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 [phone] FEBRUARY 2009

www.frymaster.com

E-mail: [e-mail]

*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.

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

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

iv

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

v

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

TD

HV

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

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

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

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

r

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

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

4.

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.

1-12

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.

1-13

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.

1-14

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.

1-15

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).

2

Spacer

s

4

6

5

Disassembling A Frypot

See page 1-18 for reassembly illustration.

3

8

7

(Full Vat Illustrated)

10

Spacer

9

11

1

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

1-17

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.

6

20

19

17

18

16

24

23

21

22

15

10

11

12

13

14

Re-assembling A Frypot

(Full-Vat Illustrated)

5

4

1

2

8

1

3

9

7

1-18

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.

1-19

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.

1-20

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.

1.10.3 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 computer itself, and the ignition module.

1-21

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 CM7 computers is automatic. Problems may originate from the
computer 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
computer.

1.10.4 Computer 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 CM7 computer 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 computer’s LED panel in minutes
and seconds. The maximum acceptable recovery time for Protector® series gas fryers is two minutes
and twenty-five seconds.

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 just 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 half-hour 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!

1-22

• 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.

PUMP

Sediment
Particle

Up for
reverse

• Turning the pump gears backwards will
release a hard particle and allow its
removal.

FLOW

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

Down for
forward

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.

The electronics of the FootPrint PRO system, illustrated in the schematic on the following page, are
simple and straightforward.

Microswitches, which are attached to handles for each vat and wired in parallel, provide the 24 VAC
required activating the pump relay coil when the
handles are moved to the ON position. The
activated pump relay coil pulls in the pump motor

Line VAC

Pump Heater Tape

switch, supplying power to the pump motor.

Verifying Solenoid Operation

Proper operation of the 24 VAC manifold and

24 VAC

pump solenoids can be verified by removing
the pump motor lead from terminal 4 of the
pump motor relay in the filter wiring box and

Solenoids

then activating the oil return lever. Proper
solenoid operation will be evidenced by an
audible “click” or vibration of both the pump
solenoid and the manifold solenoid.

Micro-switches

Pump Relay Coil

Pump Motor

M

Pump Motor Switch

FootPrint PRO Schematic

1-23

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

Protector® series gas fryers may be optionally equipped
with automatic basket lifts to ensure uniform cooking

100/120V Modular Basket Lift Assembly

P/N 1061807SP (TYPICAL)

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 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.

1-24

100-120V Configuration

BINDS AND JAMS

208-250V Configuration

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® or similar lightweight white grease to the rod and
bushings to correct the 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.

MOTORS AND GEARS

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.

ELECTRONICS

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

Troubleshooting the electronics of 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.

1-25

The wiring diagram on the Pages 1-45 and 46 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
BIGLA30 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 computer is on and is calling for heat
(green dot appears under heat indicator and display toggles between LOW and 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 computer 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. Verify that
the F2 fuse is not blown.
a. If 24 VAC is not present, the probable cause is a fa iled interface board, blown fuse or a

defective heat relay.

b. If 24 VAC is present, check for 24 VAC on V1S.

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.

• 24 VAC is present on interface board J3 pin 9 (LED 5 (GV)).

ii. If 24 VAC is present, the probable cause is a failed interface board.

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. It
may also be caused by a failed drain safety switch.
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.

1-26

1-27

1.11.2 Troubleshooting the Gas Valve

Prior to checking for problems associated with the gas valve, ensure that the unit is calling for heat.
Also, for non-CE units, verify that the gas valve is in the ON position.

The following processes will assist you in troubleshooting the gas valve and ruling it out as a
probable cause:

• If 24 VAC is not present across gas valve main coil, the probable cause is the 24 VAC circuit.
Refer to the 24 VAC circuit troubleshooting guide.

• If 24 VAC is present across gas valve main coil, check the incoming gas pressure and compare
to the tables on page 2-4 of the Installation and Operation manual.

1. If incoming gas pressure is not correct, the probable cause is a problem with the gas supply

to fryer.

2. If incoming gas pressure is correct, check the burner manifold gas pressure and compare it to

the tables on page 2-7 of the Installation and Operation manual.
a. If burner manifold gas pressure is not correct, the probable cause is an improperly

adjusted or failed gas valve. Adjust the valve by following the procedure “Check Burner
Manifold Pressure” in Section 1.7 of this manual. If the valve cannot be adjusted, replace
it.

b. If outgoing gas pressure is correct, the gas valve is okay.

1.11.3 Troubleshooting the Temperature Probe

CAUTION
Disconnect the CM7 computer before testing temperature probe resistances to avoid
invalid readings

Prior to checking for problems associated with the temperature probe, inspect the probe body for
damage while it is still in the frypot. Remove and replace the probe if it is bent, dented, or cracked.
Also, inspect leads for fraying, burning, breaks, and/or kinks. If found, replace the probe.

The following processes will assist you in troubleshooting the temperature probe and ruling it out as
a probable cause:

Before testing the probe, determine the temperature the cooking oil using another thermometer or
pyrometer placed at the tip of the questionable probe.

• If resistance through J3 pins 2 and 6 is not approximately equal to that given in the Probe

Resistance Chart on the following page for the corresponding temperature, the probe has
failed and must be replaced.

• If resistance through J3 pins 2 and 6 is approximately equal to that given in the Probe

Resistance Chart on the following page for the corresponding temperature, measure the
resistance through each of the previously tested pins to ground.

1. If resistance is not 5 mega-Ohms or greater in each pin, the probe has failed and must be
replaced.

2. If resistance is 5 mega-Ohms or greater in each pin, the probe is okay.

1.11.4 Replacing the Transformer or Filter Relay

Disconnect the fryer from the electrical power supply. Remove the cover from the transformer box
in the rear of the fryer to expose the interior of the transformer box. Replace the transformer or filter

1-28

relay marking the wires to ease reassembly. Once replaced, reconnect the power. When replacing a
filter relay in the transformer, ensure the 24VAC relay (8070012) is used.

1.12 Probe Resistance Chart

Probe Resistance Chart

For use with Protector® Series fryers manufactured with Minco Thermistor probes only.

F OHMS C F OHMS C F OHMS C F OHMS C F OHMS C

60 1059 16 130 1204 54 200 1350 93 270 1493 132 340 1634 171
65 1070 18 135 1216 57 205 1361 96 275 1503 135 345 1644 174
70 1080 21 140 1226 60 210 1371 99 280 1514 138 350 1654 177
75 1091 24 145 1237 63 215 1381 102 285 1524 141 355 1664 179
80 1101 27 150 1247 66 220 1391 104 290 1534 143 360 1674 182
85 1112 29 155 1258 68 225 1402 107 295 1544 146 365 1684 185
90 1122 32 160 1268 71 230 1412 110 300 1554 149 370 1694 188

95 1133 35 165 1278 74 235 1422 113 305 1564 152 375 1704 191
100 1143 38 170 1289 77 240 1432 116 310 1574 154 380 1714 193
105 1154 41 175 1299 79 245 1442 118 315 1584 157 385 1724 196
110 1164 43 180 1309 82 250 1453 121 320 1594 160 390 1734 199
115 1174 46 185 1320 85 255 1463 124 325 1604 163 395 1744 202
120 1185 49 190 1330 88 260 1473 127 330 1614 166 400 1754 204
125 1195 52 195 1340 91 265 1483 129 335 1624 168 405 1764 207

1.13 ATO (Automatic Top-Off) Service Procedures

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

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

Figure 1

1-29

1.13.1 ATO (Automatic Top-Off) Troubleshooting

Problem Probable Causes Corrective Action

A. Ensure power is present in the

transformer box.

B. If power is present in transformer

box, check the transformer for
correct voltage.

C. Ensure the yellow LED is securely

attached to plug J6 on the ATO
board.

A. Check to see that fryer is heating.

Check probe resistance. If probe is
bad, replace the probe.

B. Ensure that the oil in the JIB is

above 70°F (21°C).

C. Power to the ATO board has been

cut off. Ensure the board has power
and cycle ALL computers off and
on to readdress system.

D. Check solenoid to see if functioning

properly.

E. If the solenoid is working, ensure

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

F. Ensure transformer in ATO box is

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

G. Check for proper voltages using the

pin position chart found on page 1-

31. If ATO found defective, replace
ATO board.

A. Check power to the pump. A hot

pump suggests a failed solenoid.

B. Ensure all wiring harnesses are

securely connected to ATO board
and solenoids.

A. Check wiring.
B. Switch flexlines to correct vat.

The yellow JIB low

light won’t illuminate.

Frypots won’t top off.

One vat tops off but

other vats fail to top

off.

Incorrect vat tops off.

A. Power not present in the transformer

box.

B. Failed transformer.
C. Loose wire connection

A. Probe temperature lower than

setpoint.

B. Oil is too cold.
C. ATO board power loss
D. Failed solenoid.
E. ATO pump failed or over tightened.
F. Failed transformer/harness.
G. Failed ATO board.

A. Failed solenoid
B. Loose wire connection.

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

1-30

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

Connector From/To Harness # Pin # Function Voltage Wire Color

Green

Red

Green

Red

Green

Red

Black
White

Black

White

Black

White

Black

Red

Blue

Brown

Red

Red

Solenoids

Top Off Pump

J8

J4 (Rear) /

J5 (Front)

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

J6 Orange LED 8074555

J7

J10

J9 CM7 J6/J7 8074646

JIB Reset Switch

Solenoids

Top Off Pump & JIB

Reset Switch

Transformer 8074553

ATO RTD

Network Resistor

(pins 2 & 3)

or to next ATO Board

(4 & 5 vat units)

8074718 (FV)

8074717 (DV)

8074719

8074718 (FV)
8074717 (DV)

8074719

8074655 - Vat #1
8074654 - Vat #2
8074654 - Vat #3

8074552

(Network Resistor)

8074546

to next ATO board.

1 Output DV - Vat #1

2 Output FV - Vat #1

3 Output DV - Vat #2

4 Output FV - Vat #2

5 Output DV - Vat #3

6 Output FV - Vat #3

7 Top Off Pump Red

8 JIB Low Reset

9 24VAC DV - Vat #1

10 24VAC FV - Vat #1

11 24VAC DV - Vat #2

12 24VAC FV - Vat #2

13 24VAC DV - Vat #3

14 24VAC FV - Vat #3

15

16 Ground

1 24VAC Ret Orange
2 24VAC
3
4
5 12VAC Ret Red
6 12VAC
7
8
1 DV - Probe Ground White

2 DV - Probe Red

3 FV - Probe Ground White

4 FV - Probe

1 16VDC Black

2 16VDC Ret

1

2

3 Ground

4 RB7/DATA

5 RB6/CLOCK

1 Ground Black

2 CAN Lo Red

3 CAN Hi White

4

5

6

1 Ground Black

2 CAN Lo Red

3 CAN Hi White

4

5

6

Ground

16VDC

24VAC

16VDC

24VAC

12VAC

Ohm

16VDC

1-31

1.13.3 Replacing the ATO Board or Transformer

Disconnect the fryer from the electrical power
supply. Locate the ATO box (see Figure 1 on
page 1-29), behind the JIB (Jug In Box).
Remove the cover to expose the transformer and
ATO board (see Figure 2). Mark and unplug
any wires or harnesses. Replace the defective
component and reattach all wires or harnesses.
Replace the cover. Once replaced, reconnect the
power. Remove and restore power to ALL
computers after power has been restored to the

Figure 2

ATO board.

1.13.4 Replacing the ATO Pump or Solenoid

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

Figure 3

1.14 CM7 Computer Service Procedures

1.14.1 CM7 Computer Troubleshooting

Problem Probable Causes Corrective Action

No Display on

Computer.

A. Computer not turned on.

B. No power to the fryer.

C. Computer has failed.

D. Damaged computer wiring
harness.

A. Press the ON/OFF switch to

turn the computer on.

B. If the computer power cord is

not plugged in, the computer
will not activate. Verify
computer power cord is
plugged in and that circuit
breaker is not tripped.

C. Swap the computer with a

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

D. Swap with a harness known to

be good. If computer
functions, replace the harness.

1-32

Problem Probable Causes Corrective Action

E. If any component in the power

supply system (including the

Computer locks up.

Heat indicator off

upon initial startup.

Display shows hi or

hot with alarm

sounding.

CM7 display is in

wrong temperature

scale (Fahrenheit or

Celsius).

CM7 display shows

hot-hi-1.

CM7 display shows

HI-LIMIT.

CM7 display shows

low temp.

CM7 display shows

ERROR RM

SDCRD

E. Power supply component or

interface board has failed.

Computer error.

Failed computer.

Incorrect display option programmed.

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

Computer in high-limit test mode.

Frypot temperature is between 180°F
(82°C) and 315°F (157°C).

Defective SD Card Replace card with another card.

transformer and interface
board) fail, power will not be
supplied to the computer and it

will not function.
Remove and restore power to the
computer.

Replace computer.

See section 1.14.2 on page 1-35 to
change temperature scale.

This in an indication of a
malfunction in the temperature
control circuitry, including a
failure of the high-limit
thermostat.
This is displayed only during a
test of the high-limit circuit and
indicates that the high-limit has
opened properly.
This display is normal when the
fryer is first turned on while in the
melt cycle mode. To bypass the
melt cycle press and hold a #2
product button under the LCD
display until a chirp is heard. The
alarm will chirp and the computer
displays EXIT MELT

alternating with YES NO. Press
the #1 YES button to exit melt. It

may appear for a short while if a
large batch of frozen product is
added to the frypot. If the display
never goes out, the fryer is not
heating.

1-33

Problem Probable Causes Corrective Action

CM7 display shows

PROBE

FAILURE.

CM7 display shows

PROBE

FAILURE

with

alarm sounding.

CM7 display shows

IGNITION

FAILURE.

Computer will not

go into program

mode or some

buttons do not

actuate.

CM7 display shows

low temp,

heating indicator

cycles on and off

normally but fryer

does not heat.

CM7 display shows

igNITION

FAILURE with

alarm sounding.

Heating indicator is

on, but fryer is not

heating.

CM7 display shows

IGNITION

FAILURE and

alarm sounds, but

fryer operates

normally (false

alarm).

CM7 display shows

HI 2 BAD.

Problem with the temperature
measuring circuitry including the
probe.

Damaged computer wiring harness or
connector.

Open drain valve, failed computer,
failed interface board, open high­limit thermostat.

Failed computer. Replace computer

A. Failed computer.

B. Damaged computer wiring

harness.

Drain valve not fully closed. Press the reset switch on the MIB

Failed computer.

Computer in high-limit test mode.

This indicates a problem within
the temperature measuring
circuitry. Check resistance of
probe, if faulty replace probe.

Swap the computer wiring harness
with one known to be good. If
problem is corrected replace the
harness.

Is displayed if the fryer loses its
ability to heat oil. It is also
displayed when the oil
temperature is above 450°F
(232°C) and the high-limit
thermostat has opened, halting the
heating of the oil.

A. Replace computer.

B. Replace computer wiring

harness.

board. All drain valves should
close. Using the ON/OFF switch,
turn the computer OFF and then
ON again.

Replace computer.

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

1-34

Problem Probable Causes Corrective Action

Check that all harnesses between

CM7 display shows

software for only

Loose or damaged harness

CM7.

1.14.2 CM7 Useful Codes

To enter any of the following codes: Press the UNLOCK ▼ button three times. TECH is
displayed. Press the 9 button. CODE is displayed. Enter a code listed below for the appropriate
function.

• Enter Setup in Tech Mode – Enter 7378.

• Change from F° to C° - Enter 1658. The computer displays off. Turn the computer

on and check temperature to see the temperature scale. If the desired scale is not displayed,
repeat.

• Reset Factory Menu - Enter 3322. The computer display flashes and quickly counts
from 1-40 and switches to off. (NOTE: This will delete any manually entered menu
items).

• Reset BADCRC Message - Disconnect board locator plug (J10). Reinsert plug. Enter

9988. Computer display switches to off. Remove and then restore power to the

computer using the 20-pin plug.

• Reset RECOVERY FAULT CALL SERVICE – Enter 0042.

• Reset CALL TECH Message - Disconnect board locator plug (J10). Reinsert plug.

Enter 1000. Computer display switches to off. Remove and then restore power to the
computer using the 20-pin plug. If this message appears at any time other than after upgrade

from a previous version, replace the computer

PASSWORDS

Program Mode: Press the UNLOCK ▼ button once. The computer displays PROGRAM.

Press the 9 button. ENTER CODE is displayed. Enter 1650.

Manager Mode: Press the UNLOCK ▼ button twice. The computer displays MANAGER.
Press the 9 button. ENTER CODE is displayed. Enter 4321.

Tech Mode: Press the UNLOCK ▼ button three times. The computer displays TECH. Press the
9 button. CODE is displayed. Enter 7378.

CM7’s and ATO are secure.
Check for loose pins. If the
problem persists, swap out
computer from one bank to
another and reinitialize.

1-35

1.14.3 CM7 Menu Summary Tree

Reflected below are the major programming sections in the CM7 and the ord er in which submenu headings will be
found under the sections in the Installation and Operation Manual.

Adding New Menu Items See section 4.10.2
Storing Menu Items in Product Buttons See section 4.10.3
Temperature Conversion from F° to C° See section 4.10.4

1-36

1.14.4 CM7 Board Pin Positions and Harnesses

Pin

Connector From/To Harness PN

Interface

J2

J6

J7

J9

J10

J11 SD Card

Board to

Computer

Previous CM7
J7 or Network

Resistor

807-4552

ATO J1 or

Next CM7 J6

Interface

Board Ground

to Computer

8074199

SMT Computer to

Interface Board

Harness

8074546

Computer

Communication

Harness

8074546

Computer

Communication

Harness

8074573

Computer Locator

Harness

# Function Voltage Wire Color

1 12VAC In 12VAC
2 Ground
3 12VAC In 12VAC
4 FV Heat Demand
5 V Relay 12VDC
6 DV Heat Demand
7 R/H B/L 12VDC
8 Analog Ground

9 L/H B/L 12VDC
10 ALARM
11 Sound Device 5VDC
12 ALARM
13 FV Probe
14 Common Probes
15 DV Probe
16
17
18
19
20

1 Ground Black

2 CAN Lo Red

3CAN Hi White

4

5

6

1 Ground Black

2 CAN Lo Red

3CAN Hi White

4

5

6

1 Vat #1

2 Vat #2

3 Vat #3

4 Vat #4

5 Vat #5

6

Black

Black

1-37

1.15 Loading and Updating Software Procedures
Loading Software from an SD card to an CM7 Computer and ATO Board

To update CM7 and ATO software follow these steps:

1. Switch all computers to OFF. Press the TEMP button to check current CM7/ATO software
version.

2. Remove the two screws on the left side cover plate of the CM7 computer.

3. With the computer folded down, insert the SD card, with the contacts facing down and the
notch on the bottom right (see Figure 4 and 5), into the slot on the left side of the CM7.

4. Once inserted, FWUPD appears on the left display and SCCRCOK on the right. Numbers
count up on the right display.

5. The display then changes to FWLOAD on the left; numbers count up on the right.

6. The computer displays OBFCRC. If updating ATO software, the computer will display FWU
ATO on the left and will count down from 2500 on the right.

7. When the update is complete the CM7 displays DONE on the left and RM SDCRD on the
right.

8. Remove the SD card using the fingernail slot on the top of the SD card.

9. Repeat steps 1-8 for all computers.

10. Remove ALL power from the fryer on the rear of the unit.

11. Restore power to the fryer. There is short delay prior to the computer powering up and
displaying OFF.

12. With the computer displaying OFF, verify software update by pressing the TEMP button to
check updated CM7/ATO version.

Figure 4 Figure 5

1-38

1.16 Principal Wiring Connections

1-39

1.17 Wiring Diagrams

1.17.1 Main

The Heat Strip is
not present here on
330’s.

Refer to "PRINCIPAL WIRING CONNECTIONS"
on Page 1-39 for detail of connection points J1,
J2, J3.

1-40

1.17.2 Transformer / Filter Boxes

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

1.18.1 FPGL30 Series Full Vat

K

R

E

N

A

L

O

I

P

U

T

S

I

D

L

N

O

A

G

M

I

U
D

T
A
E
H

­R

1

5

F

V

D

G

-

E
L

R

E
S
U

V

F

4
2

)
)

3
K

(

Y
A

L
E
R

R
E

W
O

L
B

/
T
A
E

H
N

O

I
T

C
N
U

F
L

A
U
D

E

H
C
T

0

I

3
L

W
S

G
P

Y

F

T
E

N

F

O

A

Y

S

L

N

N

I

O

A
R
D

N
O

(

D
N
A

S
T

H

I

E

C

S
L
E
D

O
M

Y
T
E
F

H

A

C

S

T

I

N

I

W

A

S
R
D

N

C

T

E

U

I

N

M

T

W

O

O

R

S

N

S

O

R

O

I

P

A

X

Y

E

L
N
O

3
J

E

P

B

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R

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R
E

W
O
L
B

E
V

S

L

A

A
V

G

L

H

A

C

N

R

T

I

O

I

I

A

T

W

P

S

O

6

2

2
1

T

H

I

G

M

I

I
L

H

9

1
1

V
4
2

2
F

8

5

4

R
O

T

T

I

H

N

G

I

G

R

V
H

D
T

E
V

V

L

H

A

+
M
R
A
L
A

E
S
U
F

3
D

E
L

D

V

N

5

G

2

R

R

W
P

4
D

E
L

3
K

V

D
1
V

Y

T

A
L

A

E

E

R

H

R

I
A

D

R

N

N

G

B

M
R
A
L
A

I

T

I
U
C

E

WIRE

SENSING

LEFT

IGNITOR

D

S

2
J

1

1

1

1

4

4

3

3

1

1

4

4

1

1

0

0

K

0

K

1

5

7

/

4

1

A

1

1

5

5

R

I

G

C

A

C

T

E

D

L

C

I

V

O

V

V

2

E

1

E

D

N

I

D

L

N
U
O
S

T
A
E
H

E
L
B
U
O
R
T

R
E

W
O
P

T

I
U
C

C

C

R

I

A

A

C

V

V

E

4

2

B

2

1

O
R

P

T

M

F
F
O

/
N
O

E
G
A

T
L

O
V

E
N

I
L

3

V
2
1

1

6

V

D

2

E

1

L

T
A
E
H

L

2
D

E
L

R

L

W
P

S
2
V

3

3

1

1

2

2

FPGL30 SERIES – FULL-VAT WITH ONE DUAL-SPARK IGNITION MODULE

1-45

1.18.2 FPGL30 Series Full Vat (Australia and Pacific Rim)

TD

HV

RIGHT IGNITION

MODULE

GND

25V+

M

ALAR

J3

TEMP

PROBE

BLOWER

DRAIN

GV

SAFETY

SWITCH

24V

AIR

SWITCH

OPTIONAL

621291185431

HIGH

LIMIT

F2

R-GV

FUSE

LED 5

24V

LED 3

R

PWR

R-

HEAT

F1

LED 4

K3

HEAT

VALVE

BNR

GND

V1S

ALARM

RELAY

AIR

RIGHT

IGNITOR

SD

11

4

13

14

10

1K

47K

1/50

A

5

LINE VOLTAGE

J2

11

4

HEAT

13

14

10

5

24 VAC

12 VDC

POWER

12 VAC

PROBE CIRCUIT

SOUND DEVICE CIRCUIT

T

M

TROUBLE

ON/

OFF

12V

LINE

12V

VOLTAGE

LED 6

L

FPGL30 SERIES – FULL-VAT – AUSTRALIA AND PACIFIC RIM

ALARM

AIR SWITCH ONLY ON CE

AND SOME EXPORT UNITS

LEFT IGNITION

MODULE

GND

25V+

3

3

1

1

2

2

HEAT

LED 2

L

ALARM

HV

GND

V2S

LEFT

IGNITOR

PWR

VALVE

BNR

T

D

1-46

1.18.3 FPGL30 Series Simplified Wiring

1-47

1.18.4 FPGL30 Series Data Network Flowchart

1-48

PROTECTOR® SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1 Accessories

ITEM PART # COMPONENT

1 803-0209 Brush, Frypot
2 803-0197 Cleanout Rod, 27-inch
3 810-2793 Hanger, Basket

4 809-0171 Thumbscrew, ¼-20 X 1⅜-inch Universal Hood (use 809-0921 for Spacer)

5 106-8930 Cover, Frypot, Full Vat
* 826-0993SP Handle Kit, Frypot Cover (includes handle and screws)
6 803-0375 Basket Support Rack, Full Vat
* 803-0136 Basket Support Screen, Full Vat (screen w/handle used in place of Item 6)
7 803-0099 Basket, Full-Vat
8 803-0271 Basket, Dual-Vat (Twin)
9 230-2975 Connecting Strip, Frypot

10 810-0478 Gas Line, 1-Inch Dormont Flexible

806-1698SP 36-Inch (for gas line only (w/o Items 11 and 12), use 810-0088)

806-1699 48-Inch (for gas line only (w/o Items 11 and 12), use 810-0085)
11 810-0074 Quick-Disconnect Fitting, 1-Inch Male
12 810-0073 Quick-Disconnect Fitting, 1-Inch Female
13 826-0900 Kit, Chain Restraint
14 826-1045 Bushing, Flexible Gas Line (813-0032)
15 810-0070 Coupling, Gas Line Female Quick Disconnect ¾-inch

810-0073 Coupling, Gas Line Female Quick Disconnect 1-inch

* 803-0170 Filter Pack, Paper – 100 Sheets
* 803-0002 Powder, Filter – 80- 1-Cup Application Packages
* 826-1157 Kit, Fuse and Fuse Puller (2 Fuses)

* Not illustrated.

2-1

2.2 Basket Lift Assembly and Associated Parts

2-2

2.2 Basket Lift Assembly and Associated Parts cont.

ITEM PART # COMPONENT

1 200-2942 Mount, Modular Basket Lift
2 806-5964SP Motor Assembly, Modular Basket Lift

3 807-2133
4 807-2572 Microswitch
5 Resistor Assembly

806-8530SP

106-2771 208-250V Modular Basket Lift

6 809-0082 Ring, Truarc Retaining
7 810-0172
8 810-1012 Rod, Modular Basket Lift

9 812-0442 Insulation, Microswitch
10 813-0035 Bushing, Bronze, .640” ID
11 816-0033 Tie Wrap, Screw Mount
12 900-5529 Gusset, Modular Basket Lift Motor
13 901-8499 Chassis, Modular Basket Lift, Left
14 902-8499 Chassis, Modular Basket Lift, Right

15 910-4776 Cover, S/S Modular Basket Lift (for CRS cover use 900-4776)

16 823-06931 Rod Assembly, Left Basket Lift
17 823-06932 Rod Assembly, Right Basket Lift
18 806-9257SP Roller Assembly, Basket Lift
19 910-8284 Bracket, Basket Lift Roller
20 810-0194 Roller, Basket Lift
21 810-0374 Spacer, Basket Lift Roller
22 809-0508 Bolt, 1/4-20 X 11/4-inch
23 809-0190 Washer, ¼-inch Flat
24 809-0047 Nut, 1/4-20 Cap

* 807-0159 Connector, 12-Pin Panel Mount

* 106-1822SP For 100-120V Modular Basket Lift

* 106-1804SP For 208-250V Modular Basket Lift

* 106-1807SP 100-120V w/o Relay

* 106-1810SP 208-250V w/o Relay

** Not illustrated.

Capacitor, 12.5 μFarad, 250VAC Motor Run

100-120V Modular Basket Lift (see Note 2 in illustration)

5/8-

Plug,

inch Stainless Steel Hole

Wire Assemblies

Basket Lift Assemblies (see Note 1 in illustration)

2-3

2.3 Doors, Sides, Flue Caps, Top Caps and Casters

2

1

6

5

4

9

3

7

8

10

ITEM PART # COMPONENT

1 211-6510 Side, Standard Cabinet Left SS (use 221-0323 for Enameled Steel)
2 212-6510 Side, Standard Cabinet Right SS (use 222-0323 for Enameled Steel)
3 810-1105 Magnet, Door (vertical) (use 810-2346 for horizontal over filter pan)
4 106-4397 Door, Left or Right (Left shown – move handle to bottom for right)
5 230-4960 Handle, Eurolook Door
6 106-4067 Pin Assembly, Door
* 810-0275 Spring, Door Pin
* 809-0970 Retaining Ring
* 230-4685 Hinge, Door Lower
7 810-1494 Caster without Brake
8 810-2970 Caster with Brake

9 Flue Cap-Stainless Steel

823-6325 Two Station Fryer
106-7977 Three Station Fryer
106-8955 Four Station Fryer

10 Top Cap

824-1846 Two Station Fryer
823-6289 Three Station Fryer
823-6591 Four Station Fryer

* Not illustrated.

2-4

2.4 Drain System Components

2.4.1 Drain Valves and Associated Parts

ITEM PART # COMPONENT

1 809-0540 Nut, ½-13 2-Way Hex Lock
2 900-2936 Retainer, Nut Drain Valve
3 810-3350 Handle, Drain Valve FV
4 810-0677 Grip, Drain Handle
5 901-2348 Cover, Safety Switch
6 807-2103 Switch, Micro
7 816-0220 Insulation, RF Switch
8 806-8137 Bracket, Switch Drain Assy
9 200-6496 Support, Drain 3” Tube

10 810-1018 Valve, 1¼-inch Drain
11 816-0135 O-Ring, Round Drain Seal
12 810-1165 Washer, Teflon Drain Valve

2-5

2.4.2 Drain Tube Sections and Associated Parts

See Section 2.4.1 for Drain Valves

ITEM PART # COMPONENT

1 823-6610 4625 Drain Tube, Full-Vat Left Closed/Right End Open
2 823-6467 Drain Tube, Dump GL30
3 823-6615 Drain Tube, Dump GL230
4 823-6611 Drain Tube, Full-Vat Right, Left, Open/Right End Open
5 823-6612 Drain Tube, Full-Vat Center, Left Open/Right End Open
6 823-6614 Drain Tube, Full-Vat GL230 Right, Left Open/Right Closed Short
7 823-6613 Drain Tube, Full-Vat Right, Left Open/Right Closed Long
8 816-0772 Sleeve

9 809-0969 Clamp
10 810-2493 Elbow, ¼-inch x 90° Tube Comptession
11 811-1071 Tube, ¼-inch OD Teflon Manifold Vent

* 816-0630 Vinyl Cap

* Not illustrated.

2-6

2.5 Electronics and Electrical Components

2.5.1 Component Boxes

2-7

2.5.1 Component Boxes cont.

ITEM PART # COMPONENT

1 810-1164 Block, One-Piece Screwless Terminal
2 816-0217 Insulation, Terminal Block Paper
3 807-3843 Fuse 3A 250V Domestic

807-3293
4 807-3483 Cable, 21-inch Ignition – For 807-3366/3365 Modules
* 826-2024 Cable, Ignition - 1 wire / 1 Rajah
* 826-1721 Cable, Ignition - 2 wire / 2 Rajah

* 807-1878 Cable, Ignition 19” (CE and Australia)

* 807-1200 Cable, Ignition 27”
5 807-3484 Connector, Rajah
6 106-0531SP Fuse Assembly, Inline
* 826-1157 Kit, Fuse and Fuse Puller (2 Fuses)
7 200-5996 Box, One-Piece Component

8 807-2971 Ignition Module, (Australia)
9 807-1006 Ignition Module, CE and Non-CE export (except Australia, Canada, HK, Mexico)

10 807-3366† Ignition Module, Dual-Spark Full-Vat (U.S., Canadian, HK, and Mexico units)

11 826-2264 Interface Board Kit SMT

807-4330 Speaker Adapter Harness SMT

807-4343 Wire Harness, SMT Interface Board to Ignition Module

12 807-0833
13 810-2243 Spring, Relay Retaining
14 807-4199 Cable, 20-pin Computer to 15-pin Interface Board - SMT
15 806-6085SP Wire Assembly, Ignitor

* 807-4403 Speaker SMT

* Not illustrated.

NOTE 1: Full-Vat units use one 807-3366 Dual-Spark Ignition Module and one latch relay (Item 12) located in

the lower right socket.

Fuse 5A 125V International Only

Relay, DPDT 5A 12VDC Latch (See NOTE 1.)

2-8

2.5.2 Transformer Boxes

2-9

2.5.2 Transformer Boxes cont.

ITEM PART # COMPONENT

Box Assembly, Transformer
A 106-9021SP FPGL230
B 106-9022 FPGL330
C 106-9734 GL230 CE Export
D 106-9710 GL330 CE Export
E 106-5801 GL430/252
1 106-8133 Cable Assembly, Transformer Box Line GL230,330, 330 CE Export
2 106-8168 Cable Assembly, Transformer Box Line GL230 CE Export
3 106-8170 Cable Assembly, Transformer Box Filter Pump GL230 and 330
4 106-9742 Cable Assembly, Transformer Box Filter Pump GL230 CE Xprt and 330 CE Export
5 106-8162 Cable Assembly, Transformer Box #1 GL230
6 106-3827 Cable Assembly, Transformer Box #1 GL330
7 106-9739 Cable Assembly, Transformer Box #1 GL230 CE Export
8 106-9746 Cable Assembly, Transformer Box #1 GL330 CE Export
9 106-3821 Cable Assembly, Transformer Box #2 GL230 and 330

10 106-9740 Cable Assembly, Transformer Box #2 GL230 CE Export
11 106-9747 Cable Assembly, Transformer Box #2 GL330 CE Export
12 106-3825 Cable Assembly, Transformer Box #3 GL330
13 106-9748 Cable Assembly, Transformer Box #3 GL330 CE Export
14 106-6996 Cable Assembly, Cordset Female
15 806-8706 Plug Assembly, Lt. 252
16 806-8707 Plug Assembly, Rt. 252
17 220-3191 Cover, Transformer Box GL
18 220-0772 Cover, Transformer Box 50/52/55
19 807-4482 Relay, Filter 30A 24VDC DPDT
20 816-0219 Paper, CE Triple Terminal Block Insulating
21 807-0070 Terminal, Ground Lug
22 807-1973 Terminal, Post
23 810-1164 Block, One-Piece Screwless Terminal
24 816-0217 Insulation, Terminal Block Paper
25 810-1163 Block, 3 Places Screwless Terminal
26 807-0800 Transformer, 100-120V/24VAC 50/60Hz 50VA
27 807-1999 Transformer, 208/222/230/240V V/F Dual Voltage
28 807-2176 Transformer, 100-120V V/F Dual Voltage

* WIR 0798 Wire Assembly, GL330 Transformer/Filter Box (used in Item B)
* WIR 0799 Wire Assembly, GL230 Transformer/Filter Box (used in Item A)
* WIR 0852 Wire Assembly, GL230 CE Transformer/Filter Box (used in Item C)
* WIR 0854 Wire Assembly, GL330 CE Transformer/Filter Box (used in Item D)

* Not illustrated

2-10

2.5.3 Computers and Associated Components

NOTE: See Page 2-7 for Interface Board to Computer Wiring Harness.

ITEM PART # COMPONENT

Replacement CM7 Computer
108-0231 Non-CE CM7 (For use in US, Canada, Mexico and all other non-CE coun-

tries)

* 810-3141 Sound Device, Universal SMT

* Not illustrated.

2-11

2.6 Wiring

2.6.1 Main Wiring Harnesses

2-PIN FEMALE

CONNECTOR

12-PIN MALE
CONNECTOR

12-PIN MALE

CONNECTOR

2-PIN FEMALE

CONNECTOR

807-1978

9-PIN MALE

CONNECTOR

12-PIN MALE

CONNECTOR

807-4014

12-PIN MALE
CONNECTOR

ITEM PART # COMPONENT

807-1978 U.S. and Non-CE Export Main Wiring Harness 50/52
807-4014 U.S. and Non-CE Export Main Wiring Harness 350/52
807-2168 CE Main Wiring Harness (not shown)

2-12

6-PIN MALE

CONNECTOR

2.6.2 CM7 and ATO Wiring Harnesses (Refer to wiring diagram on page 1-49.)

ITEM PART # COMPONENT

* 807-4546 Computer Communication (used from Computer to Computer)
* 807-4655 FV Harness RTD Medium (used from RTD to ATO Board)

* 807-4654 FV ATO/RTD Probe

* 807-4553 ATO Power (used from Transformer to ATO Board)

* 807-4719

* 807-4718 FV ATO Solenoid Harness

* 807-4555 ATO Yellow LED (used from ATO Board to Yellow LED)

* 807-4573

* 807-4552

807-4657 Jumper (used on 4 and 5 battery ATO board plug J5 pin 7 and 8)

* 106-9256SP Long Top-off Power (used between Component Box to ATO Box)

* 807-4660PK SMT Pin Service Repair Kit

* 230-2345 SMT Pin Extractor
* Not illustrated.
See page 1-31 and 1-37 for Pin Positions.

ATO Pump and JIB (used from ATO Board to Top-off Pump and JIB Reset

Switch)

Computer Locator Wire (used from Computer to Interface Board) See wiring
diagram 805-1734 for locator pin positions.
Communications Terminator (used on Computer pin J6 and ATO board pin
J10 to terminate network)

2-13

2.7 Frypots and Associated Components

2.7.1 Full-Vat Frypot Components

NOTE: All insulation and

gaskets can be ordered in

a single kit, P/N 826-2595.

Kit 826-2592 contains the

insulation and gaskets re-

quired when replacing

burners.

2-14

2.7.1 Full-Vat Frypot Components cont.

ITEM PART # COMPONENT

106-8978SP Frypot Assembly Full-Vat Protector® HE (NAT)
106-8979 Frypot Assembly Full-Vat Protector® HE (PRO)
826-2595 Insulation Kit, Complete Full-Vat

826-2592 Insulation Kit, Burner Full-Vat
1 106-7524 Flue Assembly, Full-Vat
2 220-2222 Back, Lower Full-Vat Combustion Chamber
3 220-2226 Retainer, Full-Vat Upper Insulation
4 220-2231 Retainer, Outer Frypot
5 222-2694 Plate, FV Collector Mounting
6 220-2851 Brace, FV Rear Insulation
7 220-2920 Brace, Foam Deck Insulation
8 810-3435 Burner, Universal Replacement Protector
9 812-0356 Insulation, Burner Sight Glass

10 812-0357 Insulation, Burner
11 812-0706 Insulation, Upper Burner Rail
12 812-1029 Insulation, Combustion Chamber Side
13 814-0048SP Glass, Burner Sight
14 816-0730 Insulation, FV Rear Lower
15 816-0731 Insulation, FV LH/RH Front Seal
16 816-0732 Insulation, FV Lower Inner Front
17 816-0733 Insulation, FV Front Upper
18 816-0734 Insulation, FV Outer Front
19 816-0746 Insulation, Foam Deck
20 823-6597 Frypot, FV Protector 439 SS
21 823-6047 Retainer, FV LH Upper Burner
22 823-6048 Retainer, FV RH Upper Burner
23 823-6050 Retainer, FV Front Insulation
24 823-6052 Retainer, FV Outer Front
25 824-1826 LH Upper Seal W/A
26 824-1827 RH Upper Seal W/A
27 900-1031 Retainer, Burner Sight Glass
28 930-0818 Bracket, Flue to Pot
29 900-4253 Strip, Fluecap Retainer
30 900-1049 Retainer, Plenum Gasket
31 816-0057 Gasket, Plenum

* 816-0059 Gasket, Ignitor

32 823-6660

* 910-2474 Pot-to-Pot Gap Clip

Plenum, Full-Vat LOV (use 823-6940 for CE units)

* Not illustrated.

2-15

2.7.2 Frypot Assemblies and Associated Parts

1

3

4

5

2

See page 2-5 for Drain Valve
Assemblies.

ITEM PART # COMPONENT

1 106-8978SP Frypot Assembly, Full-Vat Protector Natural

106-8979SP Frypot Assembly, Full-Vat Protector LP
2 106-9025SP Valve, Drain Assy. FV
3 826-2569 Probe, RTD and Fitting Kit
4 807-0678 Temperature Probe
* 210-0681 Probe Guard
5

* Not illustrated.

826-1177

Thermostat, High-Limit 425°F/218°C

2-16

2.8 Gas Supply and Combustion System Components

1

2

3

See pages 2-14 through 2-15 for
burners and burner insulation
part numbers.

4

FPGL30 Full Vat Gas Manifold

(Typical)

The example illustrated is typical of
FPGL30 Protector

®

Series Fryer
Gas Manifolds. Each manifold is
assembled from standard 1/2-, 3/ 4-,
and 1-inch NPT black iron pipe
nipples, elbows, tees, plugs, and
unions, which may be locally
acquired.

See page 2-19 and 20 for details of
gas valves and related components.

2-17

2.8 Gas Supply and Combustion System Components cont.

ITEM PART # COMPONENT

1 Ignitor (includes gasket 816-0059, which may be ordered separately)

826-0981 Natural Gas (G20, G25)
826-0982 Propane (G30, G31)
826-1002 Manufactured Gas

2 Blower Assembly, Combustion Air (includes harness and Items 4, and 5)

106-2996SP 100V 50/60 Hz (Left)
106-2999SP 100V 50/60 Hz (Right)
106-2994SP 115V 50/60 Hz. (Left)
106-2997SP 115V 50/60 Hz (Right)
106-2995SP 208-240V 50/60 Hz (Left)
106-2998SP 208-240V 50/60 Hz (Right)
106-3000SP 230V 50/60 Hz CE (Left)

106-3001SP 230V 50/60 Hz CE (Right)
3 816-0554 Cover, Blower Motor (component of all blowers listed above)
* 806-8806SP Harness Assembly, Blower Motor (component of all blowers listed above)
4 Orifice, Burner

812-1137 1.95 mm Propane/Butane (G30, G31) (0-4999 Ft, 0-1524 M) (CE)

810-1221 2.00 mm Propane/Butane (0-4999 Ft, 0-1524 M) (Japan only)

810-0386 2.10 mm Propane/Butane (0-4999 Ft, 0-1524 M)

810-0413 2.16 mm Propane/Butane (G30, G31) (5000-6999 Ft, 1525-2133 M)

812-1028 2.20 mm Propane/Butane (G30, G31) (7000-10,999 Ft, 2134-3352 M)

812-1134 3.10 mm Natural Gas (G20, G25) (0-4999 Ft, 0-1524 M) (Japan only)

810-0403 3.40 mm Natural Gas (G20, G25) (0-4999 Ft, 0-1524 M)

810-0437 3.60 mm Natural Gas (G20, G25) (5000-6999 Ft, 1525-2133 M)

812-1144 3.65 mm Natural Gas (G20, G25) (7000-8999 Ft, 2134-2743 M)

812-1145 3.70 mm Natural Gas (G20, G25) (9000-10,999 Ft, 2744-3352 M)

810-0642 5.95 mm Manufactured Gas (0-4999 Ft, 0-1524 M)
* 826-1196 Conversion Kit, Natural Gas (G20, G25) to Propane/Butane (G30, G31) CE

only

* 826-1197 Conversion Kit, Propane/Butane (G30, G31) to Natural Gas (G20, G25) CE

only

* 807-2263

* Not illustrated.

Switch, Air Pressure (use 807-2262 in units with 100VAC power supply)

2-18

2.9 Gas Valves and Associated Components

2-19

2.9 Gas Valves and Associated Components cont.

ITEM PART # COMPONENT

1 Valve, Non-CE Gas

826-1122 Natural Gas (G20, G25)

826-1120 Kit Natural Gas w/ flexlines and hardware

826-1123 Propane Gas (G30, G31)

826-1121 Kit, Propane Gas w/ flexlines and hardware
2 810-1715 Valve, CE Gas (G20, G25, G30, G31)
3 810-1041 Accessory Kit (contains parts to adapt Item 2 to specific fryer configuration)
4 806-9678SP Plug Assembly, CE Gas Valve
5 810-0494 Ferrule (Nut), Orifice
6 810-1355 Gas Line, ⅜-inch OD X 15-inch SS Flexible
7 810-1354 Gas Line, ⅜-inch OD X 12-inch SS Flexible

810-1353 Gas Line, ⅜-inch OD X 9-inch SS Flexible (Used on some split pots)
8 811-0800 Tube, ⅛-inch OD X 12.5-inch Enrichment (cut and form to fit)
9 813-0301 Tee, ¼-inch Male NPT to ⅜-inch Tube

10 813-0302 Elbow, ¼-inch Male NPT to ⅜-inch Tube 90° (used on DV valve)
11 813-0304 Bushing, ½-inch NPT to ¼-inch NPT Flush Reducing
12 813-0405 Nipple, ⅛-inch NPT X 2-inch
13 813-0378 Fitting, ⅛-inch NPT Cross
14 813-0340 Adapter, ⅛-inch NPT to ⅛-inch Tube
15 813-0154 Plug, ⅛-inch NPT Hex Head Pipe
16 810-1176 Tap, ⅛-inch NPT Pressure
17 813-0377 Tee, ⅛-inch NPT Female
18 813-0354 Elbow, ⅛-inch NPT X ⅛-inch Tube Compression
19 813-0016 Nipple, ⅛-inch NPT X Close
20 810-1006 Bushing, ¼-inch NPT to ⅛-inch NPT Reducing
21 813-0495 Tee, ¼-inch Male NPT to Female NPT
22 810-1025 Connector, ¼-inch Male NPT to ⅜-inch Tube
23 810-1026 Tee, ¼-inch Male NPT to Female NPT Street
24 813-0700 Nipple, ¼-inch NPT x 3-inch
25 810-0691 Tube, ⅛-inch Vent

2-20

2.10 Filtration System Components

20

9

17

8

10

7

18

17

6

1

15

19

11

16

15

14

13

12

10

2

3

4

5

2-21

2.10 Filtration System Components cont.

ITEM PART # COMPONENT

1 823-6616 Lid, Multi-Vat Fryers, Standard Size Filter Pan

823-6333 Lid, Two-Vat Fryer, Half Size Filter Pan

2 810-2874 Crumb Tray, Standard Size Filter Pan 3, 4 and 5 Vat

810-3288 Crumb Tray, Two-Vat Fryer, Half Size Filter Pan

3 810-2091 Hold-Down Ring 13.65 x 21.41, Standard Size Pan 3, 4, and 5 Vat

810-3289 Hold-Down Ring 11.20 x 19.10, Two-Vat Fryer, Half Size Filter Pan

4 812-2024 SanaGrid Filter Screen, Standard Size Filter Pan

812-2041 SanaGrid Filter Screen, Two-Vat Fryer, Half Size Filter Pan

5 106-8677 Pan, One-Piece Filter Standard Size

106-8211SP Pan, Two-Vat Fryer, Half Size
* 826-1392 O-Ring (Pkg. of 5; used with Item 5)
* 813-0568 Plug, ⅛-inch Socket Head Pipe (used with Item 5; two required)
6 823-3879 Suction Tube Standard

823-6458 Suction Tube Two Vat
7 Motor and Gasket Kit

826-1785 100V 50/60 Hz

826-1712 115V 50/60 Hz

826-1756 208V 50/60 Hz

826-1270 220-240V 50/60 Hz

826-1755 250V 50/60 Hz

8 826-1264 Pump and Gasket Kit, 4 GPM

816-0093 Gasket, Pump/Motor
* 807-11973 Viking Pump Seal Kit

* 809-1020 Cap Screw, 5/16-inch-18 5.50” NC Hex (Connects pump to motor.)

9 811-1071 Tube, ¼-inch OD Teflon Manifold Vent

10 810-1055 Flexline, 11.5-inch Oil Return
11 810-1680 Flexline, 6.5-inch Oil Return
12 810-1668 Adapter, ⅝-inch to ½-inch NPT Male
13 813-0530 Tee, ½-inch x ½-inch x ¼-inch Reducing
14 813-0838 Nipple, ¼-inch NPT Close
15 106-3470 Valve, ¼-inch NPT Solenoid
16 810-2773 Adaptor, ¼-inch NPT to ½-inch NPT
17 813-0298 Nipple, ½-inch NPT x 2.00-inch
18 813-0342 Elbow, Street 45° x ½-inch NPT
19 813-0700 Nipple, ¼-inch NPT x 3.00-inch
20 810-2493 Elbow, 90° ⅛-inch NPT x ¼-inch Quick Connect

* 106-5911 Heater Strip Assembly, 100-120V 25W 18”
* 106-5912 Heater Strip Assembly, 208-250V 25W 18”

* Not illustrated.

2-22

2.11 Return Valve Assembly and Associated Parts

ITEM PART # COMPONENT

106-8018 Valve, Return Assy. FV
1 810-2201 Valve, Return ½” Ball
2 902-2772 Handle, Right Valve
3

813-0165

Elbow, Street ½” x ½” NPT 90° BM
4 813-0087 Nipple, ½” x 1.50” NPT
5 813-0062 Elbow, 90° ½” BM
6 813-0265 Nipple, ½” x 2.50 NPT BM
7 824-1601 Cover, Microswitch RR Flush
8 807-4101 Switch, Micro
9 816-0220 Insulation, RF Switch

10 810-0045 Bushing, .875 Diameter Hole 11/16
11 212-6701 Rod, Handle Right RF
12 816-0643 Grip, Oil Return Valve Handle
13 809-0601 Clip, Clevis
14 810-1668 Adaptor, Male ⅝” OD x ½”
15 810-1067 Flexline, ⅝” OD x 8.50” Long
16 Manifold, Rear Oil Return

810-3275 Two-Station Fryer
810-3245 Three-Station Fryer
810-3368 Four-Station Fryer

2-23

2.12 ATO (Auto Top-Off) Components

2.12.1 JIB (Jug In Box) Low Indicator Light Assembly

106-9033 Protector JIB Light Assembly

ITEM PART # COMPONENT

1 106-8105SP Light, Yellow 24VDC LED Flush
2 230-4142 Bracket, Protector Light

2.12.2 ATO (Automatic Top-Off) Board

106-9613 120V Assy or
106-9614 208-240V Assy

ITEM PART # COMPONENT

1 106-9258 Box, Assembly Auto Top Off 2 Board RTD
2 816-0771 Seal, Top Off Board
3 106-9611 PCB Board, Automatic Top Off 2 RTD
4 807-1999 Transformer, Dual Voltage 208-240V

807-2176 Transformer, Dual Voltage 120V

5 220-4352 Cover, Top Off Board 3, 4 or 5-Vat

220-3987 Cover, Top Off Board 2-Vat

* 807-3575 Plug, Carling Switch Hole

* Not illustrated.

2-24

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

2

8

3

5

6

9

1

7

4

ITEM PART # COMPONENT

1 106-9680SP Pump, ¼ FNPT 12VDC, 19PSI 15.1GPH
2 106-8477 Solenoid Manifold Assembly GL30-3 (includes three solenoid assemblies)
3 106-8014 Solenoid Manifold Assembly GL30-6 (includes six solenoid assemblies)
4 807-4590 Solenoid
5 813-0940 Elbow, ¼ NPT x ⅜ Flare
6 816-0708 Fitting, ¼ NPT x ½ Male Barb
7 816-0710 Fitting, ¼ NPT x ½ Barb 90°
8 813-0640 Plug, ¼ NPT SQ HD BM
9 807-4493 Switch, Momentary Flush
* 811-1139 Tubing, Braided Silicone 20-inch
* 810-3375 Flexline, ½” OD x 17-inch (used between solenoid and top off port)
* 810-3265 Flexline, ½” OD x 24-inch (used between solenoid and top off port)
* 810-3263 Flexline, ½” OD x 36-inch (used between solenoid and top off port)

* Not illustrated.

2.12.4 JIB Cradle, JIB/BIB Cap and Pick Up Assembies

ITEM PART # COMPONENT

1 220-3647 Cradle, JIB Gas LOV
2 106-8512SP Cap, JIB Assembly
3 106-9495 Cap, BIB Assembly (used internationally)
4 230-3737 Cap, JIB
5 823-6812 Cap w/ Clamp, BIB Assembly (used internationally)
6 810-3242 Hose, JIB
7 810-3300 Inlet, Oil Reservoir Tube
8 810-3334 Bushing, Heyco

2-25

2.13 Wiring Connectors, Pin Terminals and Tools

ITEM PART # COMPONENT

1
2
3
5
5
6
7
8

9
10
11
12
13
14
15
16

* Not illustrated.

807-1068
807-0158
807-0156
807-0159
807-0875
807-1067
807-0157
807-0155
807-0160
807-0804
826-1341
826-1342
807-2518
807-0928
806-4855
230-2345

2-Pin Female
6-Pin Female
9-Pin Female
12-Pin Female
15-Pin Female
2-Pin Male
6-Pin Male
9-Pin Male
12-Pin Male
15-Pin Male
Terminal, Female Split Pin (Pkg of 25)
Terminal, Male Split Pin (Pkg of 25)
Plug, Mate-N-Lock (Dummy Pin)
Extract Tool Pin Pusher
Pin Pusher Screwdriver Assembly
SMT Pin Extractor

2-26

2.14 Fasteners

ITEM PART # COMPONENT

* 809-0429 Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap
* 809-0131 Bolt, ¼-inch -20 x ¾-inch Hex
* 809-0953 Bolt, ¼-20 x ¾-inch Hex Head
* 807-1926 Bushing, .875-inch Split
* 809-0514 Capscrew, 5/16-inch-18 NC Hex
* 809-0448 Clip, Tinnerman
* 826-1351 Nut Retainer, ¼-20 (Pkg. of 10 – for basket hanger thumbscrew) Std. Fluecap
* 809-0171 Thumbscrew, ¼-20 x 1⅜-inch (for use on Standard Fluecap)
* 826-1366 Nut, 4-40 Keps Hex (Pkg. of 25) (809-0237)
* 826-1358 Nut, 6-32 Keps Hex (Pkg. of 25) (809-0049)
* 809-0247 Nut, 8-32 Keps Hex
* 809-0052 Nut, 10-24 Hex
* 826-1376 Nut, 10-32 Keps Hex (Pkg. of 10) (809-0256)
* 809-0766 Nut, 10-32 Keps Hex SS
* 809-0581 Nut, ½ NPT Locking
* 809-0020 Nut Cap 10-24 NP
* 826-1372 Nut Grip ¼-inch ¼-20 Hex NP (Pkg. of 10) (809-0059)
* 809-0417 Nut Flange ¼-inch ¼-20 Serr
* 809-0535 Nut, "T" ¼-inch-20 x 7/16 SS
* 809-0495 Nut, ¼-inch - 20 Press

809-0804 Nut, ¼- inch - 20 Keps Hex
* 826-1362 Nut, ¼-20 Hex (Pkg. of 10) (809-0071)
* 809-0540 Nut, Lock ½-inch-13 Hex 2-Way ZP
* 809-0656 Screw, 4-40 X 3/8-inch Slotted Round Head
* 826-1359 Screw, 4-40 x ¾-inch Slotted Round Head (Pkg. of 25) (809-0354)
* 826-1365 Screw, 6-32 x ⅜-inch Slot Head (Pkg. of 25) (809-0095)
* 809-0098 Screw, 6-32 x 1¼-inch Slotted Round Head
* 809-0357 Screw, 6 x ⅜-inch Phillips Head NP
* 809-0359 Screw, 8 x ¼-inch Hex Washer Head
* 809-0360 Screw, 8 x ⅜-inch Hex Washer Slot Head
* 826-1371 Screw, 8 x ½-inch Hex Head ZP (Pkg. of 25) (809-0361)
* 809-0364 Screw, 8 x ⅝-inch Hex Washer Head ZP
* 809-0441 Screw, 8 x 1½-inch Hex Washer Head
* 809-0362 Screw, 8 x 1¼-inch Hex Washer Head Drill Point
* 809-0518 Screw, 8-32 x ⅜-inch Hex Washer Slotted Head SS
* 809-0104 Screw, 8-32 x ½-inch Slotted Head ZP
* 826-1363 Screw, 8-32 x ½-inch NP (Pkg. of 25) (809-0103)
* 826-1360 Screw, 10-24 x 5/16-inch Round Slot Head ZP (Pkg. of 25) (809-0024)
* 809-0123 Screw, 10-24 x 3/4-inch Slotted Truss Head
* 826-1330 Screw, 10-32 x ⅜-inch Slot Head SS (Pkg. of 25) (809-0117)
* 809-1003 Screw, 10-32 x ⅜-inch Hex Trim Head SS
* 809-0938 Screw, 10-32 x ⅝-inch Philips Truss Head
* 826-1375 Screw, 10-32 x ¾-inch Hex Trim Head SS (Pkg. of 5) (809-0401)
* 809-1000 Screw, 10-32 x 1¼-inch Hex Sck C/S
* 826-1374 Screw, 10 x ½-inch Hex Head (Pkg. of 25) (809-0412)
* 809-0266 Screw, 10 x ½-inch Phillips Head ZP

continued on the following page

2-27

2.14 Fasteners cont.

ITEM PART # COMPONENT

* 809-0500 Screw, 10 x ½-inch Hex Washer Head 410 SS
*

* 809-0123 Screw, 10 x ¾-inch Slot Head
* 826-1389 Screw, ¼-20 x ¾-inch Hex Head ZP (Pkg. of 10) (809-0131)
* 826-1346 Spacer, Ignition Module (Pkg. of 10)
* 810-2763 Spacer, Interface Board
* 826-1340 Spacer, .25-inch x 1.187-inch (Pkg. of 10)

* 810-0500 Spacer, .25-inch x .9375-inch

810-2023 Spacer, .25-inch x .110-inch (Used on drain valves.)
* 200-6721 Plate, Strain Relief
* 826-1337 Tab, ¼-inch Terminal (Pkg. of 5)
* 807-0070 Terminal, Ground Lug
* 807-1948 Ty-Wrap

* 807-1359 Mount, Ty-Wrap
* 826-1383 Washer, ¾-inch O.D. x ¼-inch I.D. ZP (Pkg. of 5) (809-0435)
* 809-0582 Washer ½ NPT Locking
* 809-0184 Washer, #10 LK ZP

*
*
*
*
* 809-0196
* 810-1165

809-0434 Screw, 10 x ⅜-inch Hex Washer Head NP

809-0190 Washer, .625 X .275 X 40 Flat SS
809-0191 Washer, Lock ¼ Spring ZP
809-0193 Washer, Flat ¼ Nylon
809-0194 Washer, Flat 5/16 ZP

Washer, ⅜-inch Flat
Washer, ⅜-inch Teflon

2-28

THIS PAGE INTENTIONALLY LEFT BLANK

Frymaster, L.L.C., 8700 Line Avenue, Shreveport, Louisiana 71106

TEL [phone] FAX (Parts) 1-318-219-7140 FAX (Tech Support) 1-318-219-7135

PRINTED IN THE UNITED STATES

SERVICE HOTLINE

1-800-551-8633

FEBRUARY 2009

819-6345