Frymaster FPH450C User Manual

Service and Parts Manual

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

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

JUNE 2005

*8190001*

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

NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster/DEAN Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for definitions of qualified personnel.

NOTICE This equipment must be installed in accordance with the appropriate national and local codes of the country and/or region in which the appliance is installed. See NATIONAL CODE REQUIREMENTS in Chapter 2 of this manual for specifics.

NOTICE TO U.S. CUSTOMERS This equipment is to be installed in compliance with the basic plumbing code of the Building Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the U.S. Food and Drug Administration.

NOTICE Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to onsite management operational procedures.

NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS

U.S.

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet the Class B limits.

CANADA

This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES-003 standard of the Canadian Department of Communications.

Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.

DANGER Improper installation, adjustment, maintenance or service, and unauthorized alterations or modifications can cause property damage, injury, or death. Read the installation, operating, and service instructions thoroughly before installing or servicing this equipment. Only qualified service personnel may convert this appliance to use a gas other than that for which it was originally configured.

DANGER No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the Frymaster/Dean Service Hotline at 1-800-551-8633.

DANGER Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection. Single fryers equipped with legs must be stabilized by installing anchor straps. All fryers equipped with casters must be stabilized by installing restraining chains. If a flexible gas line is used, an additional restraining cable must be connected at all times when the fryer is in use.

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

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

DANGER Instructions to be followed in the event the operator smells gas or otherwise detects a gas leak must be posted in a prominent location. This information can be obtained from the local gas company or gas supplier.

DANGER This product contains chemicals known to the state of California to cause cancer and/or birth defects or other reproductive harm.

Operation, installation, and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne particles of glasswool or ceramic fibers is known to the State of California to cause cancer. Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm.

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

WARNING Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal the joint between the fry vessels. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning.

H50 SERIES GAS FRYERS

TABLE OF CONTENTS

CHAPTER 1: Service Procedures

1.1 Functional Description.......................................................................................................1-1

The Electronic Ignition System..........................................................................................1-1

Interface Boards.................................................................................................................1-2

Thermostats........................................................................................................................1-5

1.2 Accessing Fryers for Servicing..........................................................................................1-5

1.3 Cleaning the Gas Valve Vent Tube....................................................................................1-5

1.4 Checking the Burner Manifold Gas Pressure.....................................................................1-6

1.5 Measuring Flame Current ..................................................................................................1-8

1.6 Replacing Fryer Components ............................................................................................1-8

1.6.1 Replacing the Controller or the Controller Wiring Harness ...............................1-8

1.6.2 Replacing the Temperature Probe or High-Limit Thermostat............................1-8

1.6.3 Replacing the Interface Board ............................................................................1-9

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

1.6.5 Replacing an Ignitor Assembly.........................................................................1-10

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

1.6.7 Replacing a Gas Valve ......................................................................................1-13

1.6.8 Replacing a Burner Assembly...........................................................................1-14

1.6.9 Replacing the Frypot.........................................................................................1-15

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

1.7 Troubleshooting and Problem Isolation...........................................................................1-21

1.7.1 Ignition Failures................................................................................................1-21

1.7.2 Improper Burner Functioning...........................................................................1-22

1.7.3 Improper Temperature Control.........................................................................1-24

1.7.4 Computer-Related Problems.............................................................................1-25

1.7.5 Filtration Problems............................................................................................1-26

1.7.6 Leakage.............................................................................................................1-29

1.7.7 Basket Lift Malfunctions ..................................................................................1-29

1.7.8 Interpretation of Digital Controller Lights........................................................1-32

1.8 Troubleshooting Guide ....................................................................................................1-32

Probe Resistance Chart ....................................................................................................1-37

1.9 Simplified Wiring Diagrams............................................................................................1-38

1.10 Principal Wiring Connections..........................................................................................1-43

1.11 Wiring Diagrams – Main ................................................................................................1-44

1.12 Wiring Diagrams – Transformer Boxes...........................................................................1-50

1.13 Wiring Diagrams – Basket Lifts ......................................................................................1-52

1.14 Wiring Diagrams – Filter Boxes......................................................................................1-55

1.14 Wiring Diagrams – Oil Return.........................................................................................1-56

CHAPTER 2: Parts List

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

H50 SERIES GAS FRYERS

TABLE OF CONTENTS

2.2 Basket Lift Assemblies and Component Parts.................................................................. 2-3

2.2.1 Bell Crank Basket Lifts......................................................................................2-3

2.2.2 Modular Basket Lifts.......................................................................................... 2-5

2.3 Blower Assemblies and Associated Components .............................................................2-7

2.4 Burner Ignition System Components and Associated Hardware...................................... 2-9

2.5 Cabinet Assemblies and Component Parts...................................................................... 2-10

2.5.1 FPH150............................................................................................................. 2-10

2.5.2 FPH50 Batteries ............................................................................................... 2-11

2.5.3 FH150 and MJH150......................................................................................... 2-13

2.5.4 MJH50 Batteries............................................................................................... 2-14

2.5.5 FMH50 Batteries with Built-In Filtration.........................................................2-15

2.5.6 Filter Magic II Add-On ....................................................................................2-17

2.6 Casters, Legs, and Restraints........................................................................................... 2-19

2.7 Component Box Assemblies and Associated Component Parts .....................................2-20

2.8 Control Panel Assemblies, Flue Caps, Top Caps, and Related Components.................. 2-21

2.9 Controller Assemblies..................................................................................................... 2-23

2.10 Door Assemblies .............................................................................................................2-24

2.11 Drain System Components.............................................................................................. 2-25

2.11.1 Filter Magic II Square Drain Components, Standard Configuration ............... 2-25

2.11.2 Filter Magic II Square Drain Components, Non-Standard Configurations...... 2-26

2.11.3 FootPrint III Square Drain Components, Standard Configuration...................2-27

2.11.4 FootPrint III Square Drain Components, Rear Flush Configuration................ 2-28

2.11.5 FootPrint III Square Drain Components, Foodmaker Configuration............... 2-29

2.12 Drain Valves, Drain Valve Assemblies, and Associated Parts ....................................... 2-30

2.12.1 Drain Valves and Drain Extensions ................................................................. 2-31

2.12.2 MJH50 Dual Vat (1-inch) Drain Valve Assemblies......................................... 2-31

2.12.3 FMH50 Dual Vat (1-inch) Drain Valve Assemblies........................................ 2-32

2.12.4 FMH50 Full Vat (1¼-inch) Drain Valve Assembly......................................... 2-33

2.12.5 FPH50 Dual Vat (1-inch X 1¼-inch) Valve Assemblies................................. 2-34

2.12.6 FPH50 Full Vat (1¼-inch) Valve Assemblies.................................................. 2-35

2.13 Filtration Systems and Component Parts (Other Than Drain Components)...................2-36

2.13.1 Filter Magic II/Single FootPrint III Filter Pan Assembly ................................2-36

2.13.2 FootPrint III Filter Pan Assembly.................................................................... 2-37

2.13.3 FootPrint III Filter Base Assemblies................................................................ 2-38

2.13.4 Filter Magic Oil Return Plumbing Components (Including Pump & Motors) 2-39

2.13.5 FootPrint III Filter Motors and Pump Plumbing Components......................... 2-41

2.13.6 FootPrint III with Power Shower Oil Return Plumbing Components..............2-43

2.13.7 FootPrint III with Rear Flush Oil Return Plumbing Components, Standard ...2-45

2.13.8 FootPrint III with Rear Flush Oil Return Plumbing Components, KFC.......... 2-47

2.13.9 FPH150-2 Oil Return Plumbing.......................................................................2-49

2.13.10 Oil Return Handle Assembly, Filter Magic & Standard FootPrint III............. 2-51

H50 SERIES GAS FRYERS

TABLE OF CONTENTS

2.13.11 Power Shower Assemblies (All Systems).........................................................2-52

2.13.12 Oil Disposal Systems Plumbing........................................................................2-53

2.13.13 Assembly Wand Plumbing (Japan)...................................................................2-55

2.13.14 Oil Disposal Wand Assembly...........................................................................2-56

2.14 Frypot Assemblies and Component Parts........................................................................2-56

2.14.1 Replacement Frypots and Frypot Insulation Kits .............................................2-56

2.14.2 Full Vat Frypot Assembly, Component Parts...................................................2-57

2.14.3 Dual Vat Frypot Assembly, Component Parts..................................................2-59

2.15 Gas Supply System Assemblies and Component Parts ...................................................2-61

2.15.1 FM/MJH50 Gas Manifold Assemblies.............................................................2-61

2.15.2 Gas Valves, Gas Lines, and Fittings.................................................................2-63

2.16 Probe, Probe Guard, and Thermostat...............................................................................2-65

2.18 Relays, Transformers, Wiring Assemblies, and Related Parts ........................................2-66

2.18.1 Filter Box Components.....................................................................................2-66

2.18.2 Transformer Box Components.......................................................................... 2-67

2.19 Wiring Harnesses, Wiring Assemblies, and Plug Assemblies.........................................2-69

2.20 Wiring Connectors and Pin Terminals.............................................................................2-73

iii

H50 SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

H50 Series 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 their 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. In dual vat units, each burner has its own valve. All fryers in this series are equipped with 24VAC gas valve systems, and all are configured with electronic ignition.

THE ELECTRONIC IGNITION SYSTEM

An ignition module mounted in the component box or

Inside the Ignition Module

“shield” (located behind the control panel) is connected to an ignitor assembly at the burner. The ignition module performs four important functions: it provides fuse protection for the 24-volt circuit, provides an ignition

Out to Gas Valve

To Al arm

spark, supplies voltage to the gas valve, and proofs the burner flame. The module contains a 4-second time delay circuit and a coil that activates the gas valve. Three types

25 V +

Coil

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. Two single-spark

GND

modules were used on full-vat fryers built before August

2000. All dual-vat fryers use two single-spark modules.

Ignition Wire Flame Sensor

The ignitor assembly consists of a spark plug, an enrichment tube, and a flame sensor.

At start-up, the power switch is placed in the ON position, supplying approximately 12-volts DC to the heat control circuitry in the controller or 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 6 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

1-1

the other leg of the heat relay coils, which then close 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, in fryers with built-in filtration systems, a normally closed drain safety switch). Simultaneously, the module causes the ignitor to spark for 4 seconds to light the burner. A flame sensor verifies the burner ignition by measuring the flow of microamps through the flame. If the burner does not light (or is extinguished), current to the ignition module is cut, the gas valve closes, and the ignition module “locks out” until the power switch is turned off and then back on. A probe monitors the temperature in the frypot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay. This in turn cuts off the 24 VAC to the ignition module, causing the gas valve to close.

INTERFACE BOARDS

All fryers in this series have an interface board located in the component box located behind the control panel. The interface board provides a link between the controller/computer and the fryer’s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point. The H50 Series of fryers has been in production since 1983. Consequently, servicers are likely to encounter three different interface board designs. Although the boards differ slightly in appearance, basic functioning and electrical connections are the same from one to another. In the earlier design 806-3398 interface board (used between June 1996 and July

1999), the diagnostic LEDs are arrayed in a row across the bottom of the board as shown in the lefthand illustration below. In later design 806-3398 interface boards (and in the 106-0396 interface boards that replaced them in current production fryers), the LEDs (labeled D1 though D7) are scattered around the board as shown in the right-hand illustration. The primary difference between the earlier design boards and the later design boards is the combining of the separate blower motor relay (K4) and the heat relays (K1 and K2) into a pair of replaceable relays (K2 and K3) in the latter. Also, the 106-0386 interface board has an additional fuse located in the upper right hand corner. Prior to June 1996, a board with replaceable relays very similar in appearance to the 106-0386 board was used. It is distinguished from the 106-0386 board by the absence of fuses.

NOTE: Although the printing on many boards indicates 2 Amp fuses, 3 Amp fuses (P/N 807-3843) must be used.

SOUND

1 2

GND

3 6 9 12

2 5 8 11

1 4 7 10

GND

V2D

PWR

AD AS

V2S

GND GV PWR

EARLIER DESIGN INTERFACE BOARD P/N 806-3398

K3 K5

HEAT

RELAY

12 6 3 45

AL 12V

BLOWER

MOTOR

RELAY

K1 K2

AIR

10741

11852

12963

24V AL

HEAT

RELAY

PWR

GND

3 6 9 12

2 5 8 11

1 4 7 10

GND V1D PWR ALR V1S

GND

SOUND

1 2

GND

3 6 9 12

2 5 8 11

1 4 7 10

GND

V2D

PWR

AD AS

V2S

GND

LATER DESIGN INTERFACE BOARDS P/N 806-3398 and 106-0386

This Fuse is NOT

present on 806-3398 IFB.

HEAT

RELAY

PWR

AND

BLOWER

MOTOR

RELAY

K2 K3

10741

11852

12963

HEAT

24V

RELAY

AND

BLOWER

MOTOR RELAY

12V

F2 Ignition 2 AMP Module

3 6 9 12

2 5 8 11

1 4 7 10

Blower Motor 2 Amp

GND

PWR

GND

D5 GV

AIR

GND V1D PWR

ALR V1S

1-2

FREQUEN TLY US ED TEST P O INTS FOR INTER FACE BO ARD S 806-3398 AND 106-0386

Meter

Test Se t t in g Pins Res u lt s

12VAC Po w er 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 24VAC Po w er to Left Module (if present) 50VAC Scale 8 on J1 and GR O U N D 22-28 120 VAC Power 250VAC Scale 11 on J3 and GROUND 110-125 120 VAC Power to Blowers 250VAC Scale 12 on J3 and GROUND 110-125 24VAC Power to Full- or Right-vat High-Limit 50VAC Scale 9 on J3 and G RO U N D 22-28 24VAC Power to Left High-Limit (if present) 50VAC Scale 9 on J1 and GROUND 22-28 Probe Resistance (Full- or Right-vat) * Probe Resistance (Left - if present) * R x 1000 O H MS 2 and 6 on J1 or 14 and 15 on J2 ** Probe Isolation R x 1000 O H MS 6 on J1 or J3 and GRO U N D *** High-Limit Continuity (Full- or Right-vat) R x 1 OHM 9 on J3 and Wire 13C on Gas Valve 0 High-Limit Continuity (Left - if present) R x 1 OHM 9 on J1 and Wire 12C on Gas Valve 0

** Disconnect 15-pin harness from controller before testing probe circuit.

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

R x 1000 O H MS 2 and 6 on J3 or 13 and 14 on J2 **

These standard interface boards are also used in a number of fryer types besides the H50 Series. The information contained in this section applies to H50 Series applications ONLY.

Earlier design 806-3398 boards (used from June 1996 through July 1999) contain two heat relays (K1 and K2) that switch 24VAC to the ignition and gas valve circuits when the computer/controller heat logic circuit calls for heat. Relay K4 switches 120VAC to the blower motor when either K1 or K2 closes. The relays on these boards are soldered on – if one fails, the whole board must be replaced.

The later design 806-3398 (and 106-0386 boards that replaced them in current production fryers) have only two relays. In this design, 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.

The tables below identify the diagnostic LEDs and their meaning.

LATER DESIGN INTERFACE BOARD

LED DIAGNOSTIC LIGHTS

EARLIER DESIGN INTERFACE BOARD

LED DIAGNOSTIC LIGHTS

Indicates 12 VAC from transformer

12V

Indicates 24 VAC from transformer

24V

Indicates 24 VAC to gas valve (left or right)

Indicates 24 VAC to module (left or right)

PWR

Indicates module l ock-out (left or right)

CE and Japanese units only: ai r switch closed

AIR

24 VAC to left gas valve (dual vat onl y)

24 VAC to left ignition module

24 VAC from transformer

24 VAC to right ignition module

24 VAC to gas valve (right valve if dual vat )

12 VAC from transformer

CE and Japanese units only: ai r switch closed

1-3

INTERFACE BOARD

12 VAC TO CPTR

GROUND

COMPUTER (12 VAC)

COMPUTER RT HT RELAY

COMPUTER 12 VDC TO RELAYS

COMPUTER LT HT RELAY

COMPUTER

NOT USED NOT USED

COMPUTER LT BL RELAY

RT ALARM OUT

COMPUTER SOUND DEVICE

LT ALARM OUT

COMPUTER

COMPUTER J1 PIN 6

RT BL RELAY

ALR (RIGHT)

J1 PIN 2 & J3 PIN 2

NOT USED NOT USED

NOT USED

TEMP PROBE J2 PIN 15

BASKET LIFT (DN)

24 VAC IN

MAIN GAS VALVE

via HLS

BASKET LIFT (UP)

NOT USED NOT USED

PWR via LT HT RELAY

J3 PIN 1

GROUND

J3 PIN 3

AD (LEFT)

J3 PIN 6

J2 PIN 14TEMP PROBE

NOT USEDNOT USED

NOT USED

NOT USEDNOT USED

LT BL RELAY

V2D

LT BL RELAY

** Dual Vat configurations

** Full Vat configurations

J2 PIN 1

J2 PIN 14 TEMP PROBE

J2 PIN 3

NOT USED

NOT USED NOT USED

J2 PIN 13

RT BL RELAY BASKET LIFT (DN)

PWR via RT HT RELAY

V1S OR V1D

RT BL RELAY

BLOWER via K4 (ol d)

or K2/K3 (new)

BLOWER XFMR BOX

12 VAC XFMR

NOT USED

TEMP PROBE

24 VAC IN

MAIN GAS VALVE

via HLS

BASKET LIFT (UP)

120 VAC IN

MOD 25V GROUND GROUND

MOD V2D

MOD 25V TERM

DRAIN SWITCH (OPT)

NOT USED NOT USED

GND

V2D

J1 PIN 8 via LT HT RELAY

PWR

V2S

J1 PIN 9

J2 PIN 12

LEFT VAT FULL OR RIGHT VAT

INTERFACE BOARDS 806-3398 AND 106-0386

GROUND MOD 25V GROUND

J3 PIN 9

J3 PIN 8 via RT HT RELAY

J2 PIN 10

J3 PIN 9

CURRENT FLOW T HROU G H

(H50 APPLICATION)

1-4

GND

V1D

PWR

ALR

V1S

MOD V1D *

MOD 25V TERM

DRAIN SWITCH (OPT)

MOD V1S **

THERMOSTATS

All fryers in the H50 Series have temperature probes located on the front centerline of each frypot. (Dual-vat frypots have two probes, one in each vat.) In this type thermostat, the probe resistance varies directly with the temperature. That is, as the temperature rises, so does resistance, at a rate of approximately 2 ohms for every 1º F. Circuitry in the controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints). The temperatures are programmed by means of a keypad on the face of the controller.

H50 Series 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.

1.2 Accessing Fryers for Servicing

DANGER

Moving a fryer filled with cooking oil may cause spilling or splattering of the hot

liquid. Drain the fryer 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.

3. Relocate the fryer for service accessibility.

4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and plug in the electrical cords.

1.3 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 in 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.

1-5

1.4 Checking the Burner Manifold Gas Pressure

1. On non-CE fryers, ensure that the gas valve knob is in the OFF position.

Honeywell

OFF

2. Remove the pressure tap plug from the gas valve assembly.

Pressure Tap Plug

Typical Non-CE Valve Assembly

Typical CE Valve

Assembly

2. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.

3. On non-CE fryers only, place the gas valve in the ON position.

4. 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 found 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.

1-6

CE Standard

Burner Manifold Gas Pressures

for Fryers Manufactured After April 1999

Pressure (mbar)

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 (single or dual)

Vat

10 10

17 17

20 20

Burner Manifold Gas Pressures

for Fryers Manufactured Through April 1999

Dual

Vat

Natural Gas Lacq (G20) under 20 mbar

Natural Gas Gronigue * (G25) under 25 mbar

Natural Gas Gronigue (G25) under 20 mbar

Butane (G30) at 28/30 or 50 mbar

Propane (G31) under 37 or 50 mbar

* Belgian G25 = 7,0 mbar (single) or 6,5 (dual)

Gas

CE Standard

Pressure (mbar)

Single

Vat

76,5

10 9

17 16,5

20,2 18,5

Dual

Vat

Non-CE Standard

Bur ner Ma nifold G as Pr e ssur e s

Gas Pre ssur e

Natural

Propane

3" W.C.

0.73 kPa

8.25" W.C.

2.5 kPa

5. To adjust the burner gas pressure, remove the cap from the gas valve regulator and adjust to the correct pressure.

Non-CE

Valve

Earlier Model CE Valve

Later Model

CE Valve

GAS VALVE REGULATOR CAP

6. 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.

1-7

1.5 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.

3. Place the fryer power switch in the ON position to light the burners. Wait at least one minute

after the frypot temperature reaches 200°F (93°C) before checking the reading. NOTE: The closer the unit is to normal operating temperature, the more accurate the reading will be.

1.6 Replacing Fryer Components

1.6.1 Replacing the Controller or the Controller Wiring Harness

1. Disconnect the fryer from the electrical supply.

2. Remove the two screws in the upper corners of the control panel and swing the panel open from

the top, allowing it to rest on its hinge tabs.

3. Disconnect the wiring harness from the back of the controller and, if replacing the harness,

disconnect it from the interface board.

4. Disconnect the ground wire from the controller, and remove the controller by lifting it from the

hinge slots in the control panel frame.

5. Reverse the procedure to install a new controller or wiring harness. NOTE: Ensure that the fer-

rite bead (black ring) in the harness is at the controller end.

1.6.2 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. Remove the screws from the upper corners of the control panel and swing the panel open from the top, allowing it to rest on its hinge tabs.

4. Unplug the controller wiring harness from the back of the controller.

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

6. If the fryer has a built-in filtration system, loosen the bolt securing the oil return handle to the oil return operating rod.

1-8

7. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward

you.

8. Remove the component box mounting screws.

9. Rotate the top of the component box out of the frame and carefully pull it out enough to

disconnect the wiring harness plug(s) from the back of the box.

10. Remove the box and set it aside.

11. Make a note of the location of the existing wires. Using a pin-pusher, disconnect the tempera-

ture probe wires (or high-limit thermostat wires) from the connector plug.

12. Unscrew and remove the temperature probe (or high limit thermostat) from the frypot.

13. Apply Loctite® PST56765 pipe thread sealant or equivalent to the replacement part threads.

14. Screw the replacement part into the frypot and torque to 180 inch-pounds.

15. Connect the wires from the new component to the connector plug, referring to the note made in

step 11.

16. Reverse steps 1 through 9 to complete the procedure.

1.6.3 Replacing the Interface Board

1. Remove the component box per steps 1 through 10 of Section 1.6.2.

2. Unplug the controller wiring harness from the interface board.

3. Disconnect the wires attached to the interface board, marking or making a note of the wires and

terminals to facilitate reconnection.

4. Remove the nuts at each corner of the interface board and pull it from the studs.

5. Reverse the procedure to install the replacement board, being sure to reinstall the spacers behind

the interface board.

1.6.4 Replacing an Ignition Module

1. Disconnect the fryer from the electrical supply.

2. Remove the screws from the upper corners of the control panel and swing the panel open from

the top, allowing it to rest on its hinge tabs.

3. Disconnect the wires from the ignition module, marking or making a note of the wires and

terminals to facilitate reconnection.

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

1-9

5. Reverse the procedure to install the replacement module.

1.6.5 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 ignition cable from the ignitor by grasping the boot and gently pulling toward you.

3. Remove the sheet metal screw securing the ignitor to the mounting plate and pull the ignitor from the fryer.

4. Reverse the procedure to install the replacement ignitor.

1.6.6 Replacing or Cleaning a Combustion Air Blower

A sheet metal shield or shield assembly prevents inadvertent access to the blower assembly. The specific design varies depending upon the particular configuration of the fryer and the country for which manufactured, but in all cases, the shield is attached to the cabinet framing by sheet metal screws. Remove the screws that secure the shield or shield assembly to the cabinet framing and pull the shield out of the fryer to expose the combustion air blower assembly.

1. Disconnect the blower wiring harness and remove the blower assembly mounting nuts.

Wiring connection

Blower assembly mounting

nuts

2. Remove the three fasteners that secure the blower motor assembly to the blower housing, and

separate the two components.

1-10

Remove these fasteners. (On black-colored FASCO blowers there are three nuts. On silver-colored KOOLTRONICS blowers there are three screws.)

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.

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 assembly in the fryer.

5. Reinstall the blower shield or shield assembly.

6. Light the fryer in accordance with the procedure described in Chapter 3, Section 3.1 of the H50

Series Installation and Operation Manual (P/N 819-5000).

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.

1-11

Left Viewing

Port is Behind

Motor

(NOTE: Blower

shield omitted

for clarity.)

Right

Viewing

Port

The air/gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable table on page 1-7 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.

Adjusting Air/Gas Mixture

Non-CE Units and CE Units Built After April 1999

On the side of the blower housing opposite the motor is a plate with one or two locking nuts. Loosen the nut(s) enough to allow the plate to be moved, then adjust the position of the plate to open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold the plate in position and tighten the locking nut(s).

TYPICAL NON-CE BLOWER ASSEMBLY TYPICAL CE BLOWER ASSEMBLY

ON UNITS BUILT AFTER APRIL 1999

1-12

Adjusting Air/Gas Mixture

CE Units Built Through April 1999

CE units built through April 1999 are equipped with a shield assembly in front of the blowers. An air shutter plate on the face of the shield assembly regulates the amount of airflow to the blower intake. To adjust the shutter plate, loosen the locking screws and slide the shutter to the left or right as necessary to obtain a bright orange-red glow. Carefully hold the shutter plate in position and tighten the locking screws.

TYPICAL CE BLOWER SHIELD ASSEMBLY

ON UNITS BUILT THROUGH APRIL 1999

1.6.7 Replacing a Gas Valve

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

1. Disconnect fryer from electrical and gas supplies.

2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate its reconnection.

3. Remove the vent tube and the enrichment tube fitting from the valve.

4. Disconnect the flexible gas line(s).

5. 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.

6. Remove all fittings from the old gas valve and install them on the replacement valve, using Loctite

7. Apply Loctite union). Reverse steps 1-5 to install the replacement gas valve.

PST56765 or equivalent pipe thread sealant.

PST 56765 or equivalent pipe thread sealant to the threads of the manifold (or

1-13

1.6.8 Replacing a Burner Assembly

DANGER

Drain the frypot or remove the handle from the drain valve before proceeding further.

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 will be necessary to remove the drain valve handles before the

plenum can be removed.

4. Disconnect the ignition cables from the ignitors by grasping their boots and pulling toward you.

5. Disconnect the gas lines and enrichment tubes from the burner orifices and ignitor assemblies.

6. Remove the four ¼” (6mm) 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 1.6.9 for procedure.

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

Refer to Section 1.6.10 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.

1-14

15. 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.

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.

1.6.9 Replacing the Frypot

1. Drain cooking oil from the frypot.

2. Remove all accessories, e.g., frypot covers, basket lift arms, etc. from the fryer.

4. Disconnect the fryer from gas and electrical supplies.

5. Remove the screws from the topcap above the control panel and lift it up and off the fryer(s).

6. Remove the screws from the upper left and right corners of the control panel. Open the panel,

disconnect the controller wiring harness and ground wire. Remove the controller from the fryer.

7. Disconnect the ignition wires from the ignitor plugs by grasping their boots and pulling toward

you.

8. Remove the screws securing the component box to the frame, and then rotate the top of the box

forward and out of the fryer enough to disconnect the wiring harness connector plug(s) on the rear of the box. Set the component box aside.

9. Using a pin pusher, remove the temperature probe and high-limit thermostat wires from the

plug(s), marking each wire to facilitate re-assembly.

10. On fryers with built-in filtration, remove the cover from the safety drain switch, disconnect the

wires from the switch, and pull them out of the switch box.

11. On fryers with built-in filtration, remove the section(s) of square drain from the drain valve(s) of

the frypot to be removed.

12. Disconnect the gas lines and enrichment tubes from the burner orifices and ignitor assemblies.

13. Remove the frypot hold down bracket.

14. Remove the screws from the flue cap sides and back and lift it clear of the fryer(s).

15. On units equipped with built-in filtration, disconnect the oil return line(s) from the frypot to be

removed.

1-15

16. Carefully lift the frypot from the fryer cabinet.

17. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), 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, but this remains the customer’s decision.

18. Reverse steps 1-16 to reassemble fryer.

19. Perform steps 14 through 18 of Section 1.6.8 to ensure that there are no leaks in the burner insulation.

CAUTION

Before installing the temperature probe, high-limit thermostat, and drain valve on the

replacement frypot, clean their threads and apply Loctite® PST56765 thread sealant

or equivalent.

1.6.10 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 on page 1-18 for component identification. A CD containing a PowerPoint presentation detailing the procedure is also available (P/N 819-5805).

1. Remove the frypot per Section 1.6.9.

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.

1-16

10. Remove the flue assembly (10).

11. Remove the upper burner rails (11). NOTE: For the following steps, refer to the frypot exploded view on page 3-19 for component iden-

tification.

12. Remove any residual insulation, sealant, and/or oil from the exterior of the frypot.

13. Place the “L” shaped pieces of combustion chamber insulation (1) in the front and rear corners of

both upper rail-retaining slots.

14. Use a small amount of furnace or muffler repair cement to seal the gaps at each end of both

lower rails. (See inset, page 3-19.)

15. Install the upper burner rails (2) with the heat deflectors slanting toward the rear of the frypot.

The rails will cover the “L” shaped pieces of combustion chamber insulation previously installed.

16. Place the upper inner combustion chamber insulation and insulation retainers (3) on the top two

studs on each side of the front of the frypot and secure with ¼-20 washer-nuts. (It is normal for the retainers to slice off the overhanging insulation.)

17. Place the lower rear combustion chamber insulation (4) on the lower four studs at the rear of the

frypot.

18. Place one 1.625-inch tubular spacer (5) on each of the flue assembly (upper) studs at the rear of

the frypot. NOTE: There are three different sizes of spacers. Verify the size to ensure the correct spacers

are installed.

19. Press the flue assembly (6) over the burner rails. It may be necessary to use a rubber mallet or

screwdriver to align the components. Use four ¼-20 washer nuts to secure the flue assembly. Do not tighten the retainer nuts at this point. They should be finger-tight only.

NOTE: The flue edge will cover one to two inches of the lower insulation.

20. Install the lower rear combustion chamber back(s) and retainer(s) (7) with the flanged edge(s)

against the flue. Secure with ¼-20 washer nuts. NOTE: Full vat units have two-piece backs and four retainers. Dual vat units come with one-

piece backs and only two retainers.

1-17

Spacer

(Full Vat Illustrated)

Spacers

Disassembling A Frypot

1-18

(Full Vat Illustrated)

Re-assembling A Frypot

here

Apply cement

1-19

21. Insert the burners (9) into the rails to ensure the rail spacing and alignment are correct. The burner should slide freely into and out of the rails. The upper rail can be bent slightly to increase or decrease tension on the burner, and the edges of the slot can be closed or opened slightly to best fit the burner frame.

22. Carefully wrap a strip of burner insulation (8) tightly around the rear and sides of the burner frame (9), with the glass-tape side of the strip on the outside. Do not use duct tape or adhesive to secure the strip to the burner frame.

23. Align the burner to the burner rails while maintaining tension on the insulation strip. Insert the burner at a slight angle and begin pushing the burner slowly into the rails until it contacts the rear combustion chamber. The fit should be snug, but not excessively tight.

24. Verify that the burners are flush with the front edge of the burner rails. Remove the excess burner insulation by cutting with a knife or diagonal pliers. Do not try to tear the insulation!

25. Insert the upper front insulation (10) into its retainer (11), making sure that the holes in each piece are aligned with one another. Install the assembly with the insulation side toward the frypot and secure with ¼-20 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 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 locknuts.

1-20

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 pipefittings using Loctite

PST56765 sealant or equivalent on their threads.

1.7 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 seven broad categories:

1. Ignition failures

2. Improper burner functioning

3. Improper temperature control

4. Computer-related problems

5. Filtration problems

6. Leakage

7. Basket lift malfunctions.

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 identifying some of the more common problems.

1.7.1 Ignition Failures

Ignition failure occurs when the ignition module fails to sense a flame within the 4-second time delay period and locks out. When this happens, the module sends 24 VAC through the interface board alarm circuit to the controller/computer.

Analog controllers indicate ignition failure by illuminating the heat light and trouble light simultaneously. Digital, Computer Magic III, and Basket Lift Timer controls display “

H E L p.”

The three primary reasons for ignition failure, listed in order of probability, are:

1. Problems related to the gas and/or electrical power supplies

2. Problems related to the electronic circuits

3. Problems related to the gas valve.

1-21

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, 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. If the fryer is equipped with a built-in filtration system, first 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, or the fryer does not have a builtin filtration system, refer to the troubleshooting guides

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.

Occasionally you may encounter an ignition failure situation 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, but 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, but before replacing the gas valve refer to TROUBLE SHOOTING THE GAS VALVE.

1.7.2 Improper Burner Functioning

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

● A defective or incorrectly adjusted combustion air blower

● Inadequate make-up air

● Heat damage to the controller or ignition module

● A cracked ignitor or broken ignition wire

● A defective ignition module

● Cracked burner tile (this typically causes a very loud pop)

1-22

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 table below, and that the pressure remains constant throughout all hours of usage. Refer to Check Burner Manifold Pressure in the section of 1.4 for the procedure for checking the pressure of gas supplied to the burner.

CE Standard

for Incoming Gas Pressures

for Fryers Manufactured After April 1999

Pressure

Gas

G20 20 2 x 3.40 2 x 3.40 7 mbar 7 mbar G25 20 or 25 2 x 3.40 2 x 3.40 10 mbar 10 mbar G30 28/30 or 50 2 x 2.05 2 x 2.05 17 mbar 17 mbar G31 37 or 50 2 x 2.05 2 x 2.05 20 mbar 20 mbar

(1) mbar = 10,2 mm H

(mbar)

Orifice Diameter Single

(1)

Vat

Dual

Vat

Regulator Pressure

Single

Vat

Dual

Vat

for Fryers Manufactured Through April 1999

Gas

G20 20 2 x 3.40 2 x 3.40 7 mbar 7 mbar G25 20 or 25 2 x 3.40 2 x 3.40 10 mbar 9 mbar G30 28/30 or 50 2 x 2.05 2 x 2.05 17 mbar 16,5 mbar G31 37 or 50 2 x 2.05 2 x 2.05 20,2 mbar 18,5 mbar

(1) mbar = 10,2 mm H

CE Standard

for Incoming Gas Pressures

Pressure

(mbar)

Orifice Diameter Single

(1)

Vat

Dual

Vat

Regulator Pressure

Single

Vat

Dual

Vat

Non-CE Standard

for Incoming Gas Pressures

Gas Minimum M aximum

Natural

6" W.C.

1.49 kPa

14.93 mbar 11" W.C.

2.74 kPa

27.37 mbar

14" W.C.

3.48 kPa

34.84 mbar 14" W.C.

3.48 kPa

34.84 mbar

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 okay, the problem is most likely with one of the electrical components. Examine the ignition module and controller for signs of melting/distortion and/or discoloration due to excessive heat build-up in the fryer. (This condition usually indicates improper flue performance.) A melted or distorted ignition module is automatically suspect and should be replaced, but unless the condition causing excessive heat is corrected, the problem is likely to recur.

Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage. Again, if damage is due to excessive heat in the fryer, that problem must also be corrected.

Check for proper operation by disconnecting the wire from the ignitor (spark plug), inserting the tip of a screw driver into the terminal, and holding it 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 4 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.

1-23

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 cracks are 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. 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 procedure in Section 1.4.

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 are an over-filled vat, a dirty or out-ofadjustment 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 the Check Burner Manifold Pressure procedure Section 1.4.

1.7.3 Improper Temperature Control

Temperature control, including the melt cycle, is a function of several interrelated components, each of which must operate correctly. The principle component is the temperature probe. Other components include the interface board, the controller itself, and the ignition module.

Improper temperature control problems can be categorized into melt cycle problems and failure to control at setpoint problems.

MELT CYCLE PROBLEMS

In fryers equipped with analog controls, the melt cycle must be initiated by pressing the melt cycle switch. With all other controllers, initiation of the melt cycle is automatic. Problems may be with the controller itself, the temperature probe, or a malfunctioning heat relay on the interface board.

1-24

+ 108 hidden pages