................................. 1-20
1.10.5 Filtration Malfunction .................................................................................................. 1-20
1.10.6 Leakage ........................................................................................................................ 1-21
1.10.7 Basket Lift Malfunction ............................................................................................... 1-21
1.11 Troubleshooting Guides ............................................................................................................... 1-23
1.11.1 Troubleshooting the 24 VAC Circuit ........................................................................... 1-23
1.11.2 Troubleshooting the Gas Valve .................................................................................... 1-26
1.11.3 Troubleshooting the Temperature Probe ...................................................................... 1-27
1.11.4 Replacing the Transformer, Reset Switch or Filter Relay ............................................ 1-27
1.12 Probe Resistance Chart ................................................................................................................. 1-28
1.13 ATO (Automatic Top-Off) Service Procedures ........................................................................... 1-28
1.13.1 ATO (Automatic Top-Off Troubleshooting ................................................................. 1-28
1.13.2 ATO (Automatic Top-Off) Board Positions and Harnesses......................................... 1-31
1.13.3 Replacing the ATO Board, Pump Relay or Transformer ............................................. 1-32
1.13.4 Replacing the ATO Pump ............................................................................................ 1-32
1.13.5 Replacing the ATO Solenoid ....................................................................................... 1-32
1.13.6 Control Power Reset..................................................................................................... 1-33
1.13.7 Testing ATO RTD Probes ............................................................................................ 1-33
1.13.8 Replacing ATO Probe .................................................................................................. 1-33
1.14 3000 Computer Service Procedures ............................................................................................. 1-33
1.14.1 3000 Computer Troubleshooting ................................................................................. 1-33
1.14.2 3000 Useful Codes and Passwords ............................................................................... 1-36
iv
OCF30™ SERIES GAS FRYERS
TABLE OF CONTENTS cont.
1.14.4 Error Log Codes ........................................................................................................... 1-37
1.14.5 3000 Menu Summary Tree ........................................................................................... 1-38
1.14.6 3000 Controller Pin Positions and Harnesses............................................................... 1-39
1.15 Loading and Updating Software Procedures ................................................................................ 1-40
1.16 Principal Wiring Connections ...................................................................................................... 1-41
1.17 Wiring Diagrams .......................................................................................................................... 1-42
1.17.1 FPGL230/430 Wiring 120V, CE and Export ............................................................... 1-42
1.17.1.2 FPGL230/430 Wiring 250V Australia ......................................................................... 1-43
1.17.2 FPGL330 Wiring120V, CE and Export ....................................................................... 1-44
1.17.2.2 FPGL330 Wiring120V, CE Australia .......................................................................... 1-45
1.17.3 FPGL430 Wiring .......................................................................................................... 1-46
1.17.4 Modular Basket Lift (100/120V) .................................................................................. 1-47
1.17.5 Modular Basket Lift (208/250V) .................................................................................. 1-48
1.17.6 Basket Lift Interface Wiring ........................................................................................ 1-49
1.18 Simplified Wiring Diagrams ........................................................................................................ 1-50
1.18.1 FPGL30 Full-Vat Dual-Spark Module ........................................................................ 1-50
1.18.2 FPGL30 Full-Vat Single-Spark Module ..................................................................... 1-51
1.18.3 FPGL30 Dual-Vat Single-Spark Module .................................................................... 1-52
1.18.4 FPGL30 Series Simplified Wiring ............................................................................... 1-53
1.18.5 FPGL30 Series Data Network Flowchart ..................................................................... 1-54
1.18.6 Shortening Melting Unit Wiring Diagram prior to Mar 2012 ...................................... 1-55
1.18.6.2 Shortening Melting Unit Wiring Diagram after to Mar 2012 ...................................... 1-56
1.18.7 Bulk Oil Wiring Diagram 120V, CE and Export ......................................................... 1-57
1.18.7.1 FPGL230/430 Wiring 120V, CE and Export Bulk Oil ................................................ 1-57
1.18.7.2 FPGL230/430 Wiring 250V Australia Bulk Oil .......................................................... 1-58
1.18.7.3 FPGL330 Wiring 120V, CE and Export Bulk Oil ....................................................... 1-59
1.18.7.4 FPGL330 Wiring 250V Australia Bulk Oil ................................................................. 1-60
1.18.8 Bulk Oil Box Wiring Diagram ..................................................................................... 1-61
CHAPTER 2: Parts List
2.1 Accessories ..................................................................................................................................... 2-1
2.2 Basket Lift Assemblies and Associated Parts ................................................................................. 2-2
2.3 Doors, Sides, Flue Caps, Top Caps and Casters ............................................................................. 2-4
2.4 Drain System Components ............................................................................................................. 2-5
2.4.1 Drain Valves and Associated Parts ................................................................................ 2-5
2.4.2 Drain Tube Sections and Associated Parts ..................................................................... 2-6
2.5 Electronics and Electrical Components .......................................................................................... 2-7
2.5.1 Computers and Associated Components ......................................................................... 2-7
2.5.2 Component Boxes .......................................................................................................... 2-8
2.5.3 Transformer Boxes ....................................................................................................... 2-10
2.6 Wiring ........................................................................................................................................... 2-12
2.6.1 Main Wiring Harnesses ................................................................................................ 2-12
2.6.2 3000 and ATO Wiring Harnesses ................................................................................ 2-13
2.7 Frypots and Associated Components ........................................................................................... 2-14
2.7.1 Full-Vat Frypot Components ....................................................................................... 2-14
2.7.2 Dual-Vat Frypot Components ...................................................................................... 2-16
2.7.3 Frypot Probes and Thermostats .................................................................................... 2-18
2.8 Gas Valves, Supply and Combustion System Components ......................................................... 2-19
2.9 Filtration System Components ..................................................................................................... 2-21
2.10 Filter Pump, Motor and Associated Components ......................................................................... 2-22
1.14.3 Service required Errors ................................................................................................. 1-36
v
2.11 Frypot Assemblies and Associated Components .......................................................................... 2-23
2.12 Oil Return System Components ................................................................................................... 2-24
2.13 ATO (Auto Top-Off) Components ............................................................................................... 2-25
2.13.1 JIB (Jug In Box) Basket and ATO Box Assembly ...................................................... 2-25
2.13.2 JIB Cap and Pick Up Assembly .................................................................................. 2-25
2.13.3 ATO (Automatic Top-Off) Pump Assembly ............................................................... 2-26
2.13.4 ATO Top off Manifolds and Components ................................................................... 2-27
2.13.5 Shortening Melting Unit .............................................................................................. 2-28
2.13.6 Bulk Oil Relay Box and Switch .................................................................................. 2-29
2.13.7 Bulk Oil Plumbing ....................................................................................................... 2-30
2.13.8 Bulk Oil Dispose Waste Valve .................................................................................... 2-31
2.14 Wiring Connectors, Pin Terminals, and Tools ............................................................................. 2-32
2.15 Fasteners ...................................................................................................................................... 2-33
vi
OCF30™ SERIES GAS FRYER
CHAPTER 1: SERVICE PROCEDURES
1.1 Functional Description
OCF30™ series gas fryers contain a welded stainless steel frypot that is directly heated by a high efficiency
infrared burner system, requiring approximately 43% less energy than conventional burners to cook the same
volume.
Self-contained combustion chambers (referred to as “burners”) are fitted into rails attached to the sides of the
frypot, one on each side. Each combustion chamber is fitted with special ceramic tiles that are heated by the
burning of a forced air/gas mixture. The tiles transfer heat to the frypot by means of infrared radiation,
providing much more constant and uniform heat dispersion over the surface of the frypot than do
conventional burners. Because less heat is lost to the atmosphere in the process, compared to “open-burner”
designs, less fuel is required to achieve and maintain a given frypot temperature.
In full-vat units, gas flow to both of the burners is regulated by one electromechanical gas valve. All fryers in
this series are equipped with 24 VAC gas valve systems, and all are configured with electronic ignition.
1.2 The Electronic Ignition System
An ignition module mounted below the component box (located behind the control panel) is connected to an
ignitor assembly at the burner. The ignition module performs five important functions: it provides fuse
protection for the 24-volt circuit, provides an ignition spark, supplies voltage to the gas valve, provides the
alarm circuit (24V) to the controller and proofs the burner flame. The module contains a four second time
delay circuit and a coil that activates the gas valve. Three types are in use. A closed-box design is used in
most fryers, but in some fryers built for export, the module resembles an interface board. A single dual-spark
module is used on current production full-vat fryers
The ignitor assembly consists of a spark plug, an enrichment tube, and a flame sensor.
At start-up, the power switch is placed in the ON position,
supplying approximately 12-volts DC to the heat-control circuitry
in the controller and to one side of the heat relay coils on the
interface board. If resistance in the temperature probe indicates the
temperature in the frypot is below 180ºF (82ºC), the current flows
through a melt cycle circuit where a timer switch alternately closes
for six seconds and opens for 24 seconds. If the temperature is
180ºF (82ºC) or above, the current flows through a heat circuit,
bypassing the timer switch. In either case, ground is supplied to
the other leg of the heat relay coils, which closes electronic
switches in the 24 VAC circuit to provide current to the ignition
module. Circuitry in the ignition module sends 24 VAC to the gas
valve via a normally closed high-limit switch and a normally
closed drain safety switch. Simultaneously, the module causes the
ignitor to spark for four seconds to light the burner. A flame
sensor verifies the burner ignition by measuring the flow of
microamps through the flame. If the burner does not light (or is extinguished), current to the ignition module
is cut, the gas valve closes, and the ignition module “locks out” until the power switch is turned off and then
back on. A 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 to the ignition module, causing the gas valve to close.
.
1-1
1.3 Interface Board
All fryers in this series have an interface board located in the component box behind the control panel. The
interface board provides a link between the controller and the fryer’s individual components without requiring
excessive wiring, and allows the controller to execute commands from one central point.
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,
that relay can be replaced.
LEDs (labeled D1 through D7) are arrayed around the board to assist in troubleshooting.
INTERFACE BOARD
LED DIAGNOSTIC LIGHTS
D1 24 VAC to left gas valve (dual vat only)
D2 24 VAC to left ignition module (dual vat only)
D3 24 VAC from transformer
D4 24 VAC to right ignition module
D5 24 VAC to gas valve (right valve if dual vat)
D6 12 VAC from transformer
D7 CE and Japanese units only: air switch closed
NOTE: In full-vat fryers, the relay for the left side (K2) may not be present.
The chart on the following page illustrates current flow through the board, and the table at the top of page 1-4
identifies frequently used test points.
1-2
1-3
FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD 106-6706
TEST
12VAC Power to Controller 50VAC Scale 1 and 3 on J3 or J2 12-18
24VAC Power to Right Module 50VAC Scale 8 on J3 and GROUND 22-28
120 VAC Power 250VAC Scale 11 on J3 and GROUND 110-125
120 VAC Power to Blowers 250VAC Scale 12 on J3 and GROUND 110-125
24VAC Power to Full or Right vat High-Limit 50VAC Scale 9 on J3 and GROUND 22-28
24VAC Power to Left High-Limit (if present) 50VAC Scale 9 on J1 and GROUND 22-28
Probe Resistance (Full or Right Vat) * R x 1000 OHMS 2 and 6 on J3 or 13 and 14 on J2 **
Probe Resistance (Left - if present) * R x 1000 OHMS 2 and 6 on J1 or 14 and 15 on J2 **
Probe Isolation R x 1000 OHMS 6 on J1 or J3 and GROUND ***
High-Limit Continuity (Full or Right Vat) R x 1 OHM 9 on J3 and Wire 13C on Gas Valve 0
High-Limit Continuity (Left - if present) 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 Chart on page 1-28.
*** 5 mega-Ohms or greater.
METER
SETTING
PINS RESULTS
1.4 Thermostats
OCF30™ series gas fryers have temperature probes located on the front centerline of each frypot. In this type of
thermostat, 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 1º F. Circuitry in the controller monitors the probe resistance
and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints).
OCF30™ series gas fryers are also 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 highlimit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 425ºF to
450ºF (218ºC to 232ºC). The different types of thermostats have different part numbers for CE and Non-CE models,
and are not interchangeable.
1.5 Accessing Fryers for Servicing
DANGER
Moving a fryer filled with oil may cause spilling or splattering of the hot liquid. Follow the
draining instructions in Chapter 5 of the OCF30™ Series Gas Fryer Installation and
Operation Manual (P/N 819-6687) 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 and relocate the fryer for service accessibility.
3. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and plug in the
electrical cords.
1-4
1.6 Cleaning the Gas Valve Vent Tube
1. Set the fryer power switch and the gas valve to the OFF position.
2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened for ease of
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 the tube and bend it so that the opening is pointing downward.
1.7 Checking the Burner Manifold Gas Pressure
1. On non-CE fryers only ensure that the gas valve knob is in the OFF position.
Honeywell
ON
OFF
2. Remove the pressure tap plug from the gas valve assembly.
Pressure Tap Plug
Typical Non-CE
Valve Assembly
Typical CE Valve
Assembly
3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.
4. On non-CE fryers only, place the gas valve in the ON position.
5. Place the fryer power switch in the ON position. When the burner has lit and burned steadily for at least one
minute, compare the gas pressure reading to the pressure for the corresponding gas in the appropriate table on the
following page. The tables list the burner manifold gas pressures for each of the gas types that can be used with
this equipment.
1-5
CE Standard
Burner Manifold Gas Pressures
Pressure
(mb a r )
Single
Gas
Natural Gas Lacq
(G20) under 20 mbar
Natural Gas Gronique
(G25) under 25 mbar
Natural Gas Gronique
(G25) under 20 mbar
Butane/Propane
(G30) at 28/30 or 50 mbar
Propane
(G31) under 37 or 50 mbar
* Belgian G25 = 7,0 mbar
*
Vat
7
10
10
17
20
Non-CE Standa rd
Bur ne r Mani fold Ga s Pre ssures
Gas Pressure
Natural
Propane
3" W.C.
0.73 kPa
8.25" W.C.
2.5 kPa
6. To adjust the burner gas pressure, remove the cap from the gas valve regulator and adjust to the correct pressure.
Non-CE
Valve
CE
Valve
GAS VALVE REGULATOR CAP
7. Place the fryer power switch (and the gas valve in non-CE fryers) in the OFF position. Remove the fitting from
the pressure tap hole and reinstall the pressure tap plug.
1.8 Measuring Flame Current
When the burner flame is properly adjusted, it will produce a current between 2.5 A and 3.5 A. Flame current is
measured by placing a microamp (not milliamp) meter in series with the sensing wire on the ignitor. This is
accomplished as follows:
1. Place the fryer power switch in the OFF position.
1-6
r
2. Disconnect the sensing wire from one of the burner ignitors and connect it to the positive lead of the meter.
Connect the negative lead of the meter to the terminal from which the sensing wire was removed.
Flame Sensor Wire
3. Place the fryer power switch in the ON position to light the burners. After the frypot temperature reaches 200F
(93C), wait at least one minute before checking the reading. NOTE: The closer the unit is to normal operating
temperature, the more accurate the reading will be.
1.9 Replacing Fryer Components
1.9.1 Replacing the Controller or the Controller Wiring Harnesses
1. Disconnect the fryer from the electrical power supply.
2. Open the control panel by removing the screws on the bottom of the bezel. Carefully lower the bezel.
3. Remove the two screws from the upper corners of the controller. The controller 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 controller marking their position for
reassembly and disconnect the grounding wires from the terminals. Remove the controller by lifting it from the
hinged slots in the control panel frame.
Ground Wire Terminal
Communication Wires
Ground Wire Terminal
20-Pin Connecto
Locator Wire
3000 controller illustrated. CM3.5 not illustrated.
5. Install the replacement controller. Reverse steps 1 thru 4.
6. Setup the 3000 controller following the instructions on page 4-3 in the Installation and Operation manual. Setup
MUST be performed after replacement. See Frymaster Controller Manual 819-5871 for CM3.5 setup.
7. Once setup is complete on all replaced controllers, reset all control power following the instructions in section
1.13.6 on page 1-33 to readdress the new 3000 controller. Check software version and if necessary update the
software. If a software update was necessary, follow the instructions to update the software in section 1.15 on
page 1-40.
1.9.2 Replacing the Temperature Probe, ATO Probe or High-Limit Thermostat
1. Disconnect the fryer from the electrical supply.
2. Drain cooking oil below the level of the probe or thermostat.
3. Remove the screws on the bottom of the bezel. Carefully lower the bezel.
4. Remove the top two screws in the upper corners of the controller.
5. Swing the controller out from the top and allow it to rest on its hinge tabs.
6. Disconnect the controller wiring harness(es) and ground wire from the back of the controller and remove the
controller by lifting it from the hinge slots in the control panel frame.
7. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you.
8. Disconnect the flame sensor wires from the flame sensors.
9. Disconnect the sound device lead from the interface board.
1-7
10. If working on the left frypot, cut the wire tie on the wiring bundle and disconnect the main wiring harness 15-pin
connector.
11. Remove the component box mounting screws.
12. Rotate the top of the component box out of the frame and carefully pull it out enough to disconnect the wiring
harness plug from the back of the box. This will leave one set of wires, enclosed in spiral wrap, connected to the
component box.
13. Remove the box and set it atop the fryer to expose the temperature probe and high-limit thermostat.
14. Unscrew the probe or thermostat from the frypot.
15. Apply Loctite
®
PST56765 pipe thread sealant or equivalent to the replacement part threads and screw the
replacement part into the frypot, torquing to 180 inch-pounds.
16. If replacing the ATO probe, disconnect the harness from the ATO board or extension harness. Ensure when
replacing the new probe that it does not extend past the wall of the frypot before tightening the ferrule.
17. Connect the wires from the new component as follows:
a. If replacing the temperature probe, use a pin pusher to disconnect (one at a time) the red and white leads from
the connector and insert the corresponding leads from the new probe into the plug..
b. If replacing the high-limit thermostat, use a pin pusher to disconnect the lead running to the connector and
insert the corresponding lead from the new thermostat.
c. Disconnect the other lead from the drain safety switch and connect the remaining lead from the new
thermostat.
18. Reverse steps 1 through 13 to complete the procedure.
1.9.3 Replacing the Interface Board
1. Perform steps 1 through 4 from section 1.9.1.
2. Disconnect the wires attached to the interface board, marking or making a note of the wires and terminals to
facilitate reconnection.
3. Remove the nuts at each corner of the interface board and carefully pull it from the studs far enough to allow the
connector on the back of the board to be disconnected, then remove the board from the box. When removing the
board, be careful not to lose the spacers that fit over the studs behind the board.
4. Recover the relay(s) from the failed interface board and install on the replacement board.
5. Reverse the procedure to install the replacement board, being sure that the spacers behind the board are in place
and the computer locator ground wire is attached to a stud.
1.9.4 Replacing an Ignition Module
1. Disconnect the fryer from the electrical supply.
2. Remove the screws on the bottom of the bezel. Carefully lower the bezel.
3. Remove the top two screws in the upper corners of the controller.
4. Swing the controller out from the top and allow it to rest on its hinge tabs.
5. Loosen the nuts attached to the screws of the module. Slide the module towards the rear of the component box
until the nuts drop through the keyholes.
6. Carefully rotate the module and pull forward. On some units it may be necessary to remove the blower.
7. Disconnect the wires from the ignition module, marking or making a note of the wires and terminals to facilitate
reconnection.
8. Remove the screws from the module.
9. Move the screws and spacers to the new module.
10. Reverse the procedure to install the replacement module.
1.9.5 Replacing an Ignitor Assembly
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1. Disconnect the fryer from the electrical supply.
1-8
2. Disconnect the flame sensor wire by carefully pulling its push-on terminal from the terminal strip on the ignitor.
Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition cable from the
ignitor by grasping its boot and gently pulling toward you. (See photo below)
Flame Sensor Wire
Gas Enrichment Tube
Ignition Cable
3. Remove the sheet metal screws securing the ignitor to the mounting plate and pull the ignitor from the fryer.
4. Reverse the procedure to install the replacement ignitor.
1.9.6 Replacing or Cleaning a Combustion Air Blower
1.
Disconnect the blower wiring harness, remove the blower assembly mounting nuts, and remove the blower
assembly from the fryer. If cleaning the motor, continue with Step 2; otherwise, install the replacement blower,
reconnect the wiring harness, and then go to Step 6.
Blower assembly
mounting nuts
Wiring connection
2. Remove the blower motor shield and separate the blower motor from the housing as shown in the illustration
below.
Remove these screws to
remove the shield from the
blower assembly.
Remove these nuts to
separate the blower
motor from the housing.
3. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreaser or detergent on the blower
wheel and the blower housing. Allow it to soak for five minutes. Rinse the wheel and housing with hot tap water,
then dry with a clean cloth.
NOTICE- Australia Only
The air pressure switch on the combustion blower should read: Full Vat units-122pa (0.5
inches W.C.) and for Split Vat units-180pa (0.72 inches W.C.).
1-9
Wrap the motor and wires
with plastic wrap or a
plastic bag.
Blower Housing
Blower Wheel
4. Remove the plastic wrap from the blower motor assembly. Reassemble the blower motor assembly and blower
housing. Reinstall the blower shield.
5. Reinstall the blower assembly in the fryer and reconnect the wiring disconnected in Step 1.
6. Light the fryer in accordance with the procedure described in Chapter 3, Section 3.2.2 of the OCF30™ Series Gas
Fryer Installation and Operation Manual (P/N 819-6687).
7. After the burners have been lit for at least 90 seconds, observe the flames through the burner viewing ports
located on each side of the combustion air blower.
Right
Viewing Port is
behind motor.
Left Viewing
Port.
The air/gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable
table on page 1-6 and the burners display a bright orange-red glow. If a blue flame is observed or if there are dark
spots on a burner face, the air/gas mixture requires adjustment.
result in whistling. It should not be more than 1/3 open.
NOTE: Opening the air shutter too much may
1.9.7 Adjusting the Air/Gas Mixture
On the side of the blower housing opposite the motor is a shutter plate with a locking nut. Loosen the nut enough to
allow the shutter to be moved, then adjust the position of the shutter to open or close the air intake opening until a
bright orange-red glow is obtained. Carefully hold the shutter in position and tighten the locking nut (see illustration
on the following page).
1-10
On non-CE blowers
loosen this nut and rotate
shutter to open or close
air intake.
On CE blowers loosen
both wing nuts and slide
the shutter to adjust the
air intake.
1.9.8 Replacing a Gas Valve
1. Disconnect fryer from electrical and gas supplies.
2. Disconnect the drain safety and high-limit thermostat wires from the gas valve. Mark each wire to facilitate
reconnection.
3. Remove the vent tube (on non-CE fryers) and the enrichment tube fitting from the valve. Disconnect the flexible
gas line(s).
If replacing the left-most valve on any configuration, or the right valve on a two-fryer battery, follow the
instructions below. If replacing valves in other positions, skip to “ALL OTHER VALVES.”
A. Remove the filter pan from the unit. Remove the door adjacent to the valve being replaced.
B. Remove the screws that attach the pan rails adjacent to the valve being replaced.
C. Uncouple the pipe union and remove the gas valve and associated piping from the unit.
D. Remove the fittings and associated piping from the failed valve and install them on the replacement valve using
Loctite
E. Reconnect the gas valve assembly to the fryer using Loctite
reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the highlimit thermostat wires and drain safety wires to the valve.
F. Reconnect the fryer to the gas supply and open the cut off valve. Apply a thick soapy solution of water around
each connection to check for gas leaks and ensure there are no bubbles. Eliminate any that are found. There
should be no smell of gas.
G. Position the pan rail assembly beneath the fryer and rest the rear end of the rail on the cabinet frame. Install the
two nuts and bolts behind the front face of the rail, but do not tighten them. Install the nut and bolt at the rear end
of the filter rail and tighten securely.
H. Reattach the screws for the pan rails. Install the filter pan in the unit to make sure that all components are properly
aligned.
I. Reconnect the fryer to the electrical power supply and check for proper operation. When proper operation has
been verified, reinstall the door removed in Step A.
ALL OTHER VALVES
4. Carefully unscrew the valve from the manifold. NOTE: Some models may have the valve attached to the
manifold by means of a pipe union. In such cases, remove the valve by uncoupling the union.
5. Remove all fittings from the old gas valve and install them on the replacement valve, using Loctite
equivalent pipe thread sealant.
6. Reconnect the gas valve assembly to the fryer using Loctite
reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the highlimit thermostat wires and drain safety wires to the valve.
7. Reconnect the fryer to the gas supply and open the cut off valve. Apply a thick soapy solution of water around
each connection to check for gas leaks and ensure there are no bubbles. Eliminate any that are found. There
should be no smell of gas.
8. Reconnect the fryer to the electrical power supply and check for proper operation.
®
PST56765 or equivalent pipe thread sealant.
®
PST56765 or equivalent pipe thread sealant, and
®
PST56765 or
®
PST56765 or equivalent pipe thread sealant, and
1-11
1.9.9 Replacing a Burner Assembly
1. Disconnect the unit from the electrical and gas supplies.
2. Remove the gas line and enrichment tube using a 7/16” and 5/8” wrench from the front of the burner.
3. Remove the elbow and tee off the bottom of the burner to ensure easier
removal of the burner.
4. Remove the fryer back.
5. Remove the screws attaching the flue cap to the brace.
6. Remove the top cross brace in the back.
7. Remove the flue by removing the two screws in the rear and one screw in
the front of the flue.
Figure 1
8. Remove all the screws on the flue collector and bend back the tabs and remove the
collector.
9. Remove four screws on the collector insulation plate (see Figure 1).
10. Remove the four nuts and cover of the lower insulation retaining cover (see Figure
2).
11. Carefully remove the insulation.
12. Grasp the burner firmly and slide the burner out the rear of the fryer. Pull it toward
you until it clears the burner channels, taking care not to damage the ceramic tiles in
the process.
Figure 2
13. Slide the burner out the rear of the fryer.
14. Clean all debris from the burner channels and combustion area.
15. Inspect the upper and lower burner rails for cracked or burned out welds.
a. If the welds in the lower rail are cracked or burned out, the frypot must be
replaced. Refer to Section 1.9.11 for procedure.
b. If the welds in the upper rail are cracked or burned out, the upper rail must be
replaced. Refer to Section 1.9.12 for procedure.
16. Wrap a new insulating strip along the top, rear, and bottom edge of the burner.
NOTE: Use P/N 826-0931 for full-vat frypots and P/N 826-0932 for dual-vat
frypots.
17. Carefully slide the replacement burner into the rails starting at the top and lifting
slightly up on the bottom (see Figure 3). Ensure that the insulation is not torn or
Figure 3
damaged.
18. In reverse order, reassemble insulation and holding plates.
19. Install flue collector.
20. Install the flue.
21. Install the cross brace, ensuring the flue cap is secured to the brace.
22. Replace the fryer back.
23. Reattach the elbow, gas line and enrichment tubes to the front of the burner.
24. Fill the frypot with oil. Turn the fryer on; turn off or by pass the melt cycle and operate the unit for at least 10
minutes.
25. Examine the burner flame. The color and intensity on both sides should be the same.
Use an inspection mirror to check for leaks in areas that cannot be directly
26.
observed.
27. If a leak is detected, tighten all the lower insulation retainer nuts, allow the frypot to heat for five additional
minutes, and repeat steps 25 and 26.
28. If a leak persists, use a rubber hammer and a small block of wood to tap the corners of the lower combustion
chamber insulation retainers. Repeat steps 25 through 27. Repeat this step until no leakage is detected.
1-12
1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve
1. Disconnect the unit from the electrical power supply.
2. Remove the filter pan from the unit.
3. Position a container beneath the oil return fitting at the front of the cabinet. Disconnect the flexible oil lines from
the fittings, allowing any residual oil to drain into the container.
4. At the rear of the fryer, unplug the left connector (as viewed from the rear of the fryer) from the transformer box.
5. Remove the four nuts and bolts attaching the motor mount to the rear motor mount support.
6. At the front of the fryer, remove the cover plate from the front of the motor and disconnect the motor wires.
7. Place a 1-foot (30.5-cm) length of wood (or similar support) beneath the motor mount near the front of the unit
and remove the two remaining nuts and bolts attaching the motor mount to the front cabinet cross-brace.
8. Carefully remove the support and lower the motor mount to the floor, allowing the rear of the mount to slide
forward and off the rear motor mount support.
9. Disconnect the return flexline from the pump. The motor and pump assembly can now be pulled from beneath the
fryer and the failed component can be removed and replaced.
10. Position the replacement motor and pump assembly beneath the fryer and reconnect the oil return flexline to the
pump. Lift the rear of the motor mount up and onto the rear motor mount support.
11. Lift the front of the motor mount up and support it with a 1-foot (30.5-cm) piece of wood or a similar support.
Install but do not tighten the two nuts and bolts that attach the motor mount to the front cabinet cross-brace.
12. Install and tighten the four nuts and bolts that secure the motor mount to the rear motor mount support.
13. At the front of the fryer, tighten the two nuts and bolts at the front of the motor mount. Reconnect the motor
power wires and reinstall the wiring cover plate.
14. Reconnect the oil return flexline and reinstall the filter pan.
15. Reconnect the unit to the electrical power supply, fill the frypots with oil and check for proper operation.
1.9.11 Replacing the Frypot
1. Disconnect the fryer from the electrical and gas supplies.
2. Remove the filter pan from the unit and drain one frypot at a time into a Shortening Disposal Unit (SDU) or other
appropriate metal container.
DANGER
DO NOT attempt to drain more than one full frypot into the SDU at one time.
3. Open the control panel by removing the two screws on the bottom of the bezel. Carefully lower the bezel.
4. Remove the top screws in the upper corners of the controller.
5. Grasp the upper edge of each controller and swing the controller downward. Unplug the controller wiring harness
and grounding wire from the back of each controller.
6. Remove the controllers by lifting them from the hinge slots in the control panel frame.
7. Disconnect the sound device wire from the interface board.
8. Disconnect the flame sensor wires by carefully pulling the push-on terminals from the terminal strips on the
ignitors. Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition
cables from the ignitors by grasping the boots and gently pulling toward you.
9. Dismount the topcap by removing the screws on the bottom of each front corner and lifting the topcap straight up.
10. Remove the two mounting screws on each side of the component box and rotate the top of the box out of the
frame. Carefully pull it out enough to disconnect the wiring harness connector from the back of the box. Cut any
ties that prevent the box from being pulled out of the control panel frame.
11. Carefully pull the box clear of the frame and rest it on top of the fryer.
12. Using a pin pusher, remove the temperature probe, high-limit thermostat wires and RTD probe wires from the
plugs or terminals, marking each wire to facilitate re-assembly.
13. Remove the cover from the safety drain switch. Disconnect the wires from the switch.
14. Disconnect any auto top-off sensors if equipped and wiring.
15. Remove the section(s) of drain from the drain valve(s) of the frypot to be removed.
1-13
16. Disconnect the gas lines from the burner orifices and ignitor assemblies.
17. Remove the frypot hold down bracket.
18. Remove the screws in the back panel and inside the flue cap at each end that secure the flue cap to the fryer and
lift it clear of the fryer.
19. Disconnect the oil return line(s) from the frypot to be removed.
20. Carefully lift the frypot from the fryer cabinet.
21. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), RTD probes, auto top-off sensors if
equipped and ignitor assemblies. Inspect each of these components carefully and install them in the replacement
frypot if they are in serviceable condition. Use Loctite
®
PST56765 sealant or equivalent on component threads.
NOTE: Some servicers, based upon their experience, recommend that probes and thermostats be replaced
whenever a frypot is replaced; however, this remains the customer’s decision.
20. Reverse steps 1-19 to reassemble fryer.
NOTE: Care should be taken not to over-torque nuts on frypots made of 400-series stainless steel, as this could
tear the material. One turn past hand-tight is sufficient torque.
21. Perform steps 14 through 18 of Section 1.9.9 to ensure that there are no leaks in the burner insulation.
CAUTION
Before installing temperature probe, high-limit thermostat, RTD probe and drain valve on
replacement frypot, clean the threads and apply Loctite® PST56765 thread sealant or
equivalent.
1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails
NOTE: Replacing the burner rails requires completely tearing down the frypot and installing new frypot insulation.
Refer to the frypot exploded view below for component identification.
1. Remove the frypot per Section 1.9.11.
2. Remove the burner assemblies (1).
3. Remove insulation retainers and blanket insulation (2).
4. Remove the upper oil zone insulation bracket and upper oil zone insulation (3).
5. Remove the plenum (4).
6. Remove the front lower combustion chamber insulation retainer and insulation (5) and the front lower combustion
chamber inner insulation retainer and insulation (6). NOTE: Full-vat units have two-piece insulation retainer and
insulation components. Dual-vat units have one-piece components.
7. Remove the upper combustion chamber insulation retainer and insulation (7).
8. Remove the inner upper combustion chamber insulation retainer and insulation (8).
9. Remove the rear lower combustion chamber retainers, back, and insulation (9). NOTE: Full-vat units have two-
piece backs and four retainers. Dual-vat units have one-piece backs and two retainers.
10. Remove the flue assembly (10).
1-14
10
Spacer
2
9
3
Spacer
s
8
11
1
4
7
6
5
Disassembling A Frypot
(Full Vat Illustrated)
See page 1-17 for reassembly illustration.
11. Remove the upper burner rails (11). NOTE: For the following steps, refer to the frypot exploded view on page 1-
16 for component identification.
12. Remove any residual insulation, sealant, and/or oil from the exterior of the frypot.
13. Place the “L” shaped pieces of the combustion chamber insulation (1) in the front and rear corners of both upper
rail-retaining slots. (See page 1-17).
14. Using a mallet and short piece of wood, tap the corner tabs of the combustion chamber over the insulation to
ensure a solid seal of the burner.
15. Install the upper burner rails (2) with the heat deflectors slanting toward the rear of the frypot. The rails will
cover the “L” shaped pieces of combustion chamber insulation previously installed.
16. Place the upper inner combustion chamber insulation and insulation retainers (3) on the top two studs on each side
of the front of the frypot and secure with ¼”-20 washer-nuts. It is normal for the retainers to slice off the
overhanging insulation.
17. Place the lower rear combustion chamber insulation (4) on the lower four studs at the rear of the frypot.
18. Place one 1.625-inch tubular spacer (5) on each of the flue assembly (upper) studs at the rear of the frypot.
NOTE: There are three different sizes of spacers. Verify the size to ensure the correct spacers are installed.
19. Press the flue assembly (6) over the burner rails. It may be necessary to use a rubber mallet or screwdriver to
align the components. Use four ¼”-20 washer nuts to secure the flue assembly. Do not tighten the retainer
nuts at this point. They should be finger-tight only. NOTE: The flue edge will cover one to two inches of the
lower insulation.
20. Install the lower rear combustion chamber back(s) and retainer(s) (7) with the flanged edge(s) against the flue.
Secure with ¼”-20 washer nuts. NOTE: Full-vat units have two-piece backs and four retainers. Dual-vat units
come with one-piece backs and only two retainers.
1-15
21. Insert the burners (9) into the rails to ensure the rail spacing and alignments are correct. The burner should slide
freely into and out of the rails. The upper rail can be bent slightly to increase or decrease tension on the burner
and the edges of the slot can be closed or opened slightly to best fit the burner frame.
22. Carefully wrap a strip of burner insulation (8) tightly around the rear and sides of the burner frame (9), with the
glass-tape side of the strip on the outside. Do not use duct tape or adhesive to secure the strip to the burner
frame.
23. Align the burner to the burner rails while maintaining tension on the insulation strip. Insert the burner at a slight
angle and begin pushing the burner slowly into the rails until it contacts the rear combustion chamber. The fit
should be snug, but not excessively tight.
24. Verify that the burners are flush with the front edge of the burner rails. Remove the excess burner insulation by
cutting with a knife or diagonal pliers. Do not try to tear the insulation!
25. Insert the upper front insulation (10) into its retainer (11), making sure that the holes in each piece are aligned
with one another. Install the assembly with the insulation side toward the frypot and secure with ¼”-20 washernuts. Do not over tighten.
26. Place a washer on each of the four lower studs on the front of the frypot. Install the lower inner front insulation
(12) with the rectangular openings toward the drain valve nipple. Install the lower inner front insulation
retainer(s) (13). NOTE: Full-vat units have a two-piece insulation retainer. Dual-vat units have a one-piece
retainer.
27. If necessary, replace the sight-glasses and insulation (14).
28. Place one washer and one 1.888-inch spacer (15) on each stud. NOTE: There are three different sizes of spacers.
Verify the size to ensure the correct spacers are installed.
29. Insert the front lower insulation (16) into the front lower insulation retainer(s) (17) and install assembly on
frypot. Secure with ¼”-20 washer-nuts. If frypot uses two retainers, connect them together with two ¼” selftapping screws. NOTE: Full-vat units have a two-piece insulation retainer and two pieces of insulation. Dual-vat
units have one-piece components.
30. Return to the rear of the frypot and fully tighten all washer-nuts.
31. Remove and replace the plenum gaskets (18).
32. Place a 0.938-inch spacer (19) on the plenum-mounting studs, and mount the plenum (20). Ensure the gaskets
are clear of the burner tubes by pulling the plenum back slightly. Place a washer on each stud and secure plenum
with ¼”-20 lock-nuts.
33. Install the upper oil-zone insulation (21) by pressing it under the upper combustion chamber metalwork. Secure
the insulation with the bracket (22) and ¼” self-tapping screws.
34. Install the upper burner rail blanket insulation (23). Position any excess insulation toward the top of the frypot.
Avoid overhang past the bottom of the upper burner rail. Overhang in this area will make future burner
replacement more difficult.
35. Cover the insulation with the insulation retainer (24), and secure with ¼” self-tapping screws.
36. Reinstall probes, drain valves, high-limit thermostats, and other pipe fittings using Loctite® PST56765 sealant or
equivalent on the threads.
1-16
6
5
24
4
23
21
22
1
2
7
8
1
9
17
16
15
3
10
20
19
12
11
13
14
18
Re-assembling A Frypot
(Full-Vat Illustrated)
1.10 Troubleshooting and Problem Isolation
Because it is not feasible to attempt to include in this manual every conceivable problem or trouble condition that
might be encountered, this section is intended to provide technicians with a general 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 six categories:
1. Ignition failure
2. Improper burner function
3. Improper temperature control
4. Controller malfunctions
5. Filtration malfunctions
6. Leakage
The probable causes of each category are discussed in the following sections. A series of Troubleshooting Guides is
also included at the end of the chapter to assist in solving some of the more common problems.
1-17
1.10.1 Heating (Ignition) Failure
Heating (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.
3000 controllers display “HEATING FAILURE.”
The three primary reasons for ignition failure, listed in order of probability, are problems related to:
1. Gas and/or electrical power supplies
2. Electronic circuits
3. Gas valve.
PROBLEMS RELATED TO THE GAS AND/OR ELECTRICAL POWER SUPPLIES
The main indicators of this are that an entire battery of fryers fails to light and/or there are no indicator lights
illuminated on the fryer experiencing ignition failure. Verify that the quick disconnect fitting is properly connected,
the fryer is plugged in with connector twisted and locked, the main gas supply valve is open, and the circuit breaker
for the fryer electrical supply is not tripped.
PROBLEMS RELATED TO THE ELECTRONIC CIRCUITS
If gas and electrical power are being supplied to the fryer, the next most likely cause of ignition failure is a problem in
the 24 VAC circuit. Verify that the drain valve is fully closed. The valve is attached to a microswitch that must be
closed for power to reach the gas valve (often, although the valve handle appears to be in the closed position, the
microswitch is still open). If the valve is fully closed, refer to Section 1.11.1, TROUBLESHOOTING THE 24 VAC
CIRCUIT.
Some typical causes of heating failure in this category include a defective sensing wire in the ignitor assembly, a
defective module, a defective ignition wire, and a defective ignitor.
Occasionally, a heating failure occurs in which all components appear to be serviceable and the microamp reading is
within specification, but the unit nevertheless goes into ignition failure. The probable cause in this case is an
intermittent failure of an ignition module. When the unit is opened up for troubleshooting, the module cools down
enough to operate correctly; however, when the unit is again closed up and placed back into service the module heats
up and fails.
PROBLEMS RELATED TO THE GAS VALVE
If the problem is not in the 24 VAC circuit, it is most likely in the gas valve, itself. Before replacing the gas valve,
refer to Section 1.11.2
1.10.2 Improper Burner Function
TROUBLESHOOTING THE GAS VALVE.
With problems in this category, the burner ignites but exhibits abnormal characteristics such as “popping,” dark spots
on the burner ceramics, fluctuating flame intensity, and flames shooting out of the flue.
“Popping” indicates delayed ignition. In this condition, the main gas valve is opening but the burner is not
immediately lighting. When ignition does take place, the excess gas “explodes” into flame, rather than smoothly
igniting.
The primary causes of popping are:
Incorrect or fluctuating gas pressure
Defective or incorrectly adjusted
combustion air blower
Inadequate make-up air
Heat-damaged computer or ignition module
1-18
Cracked ignitor or broken ignition wire
Defective ignition module
Cracked burner tile (typically causes a very
loud pop).
If popping occurs only during peak operating hours, the problem may be incorrect or fluctuating gas pressure.
Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the appropriate CE or
Non-CE Standard found in Section 2.3 page 2-4 of the OCF30™ Series Gas Fryer Installation and Operation
Manual (PN 819-6687), and that the pressure remains constant throughout all hours of usage. Refer to
Section 1.7, Checking the Burner Manifold Gas Pressure in this manual for the procedure for checking the
pressure of gas supplied to the burner.
If popping is consistent during all hours of operation, the most likely cause is an insufficient air supply.
Check for “negative pressure” conditions in the kitchen area. If air is flowing into the kitchen area, this
indicates that more air is being exhausted than is being replenished and the burners may be starved for air.
If the fryer’s gas and air supplies are correct, the problem is most likely with one of the electrical components.
Examine the ignition module and controller for signs of melting, distortion, and/or discoloration due to
excessive heat build-up in the fryer (this condition usually indicates improper flue performance). A melted or
distorted ignition module is automatically suspect and should be replaced; however, unless the condition
causing excessive heat is corrected, the problem is likely to recur.
Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage. Again, if
damage is due to excessive heat in the fryer, that problem must also be corrected. Check for proper operation
by disconnecting the wire from the ignitor (spark plug), inserting the tip of a screw driver into the terminal.
With the insulated handle of the screwdriver, hold the shaft near the frame of the fryer as the power switch is
placed in the ON position. A strong, blue spark should be generated for at least four seconds.
DANGER
Make sure you are holding the insulated handle of the screwdriver and not the blade.
The sparking charge is approximately 25,000 volts.
Examine the ignitor (spark plug) for any signs of cracking. A cracked ignitor must be replaced.
If all other causes have been ruled out, examine the burner tiles for any signs of cracking. If cracking is
found, the burner must be replaced.
Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure, but
may also be the result of variations in the kitchen atmosphere. Verify incoming gas pressure in the same way
as for “popping,” discussed in the preceding paragraphs. Variations in the kitchen atmosphere are usually
caused by air conditioning and/or ventilation units starting and stopping during the day. As they start and
stop, the pressure in the kitchen may change from positive or neutral to negative, or vice versa. They may
also cause changes in airflow patterns that may affect flame intensity.
Dark spots on the burner tiles are the result of an improper air/gas mixture. Adjust the combustion air
blower to reduce the amount of air in the mixture to correct this problem
Flames shooting out of the flue are usually an indication of negative pressure in the kitchen. Air is being
sucked out of the burner enclosure and the flames are literally following the air. If negative pressure is not the
cause, check for high burner manifold gas pressure in accordance with the procedures in Section 1.7.
An excessively noisy burner, especially with flames visible above the flue opening, may indicate that the gas
pressure is too high, or it may simply be that the gas valve vent tube is blocked. If the incoming gas pressure
is correct and the vent tube is unobstructed, the gas valve regulator is probably defective.
Occasionally a burner may apparently be operating correctly, but nevertheless the fryer has a slow recovery
rate (the length of time required for the fryer to increase the oil temperature from 250ºF to 300ºF (121ºC to
149ºC)). The primary causes of this include an over-filled frypot, a dirty or out-of-adjustment combustion air
blower, low burner manifold pressure, and/or damaged burner tiles. Adding oil to the frypot during the
recovery process will also cause a slow recovery rate.
If these causes are ruled out, the probable cause is a misadjusted gas valve regulator. Refer to Section 1.7,
Checking the Burner Manifold Gas Pressure, for the gas valve adjustment procedure.
1-19
1.10.3 Improper Temperature Control
Temperature control, including the melt cycle, is a function of several interrelated components, each of which
must operate correctly. The principle component is the temperature probe. Other components include the
interface board, the controller itself, and the ignition module.
Improper temperature control problems can be categorized into melt cycle problems and failure to control at
setpoint problems.
MELT CYCLE PROBLEMS
Initiation of the melt cycle with 3000 controllers is automatic. Problems may originate from the controller
itself, the temperature probe, or a malfunctioning heat relay on the interface board.
FAILURE TO CONTROL AT SETPOINT
Problems in this category may be caused by the temperature probe, the interface board, or the controller.
1.10.4 Controller Malfunctions
RECOVERY TIME
Recovery time – is a method of measuring a fryer’s performance. Put simply, it is the time required for the
fryer to increase the oil temperature from 250ºF to 300ºF (121ºC to 149ºC). This range is used as a standard
since ambient kitchen temperatures can affect the test if lower ranges are used.
The 3000 controller performs the recovery test each time the fryer warms up. An operator can view the
results of the test any time the fryer is above the 325ºF (163ºC) point by pressing the INFO button once when
the fryer is on. The test results will be displayed in the controller’s LED panel in minutes and seconds. The
maximum acceptable recovery time for OCF30™ series gas fryers is two minutes and twenty-five seconds
(2:25).
1.10.5 Filtration Malfunctions
The majority of filtration problems arise from operator error. One of the most common errors is placing the
filter pad on the bottom of the filter pan rather than over the filter screen.
Whenever the complaint is “the pump is running, but no oil is being filtered,” check the installation of the
filter pad, including that the correct size is being used. While you are checking the filter paper/pad, verify
that the O-rings on the filter pan suction tube are present and in good condition. Missing or worn O-rings will
allow the pump to suck air and decrease its efficiency.
If the pump motor overheats, its 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
located on the front of the motor. If the pump then
starts, something caused the motor to overheat. It may
be that several frypots in a large battery of fryers were
being filtered one after the other and the pump became
hot. Letting the pump cool down for at least a halfhour is all that is required in this case. More often, the
pump overheated for one of the following reasons:
Shortening that remained in the pan, after
previous filtering, solidified in the suction
tube recess in the bottom of the pan or the
suction tube, itself. Adding hot oil to the pan and waiting a few minutes will usually correct this
problem. A flexible wire can be used to clean out the suction tube and the recess in the bottom of the
pan. NEVER use compressed air to blow solidified shortening out of the suction tube!
FLOW
FREEING A SEIZED PUMP
Sedim ent Particle
Up fo r re v e rse
Down for forward
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The operator attempted to filter oil that was not heated. Cold oil is thicker and causes the pump
motor to work harder and overheat.
If the motor hums but the pump does not rotate, 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 into the pump. When sediment
enters the pump, the gears can bind up and cause the motor to overload, tripping the thermal overload.
Solidified shortening in the pump will also cause it to seize, with similar results.
A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a
screwdriver or other instrument as illustrated on the following page. Make sure power to the pump motor
is off before trying this.
1. Disconnect power to the filter system.
2. Remove the input plumbing from the pump.
3. Use a screwdriver to manually turn the gears.
Turning the pump gears backwards will release a hard particle and allow its removal.
Turning the pump gears forward will push softer objects and solid shortening through the pump and
allow free movement of the gears.
Filter paper/pads that are installed incorrectly will also allow food particles and sediment to pass through and
clog the suction tube recess on the bottom of the filter pan or the suction tube, itself. Particles large enough to
block the suction tube recess or the suction tube may indicate that the crumb tray is not being used.
1.10.6 Leakage
Leakage of the frypot will usually be due to improperly sealed high-limit thermostats, RTD’s, temperature
probes, and drain fittings. When installed or replaced, each of these components must be sealed with Loctite
®
PST56765 sealant or equivalent to prevent leakage. In very rare cases, a leak may develop along one of the
welded edges of the frypot. When this occurs, the frypot must be replaced.
If the sides or ends of the frypot are coated with oil, the most likely cause is spillage over the top of the frypot
rather than leakage.
The clamps on the rubber boots that hold the drain tube sections together may loosen over time as the tubes
expand and contract with heating and cooling during use. Also, the boot itself may be damaged. If the
section of drain tube connected to the drain valve is removed for any reason, ensure that its rubber and clamps
are in good condition and properly fitted around the drain tube when it is reinstalled. Also, check to ensure
that the drain tube runs downward from the drain along its whole length and has no low points where oil may
accumulate.
1.10.7 Basket Lift Malfunctions
OCF30™ series gas fryers may be optionally equipped with automatic basket lifts to ensure uniform cooking
times. Basket lifts will always come in pairs, although each operates independently of the other. A modular
basket lift 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. A gear on the motor shaft engages teeth in the rod. Depending upon
the direction of motor rotation, the gear drives the rod up or down.
Timing circuitry in the controller initiates and stops operation of the basket lift depending upon the variables
programmed by the operator. When a product button is pressed, the timing circuitry activates a coil to supply
power to the motor, which lowers the basket into the frypot.
When the rod contacts and closes the lower microswitch, power to the motor is cut and the direction of
current flow is reversed; this reverses the direction of motor rotation. When the programmed cooking time
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has elapsed, power is again supplied to the motor. The motor raises the basket from the frypot until the rod
loses contact with the upper microswitch, cutting power to the motor and again reversing the direction of
current flow.
Problems with the basket lift can be grouped into three categories:
Binds and jams
Motors and gears
Electronics.
100-120V Configuration
208-250V Configuration
Binding and Jamming Issues
Noisy, jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and bushings.
Apply a light coat of Lubriplate
problem.
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.
®
or similar lightweight white grease to the rod and bushings to correct the
Motor and Gear Issues
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.
Correct the problem 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. This cannot be repaired and the motor must be
replaced.
If power is reaching the motor but the motor fails to run, it is burned out and must be replaced.
Electronic Issues
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.
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Troubleshooting the electronics of the basket lift is the 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 wiring
diagram on the pages 1-44 and 45 identifies the components and wiring connection points.
1.11 Troubleshooting Guides
The troubleshooting guides on the following pages are intended to assist service technicians in quickly
isolating the probable causes of equipment malfunctions by following a logical, systematic process. An
additional set of operator troubleshooting guides are contained in Chapter 7 of the OCF30 Series Installation
and Operation Manual. It is suggested that service technicians thoroughly familiarize themselves with both
sets.
1.11.1 Troubleshooting the 24 VAC Circuit
Prior to checking for problems associated with the 24 VAC circuit, ensure that the unit is connected to a
power supply, the drain valve is fully closed, and the controller is on and is calling for heat (green dot appears
under heat indicator and display toggles between LOW TEMP).
NOTE: All voltage measurements must be made within 4 seconds of the unit calling for heat. If unit does not
fire within 4 seconds, ignition modules will lock out and controller must be turned off, then on to reset.
The following processes will assist you in troubleshooting the 24 VAC circuit and ruling it out as a probable
cause:
24 VAC is not present on the interface board J3 pin 9 (LED 5 (GV)).
1. If LED 3 is not continually lit, the probable causes are a failed 24 VAC transformer or failed wiring
between the transformer and interface board.
2. If LED 3 is continually lit, check the right PWR terminal (LED 4) for 24 VAC.
check the left PWR terminal (LED 2) for 24 VAC.
Verify that the F2 fuse is not blown.
a. If 24 VAC is not present, the probable cause is a failed interface board, blown fuse or a defective
heat relay.
b. If 24 VAC is present, check for 24 VAC on V1S
(or V1D and V2D, if dual unit)..
i. If 24 VAC is not present, check the fuses. If they are good, the probable causes are failed
ignition module(s) or a failed interface board. Replace the questionable ignition module with
one known to be good to isolate the cause.
On dual units, also
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ii. If 24 VAC is present, the probable cause is a failed interface board.
24 VAC is present on interface board J3 pin 9 (LED 5 (GV))
(GV)).
1. If 24 VAC is not present across the gas valve main coil (MV terminals), probable causes are an open
high-limit thermostat or a failed wire between the interface board and gas valve.
valves on dual units.
a. Check continuity of high-limit thermostat and drain safety switch. If both are zero, problem is in
wiring.
2. If 24 VAC is present across the gas valve main coil (MV terminals), the 24 VAC circuit is working
and the problem may be with the gas valve.
Be sure to check both valves on dual vat units.
and, on dual units, on J1 pin 9 (LED 1
Be sure to check both
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