Frymaster FQGLA-T SERVICE MANUAL

FilterQuick™ FQGLA-T

Gas Fryer

Service Manual

This manual is updated as new information and models are released. Visit our website for the latest manual.

FOR YOUR SAFETY Do Not Store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

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*8197443*

Part Number: FRY_SM_8197443 02/2018

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NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS FRYMASTER EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS FACTORY AUTHORIZED SERVICERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR 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 SERVICER.

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

NOTICE

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

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

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

NOTICE TO OWNERS OF UNITS EQUIPPED WITH CONTROLLERS

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.

NOTICE The instructions in this manual for using a bulk oil system for filling and discarding oil are for an RTI system. These instructions may not be applicable to other bulk oil systems.

WARNING

After installation of a gas fryer and after any maintenance to the gas system of a gas fryer-manifold, valve, burners, etc. – check for gas leaks at all connections. Apply a thick soapy solution to all connections and ensure there are no bubbles. There should be no smell of gas.

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.

DANGER

Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection. 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 this appliance is not a step! Do not stand on the appliance. 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

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.

WARNING

Use caution and wear appropriate safety equipment to avoid contact with hot oil or surfaces that may cause severe burns or injury.

DANGER

Keep all items out of drains. Closing actuators may cause damage or injury.

Table of Contents

Section 1: Service Procedures

1.1 FQ4000 Menu Summary Trees ......................................................................................................... 1-1

1.1.1 FQ4000 Menu Tree General Market/Burger King ................................................................. 1-1

1.1.2 FQ4000 Information Statistics Menu Tree General Market/Burger King .......................... 1-2

1.1.3 FQ4000 Menu Tree Taco Bell ................................................................................................... 1-3

1.1.4 FQ4000 Information Statistics Menu Tree Taco Bell ............................................................ 1-4

1.2 FQ4000 Password Codes ................................................................................................................... 1-5

1.3 Service Required Errors ..................................................................................................................... 1-5

1.4 Error Log Codes .................................................................................................................................. 1-5

1.5 Component Check .............................................................................................................................. 1-7

1.6 Functional Description ....................................................................................................................... 1-8

1.7 The Electronic Ignition System .......................................................................................................... 1-8

1.8 Smart Interface Board (SIB) ............................................................................................................... 1-9

1.8.1 Full Vat flow through the SIB Board .............................................................................. 1-10

1.8.2 Split Vat flow through the SIB Board ............................................................................ 1-11

1.8.3 Frequently Used Test Points for SIB .............................................................................. 1-12

1.8.4 SIB (Smart Interface Board) Troubleshooting .............................................................. 1-12

1.8.5 SIB (Smart Interface Board) Pin Positions and Harnesses ......................................... 1-13

1.9 Thermostats ...................................................................................................................................... 1-14

1.10 Accessing Fryers for Servicing ......................................................................................................... 1-14

1.11 Cleaning the Gas Valve Vent Tube .................................................................................................. 1-14

1.12 Checking the Burner Manifold Gas Pressure ................................................................................ 1-15

1.13 Measuring Flame Current ................................................................................................................ 1-17

1.14 Replacing Fryer Components .......................................................................................................... 1-17

1.14.1 Replacing the Controller or the Controller Wiring Harnesses ................................... 1-17

1.14.2 Replacing the SIB ............................................................................................................. 1-18

1.14.3 Replacing the OIB Relay, OIB Relay Board, Transformer or Blower Relay .............. 1-18

1.14.4 Replacing the Temp Probe, ATO Probe, VIB Probe, OIB Sensor or High-Limit ....... 1-18

1.14.5 Replacing an Ignition Module ........................................................................................ 1-19

1.14.6 Replacing an Ignitor Assembly ....................................................................................... 1-19

1.14.7 Replacing or Cleaning a Combustion Air Blower ......................................................... 1-20

1.14.8 Adjusting the Air/Gas Mixture ........................................................................................ 1-21

1.14.9 Replacing a Gas Valve ..................................................................................................... 1-22

1.14.10 Replacing a Burner Assembly ........................................................................................ 1-23

1.14.11 Replacing the Filter Motor or Filter Pump .................................................................... 1-24

1.14.12 Replacing the Frypot ....................................................................................................... 1-25

1.14.13 Replacing Frypot Insulation and/or Upper Burner Rails ............................................ 1-25

1.15 Troubleshooting and Problem Isolation ..................................................................................

1.15.1 Heating (Ignition) Failure ................................................................................................ 1-29

1.15.2 Improper Burner Function ............................................................................................. 1-30

1.15.3 Improper Temperature Control .................................................................................... 1-31

1.15.4 Controller Malfunctions .................................................................................................. 1-31

1.15.5 Filtration Malfunctions .................................................................................................... 1-31

1.15.6 Leakage ............................................................................................................................. 1-32

1.16 Troubleshooting Guides .................................................................................................................. 1-32

1.16.1 Troubleshooting the 24 VAC Circuit .............................................................................. 1-33

....... 1-28

1.16.2 Troubleshooting the Gas Valve ...................................................................................... 1-34

1.16.3 Troubleshooting the Temperature Probe .................................................................... 1-34

1.16.4 Replacing the Reset Switch............................................................................................. 1-34

1.17 Probe Resistance Chart .................................................................................................................... 1-35

1.18 ATO (Automatic Top-Off) and Filtration Service Procedures ...................................................... 1-35

1.18.1 ATO (Automatic Top-Off Troubleshooting) .................................................................. 1-35

1.18.2 Filtration Troubleshooting .............................................................................................. 1-38

1.18.3 Test points on rear of FIB box ........................................................................................ 1-40

1.18.3.1 12-pin connector on rear FIB box .............................................................. 1-40

1.18.3.2 Connections on rear of FIB box ................................................................. 1-40

1.18.4 FIB (Filter Interface Board) Filtration Top-off Pin Positions and Harnesses ............ 1-41

1.18.5 Replacing FIB Board, Power Supply, Filter Relay or Transformer ............................. 1-42

1.18.6 Replacing the ATO Pump or Solenoid ........................................................................... 1-43

1.19 FIB (Filter Interface Board) Service Procedures ............................................................................ 1-43

1.19.1 Manually Draining, Refilling, Filtering or Topping off - Manual Filtration Mode .... 1-43

1.19.2 Control Power Reset Switch ........................................................................................... 1-43

1.20 Bulk Oil Service Issues ..................................................................................................................... 1-44

1.20.1 Bulk FIB Tests ................................................................................................................... 1-44

1.20.2 Bulk Oil Wiring Connection behind Fryer ..................................................................... 1-45

1.20.3 Frymaster FQ-T Fryer and Bulk Oil System Plumbing Schematic ............................. 1-45

1.20.4 Bulk Test Quick Reference .............................................................................................. 1-46

1.20.4.1 Dispose to Waste, Refill Vat from Bulk ...................................................... 1-46

1.20.4.2 Dispose to Waste ......................................................................................... 1-46

1.20.4.3 Fill Vat from Bulk .......................................................................................... 1-47

1.20.4.4 Fill Oil Reservoir from Bulk ......................................................................... 1-47

1.20.5 Troubleshooting Oil Reservoir Filling ............................................................................ 1-47

1.21 VIB (Valve Interface Board) Service Procedures ........................................................................... 1-48

1.21.1 VIB (Valve Interface Board) Troubleshooting ............................................................... 1-49

1.21.2 VIB (Valve Interface Board) Pin Positions and Harnesses .......................................... 1-50

1.21.3 Replacing a VIB (Valve Interface Board) Board ............................................................ 1-51

1.21.4 Replacing a Rotary Actuator ........................................................................................... 1-51

1.21.5 Oil Level Sensor ............................................................................................................... 1-51

1.21.5.1 Oil Level Sensor Troubleshooting .............................................................. 1-52

1.21.5.2 Oil Level Sensor Diagram ............................................................................ 1-52

1.22 FQ4000 Controller Service Procedures.......................................................................................... 1-53

1.22.1 FQ4000 Controller Troubleshooting ............................................................................... 1-53

1.22.1.1 FQ4000 Controller Functional Troubleshooting ...................................... 1-55

1.23 Loading and Updating Software Procedures ................................................................................ 1-58

1.24 Wiring Diagrams ............................................................................................................................... 1-61

1.24.1 Power Distribution Box Export ...................................................................................... 1-61

1.24.2 Power Distribution Box Domestic US ........................................................................... 1-62

1.24.3 FQGLA-T Series LOV™ Simplified Wiring with Color Legend ...................................... 1-63

1.24.4 FQGLA-T Series LOV™ Simplified Wiring with OQS CAN Bridge Board .................... 1-64

1.24.5 FQGLA-T Series LOV™ Simplified Wiring without OQS CAN Bridge Board .............. 1-65

1.24.6 Filtration Interface Box (FIB) Wiring .............................................................................. 1-66

1.24.7 Full Vat Direct Spark Wiring Diagram with Optional OIB Sensor .............................. 1-67

1.24.8 Dual Vat Direct Spark Wiring Diagram with Optional OIB Sensor ............................ 1-68

FQGLA-T SERIES FILTERQUICK GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 FQ4000 Menu Summary Trees

1.1.1 FQ4000 Menu Tree General Market/Burger King

Reflected below are the major programming sections in the FQ4000 and the order in which the headings will be found in the controller.

Filtration Menu

Quick Filter Clean and Filter (with OQS) OQS-Filter Dispose Fill Vat from Pan Fill Vat from Bulk (Bulk Only) Pan to Waste (Bulk Only) Drain to Pan Clean Polish

Home Button

Crew Mode (Cooking Mode) Menus (1650)

Create New

Recipes (1650)

Product Name Temp Cook Time Sensitivity Hold Timer Shake 1 Shake 2 Filter

Settings

Manager (1656)

Language

Date & Time F° to C°/ C° to F° (Toggles Temperature Scale) Sound

Filter Attributes

Energy Savings (Enabled, Temperature, Time) Lane Assignments (# of Baskets) Brightness Screen Saver Alarm Attributes

Temperature Oil Dragout Basket Lift

Service (3000)

Locale (CE / Non-CE) Energy Type (Gas / Electric) Vat Type (Full / Split)

Oil System Type (JIB / Bulk) Waste Oil (None / Bulk/Front Dispose) Auto Top Off Vat (On / Off) ATO Delay Time ATO Type (Auto, Push Button, Both)

Filtration Time Settings OQS Setup

Basic Auto Filter (Enable/Disable)

Primary Secondary

Volume Tone

Filter After (Cooks) Filter Time (Hours) Filter Off Time Filtration Off Settings Clean (Cold/Hot)

Shake Alarm Mode (Auto / Manual) Hold Alarm Mode (Auto / Manual) Alarm Timer (Shake Timer / Hold Timer)

Basket Configuration

OQS (Enable/Disable) Oil Type (Oil Curve) Display Type (Number/Text) Discard Now (TPM Value) Discard Soon (TPM Offset Value) Dispose Delay Timer

Service

Manager (1656)

E-Log Passcode Setup USB Menu Operation

Service (3000)

Crew

Copy Menu from USB to Fryer

Manual Filtration Password Reset Tech Modes

Resets

Toggle to Select

Filter Pad Time Setup Clear Statistics

Software Upgrade Vat Tuning (Engineering only) Component Check (9000) Blower Demo Mode

FIB Reset 1 FIB Reset 2

Hi-Limit Test

Factory Menu (Resets Product Recipes) Bad CRC (Resets Alert) Recovery Fault Call Service (Resets Alert) Reset Factory Resets (Resets to Factory Default) Reset Report Card (Resets Report Card)

F° to C°/ C° to F° (Toggles Temperature Scale)

Filter Stats Data (Clears Filter Stats) E-Log (Clears E-Log Errors)

1-1

1.1.2 FQ4000 Information Statistics Menu Tree General Market/Burger King

Reflected below are the information statistics in the FQ4000 and the order in which the headings will be found in the controller.

1-2

1.1.3 FQ4000 Menu Tree Taco Bell

Reflected below are the major programming sections in the FQ4000 and the order in which the headings will be found in the controller.

1-3

1.1.4 FQ4000 Information Statistics Menu Tree Taco Bell

Reflected below are the information statistics in the FQ4000 and the order in which the headings will be found in the controller.

1-4

1.2 FQ4000 Password Codes

Press the HOME button to enter MENUS, RECIPES, SETTINGS or SERVICE menus.

 1650 – MENUS, RECIPES,  1656 – SETTINGS (MANAGER), SERVICE (MANAGER)  3000 – SETTINGS (SERVICE), SERVICE (SERVICE) Enter Tech Mode  9000 – Component Check [SETTINGS (SERVICE), SERVICE (SERVICE) Enter Tech Mode]

The following code is entered when prompted to do so.

 1111 – Reset SERVICE REQUIRED Message – Enter when the issue is fixed and prompted to enter

code.

1.3 Service Required Errors

A SERVICE REQUIRED error with a description of the error displays on the controller. After YES is pressed the alarm is silenced. The controller displays an error message from the list below three times with the location of the error. Then the controller displays SYSTEM ERROR FIXED? YES/NO. If yes is chosen, enter code 1111. If NO is chosen, the system returns to cook mode if possible for 15 minutes, then redisplays error until issue is fixed.

1.4 Error Log Codes

To access the error log, press the home button. Press the service button. Press the manager button. Enter 1656 and press the check button. Press the E-log button. The ten most recent errors are listed from top to bottom, with the top error being the most recent error. A “G” indicates a global error such as a filtration error. Side specific errors in split vats are indicated by L for left or R for right. Pressing the left down arrow allows scrolling through the

errors. If no errors are present the screen will be blank.

Code ERROR MESSAGE EXPLANATION

E13 E16

E17 E18

E19

E25 E27

E28 E29

E32 E33 E34 E35 E36

E37

E39 E41

TEMPERATURE PROBE FAILURE TEMP Probe reading out of range HIGH LIMIT 1 EXCEEDED High limit temperature is past more than 410°F

(210°C), or in CE countries, 395°F (202°C) HIGH LIMIT 2 EXCEEDED High limit switch has opened. HIGH LIMIT PROBLEM DISCONNECT POWER

Vat temperature exceeds 460°F (238°C) and the

high limit has failed to open. Immediately

disconnect power to the fryer and call service. HEATING FAILURE – XXX F or XXX C Heating Control latch circuit failed.

Heat Contactor failed to latch. HEATING FAILURE - BLOWER The air pressure switch(s) failed to close.

HEATING FAILURE - PRESSURE SWITCH -

The air pressure switch has failed closed. CALL SERVICE HEATING FAILURE – XXX F or XXX C The fryer has failed to ignite and has locked out the

ignition module. TOP OFF PROBE FAILURE - CALL SERVICE ATO RTD reading out of range DRAIN VALVE NOT OPEN - FILTRATION AND TOP OFF DISABLED - CALL SERVICE DRAIN VALVE NOT CLOSED - FILTRATION AND TOP OFF DISABLED - CALL SERVICE RETURN VALVE NOT OPEN - FILTRATION AND TOP OFF DISABLED - CALL SERVICE RETURN VALVE NOT CLOSED - FILTRATION AND TOP OFF DISABLED - CALL SERVICE VALVE INTERFACE BOARD FAILURE - FILTRATION AND TOP OFF DISABLED -

Drain valve was trying to open and confirmation is

missing

Drain valve was trying to close and confirmation is

missing

Return valve was trying to open and confirmation is

missing

Return valve was trying to close and confirmation is

missing

Valve Interface Board connections lost or board

failure. CALL SERVICE AUTOMATIC INTERMITTENT FILTRATION

AIF (VIB Probe) RTD reading out of range. PROBE FAILURE - FILTRATION DISABLED CALL SERVICE CHANGE FILTER PAD 25 hour timer has expired or dirty filter logic has

activated. OIL IN PAN ERROR The system detects that oil may be present in the

filter pan.

1-5

Code ERROR MESSAGE EXPLANATION

E42 E43 E44 E45

E46 E51

E52 E53

E55 E62 E63

E64

E65 E66

E67 E68 E69

E70

E71

E72

E73 E74 E75

E76

E81

CLOGGED DRAIN (Gas) Vat did not empty during filtration OIL SENSOR FAILURE - CALL SERVICE Oil level sensor may have failed. RECOVERY FAULT Recovery time exceeded maximum time limit. RECOVERY FAULT – CALL SERVICE Recovery time exceeded maximum time limit for two

or more cycles. SYSTEM INTERFACE BOARD 1 MISSING CALL SERVICE DUPLICATE BOARD ID - CALL SERVICE Two or more controllers have the same location ID. USER INTERFACE CONTROLLER ERROR CALL SERVICE CAN BUS ERROR - CALL SERVICE Communications are lost between boards. SYSTEM INTERFACE BOARD 2 MISSING CALL SERVICE SLOW HEATING FAILURE XXXF OR XXXC CHECK ENERGY SOURCE - CALL SERVICE RATE OF RISE Rate of rise error occurred during a recovery test. FILTRATION INTERFACE BOARD FAILURE - FILTRATION AND TOP OFF DISABLED CALL SERVICE CLEAN OIB SENSOR – XXX F OR XXX C CALL SERVICE DRAIN VALVE OPEN – XXXF OR XXXC Drain valve is opened during cooking. SYSTEM INTERFACE BOARD NOT CONFIGURED - CALL SERVICE OIB FUSE TRIPPED – CALL SERVICE The VIB board OIB fuse has tripped and didn’t

RECIPES NOT AVAILABLE The controller has not been programmed with

OQS TEMP HIGH Oil temperature is too high for a valid OQS reading.

OQS TEMP LOW Oil temperature is too low for a valid OQS reading.

TPM RANGE LOW The TPM is too low for a valid OQS reading. This

TPM RANGE HIGH The TPM reading is too high for a valid OQS OQS ERROR The OQS has an internal error. If issue continues OQS AIR ERROR The OQS is detecting air in the oil. Check the O-

OQS ERROR The OQS sensor has a communication error. Check

SAFE MODE FAILURE ERROR The system has detected the fryer is not heating

SIB board 1 connection lost or board failure.

The controller has an unknown error.

SIB board 2 connection lost or board failure.

The vat is not heating properly.

Filtration Interface Board connections lost or board

failure.

Gas -The oil is back sensor does not detect oil.

Clean optional oil sensor.

Controller is turned on when the SIB board is not

configured.

reset.

product recipes. Replace controller with factory

programmed controller.

Filter at a temperature between 300ºF (149ºC) and

375ºF (191ºC).

Filter at a temperature between 300ºF (149ºC) and

375ºF (191ºC).

may also be seen with fresh new oil. The incorrect

oil type may be selected in the setup menu. The

sensor may not be calibrated for the oil type. See oil

type chart in instruction document 8197316. If issue

continues contact an FAS.

reading. Dispose the oil.

contact an FAS.

rings and check/tighten prescreen filter to ensure no

air is entering the OQS sensor. If issue continues

contact an FAS.

connections to the OQS sensor. Power cycle the

entire fryer battery. If issue continues contact an

FAS.

properly due to low oil conditions. Ensure the fryer

has oil to the bottom fill line or higher. If not, add oil

to the bottom fill line.

1-6

1.5 Component Check

The FQ4000 controller has a function to check the major components and their status.

With the controller soft powered OFF, press the HOME button. Select Service, Service, Enter 9000, Select Tech Modes, scroll down and select Component Check.

The component name is above each button. The status of the component is below the function. Pressing the button will change the status of the function to what is stated on the button. If the button is shaded that function is not available unless that function is enabled (such as bulk). The JIB reset button and Waste Tank full only displays the status of the switch.

Pressing the home button to exit the function will display driving valves to ensure all valves return to home state. Once completed the controller will display FILL VAT FROM DRAIN PAN? YES NO. Press YES to ensure that any oil in the filter pan is returned to the vat.

1-7

1.6 Functional Description

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

1.7 The Electronic Ignition System

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

Out to Oil Level Sensor and Gas Valve

To Alarm

Inside the Ignition

Module

time delay circuit and a coil that activates the gas valve. All full and dual vat fryers use two single-spark modules

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

At start-up, the power switch on the touchscreen controller is placed in the ON position, supplying approximately 24 VAC to

24 V +

GND

Coil

H V

the heat-control circuitry in the Smart Interface Board and to one side of the heat relay coils on the Smart Interface Board. If the

Ignition Wire Flame Sensor

resistance in the temperature probe indicates the temperature in the frypot is below 180ºF (82ºC), the melt cycle function is activated where a timer activates for six seconds and deactivates for 24 seconds. If the temperature is 180ºF (82ºC) or above, the melt cycle is bypassed. 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 an oil level sensor which is controlled by electronics inside an egg shaped housing and a 7 second time delay relay board. Simultaneously, the module causes the ignitor to spark for four seconds to light the burner. A flame sensor verifies the burner ignition by measuring the flow of micro amps 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 SIB board 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.

1-8

1.8 Smart Interface Board (SIB)

All fryers in this series have a smart interface board (SIB) located in the component box behind the

controller panel. The SIB board provides a link between the controller and the fryer’s individual components without requiring excessive wiring, and

executes commands from one central point.

SMART INTERFACE BOARD LED

DIAGNOSTIC LIGHTS

LED 1 LED 2 LED 3 LED 4 LED 6 LED 7

24VAC Heat Relay 12VDC to Controller 24VAC Latch Relay 5VDC to probes and switches

3.3VDC to Micro Processor Communication to/from Micro Processor

K2 is a single-pole-double throw (SPDT) relay that supplies 24VAC to the ignition and gas valve circuits. The relays on this board are soldered to the board. If a relay fails, the board must be replaced. K1 is a single-pole-double throw (SPDT) relay that supplies voltage through the high limit and the optional air pressure switch.

The SIB LEDs (labeled LED1 through LED7) are arrayed around the board to assist in troubleshooting.

12VDC should be lit and bright at all times. If LED is dim then something is pulling voltage down. Short to ground on 12VDC circuit will cause dim LED.

5VDC should be lit and bright at all times. If LED is dim then something is pulling voltage down. Short to ground on 5VDC circuit will cause dim LED.

When UI is soft powered on this Latch Relay LED will come on first confirming high limit is closed. The blower will then come on and prove the air switch. The relay is a true latch circuit and when broken or turned off the heat relay will also turn off.

When UI calls for HEAT this LED will come on with the heat relay only after latch relay has been latched in and AIR switch has been proven. This LED

Blinking red LED, (Heart Beat). This LED should be blinking and bright at all times when board is powered. The other green LED’s being dim or off will cause this LED to be off.

3.3VDC LED should be lit and bright at all times. If dim then something is pulling voltage down. Short to ground on

3.3VDC circuit will cause dim LED.

NOTE: Refer to Section 1.16.1 for troubleshooting flowchart.

The charts on pages 1-8 and 1-9 illustrate current flow through the board, and the table at the top of page 1-10 identifies frequently used test points.

1-9

1.8.1 Full Vat flow through the SIB board

MV PV

GAS VALVE

IGNITION 1

Pin 3

VALVE

Pin 11

SPARK

MODULE

Pin 8

24V Pin 6

SENSE

GND Pin 5

MODULE GROUND

HEAT 24VAC OUT

Optional

ALARM Pin 7

MODULE GAS VALVE 24VAC

MODULE ALARM 24VAC

AIR OUT 24VAC

34567

AIR PROVER

SWITCH

AIR IN 24VAC

10111214151720

MODULE POWER 24VAC 2

MODULE GAS VALVE 24VAC 2

IGNITION

MODULE

MODULE GROUND 2

Pin 11

SPARK

-12VDC AC BLOWER RELAY 21

Pin 3

VALVE

Pin 8

SENSE

24V Pin 6

GND Pin 5

+12VDC AC BLOWER RELAY

HEAT

RELAY

FULL VAT

IGNITION MODULES

TWO SINGLE SPARK

LATCH

CIRCUIT

1345678

24VAC

HIGH

LIMIT

AIR OUT 24VAC

HIGH LIMIT 24VAC

HIGH LIMIT RETURN 24VAC

AIR BYPASS

AIR IN 24VAC

JUMPER IF AIR

PROVER SWITCH IS

BOARD

(SIB)

SMART

INTERFACE

SENSORS

101112

HOOD RELAY 12VDC

NOT INSTALLED

JUMPER

1-10

1.8.2 Split Vat flow through the SIB board

1-11

1.8.3 Frequently Used Test Points for SIB (Smart Interface Board)

NOTE: DO NOT CHECK WITH HARNESSES UNPLUGGED AS SHORTING THE PINS MAY OCCUR WHICH WILL DAMAGE THE BOARD.

FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD 1085980

Meter

Test

24VAC Power to SIB 50VAC Scale 1 on J1 and GROUND 22-28 12VDC Power to Controller 50VDC Scale 7 and 8 on J6 12-18 24VAC Power to Right Module 50VAC Scale 1 on J2 and GROUND 22-28 24VAC Power to Left Module (if present) 50VAC Scale 12 on J2 and GROUND 22-28 120 VAC Power 250VAC Scale Blower Connections 110-125 120 VAC Power to Blowers 250VAC Scale Blower Connections 110-125 24VAC Power to High-Limit 50VAC Scale 3 on J1 and GROUND 22-28 Probe Resistance R x 1000 OHMS Disconnect and test across probe leads ** Probe Isolation R x 1000 OHMS 2 on Probe Connector and GROUND *** High-Limit Continuity R x 1 OHM 3 on J1 and 4 on J1 0

** See Probe Resistance Chart in section 1.17. *** 5 mega-Ohms or greater.

Pins Results Setting

1.8.4 SIB (Smart Interface Board) Troubleshooting

Problem Probable Causes Corrective Action

A. J1 connection unplugged

No power to SIB board

SIB BOARD 1

MISSING displayed on

the controller.

SIB BOARD 2

MISSING displayed on

the controller.

SIB NOT CONFIGURED displayed on the

controller.

B. Fuse blown. C. Transformer malfunction

A. Loose wire connection. A. Loose wire connection. A. Ensure all wiring harnesses are securely

A. SIB board not configured A. Replace the SIB board.

A. Check to ensure J1 on front of SIB board

is fully locked into connector.

B. Ensure fuse located at the bottom of the

control box is not blown and cap is securely tightened.

C. Check that proper voltage is present at

transformer. See table in section 1.8.3.

A. Ensure the connector is securely attached

to plug J6 on the SIB board.

connected between J9 and J10 between SIB boards.

1-12

1.8.5 SIB (Smart Interface Board) Pin Positions and Harnesses

NOTE: DO NOT CHECK WITH HARNESSES UNPLUGGED (except ATO and Temp Probes) AS SHORTING THE PINS MAY OCCUR WHICH WILL DAMAGE THE BOARD.

Connector From/To Harness #

From Transformer

To High Limit

From High Limit

To Air Switch Jumper

From Air Switch Jumper

From Drain Switch Jumper

J3 ATO Probe 8263286

J6 Controller

P-Bus Power Communication

J10

To Hood Relay

Left SIB Jumper Left SIB Jumper

To Drain Switch Jumper

To 24VAC Ignition Module

From Gas Valve From Gas Valve From Gas Valve

To Air Switch

From Air Switch

To 2nd Ignition Module From 2nd Ignition Module From 2nd Ignition Module

Valve

To AC Blower Relay To AC Blower Relay

C-Bus Harness

C-Bus Harness or

Network Resistor

(pins 2 & 3)

from SIB to VIB or between

SIB’s

RJ11

from SIB to VIB or between

SIB’s

RJ11

8075888 Full

8075886 Split

8075549 or

8075551

8075549 or 8075551 or

(8075632 Resistor)

8075555 or

8075553

8075555 or

8075553

# Function Voltage

1 24VAC Input 2 Ground 3 24VAC Out 4 24VAC Input 5 24VAC Out 6 24VAC Input 9 12VDC Out

10 11

14 24VAC Input 16 17 Ground 18 5VDC Out 20 24VAC Out

1 24VAC Out

2 Ground

3 Alarm In 4 24VAC In 5 24VAC Out 6 2VAC In

12 24VAC Out 13 Ground

14 24VAC In

21 AC Blower Relay 22 AC Blower Relay

1 Ground Yellow 2 RTD 3.3VDC Red

1 C-BUS + 5VDC 2 C-BUS - 5VDC 3 5VDC 5VDC 4 RS485 - 5VDC 5 RS485 + 5VDC 6 Signal Ground 7 12VDC 12VDC 8 Signal Ground 1 5VDC+ +5VDC 2 CAN High 3 CAN Low 4 Ground 1 5VDC+ +5VDC 2 CAN High 3 CAN Low 4 Ground 1 Ground 2 P-BUS power +5VDC 3 Modbus RS485 B 4 Modbus RS485 A 5 Signal ground 6 P-BUS power +12VDC 1 Ground 2 P-BUS power +5VDC 3 Modbus RS485 B 4 Modbus RS485 A

24VAC Orange

Blue 24VAC Orange 24VAC Blue 24VAC Gray 24VAC Gray 12VDC Purple

Yellow

Brown

24VAC Blue

Blue

Purple

5VDC Purple 24VAC Orange 24VAC Red

Green

24VAC Yellow 24VAC Orange 24VAC Orange 24VAC Blue

Blue

24VAC Red

Green

24VAC Orange

Orange

-12VDC Black

+12VDC Yellow

Wire

Color

1-13

Connector From/To Harness #

J11 Cooking Probe 8263285

1.9 Thermostats

# Function Voltage

5 Signal ground 6 P-BUS power +12VDC 1 Ground Yellow 2 Probe 3.3VDC Red

Wire

Color

The fryers are equipped with temperature probes located on the front centerline of each frypot (dual-vat frypots

have two probes, one in each vat). In this type of thermostat, the probe resistance varies directly with the temperature. That is, as the temperature rises, so does resistance, at a rate of approximately 2 ohms for every 1º F. Circuitry in the controller monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (set points).

The 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 high limit thermostats have different part numbers for CE and Non-CE models, and are not interchangeable.

1.10 Accessing Fryers for Servicing DANGER

Moving a fryer filled with oil may cause spilling or splattering of the hot liquid. Follow the Drain to Pan instructions in Chapter 5 of the FQGLA-T Installation and Operation Manual 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 and turn on gas supply, reattach restraining

devices, and plug in the electrical cords. NOTE: To ensure the safe and efficient operation of the fryer

and hood, the electrical plug for the 100-120 volt line, which may power the hood, must be fully engaged and locked in its pin and sleeve socket.

1.11 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.

1-14

1.12 Checking the Burner Manifold Gas Pressure

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

Honeywell

OFF

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

Pressure Tap Plug

Typical Non-CE Valve Assembly

Typical CE Valve

Assembly

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

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

5. Place the fryer power switch in the ON position. When the burner has lit and burned steadily for at least

one minute, compare the gas pressure reading to the pressure for the corresponding gas in the appropriate table on the following page. The tables on the following page list the burner manifold gas pressures for each of the gas types that can be used with this equipment.

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

pressure.

Non-CE

Valve

GAS VALVE REGULATOR CAP

7. Place the fryer power switch (and the gas valve in non-CE fryers) in the OFF position. Remove the fitting

from the pressure tap hole and reinstall the pressure tap plug.

Valve

1-15

Non-CE Standard for Gas Pressure

Fryer Model FQGLA30-T Gas Type Nat

(Natural)

Incoming Min Pressure

6/1.49/14.93 11/2.74/27.37

LP (Propane)

WC/kPa/mbar Incoming Max Pressure

14/3.48/34.84 14/3.48/34.84

WC/kPa/mbar Orifice Size (mm)

Number of Orifices Burner Manifold

3.18 2.10

2 2

3.00/0.73 8.25/2.5

Pressure WC/kpa

(1) mbar = 10,2 mm H2O

Korea Standard for Gas Pressure

Fryer Model FQGLA30-T Gas Type LNG

(Natural)

Incoming Min Pressure

4/1.00/10.00 9.2/2.30/23.00

LPG (Propane)

WC/kpa/mbar Incoming Max Pressure

10/2.50/25.00 13.2/3.30/33.00

WC/kpa/mbar Orifice Size (mm)

Number of Orifices Burner Manifold

3.18 2.10

2 2

3.00/0.73 8.25/2.5

Pressure WC/kPa

(1) mbar = 10,2 mm H2O

Japan Standard for Gas Pressure

Fryer Model FQGLA30-T

CE Standard for Gas Pressure

Fryer Model FQGA30-T Gas Type G20

Natural

Gas

Lacq

Incoming Min

20 20 28/30 37

G25

Natural

Gas

Groniqu

Pressure (mbar) Incoming Max

20 25 50 50

Pressure (mbar) Orifice Size (mm)

Number of

3.18 3.18 1.95 1.95

2 2 2 2

Orifices Regulator

7 10 17 20.6

Pressure Full Vat (mbar) Regulator

8 11.2 17 20.6

Pressure Dual Vat (mbar) Burner Manifold

7 10 17 20.6

Pressure (mbar) Full Vat Burner Manifold

8 11.2 17 20.6

Pressure (mbar)

G30

Butane

/Propane

G31

Propane

Gas Type

Incoming Min Pressure WC/kpa/mbar Incoming Max Pressure WC/kpa/mbar Orifice Size (mm)

Number of Orifices Burner Manifold

Pressure WC/kPa

(1) mbar = 10,2 mm H2O

13A

4/1.00/10.00 9.2/2.30/23.00

10/2.50/25.00 13.2/3.30/33.00

3.18 1.95

2 2

3.00/0.73 8.25/2.5

Propane (LP)

1-16

1.13 Measuring Flame Current

Flame Sensor

When the burner flame is properly adjusted, it will produce a current between

2.0A and 2.5A on Fenwal modules. Lockouts can occur at currents 0.5A or

below on Fenwal modules. 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 controller power switch in the OFF position.

2. Disconnect the sensing wire from one of the burner ignitors (see Figure 1) 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 controller power switch in the ON position to light the burners. After

Figure 1

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.

1.14 Replacing Fryer Components

1.14.1 Replacing the Controller or the Controller Wiring Harnesses

1. Disconnect the fryer from the electrical power supply. The fuse located at the bottom of the control

box can be removed to remove power from individual control boxes.

2. The controller is held in place by two screws in upper corners.

3. Remove the two screws from the upper corners of the controller.

4. Slide the controller up and it and will swing open from the top.

5. Disconnect the RJ45 cable from the SIB board first.

6. Disconnect the other cables from the connectors on the back of the controller marking their position for

reassembly.

7. Disconnect the lanyard tether.

8. Remove the controller.

RJ-45 Power /

Communication

Ground Wire

Lanyard Tether

Wire

Speaker Harness

Locator Wire

USB Harness

Figure 2

5. With the replacement controller face down resting in the control box, reattach the lanyard tether first.

Failure to reinstall lanyard could result in damage to the SIB board.

6. Reinstall the controller by reversing steps 1 thru 6.

7. Setup the controller following the instructions in section 4.7 of the FQGLA-T Installation and Operation

manual. If the controller being replaced is in the far left position the current date and time will need to be

setup following the instruction in section 4.8 of the Installation and Operation manual. Setup MUST be

performed prior to reset.

8. Once setup is complete on all replaced controllers, CYCLE POWER TO ENTIRE FRYER SYSTEM. See

section 1.19.2 to reset control power.

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