Frymaster FPGL230 Service Manual

PROTECTOR

Service & Parts Manual

SERIES

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 FEBRUARY 2009

www.frymaster.com

E-mail: service@frymaster.com

*8196345*

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 AUTHORIZED SERVICE CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR 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 DEAN Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for definitions of qualified personnel.

NOTICE This equipment must be installed in accordance with the appropriate national and local codes of the country and/or region in which the appliance is installed. 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.

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

PROTECTOR® 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.................................................................................................. 1-7

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

1.9.3 Replacing the Interface Board............................................................................ 1-8

1.9.4 Replacing an Ignition Module............................................................................ 1-9

1.9.5 Replacing an Ignitor Assembly.......................................................................... 1-9

1.9.6 Replacing or Cleaning a Combustion Air Blower............................................1-10

1.9.7 Adjusting the Air/Gas Mixture.........................................................................1-11

1.9.8 Replacing a Gas Valve.....................................................................................1-12

1.9.9 Replacing a Burner Assembly.......................................................................... 1-13

1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve....... 1-14

1.9.11 Replacing the Frypot ........................................................................................1-14

1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails..................................1-16

1.10 Troubleshooting and Problem Isolation.......................................................................... 1-19

1.10.1 Ignition Failure.................................................................................................1-19

1.10.2 Improper Burner Function................................................................................1-20

1.10.3 Improper Temperature Control ........................................................................ 1-21

1.10.4 Computer Malfunctions.................................................................................... 1-22

1.10.5 Filtration Malfunctions.....................................................................................1-22

1.10.6 Leakage ............................................................................................................1-24

1.10.7 Basket Lift Malfunctions..................................................................................1-24

1.11 Troubleshooting Guides..................................................................................................1-26

1.11.1 Troubleshooting the 24 VAC Circuit............................................................... 1-26

1.11.2 Troubleshooting the Gas Valve........................................................................ 1-28

1.11.3 Troubleshooting the Temperature Probe.......................................................... 1-28

Probe Resistance Chart.................................................................................................... 1-29

1.12

1.13 ATO (Automatic Top-Off) Service Procedures.............................................................. 1-29

1.13.1 ATO (Automatic Top-Off Troubleshooting.....................................................1-30

1.13.2 ATO (Automatic Top-Off) Board Positions and Harnesses ............................ 1-31

1.13.3 Replacing the ATO Board or Transformer....................................................... 1-32

1.13.4 Replacing the ATO Pump or Solenoid.............................................................1-32

1.14 CM7 Computer Service Procedures................................................................................ 1-32

1.14.1 CM7 Computer Troubleshooting ..................................................................... 1-32

1.14.2 CM7 Useful Codes and Passwords ..................................................................1-35

1.14.3 CM7 Menu Summary Tree...............................................................................1-36

1.14.4 CM7 Board Pin Positions and Harnesses.........................................................1-37

PROTECTOR® SERIES GAS FRYERS

TABLE OF CONTENTS cont.

1.15 Loading and Updating Software Procedures...................................................................1-38

1.16 Principal Wiring Connections.........................................................................................1-39

1.17 Wiring Diagrams............................................................................................................. 1-40

1.17.1 Main Wiring..................................................................................................... 1-40

1.17.2 Transformer / Filter Boxes...............................................................................1-41

1.17.2.1 FPGL230 and 430 Transformer/Filter Box (Domestic)................... 1-41

1.17.2.2 FPGL330 Transformer/Filter Box (Domestic).................................1-42

1.17.3 Modular Basket Lift (100/120V)...................................................................... 1-43

1.17.4 Modular Basket Lift (208/250V)...................................................................... 1-44

1.18 Simplified Wiring Diagrams........................................................................................... 1-45

1.18.1 FPGL30 Full-Vat Dual-Spark Module ............................................................1-45

1.18.2 FPGL30 Full-Vat Single-Spark Module (Australia & Pacific Rim)................ 1-46

1.18.3 FPGL30 Series Simplified Wiring ................................................................... 1-47

1.18.4 FPGL30 Series Data Network Flowchart......................................................... 1-48

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

2.5.2 Transformer Boxes.............................................................................................2-9

2.5.3 Computers and Associated Components.......................................................... 2-11

2.6 Wiring.............................................................................................................................. 2-12

2.6.1 Main Wiring Harnesses.................................................................................... 2-12

2.6.2 CM7 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 Frypot Assemblies and Associated Parts..........................................................2-16

2.8 Gas Supply and Combustion System Components.........................................................2-17

2.9 Gas Valves and Associated Components........................................................................ 2-19

2.10 Filtration System Components........................................................................................ 2-21

2.11 Return Valve Assembly and Associated Parts................................................................ 2-23

2.12 ATO (Auto Top-Off) Components..................................................................................2-24

2.12.1 JIB (Jug In Box) Low Indicator Light Assembly...........................................2-24

2.12.2 ATO (Automatic Top-Off) Board.................................................................. 2-24

2.12.3 ATO (Automatic Top-Off) Solenoid and Pump Assemblies......................... 2-25

2.12.4 JIB Cradle, JIB/BIB Cap and Pick Up Assemblies........................................2-25

2.13 Wiring Connectors, Pin Terminals, and Tools................................................................ 2-26

2.14 Fasteners.......................................................................................................................... 2-27

THIS PAGE INTENTIONALLY LEFT BLANK

PROTECTOR® SERIES GAS FRYER

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

Protector® 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 in the component box

Inside the Ignition Module

(located behind the control panel) is connected to an ignitor assembly at the burner. The ignition module performs four important functions: it provides fuse

Out to Gas Valve

To Al ar m

protection for the 24-volt circuit, provides an ignition spark, supplies voltage to the gas valve, and proofs the burner flame. The module contains a four second time delay circuit and a coil that activates the gas valve. Three

25 V +

Coil

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

GND

Ignition Wire Flame Sensor

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 computer 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

1-1

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 computer 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.

1.3 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 computer and the fryer’s individual components without requiring excessive wiring, and allows the computer 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

Meter

Test Pins Results

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 Vat High-Limit 50VAC Scale 9 on J3 and GROUND 22-28

Probe Resistance (Full Vat) * R x 1000 OHMS 2 and 6 on J3 or 13 and 14 on J2 **

Probe Isolation R x 1000 OHMS 6 on J1 or J3 and GROUND ***

High-Limit Continuity (Full Vat) R x 1 OHM 9 on J3 and Wire 13C on Gas Valve 0

** Disconnect 20-pin harness from controller before testing probe circuit.

** See Probe Resistance Chart at end of chapter. *** 5 mega-Ohms or greater.

Setting

1.4 Thermostats

Protector® 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 computer monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints).

Protector® 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 high-limit 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 Protector® Series Gas Fryer Installation and Operation Manual (P/N 819-6339) 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

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

Non-CE Standa rd

Burne r Ma nifold G a s Pre ssu res

Gas Pressure

Nat ur al

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

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.

1-6

1.8 Measuring Flame Current

When the burner flame is properly adjusted, it will produce a current between 2.5 μA and 3.5 μA. 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.

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

(Right Burner)

3. Place the fryer power switch in the ON position to light the burners. After the frypot temperature reaches 200°F (93°C), 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 Computer or the Computer Wiring Harnesses

1. Disconnect the fryer from the electrical power supply.

2. The computer 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 computer. The computer 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 (see following page) marking their position for reassembly and disconnect the grounding wires from the terminals. Remove the computer by lifting it from the hinged slots in the control panel frame.

Ground Wire Terminal

20-Pin Connecto

Communication Wires

Locator Wire

5. Install the replacement computer. Reinstall the control panel assembly by reversing steps 1 thru

6. Readdress the new CM7 computer. The readdress procedure can be performed from any one CM7 computer in the bank.

1-7

1.9.2 Replacing the Temperature 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. Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame.

4. Remove the top two screws in the upper corners of the computer.

5. Swing the computer out from the top and allow it to rest on its hinge tabs.

6. Disconnect the computer wiring harness and ground wire from the back of the computer and remove the computer 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.

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. 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. Disconnect the other lead from the drain safety switch and connect the remaining lead from the new thermostat.

17. 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.

6. Reverse the steps to reinstall the computer.

1-8

1.9.4 Replacing an Ignition Module

1. Disconnect the fryer from the electrical supply.

2. Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame.

3. Remove the top two screws in the upper corners of the computer.

4. Swing the computer out from the top and allow it to rest on its hinge tabs.

5. Disconnect the wires from the ignition module, marking or making a note of the wires and terminals to facilitate reconnection.

6. Remove the four ignition module screws and pull the module from the component box.

7. Move the spacers to the new module.

8. 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.

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

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.

Wiring connection Blower assembly

mounting nuts

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.

1-10

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 Protector® Series Gas Fryer Installation and Operation Manual (P/N 819-6339).

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

Left Viewing

Port is behind

motor.

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.

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).

Viewing

Port.

1-11

Loosen this nut and rotate shutter to open or close 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. Uncouple the pipe union and remove the gas valve and associated piping from the unit. C. Remove the fittings and associated piping from the failed valve and install them on the

replacement valve using Loctite® PST56765 or equivalent pipe thread sealant.

D. Reconnect the gas valve assembly to the fryer using Loctite® PST56765 or equivalent pipe thread

sealant, and reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the high-limit thermostat wires and drain safety wires to the valve.

E. Reconnect the fryer to the gas supply and open the cut off valve. Apply a solution of soapy water

around each connection to check for gas leaks. Eliminate any that are found.

F. 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.

G. Reattach the screws for the pan rails. Install the filter pan in the unit to make sure that all

components are properly aligned.

H. 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.

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5. Remove all fittings from the old gas valve and install them on the replacement valve, using Loctite® PST56765 or equivalent pipe thread sealant.

6. Reconnect the gas valve assembly to the fryer using Loctite® PST56765 or equivalent pipe thread sealant, and reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the high-limit 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 solution of soapy water around each connection to check for gas leaks. Eliminate any that are found.

8. Reconnect the fryer to the electrical power supply and check for proper operation.

1.9.9 Replacing a Burner Assembly

1. Disconnect the unit from the electrical and gas supplies.

2. Remove the combustion air blower per the procedure found in Section 1.6.6.

3. Remove the four nuts from the air plenum assembly and pull the assembly straight out toward you until it clears the burner tubes. NOTE: On a dual-vat fryer, it may be necessary to remove the drain valve handles before the plenum can be removed. NOTE: If the flexible oil return lines are blocking the plenum, carefully bend them upward enough to clear the plenum.

4. Disconnect the ignition cable from the ignitor by grasping its boot and pulling gently toward you. Disconnect the flame sensor wire from the ignitor by gently pulling its push-on terminal from the terminal strip on the ignitor.

5. Disconnect the flexible gas lines from the burner orifice and the enrichment tube from the ignitor assembly.

6. Remove the four ¼-inch nuts securing the outer front covers to the frypot assembly.

7. Remove the sheet metal screws at the top of the outer front covers and pull the covers straight out toward you until clear of the mounting studs.

8. Remove the washers and tubular spacers from the mounting studs, then pull the inner covers straight out toward you until clear of the mounting studs.

9. Grasp the burner firmly and pull it toward you until it clears the burner channels, taking care not to damage the ceramic tiles in the process.

10. Clean all debris from the burner channels and combustion area.

11. 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 1.6.11 for procedure.

b. If the welds in the upper rail are cracked or burned out, the upper rail must be replaced. Refer

to Section 1.6.12 for procedure.

12. Place a new insulating strip along the top, rear, and bottom edge of the burner and carefully slide it straight into the rails. NOTE: Use P/N 826-0931 for full-vat frypots and P/N 826-0932 for dual-vat frypots.

13. Reverse steps 1 through 9 to reassemble the components.

14. Fill the frypot with oil. Turn the fryer on, turn off or bypass the melt cycle, and operate the unit for at least 10 minutes.

15. Visually examine the burner flame. The color and intensity on both sides should be the same.

16. Use an inspection mirror to check for leaks in areas that cannot be directly observed.

17. If a leak is detected, tighten all the lower insulation retainer nuts, allow the frypot to run for five additional minutes, and repeat steps 15 and 16.

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18. If the 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 15 through 17. Repeat this step until no leakage is detected.

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 line from the fitting, 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. Dismount the topcap by removing the screws on the bottom of each front corner and lifting the topcap straight up.

4. Remove the bezels by lifting them up to disengage the tabs along the lower edges from the slots in the control panel frame. Remove the top screws in the upper corners of the computer.

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5. Grasp the upper edge of each computer and swing the computer downward. Unplug the computer wiring harness and grounding wire from the back of each computer.

6. Remove the computers 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. 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.

10. Carefully pull the box clear of the frame and rest it on top of the fryer.

11. 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.

12. Remove the cover from the safety drain switch. Disconnect the wires from the switch.

13. Remove the section(s) of drain from the drain valve(s) of the frypot to be removed.

14. Disconnect the gas lines from the burner orifices and ignitor assemblies.

15. Remove the frypot hold down bracket.

16. 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.

17. Disconnect the oil return line(s) from the frypot to be removed.

18. Carefully lift the frypot from the fryer cabinet.

19. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), RTD probes 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.

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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).

Spacer

Disassembling A Frypot

See page 1-18 for reassembly illustration.

(Full Vat Illustrated)

Spacer

1-16

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 1-16).

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.

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!

Insert the upper front insulation (10) into its retainer (11), making sure that the holes in each

25.

piece are aligned with one another. Install the assembly with the insulation side toward the frypot and secure with ¼”-20 washer-nuts. 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

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together with two ¼” self-tapping 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.

Re-assembling A Frypot

(Full-Vat Illustrated)

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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. Computer 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.

1.10.1 Ignition Failure

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 computer.

CM7 computers display “IGNITION 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 ignition failure in this category include a defective sensing wire in the ignitor assembly, a defective module, a defective ignition wire, and a defective ignitor.

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Occasionally, an ignition failure situation occurs in which all components appear to be serviceable and the microamp reading is within specification, but the unit nevertheless goes into ignition failure during operation. 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 TROUBLESHOOTING THE GAS VALVE.

1.10.2 Improper Burner Function

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

• 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 Protector® Series Gas Fryer Installation and Operation Manual (PN 819-6339), 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 computer 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.

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