Frymaster GBC User Manual

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GSMS, GBC and GC

Gas Cooker Models

(Including GSW and GWB Variants)

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

819-5312

AUG 2009

DANGER

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR

MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ THE

INSTALLATION, OPERATING, AND SERVICE INSTRUCTIONS THOROUGHLY BEFORE

INSTALLING OR SERVICING THIS EQUIPMENT.

DANGER

FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE

LIQUIDS OR VAPORS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

DANGER

POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE

EVENT THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY

CONSULTING THE LOCAL GAS SUPPLIER.

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 FOOD AND

DRUG ADMINISTRATION.

COMPUTERS

FCC

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 interfere nce

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

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.

FRYMASTER FRYERS EQUIPPED WITH LEGS ARE FOR PERMANENT INSTALLATION.

FOR MOVEABLE OR PORTABLE INSTALLATION, FRYMASTER OPTIONAL EQUIPMENT

CASTERS MUST BE USED.

QUESTIONS??? CALL 1-800-551-8633.

Do not use deliming solution to clean water bath units. Use of deliming solution will damage all stainless

steel parts.

GAS COOKERS GSMS, GBC AND GC

SERVICE & PARTS MANUAL

TABLE OF CONTENTS

CHAPTER 1: Service Procedures

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

1.2 Accessing Equipment for Servicing...................................................................................1-2

1.3 Replacing Equipment Components....................................................................................1-3

1.3.1 Replacing the Controller................................................................................................1-3

1.3.2 Replacing Electronic Components Other than the Controller.......................................1-3

1.3.3 Replacing a Water-Level Sensor or the Temperature Probe.........................................1-4

1.3.4 Replacing the Pressure Regulator or Solenoid Valve....................................................1-5

1.3.5 Replacing the Water Faucet...........................................................................................1-5

1.3.6 Replacing a Basket Lift Motor or Microswitch.............................................................1-6

1.3.7 Replacing Gas Supply System Components or Ignitor Assemblies..............................1-7

1.3.8 Replacing the Cookpot or Rinse Tank...........................................................................1-8

1.4 Troubleshooting.................................................................................................................1-9

1.4.1 How the Power Supply System Works .........................................................................1-9

1.4.2 How the Controller Works ............................................................................................1-9

1.4.3 How the Autofill/Autoskim System Works ................................................................1-10

1.4.4 How the Water Heating System Works.......................................................................1-10

1.4.5 How the Basket Lift System Works............................................................................1-11

1.4.6 Technician Troubleshooting Guides............................................................................1-11

1.4.7 Probe Resistance Chart and Wiring Diagrams............................................................1-15

CHAPTER 2: Parts List

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

2.2 Basket Lift Components ....................................................................................................2-2

2.3 Cabinetry............................................................................................................................2-4

2.4 Combustion System Components......................................................................................2-8

2.5 Control Box and Related Components ............................................................................2-10

2.6 Controllers and Control Panel Components ....................................................................2-12

2.7 Cookpot, Rinse Tank and Associated Components.........................................................2-13

2.8 Drain Components ...........................................................................................................2-15

2.9 Gas Supply System Components.....................................................................................2-16

2.10 Water Supply Components..............................................................................................2-18

Appendix A: Notes Concerning and Parts Unique to GSW/GWB Variants

Accessories..................................................................................................................................A-1

Control Components....................................................................................................................A-2

Service Cookpot ..........................................................................................................................A-3

Water Supply Components..........................................................................................................A-4

Wiring Diagrams.........................................................................................................................A-6

GAS COOKERS GSMS, GBC, AND GC SERVICE AND PARTS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

The GSMS, GBC, and GC Gas Cookers all have a 12.7-gallon (48.1-liter) stainless steel cookpot. The water in the cookpot is heated by a high-efficiency infrared heating system that requires approximately 43% less energy than conventional burner systems to heat the same volume of water.

Two self-contained combustion chambers (commonly referred to as burners) are located beneath the cookpot. 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 cookpot by means of infrared radiation, providing much more constant and uniform heat dispersion over the surface of the cookpot than do conventional burners. Because relatively 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 cookpot temperature.

Gas flow to both of the burners is regulated by one electromechanical gas valve.

Operational control of the burner system is accomplished through a solid-state SMS III Spaghetti Magic controller. NOTE: The SMS III controller used in this model series is identical in appearance to the SMS III controllers used in other model series, but differs internally. Use only the part numbers listed in Chapter 2 when replacing controllers on this equipment. The GSMS is

equipped with a basket lift, and also features automatic filling (Autofill), automatic skimming (Autoskim), a swing-away jointed faucet, and an attached 16.5-gallon (62.5-liter) rinse-tank. The GBC model is identical to the GSMS except that it does not have the swing-away faucet and attached rinse-tank. The GC has no basket lift, no faucet, and no rinse tank.

When the controller Power switch is pressed, a logic circuit in the controller automatically checks the water level in the cookpot. A normally closed solenoid valve on the water supply line automatically opens if the normal water-level sensor is not grounded by contact with water in the cookpot. When sufficient water has been added to ground the low water-level sensor, the unit

automatically enters the SIMMER mode and remains there unless the operator presses the BOIL

mode switch or turns the unit off. When the water level in the cookpot reaches and grounds the normal water-level sensor, the solenoid valve in the water supply line closes. Anytime the water level in the cookpot drops below the normal water-level sensor, the solenoid valve opens to refill the cookpot to the proper level.

While in the SIMMER mode, logic circuits in the controller monitor the temperature of the water and cycle the burners on and off to maintain the temperature at the setpoint programmed into the controller. (See Chapter 3 for instructions on adjusting the setpoint.) The cooker also has low-water safety. If the water in the cookpot falls below the low water-level sensor, the controller cuts power to the gas valve, causing it to close and cut off the gas supply to the burners.

The Autoskim feature (on units so equipped) is activated by pressing the Skim switch. When the feature is activated, a logic circuit in the controller automatically opens the solenoid valve in the

1-1

water supply line for three seconds every minute until the option is turned OFF by again pressing the Skim switch.

The operator enters a specified cooking time by pressing the number pads on the controller. When the Start switch is pressed, the controller begins to count down to zero. When the controller times out, an alarm sounds briefly, then the timer reverts to the last time entered.

When the START switch is pressed to start the cooking cycle, logic circuits in the controller activate the basket lift motors (on units so equipped), lowering the basket into the cookpot. As the motors drive the basket lift arms down, a cam attached to the left motor eventually loses contact with a roller-activated microswitch and power to the motors is cut. When the controller times out, logic circuits reverse the switch positions so that the motor circuit is again completed and the motors are restarted, raising the basket from the cookpot. At the fully raised position, the cam again makes contact with the microswitch, cutting power to the motors and stopping the lift in the up position.

THE ELECTRONIC IGNITION SYSTEM

The ignition module, located in the component box, is connected to ignitor assemblies at each burner. The ignition module performs three important functions: it provides an ignition spark,

supplies operating voltage to the gas valve, and proofs the burner flame. NOTE: GSMS/GBC/GC

units manufactured before September 2000 have two single-spark ignition modules. Those manufactured September 2000 and later have only one dual-spark ignition module.

The ignition module contains a 4-second time delay circuit and a coil that activates the gas valve. The ignitor assembly consists of a spark plug, an enrichment tube, and flame sensor.

At start-up, the controller power switch is placed in the ON position, supplying approximately 12-volts DC to the heat control circuitry in the controller. If the controller senses the correct operating parameters (i.e., the correct water level in the cookpot), it sends a signal to the 24VAC relay in the component box to close the blower contacts. This supplies line voltage to the blower motor. A centrifugal switch in the blower closes if the blower is operating correctly, which allows 24VAC to flow through the closed contacts of the 24VAC relay to the ignition module.

Circuitry in the ignition modules sends 24VAC to the gas valve. Simultaneously, the module causes the ignitors to spark for 4 seconds to light the burners. A flame sensor for each burner verifies that the burner is lit 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, preventing the gas valve from opening, and the ignition module “locks out” until the controller power switch is turned off and then back on.

A probe monitors the temperature in the cookpot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current to the 24VAC relay, thus cutting line voltage to the blower. This cuts the 24VAC to the ignition module, causing the gas valve to close.

1.2 Accessing Equipment for Servicing

DANGER

Moving this equipment while it is filled with hot water may cause spilling or

splattering of the hot water. Always drain the cookpot before attempting to relocate

this equipment for servicing.

1-2

1. Disconnect the unit from the electrical power supply, the gas supply and the water supply.

2. Disconnect any attached restraining devices.

3. Relocate the unit for service accessibility.

4. After servicing is complete, reconnect the unit to the water supply and the gas supply. Reattach

the restraining devices, and reconnect the unit to the electrical power supply.

1.3 Replacing Equipment Components

1.3.1 Replacing the Controller

1. Open the control panel by removing the screws in the upper edge of the panel. Swing the panel

down and disconnect the 15-pin connector, trouble light wires, and ground wire. Remove the control panel by lifting the panel out of the slots in the control panel frame.

2. Remove the failed controller from the control panel and replace with the new controller. Re-

verse Step 1 to complete the process.

1.3.2 Replacing Electronic Components Other than the Controller

1. Drain the cookpot and disconnect the cooker form the electrical power supply.

2. Remove the control panel in accordance with Step 1 of Section 1.3.1.

3. Remove the lower cover from the component box. Refer to the illustration below to locate the

component to be replaced.

(Present in GSMS and

GBC models only)

Cooker with Control Panel and

Component Box Cover removed.

NOTE: Wiring not show to provide a clearer view.

Basket Lift Relay

Transformer

Terminal Strip 24VAC Relay

Ignition Module (There are 2 modules in units built before September 2000.)

4. On the component to be replaced, make a note of the wiring connection points. Disconnect the

wires and remove the failed component. Install the replacement component and reconnect the wiring in accordance with the notes made, or with the wiring diagram on the door of the unit.

1-3

5. Replace the component box cover, and reinstall the controller being sure to reconnect the ground

wire and trouble light wires. Reconnect the cooker to the electrical power supply.

1.3.3 Replacing a Water-Level Sensor or the Temperature Probe

1. Drain the cookpot and disconnect the cooker from the electrical power supply.

2. Remove the screws in the upper edge of the control panel and swing the panel down. Disconnect

the 15-pin connector, trouble light wires, and ground wire, and lift the panel out of the slots in the control panel frame.

3. Remove the topcap from the unit by removing the four screws (two on the front and two on each

end) that secure it to the cabinet.

4. Remove the control panel frame by removing the screws in the top and bottom corners and, on

GSMS units, the screw in the center bracket.

5. If replacing a water-level sensor (see illustration below): a. Disconnect the sensor lead by pulling it from its terminal then remove the Keps nut, terminal,

and washer from the sensor.

b. Inside the cookpot, remove the screw from the sensor flange. c. Carefully pull the failed sensor from the probe block and replace with the new sensor. d. Reassemble the washer, terminal, and Keps nut onto the sensor, and reattach the lead. e. Reverse Steps 1-4 to complete the procedure.

If replacing the temperature probe, mark the wiring harness leads and disconnect the probe leads at the push on connectors.

Remove the s c r ews from the probe brac ket and push the probe out t h e ba ck of the probe block.

Temperature Probe

Water-Level Sensors

If replacing a water-level sensor, disconnect its lead and remove it s K e ps nut, termin al an d wash er .

Remove the s c r ew fr om the sensor f l an ge a nd pull the sensor out the front of the probe block.

6. If replacing the temperature probe (see illustration above): a. Mark the wiring harness leads and disconnect them from the probe leads at the push-on

connectors.

b. Remove the two screws in the probe bracket. c. Carefully pull the probe from the probe clock and replace with the new probe. d. Reattach the leads and reverse Steps 1-4 to complete the procedure.

1-4

1.3.4 Replacing the Pressure Regulator or Solenoid Valve

1. Drain the cookpot and disconnect the cooker from the electrical power supply. Turn off or

disconnect the water supply to the cooker.

2. Disconnect the solenoid leads at the push-on connectors. Disconnect solenoid and regulator

subassembly at the compression fittings on the water lines running to and from these components. Remove the two screws in the mounting bracket and remove the solenoid and

regulator subassembly from the unit. (NOTE: If the cooker is not equipped with the optional

Autofill feature, the cookpot water tube will be connected directly to the regulator and there will be no solenoid valve.)

The incoming water line will be connected

Remove the two screws

at the bottom of this

bracket to dismount the

solenoid and regul a t o r

sub-assembly.

Solenoid Valve

used, disconnect the regulator at this point.

to the nipple at th e i nlet side of the

regulator using some type of field

connection fitting. Whatever type fitting is

Solenoid Valve

Remove the two

screws at the bottom of this

bracket to

dismount the

solenoid and

regulator sub-

assembly.

Disconnect the water tubes at thes e compression fittings.

GSMS with Autofill Configuration GBC/GC with Autofill Configuration

Disconnect t h e wat er tube at this compression fitting.

3. If replacing the regulator, adjust the replacement regulator output pressure to not more than 40

PSI (28.15 kg/cm2) before installation in the cooker.

4. Recover the fittings from the failed component (regulator or solenoid valve) and install them on

the replacement, using thread sealer on all connections.

5. Reverse Steps 1 and 2 to complete the procedure, being sure to apply thread sealer to all

connections.

1.3.5 Replacing the Water Faucet

1. Drain the cookpot and disconnect the cooker from the electrical power supply. NOTE: Refer to the illustration at the top of Page 1-6 for the following steps.

2. Turn off the water supply to the cooker and disconnect the incoming water lines where they

attach to the stubs at the rear of the cooker.

3. Remove the two screws securing the access panel in place and remove the panel.

4. Disconnect the water supply line at the compression fitting where it attaches to the water inlet

manifold. Remove the screws from the faucet mounting plate and lift the faucet assembly from the unit.

1-5

Remove the six screws in the faucet mounting plate.

Remove this nut to separate the faucet from the mounting plate.

Disconnect wate r line at this compression fitting.

Loosen this nut to separate the faucet from the water inlet manifold.

5. Separate the faucet from the water inlet manifold and mounting plate as shown in the illustration

above.

6. Reverse Steps 1-5 to complete the procedure.

1.3.6 Replacing a Basket Lift Motor or Microswitch

1. Disconnect the cooker from the electrical power supply.

2. If rigid water connections have been used, disconnect the cooker from the incoming water

supply.

3. Remove the basket lift arms from the lifter rods and then reposition the cooker to gain access to

the rear. Remove the upper and lower basket lift rear panels.

4. Disconnect the basket lift synchronizer link from the lifter cam (bell crank) assemblies one at a

time. When the link is disconnected from a cam, slip the corresponding lifter rod down and out of the assembly (see illustration on below).

Lifter Rods

Note the collection of washers and spacers between the li nk and lifter rods.

Synchronizer Link

Lifter Cams

1-6

Disconnect the basket lift synchron izer

link from the lifter cams and slip the lifter

rods down and out of the ass embly.

5. Remove the four bolts securing the motor mount to the frame, then remove the motor and mount

assembly from the unit. NOTE: It is possible to replace a motor or the microswitch without

removing the motor and mount assembly, but it is much more difficult.

6. Dismount the motor or microswitch as shown below and install the replacement.

NOTE: The right motor dismount s

in the same way as the left.

Loosen setscrew in

bottom of cam (bell crank)

7. Reverse Steps 1-6 to complete the procedure.

1.3.7 Replacing Gas Supply System Components or Ignitor Assemblies

1. Disconnect the cooker from the electrical power supply and from the gas supply. If necessary,

disconnect restraints to gain proper access to components.

2. Disconnect the component to be replaced (see illustration below) and install the replacement

component. NOTE: If replacing the gas valve, disconnect the enrichment tubes and gas supply

tubes at the valve, then unscrew the valve from the mounting bracket. Recover the fittings from the failed valve and install them on the replacement valve using a thread sealer suitable for gas appliances (Loctite™ PST 56765 is one example). Do not apply the sealer to the first two threads of the fitting. This will help prevent clogging of the burner orifices and gas valve.

Enrichment Tubes

Gas Supply Tubes

Ignitor Assembly

Ignitor Assembly Gasket

Gas Valve

Gas Valve Vent Tube

Gas Supply Tubes

connect to Burners here

When installing the Ignit or

Assembly, ensure the

spark plug is to the right.

1-7

3. Reconnect the cooker to the gas supply and check all connections for leaks using a solution of

soapy water.

DANGER

DO NOT use matches, candles, or other ignition methods to check for leaks.

4. When satisfied that there are no leaks, reconnect the unit to the electrical supply, and reconnect

any restraints disconnected in Step 1.

1.3.8 Replacing the Cookpot or Rinse Tank

NOTE: The following procedure addresses removing the cookpot or rinse tank from a GSMS unit.

The procedure is essentially the same for a GBC or GC unit, except that there is no faucet, and on the GC unit, no basket lift.

1. Remove the basket lift arms from the lifter

rods.

Remove these four screws.

2. Remove the faucet assembly from the cooker

in accordance with Steps 1-4 of Section 1.3.5.

3. Remove the screws that secure each of the

rear corners of the backsplash assembly (see

illustration at right). NOTE: To access the

screw in the lower right corner (as viewed from the rear) the upper basket lift back panel must be removed.

Remove these

screws (on both

sides) and remove

backsplash and

topcap.

4. Remove the screws along the top edge of the

control panel and open the panel by swinging it downward. Disconnect the 15-pin connector from the rear of the controller and the wires attached to the trouble light, and then lift the control panel out of the control panel frame.

5. Remove the screws that secure the backsplash

sides to the cabinet sides then remove the four screws that secure the topcap to the cabinet.

6. Remove the top connecting strip.

Remove screws along the top edge of control panel and dismount the panel.

Remove these screws to release

the pots from the standoff brack e ts.

Remove the top

connecting strip .

7. Remove the screws attaching the standoff

brackets to the cookpot or rinse tank.

8. If removing the cookpot, disconnect the

enrichment tubes and gas supply tubes from the burner assemblies. Disconnect the ignition cables and flame sensor wires from the ignitor assemblies on each burner.

9. Lift the cookpot or rinse tank straight up and out of the cabinet.

1-8

10. Invert the cookpot or rinse tank on a suitable work surface and remove the salvageable

components (e.g., probe block assembly, blower assembly, drain plumbing, etc.). Install the recovered components on the replacement cookpot or rinse tank, using thread sealer on all connections.

11. Reverse Steps 1 through 9 to complete the procedure.

1.4 Troubleshooting

Problems with this equipment maybe grouped into five broad categories:

1. Failure or malfunction of a Power-Supply System component.

2. Failure or malfunction of the Controller.

3. Failure or malfunction of an Autofill/Autoskim System component.

4. Failure or malfunction of a Water Heating System component.

5. Failure or malfunction of a Basket Lift System component.

Sections 1.4.1 through 1.4.5 briefly explain the functioning of each of the systems mentioned above. Section 1.4.6 contains troubleshooting guides that provide systematic procedures to isolate and identify the specific source of a problem. A wiring diagram is located at the end of the chapter.

1.4.1 How the Power-Supply System Works

Line voltage is supplied to the system via a power cord that is plugged or hard-wired into the store’s electrical service. The power cord is connected to pins 1 and 5 of an 8-pin terminal block. Line voltage is supplied to a 24VAC transformer from pins 2 and 8 of the terminal block. Pin 7 supplies 24VAC to a heat relay, which controls line voltage to the blower motor and 24VAC to the gas valve via the ignition module. The transformer supplies 24VAC to the controller, to the coils of the 24VAC relay, and to the solenoid valve on units equipped with the Autofill option. On units equipped with basket lifts, line voltage is supplied to a 24VDC basket lift relay from pin 6 of the power cord terminal block. Line voltage to the basket lift motors is supplied via the basket lift relay.

1.4.2 How the Controller Works

The SMS III controller provides the interface between the operator and the system components. The controller is powered by 24VAC supplied through Pins 1 and 2 of the wiring harness. Internal circuitry senses the water level and water temperature. Depending upon the conditions sensed, the controller energizes or de-energizes the solenoid valve to control water level and the 24VAC relay to control burner firing to control water temperature. The controller also controls the lowering and raising of the basket lift, and activates an audible alarm to signal the operator that a cooking cycle has completed. A rectifier in the controller converts 24VAC to the 24VDC required by the basket lift relay. The controller signals for heat via Pin 4, grounds the solenoid valve via Pin 6, and senses water level via Pins 7 (low) and 9 (full). The temperature probe connects to Pins 13 and 14. The basket lift relay connects to Pins 10 and 12. The sound device connects to Pin 11.

1-9

1.4.3 How the Autofill/Autoskim System Works

The heart of the automatic filling (Autofill) system is a normally closed solenoid valve that opens when 24VAC is applied.

The ground for the solenoid is supplied (via Pin 6 of the controller wiring harness) so long as the shorter of the two water-level sensors is not in contact with the water in the cookpot. When the water in the cookpot reaches the shorter of the two water-level sensors, the sensor is grounded. This causes the controller to break the solenoid ground, closing the valve. Starch or lime build-up on the sensor may keep it from grounding, therefore always make sure the sensor is clean and its lead (Pin 9 of the controller wiring harness) is firmly connected. Also, in order for the sensor to ground, there must be some mineral content in the water (pure water is non-conductive). Consequently, the unit will not operate correctly with distilled, highly filtered, or deionized water. If water of these types is

used, add ⅛-cup of baking soda to the water each time the cookpot is emptied and refilled. NOTE:

Do not use deliming solution to clean these units. Use of deliming solution will damage all stainless steel parts.)

On units equipped with the Autoskim feature, a logic circuit in the controller automatically opens the solenoid valve for three seconds every minute. If the Autofill feature is working properly, failure of the Autoskim feature will be due to a malfunctioning controller and not the solenoid valve. (Proper operation of the Autofill feature can be determined by draining water from the cookpot until the water level is below the shorter of the two water-level sensors. If the solenoid valve opens and then closes when the water in the cookpot again reaches the sensor, the Autofill feature is working properly.)

1.4.4 How the Water Heating System Works

To prevent lighting the burners when there is no water in the cookpot, these units are equipped with

a low-water-level sensor (the longer of the two water-level sensors). This sensor must be grounded

by contact with water in the cookpot before the control circuitry will allow firing of the burners. Starch or lime build-up on the low-water-level sensor may keep the sensor from grounding, therefore always make sure the sensor is clean and its lead (Pin 7 of the controller wiring harness) is firmly connected. Also, in order for the sensor to ground, there must be some mineral content in the water (pure water is non-conductive). Consequently, the unit will not operate correctly with distilled, highly filtered, or deionized water. If water of these types is used, add ⅛-cup of baking soda to the

water each time the cookpot is emptied and refilled. NOTE: Do not use deliming solution to clean

these units. Use of deliming solution will damage all stainless steel parts.)

In addition to the low-water-level sensor discussed above, the water heating system has three more parts: the electronic ignition system, the temperature probe, and the controller.

The electronic ignition system controls firing of the burners. See Page 1-2 for a complete

description of this system.

The temperature probe is used only when the unit is in the simmer mode. When the simmer mode

is selected, logic circuits in the controller monitor the temperature of the water. When the water temperature drops below the simmer setpoint, the controller closes the heat relay, causing the burners to fire. When the water temperature reaches the setpoint, the controller opens the heat relay,

1-10

extinguishing the burners. This process repeats as required to maintain the temperature at the setpoint programmed into the controller.

The controller is the interface between the operator and the other components of the equipment. In

the water heating system, its function is to control the firing of the burners.

1.4.5 How the Basket Lift System Works

When the Start switch is pressed to start the cooking cycle, logic circuits in the controller activate the basket lift motors, lowering the basket into the cookpot. As the motors drive the basket lift arms down, a cam attached to the left motor (when viewed from the rear) eventually loses contact with a roller-activated microswitch and power to the motors is cut. When the controller times out, logic circuits reverse the switch positions so that the motor circuit is again completed and the motors are restarted, raising the basket from the cookpot. At the fully raised position, the cam again makes contact with the microswitch, cutting power to the motors and stopping the lift in the raised position.

1.4.6 Technician Troubleshooting Guides

PROBLEM PROBABLE CAUSES CORRECTIVE ACTION

A. Water not turned on. A. Turn on Water

Autofill does not add

water when water level is below the

normal water-level

sensor (the shorter of

the two water-level

sensors).

B. Failed solenoid, failed computer,

or loose/broken wiring.

Test: Check for at least 22VAC at

Pin 5 of the 24VAC terminal block and at solenoid end of wire 66C, and check for ground (0 voltage) at Pin 6 of 15-pin connector.

B. If voltage is present at solenoid

end of wire 66C, and Pin 6 of 15-pin connector is grounded (0 voltage present), check continuity of wire 50C. If wire 50C is good, replace solenoid.

If voltage is present at solenoid

end of wire 66C and at Pin 6 of

15-pin connector, replace controller.

If voltage is not present at solenoid end of wire 66C, check wiring between solenoid and terminal block for loose connection or break in the wire.

Autofill does not shut

off when the cookpot

is full.

A. Starch accumulation on the normal

water-level sensor (the shorter of the two water-level sensors) is preventing the sensor from grounding.

B. Mineral content of water is too low

to provide a ground.

A. Clean the water-level sensors.

NOTE: Do not use deliming solu-

tion.

B. Add 1/8

cup of baking soda to

water in cookpot. DO NOT USE SALT! Doing so will

damage the cookpot.

Continued on following page.

1-11

PROBLEM PROBABLE CAUSES CORRECTIVE ACTION

Continued from

previous page.

Autoskim does not add

water when selected

(Autofill feature

verified to be working

correctly).

Basket lift does not

lower when START

button is pressed or

rise when cooking

cycle completes.

Basket lift travels up

and down

continuously.

Basket lift travels

erratically or with

jerking motion.

Burner attempts to

light but will not

remain lit.

Burner will not light;

trouble light is on.

C. Failed solenoid, failed computer,

or broken/loose wiring.

Test 1: Check sensor-lead

connections on outside of cookpot and at Pin 9 of 15-pin connector and continuity of wire 71C.

Test 2: Check for AC voltage at

Pin 6 of 15-pin connector.

Test 3: Check for at least 22VAC

at solenoid end of wire 66C.

A. Failed controller. A. Replace controller.

A. Failed basket lift relay.

Test: Check for 13-17VDC at Pin

10 of 15-pin connector with basket lift in the UP position, and for 0 volts with the basket lift in the DOWN position.

B. Failed controller.

Test: Check for 13-17VDC at Pin

12 of 15-pin connector.

C. Failed or out of adjustment

microswitch.

Test: Check continuity of switch

and verify that roller contacts cam.

A. Bell crank slipping on shaft. A. Tighten bell crank setscrew.

B. Lift arms binding in bushings B. Lubricate lift arms. C. Defective motor. C. Replace motor. A. Flame sensor wire and ignitor ca-

bles crossed.

A. Cooker gas valve is turned off. A. Turn gas valve on. B. Incoming gas line shut-off valve is

closed.

C. Action 1: Tighten connections

or replace wiring as required.

Action 2: If AC voltage is not

present, replace controller.

Action 3: If AC voltage is

present, replace solenoid.

If AC voltage is not present, check wiring between solenoid and terminal block for loose connection or break in the wire.

A. If voltages are correct, replace

relay.

B. Replace controller if voltage is

below 12VDC.

A. Replace switch if it fails

continuity check.

Adjust switch mounting to ensure roller contacts cam.

Ensure nut and locknut on shaft are tight.

A. Verify that Sense 1 and Spark 1

connect to same ignitor.

B. Open incoming gas line shut-off

valve.

1-12

PROBLEM PROBABLE CAUSES CORRECTIVE ACTION

Burner will not light;

trouble light is NOT

on, blower is NOT

running.

Burner will not light;

trouble light is ON,

blower is running

continuously.

Burner produces

popping sound when

lighting.

Controller display is

blank.

Controller does not

count down.

A. Failed 24VAC (blower) relay.

Test: Check for 24VAC on Pin 4

of 15-pin connector.

B. Failed controller. B. Replace controller. A. Failed blower centrifugal switch.

Test: Check for 24VAC at bottom

24VAC terminal of ignition module (wire 7C).

B. Failed ignition module or gas

valve.

Test: Check for 24VAC output

from module to gas valve, and for high voltage spark from module to ignitor.

A. Dirty blower inlet and fan. A. Clean blower. B. Vent tube on gas valve is clogged,

causing high burner gas pressure.

C. Cracked/broken ceramic tiles in

burner.

D. Failed ignitor. D. Replace ignitor. A. Controller not turned on. A. Turn on controller.

B. Cooker power cord not plugged in. C. Main circuit breaker tripped. C. Reset main circuit breaker.

D. Failed transformer.

Test: Check for 24VAC on

transformer secondary.

E. Failed controller. E. Replace controller. A. Operator error.

Test: Verify correct cook time is

programmed. Press START button.

B. Failed controller.

Test: Verify correct cook time is

programmed. Press the START button.

A. If voltage is present, replace

relay.

A. If voltage is not present, replace

blower.

B. If either is not present, replace

the module.

If both are present, replace the gas valve.

B. Remove and clean vent tube. C. Replace burner.

B. Plug power cord into appropriate

outlet.

D. If voltage is incorrect, replace

transformer.

A. Demonstrate proper operating

procedure to operator.

B. If timer does not count down,

replace controller.

1-13

PROBLEM PROBABLE CAUSES CORRECTIVE ACTION

A. Controller out of calibration. A. Recalibrate simmer setpoint.

Water boils in simmer

mode.

Water temperature too

low in simmer mode.

B. Failed/shorted temperature probe.

Test: Check for shorted probe

circuit. Probe resistance should be approximately 552 Ohms @ 60°F (16°C), 655 Ohms @ 100°F (38°C), and 1000 Ohms @ 212°F (100°C). See probe resistance chart on page 1-15 for other temperatures.

A. Controller out of calibration A. Recalibrate simmer setpoint. B. Temperature probe open.

Test: Check for loose

connections.

B. If resistance is out of

specification, replace the temperature probe.

B. If connections are secure, re-

place temperature probe.

1-14

1.4.6 Probe Resistance Chart and Wiring Diagrams

RESISTANCE CHART FOR USE WITH 806-4764 PROBE

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

32 486.0 0.0 83 610.0 28.3 134 751.0 56.7 185 909.1 85.0 33 488.3 0.6 84 612.6 28.9 135 754.0 57.2 186 912.4 85.7 34 490.5 1.1 85 615.2 29.4 136 756.9 57.8 187 915.6 86.1 35 492.8 1.7 86 617.8 30.0 137 759.9 58.3 188 918.9 86.7 36 495.1 2.2 87 620.5 30.6 138 762.8 58.9 189 922.2 87.2 37 497.4 2.8 88 623.1 31.1 139 765.8 59.4 190 925.5 87.8 38 499.7 3.3 89 625.7 31.7 140 768.8 60.0 191 928.8 88.3 39 502.0 3.9 90 628.4 32.2 141 771.7 60.5 192 932.1 88.9 40 504.3 4.4 91 631.0 32.8 142 774.7 61.1 193 935.4 89.4 41 506.6 5.0 92 633.7 33.3 143 777.7 61.7 194 938.7 90.0 42 509.0 5.6 93 636.3 33.9 144 780.7 62.2 195 942.1 90.6 43 511.3 6.1 94 639.0 34.4 145 783.7 62.8 196 945.4 91.1 44 513.6 6.7 95 641.7 35.0 146 786.7 63.3 197 948.8 91.7 45 516.0 7.2 96 644.3 35.6 147 789.7 63.9 198 952.1 92.2 46 518.3 7.8 97 647.0 36.1 148 792.7 64.4 199 955.5 92.8 47 520.7 8.3 98 649.7 36.7 149 795.8 65.0 200 958.8 93.3 48 523.1 8.9 99 652.4 37.2 150 798.8 65.6 201 962.2 93.9 49 525.4 9.4 100 655.1 37.7 151 801.8 66.1 202 965.6 94.4 50 527.8 10.0 101 657.8 38.3 152 804.9 66.7 203 968.9 95.0 51 530.2 10.6 102 660.6 38.9 153 807.9 67.2 204 972.3 95.6 52 532.6 11.1 103 663.3 39.4 154 811.0 67.8 205 975.7 96.1 53 535.0 11.7 104 660.0 40.0 155 814.1 68.3 206 979.1 96.7 54 537.4 12.2 105 668.8 40.6 156 817.1 68.9 207 982.5 97.2 55 539.8 12.8 106 671.5 41.1 157 820.2 69.4 208 985.9 97.8 56 542.2 13.3 107 674.3 41.7 158 823.3 70.0 209 989.4 98.3 57 544.7 13.9 108 677.0 42.2 159 826.4 70.6 210 992.8 98.9 58 547.1 14.4 109 679.8 42.8 160 829.5 71.1 211 996.2 99.4 59 549.5 15.0 110 682.6 43.3 161 832.6 71.7 212 999.7 100.0 60 552.0 15.6 111 685.3 43.8 162 835.7 72.2 61 554.4 16.1 112 688.1 44.4 163 838.8 72.8 62 556.9 16.7 113 690.9 45.0 164 842.0 73.3 63 559.4 17.2 114 693.7 45.6 165 845.1 73.9 64 561.8 17.8 115 696.5 46.1 166 848.2 74.4 65 564.3 18.3 116 699.3 46.7 167 851.4 75.0 66 566.8 18.9 117 702.1 47.2 168 854.5 75.6 67 569.3 19.4 118 705.0 47.8 169 857.7 76.1 68 571.8 20.0 119 707.8 48.3 170 860.8 76.7 69 574.3 20.6 120 710.6 48.9 171 864.4 77.2 70 576.8 21.1 121 713.0 49.4 172 867.2 77.8 71 579.3 21.7 122 716.3 50.00 173 870.4 78.3 72 581.8 22.2 123 719.2 50.6 174 873.6 78.9 73 584.4 22.7 124 722.1 51.1 175 876.8 79.4 74 586.9 23.3 125 724.9 51.7 176 880.0 80.0 75 589.4 23.9 126 727.8 52.2 177 883.2 80.6 76 592.0 24.4 127 730.7 52.8 178 886.4 81.1 77 594.5 25.0 128 733.6 53.3 179 889.6 81.7 78 597.1 25.6 129 736.5 53.9 180 892.8 82.2 79 599.7 26.1 130 739.4 54.4 181 896.1 82.8 80 602.3 26.7 131 742.3 55.0 182 899.3 83.3 81 604.8 27.2 132 745.2 55.6 183 902.6 83.9 82 607.4 27.8 133 748.1 56.1 184 905.8 84.4

1-15

WIRING DIAGRAMS

GREEN

BLUE

BROWN

CORDSET

120 VAC

WHITE

22C

200-240V

34C

MICRO

SWITCH

51C

BLACK

23C

11C

BASKET LIFT

24VDC

(OPTIONAL)

12C

BASKET LIFT SHOWN IN UP POSITION

N.O.

N.C.

RELAY

10C

4321

FOR UNITS WITH A SINGLE

DUAL-SPARK IGNITION MODULE

GEAR

MOTOR

108C

BASKET

(OPTIONAL)

LIFT

65C

VARISTOR

101C

24V

234

COM.

A 7

2 5 B

75C

13C

24VAC

C 6 4

7 9

DUAL SPARK IGNITION MODULE

8050423D

21C

RELAY.

SPLICE

CENTRIFUGAL SWITCH

BLOWER

GAS

VALVE

25C

43C

55C

RED

LIGHT

TROUBLE

76C

77C

LOAD

57C

24VAC TRANS

55C

HIGH TEMP WIRE RIGHT

24C

110C

LINE

LOAD

35C

59C

31C

66C

LOW WATER SENSOR

70C

NCNC

NORMAL WATER SENSOR

71C

SOUND DEVICE

27C

LEFT IGNITOR CABLE

50C

TEMP.

PROBE

29C

151413121110987654321

LEFT IGNITOR

SOLENIOD

24 VAC

RIGHT IGNITOR CABLE

HIGH TEMP WIRE LEFT

NOTE: SENSE 1 & SPARK 1 MUST CONNECT TO THE SAME IGNITOR. SENSE 2 & SPARK 2 MUST CONNECT TO THE SAME IGNITOR.

RIGHT IGNITOR

COMPUTER

1-16

FOR UNITS WITH TWO

SINGLE-SPARK IGNITION MODULES

GREEN

BLUE

BROWN

CORDSET

120 VAC

WHITE

22C

200-240V

GEAR

MOTOR

34C

COM.

108C

BASKET

LIFT

13C

21C

SPLICE

CENTRIFUGAL SWITCH

MICRO

SWITCH

51C

BASKET LIFT SHOWN IN UP POSIT ION

N.C.

12C

N.O.

(OPTIONAL)

BLACK

23C

11C

24V

234

65C

VARISTOR

101C

SPARK MODULE LT.

25V

ALARM

(GND)

VALVE

25V

(BURNER)

IGNITION MODULE

BASKET LIFT RELAY

24VDC

76C

77C

(OPTIONAL)

57C

LINE

LOAD

24VAC TRANS

A 7

2 5

10C

75C

4321

24C

110C

LOAD

66C

24VAC RELAY

C 6 4

7 9

25C

SPARK MODULE RT.

25V

ALARM

(GND)

54C

GND

VALVE

GND

25V

(BURNER)

IGNITION MODULE

BLOWER

43C

55C

NOTE: FLAME SENSOR WIRE MUST BE CONNE CTED TO THE S AME IGNITOR AS ITS MATCHING HIGH VOLTAGE LEAD.

HIGH TEMP. WIRE

GAS

VALVE

HIGH TEMP. WIRE

RED

LIGHT

TROUBLE

35C

59C

SOLENIOD

50C

LOW

WATER

SENSOR

31C

70C

NCNC

HIGH

WATER

SENSOR

71C

SOUND DEVICE

27C

13121110987654321

TEMP.

PROBE

29C

24 VAC

IGNITOR

8050423C

IGNITOR

COMPUTER

1-17

GAS COOKERS GSMS, GBC, AND GC SERVICE AND PARTS

2.1 Accessories

CHAPTER 2: PARTS LIST

ITEM PART # COMPONENT

1 803-0018 Cup, Single Pasta Portion (Beige) 2 810-2229 Hanger, Wire-Form Basket (extruded aluminum P/N 803-0028 no longer avail-

able)

3 803-0205 Rack, Support 4 806-5848SP Kit, Hose (Swirl and Straight w/Fittings) 5 809-0171 Thumbscrew, ¼-20 x 1⅜ 6 823-1910 Basket, GSMS Bulk 7 826-0900 Kit, Chain Restraint 8 910-7540 Strip, GSMS Top Connecting * 803-0200 Rack, 12 Portion Cup * 803-0238 Basket, 5½ x 8½ SS Round Pasta

* Not illustrated.

2-1

2.2 Basket Lift Components

35 21

DETAIL A

16 20 39

SEE DETAIL A

2-2

ITEM PART # COMPONENT

1 Motor, Basket Lift

807-0107 120 VAC

807-0108 240 VAC 2 807-0124 Bushing, Plastic 3 807-0240 Microswitch, BA-2RV22-D6 4 809-0047 Nut, ¼-20 Hex Head Cap 5 826-1358 Nut, 6-32 Hex Head (Pkg. of 25) 6 809-0050 Nut, 8-32 Hex Head 7 809-0063 Nut, ¾-inch Jam 8 809-0076 Nut, ¼-20 Expansion 9 809-0082 Ring, Retaining (secures Item 24 in place)

10 809-0097 Screw, 6-32 x 1-inch Slotted Truss Head 11 826-1363 Screw, 8-32 x ½-inch Slotted Truss Head (Pkg. of 25) 12 809-0113 Screw, 8-32 x 1½-inch Slotted Truss Head 13 809-0127 Screw, ¼-20 x ½-inch Slotted Round Head 14 826-1370 Screw, ¼-20 x 1½-inch Slotted Round Head 15 809-0155 Screw, Leveling 16 809-0190 Washer, ¼-inch SS Flat 17 809-0196 Washer, ⅜-inch Flat 18 809-0200 Washer, ¼-inch Flat 19 826-1381 Washer, ½-inch Nylatron (Pkg. of 10) 20 809-0247 Nut, 8-32 Hex Head Keps 21 826-1374 Screw, #10 x ½-inch Hex Head (Pkg. of 25) 22 809-0480 Setscrew, ¼-28 x 5⁄8-inch (secures Item 25 to motor shaft) 23 809-0508 Bolt, ¼-20 x ¼-inch SS AT Hex Head 24 813-0035 Bushing, .875 Hole 25 810-0052 Bellcrank (Cam) 26 810-0170 Pin, ¼-inch x 5⁄8-inch Spring Dowel 27 810-0172 Button, Plug 28 810-0192 Rod, Basket Lift 29 810-0194 Roller, Basket Lift 30 810-0220 Spacer, .493-inch x .200-inch Tubular 31 810-0374 Spacer, Basket Lift Roller Tubular 32 812-0138 Insulation, Paper 33 823-2007 Arm Assembly, GSMS/GBC Basket Lift 34 900-7416 Mount, Basket Lift Motor 35 900-7418 Back, Upper Basket Lift Enclosure 36 900-7419 Back, Lower Basket Lift Enclosure 37 900-7421 Support, Basket Lift Center 38 901-1927 Bracket, Left Basket Lift Roller 39 902-1927 Bracket, Right Basket Lift Roller 40 910-4525 Bar, Basket Lift Synchronizing 41 910-7420 Top, Basket Lift Enclosure 42 911-7417 Side, Basket Lift Enclosure 43 912-7417 Side, Basket Lift Enclosure 44 920-6076 Link, Basket Lift

NOTE: Order KIT0004SP to add a complete basket lift assembly to a GC unit.

2-3

2.3 Cabinetry

2.3.1 GBC/GC

15 16

See Page 2-6 for casters.

2-4

ITEM PART # COMPONENT

1 806-3853SP Door Assembly, 18.66-inch x 19.85-inch (does not include handle)

806-4487SP Door Pin Assembly

826-1343 Spring, Door Hinge (Pkg. of 10) A 810-1402 Handle, Wireform Door B 210-9214 Handle, Eurolook Door 2 809-0193 Washer, ¼-inch Nylon Flat 3 826-1371 Screw, #8 x ½-inch Drill Point Hex Head Zinc Plated (Pkg. of 25) 4 810-1508 Hinge, Universal Door 5 806-5522SP Base Assembly, GBC/GC

806-5209SP Leg Pad Assembly

900-4655 Channel, Front or Rear Base

900-7528 Channel, Left or Right Base 6 900-7912 * 200-5095 Shield, Vapor (for units with manual water fill) 7 826-1115 Leg Assembly w/Mounting Hardware 8 810-1105 Magnet, Door 9 Side, Left or Right Cabinet

910-7377 Stainless Steel

900-7377 Enameled Mild Steel

10 816-0091 11 900-4651 Shield, Control Box Water 12 900-1552 Gusset 13 900-1940 Bracket, GBC/GC Control Box Mounting 14 900-1759 Bracket, Pot Hold-Down 15 900-1932 Retainer, Flue Insulation 16 900-4654 Brace, Front or Rear Top 17 824-0434 Topcap, GBC/GC 18 809-0266 Screw, #10 x ½-inch Philips Truss Head Zinc Plated 19 806-5260SP Frame Assembly, Control Panel 20 816-0158 Insulation, 18.25-inch x 10.7-inch x .25-inch Cabinet Back 21 900-4521 Retainer, Cabinet Back Insulation 22 806-6007SP Flue Cap and Insulation Assembly

823-2105 Flue Cap

816-0169 Insulation, 8.12-inch x 18-inch x .25-inch Flue Cap

910-1181 Retainer, Flue Cap Insulation

809-0053 Nut, 10-32 Hex

23 826-1351 Nut Retainer, ¼-20 (Nutsert) (Pkg. of 10) 24 900-7379SP Back, GBC/GC Cabinet 25 812-1141 Insulation, Cabinet Back 26 826-1374 Screw, #10 x ½-inch Hex Head (Pkg. of 25) 27 812-1142 Insulation, Cabinet Back 28 900-4645 Shield, Basket Lift Heat (used on GBC units only)

* Not illustrated.

Shield, GBC/GC Vapor (See NOTE below)

Grommet, 1¼-inch Drain (See NOTE below)

NOTE: Order Moisture Control Kit 826-1492 to retrofit earlier units, which were not equipped with vapor shields. The kit contains

items 6 and 10, mounting screws, and installation instructions.

2-5

2.3.2 GSMS and GSMS/GBC Batteries

See Page 2-4 for Legs

30 31

NOTE: GSMS-GBC Battery cab i n e t r y co nsists

of one GSMS cabinet and one GBC cabinet

battered together using Fryer Joining Plates

and Flue Cap Joining Strips (9103122).

(9100404), Cabinet Joining Braces (9100177),

2-6

ITEM PART # COMPONENT

1 Topcap

824-0433 GSMS

824-0473 GSMS/GBC Battery (for rinse tank on left use 824-0921) 2 809-0266 Screw, #10 x ½-inch Philips Truss Head Zinc Plated 3 806-5487SP Control Panel Assembly, GSMS 4 900-1759 Bracket, Pot Hold-Down 5 Side, Left or Right Cabinet

910-7377 Stainless Steel

900-7377 Enameled Mild Steel 6 900-4651 Shield, Control Box Wate 7 900-4644 Mount, GSMS Control Box 8 900-8631 Shield, Cookpot-side Vapo 9 806-9744 Door Assembly (does not include handle)

806-4487SP Door Pin Assembly

826-1343 Spring, Door Hinge (Pkg. of 10)

810-1402 Handle, Wireform Doo

10 806-5488SP Base Assembly, GSMS

806-5209SP Leg Pad Assembly

900-7200SP Channel, Front orRear Base

900-7528 Channel, Left or Right Base

11 900-8632 Shield, Rinse Tank-side Vapo 12 826-1118 Caster w/Brake (includes mounting hardware) 13 826-1117 Caster w/o Brake (includes mounting hardware) 14 810-1508 Hinge, Universal Doo 15 826-1371 Screw, #8 x ½-inch Drill Point Hex Head Zinc Plated (Pkg. of 25) 16 809-0193 Washer, ¼-inch Nylon Flat 17 900-1552 Gusset 18 900-4645 Shield, Basket Lift Heat 19 900-7422SP Back, Cabinet (for rinse tank on left, use 200-2264) 20 826-1374 Screw, #10 x ½-inch Hex Head (Pkg. of 25) 21 900-1750 Cover, Faucet Connection Access 22 826-1351 Nut Retainer (Nutsert) (Pkg. of 10) 23 806-6010SP Flue Cap & Insulation Assembly, GSMS (for rinse tank on left, use 106-

823-2108 Flue Cap, GSMS (for rinse tankon left, use 823-3451)

816-0169 Insulation, 8.5-inch x 18-inch GSMS Flue

910-1181 Retainer, Flue Cap Insulation

809-0053 Nut, 10-32 Hex

24 910-4646 Mount, Faucet 25 816-0158 Insulation, 18.25-inch x 10.7-inch x .25-inch Cabinet Back 26 900-4521 Retainer, Cabinet Back Insulation 27 816-0170 Insulation, Cabinet Bac 28 812-1142 Insulation, Cabinet Bac 29 900-1932 Retainer, GSMS Flue Insulation 30 900-7390 Brace, Top Front 31 900-7389SP Brace, Top Rea 32 900-7391 Divider, Cabinet 33 900-7198 Post, Doo 34 810-1105 Magnet, Door (units with rinse tank on left also require bracket 200-2484)

2-7

2.4 Combustion System Components

Cookpot shown for reference only.

See Page 2-13 for cookpot component s .

2-8

ITEM PART # COMPONENT

1 816-0165 Insulation, GSMS/GBC/GC Ignitor 2 Ignitor

810-0521 Natural Gas

810-0608 Propane Gas

810-0923 Manufactured Gas 3 826-1371 Screw, #8 x ½-inch Drill Point Hex Head Zinc Plated (Pkg. of 25) 4 823-2685 Bracket and Tube Assembly, Right Air Hose 5

Burner Assembly (See NOTE at bottom of Page 2-13 also.)

806-5563SP Natural Gas w/3.26mm Orifice 810-0916

806-5499SP Natural Gas w/3.05mm Orifice 810-0465

806-5564SP Propane Gas w/2.00mm Orifice 810-0917

806-5583SP Manufactured Gas w/4.92mm Orifice 810-0924

810-1382 Natural or Propane Gas Burner w/o Orifice

810-1385 Manufactured Gas Burner w/o Orifice 6 823-2526 Bracket and Tube Assembly, Left Air Hose 7 900-5525 Bracket, Blower Support 8 816-0055 Insulation, Blower Mount 9 810-0507 Spacer, .23-inch x .75-inch

10 809-0441 Screw, #7 x 1½-inch Hex Washer Head Nickel Plated 11 809-0191 Washer, ¼-inch Lock 12 826-1362 Nut, ¼-20 Hex Head (Pkg. of 10) 13 816-0278 Hose,

⁄8-inch Air

14 823-2528 Mount, Blower 15 Motor, Blower

807-1564

807-1712

120VAC/60 Hz (See NOTE below) 230VAC 50/60 Hz (See NOTE below)

16 809-0433 Screw, ¼-20 x ¾-inch Slotted Flat Head

NOTE: For complete motor and mount assemblies, order 806-5259SP (120VAC/60 Hz) or

806-5574SP (230VAC 50/60 Hz). These assemblies include items 11, 12, 14, 15, and 16.

2-9

2.5 Control Box and Related Components

9 10

262

1054

266

277

4 5 10

8 26

See NOTE

NOTE: Item 23 is for use with 807-3366 ignition module (Item 7) and requires a RAJAH connector (Item 28). Item 24 is for use with 807-1006 ignition module and does not require a RAJAH connector.

2-10

ITEM PART # COMPONENT

1 900-7532 Box, Control 2 807-1396 Relay, 24VDC SPDT (Basket Lift Relay – GSMS and GBC units only) 3 810-0045 Bushing, .875 Diameter Hole 4 807-0067 Block, 8-Pin Terminal 5 807-0255 Strip, Terminal 6 Transformer

807-0800 120VAC/24VAC, 50/60 Hz, 50VA

807-0680 208-240VAC/24VAC, 50/60 Hz, 43VA 7 807-3366 8 807-0670 Relay, 24V DPDT (Heat Relay – all units) 9 900-1924 Guard, Finger

10 826-1371 Screw, #8 x ½-inch Drill Point Hex Head Zinc Plated (Pkg. of 25) 11 807-1713 Sound Device (Alarm) 12 807-1292 Fitting, Plastic Conduit

13 807-1319 Connector, 90° #5252 14† 812-1193 Conduit, ½-inch x 53-inch Flexible Plastic (cut to length from 811-0808) 15† 812-1187 Conduit, ½-inch x 18-inch Flexible Plastic (cut to length from 811-0808) 16† 812-1192 Conduit, ½-inch x 47-inch Flexible Plastic (cut to length from 811-0808)

17 809-0290 Clamp, Cable

18 807-0170 Box, Electrical Handy

19 807-1612 Clamp, ⅜-inch Twin-Screw Connector

20 900-8016 Cover, Electrical Handy Box

21 826-1363 Screw, 8-32 x ½-inch Slotted Truss Head Nickel Plated (Pkg. of 25)

22 Cordset

807-0154 120VAC (illustrated)

807-1685 208-240VAC (not illustrated) 23 106-0676SP Cable, Ignition (used with Item 7 – also requires Item 28) 24 807-1709 Cable, Ignition (used with 807-1006 Ignition Modules) 25 806-5316SP Wire Assembly, 20-inch High Temperature (Flame Sensor Wire) 26 809-0362 Screw, #8 x 1¼-inch Drill Point Hex Washer Head Zinc Plated 27 809-0441 Screw, #7 x 1½-inch Hex Washer Head Nickel Plated 28 807-3484 Connector, RAJAH (two required for each 807-3366 Ignition Module) †† 806-5632 Wiring Assembly, 120VAC GBC

* 806-8307SP Wiring Assembly, GSMS/GBC/GC (Controller Harness)

** Not illustrated. *† Number for reference only. Order appropriate length of 811-0808.

†† Not illustrated. Includes conduit, handy box, and fittings.

NOTE: Control box assemblies on units manufactured before October 2000 were built with two

single-spark ignition modules (P/N 807-1006). If an 807-1006 module fails, the control box may be retrofitted with one dual-spark ignition module (Item 7 – P/N 807-3366) and two RAJAH connectors (Item 28 – P/N 807-3484). If this option is chosen, the earlier style ignition cables (Item 24 – P/N 807-1709) must also be replaced with the new ignition cables (Item 23 – P/N 106-0676SP).

Module, Honeywell Dual-Spark FV Ignition (See NOTE below.)

2-11

2.6 Controllers and Control Panel Components

ITEM PART # COMPONENT

1 Control Panel and Controller Assembly, GSMS (does not include 4 & 7)

106-0376 Full Featured 106-0379 w/o Autoskim 106-0380 w/o Autofill or Autoskim

2 Control Panel and Controller Assembly, GBC/GC (does not include 4 & 7)

106-0377 Full Featured 106-0381 w/o Autoskim 106-0382 w/o Autofill or Autoskim

3 Controller, SMS III

106-0376E Full Featured 106-0379E w/o Autoskim

106-0380E w/o Autofill or Autoskim 4 807-1704 Lamp, 24VAC Vertical Trouble 5 823-2012 Panel, GBC/GC Control 6 823-1993 Panel, GSMS Control (for rinse tank on left, use 823-3331) 7 809-0266 Screw, #10 x ½-inch Philips Truss Head Zinc Plated

NOTE: See last item on Page 2-11 for Controller Harness.

2-12

2.7 Cookpot, Rinse Tank, and Associated Components

2.7.1 Cookpot and Rinse Tank Components (Other than Cookpot Insulation)

129

1210

11 13 12

ITEM PART # COMPONENT

1 823-4090SP

2 806-5497SP 3 823-1994SP Tank, GSMS Rinse * 106-2797SP Complete Burner, Frypot, Flue Auto Fill assembly, NAT * 106-2798SP Complete Burner, Frypot, Flue Auto Fill assembly, PRO * 106-3055SP Complete Burner, Frypot, Flue Manual Fill assembly, NAT * 106-3056SP Complete Burner, Frypot, Flue Manual Fill assembly, PRO 4 823-2022 Strainer Assembly 5 823-2791 Cover, Probe Block (angled top) (for flat-topped block, use 823-1942) 6 816-0160 Insulator, 5.25-inch x 5.00 Probe Cover 7 Probe Block Assembly, Complete

806-9365SP Angled top, for use on units without Autofill option. 806-9366SP Angled top, for use on units with Autofill option. 106-3084SP Angled top, for use on units with manual fill. 826-1082 Flat top w/pins, for use on units without Autofill option.

826-1081 Flat top w/pins, for use on units with Autofill option. * 810-1212 Replacement Pin, for use w/flat-topped probe blocks. 8 810-1697 Block, Probe (angled top) (for flat-topped block, use 810-0821) 9 823-1920 Sensor, Low Water Level (806-9365SP and 826-1082 use two each)

10 823-1921 Sensor, Normal Water Level (used in 806-9366SP and 826-1081) 11 806-4764 Probe Assembly, Temperature 12 809-0357 Screw, #6 x ⅜-inch Philips Truss Head Nickel Plated 13 910-1804 Bracket, Probe Retainer 14 826-1376 Nut, 10-32 Keps Hex Head (Pkg. of 10) 15 826-1337 Tab, Faston .25-inch (Pkg. of 5) 16 809-0193 Washer, ¼-inch Nylon Flat 17 810-0976 Nozzle, Water Inlet

* Not illustrated.

Cookpot, GSMS (Use 823-4227SP for units with manual fill. See NOTE be-

low.)

Flue Assembly, GSMS (See NOTE below.)

2-13

2.7.2 Cookpot Insulation

NOTE: Cookpot shown for reference only.

Refer to Page 2-13 for cookpot components. Refer to Page 2-8 for ignit or c o mponents.

ITEM PART # COMPONENT

1 900-4563 Retainer, Cookpot Front Insulation (19.7-inches x 7.5-inches) 2 816-0152 Insulation, Cookpot Front (19.5-inches x 7.5-inches x .25-inches) 3 816-0153 Insulation, Cookpot Side (10-inches x 24-inches x. 25-inches) 4 809-0053 Nut, 10-32 Hex 5 900-1762 Retainer, Insulation 6 816-0145 Insulation, Front Bottom (3.0-inches x 14.5-inches x .25-inches) 7 816-0166 Insulation, Rear Bottom (3.5-inches x 17.0-inches x .25-inches) 8 812-0357 Insulation, HE Burner

9 826-1371 Screw, #8 x ½-inch Drill Point Hex Head Zinc Plated (Pkg. of 25) 10 900-1031 Retainer, Sight Glass 11 816-0053 Insulation, Sight Glass 12 814-0048SP Glass, Sight

2-14

2.8 Drain Components

This rubber seal is an integral part of item 7.

NOTE: Items 1, 4, 8, and 9 are also used on the rinse tank. Plumbing from the rinse tank drain valve to the floor drain is locally procurred and installed.

This nut, for attaching the handle, is an integral part of item 1. If it must be replaced, order P/N 809-0063.

ITEM PART # COMPONENT

1 810-1825 Valve, 1¼-inch x 1¼-inch SS Drain 2 813-0070 Elbow, 1¼-inch NPT BM 90° 3 813-0146 Nipple, 1¼-inch NPT x 4¼-inch BM 4 813-0391 Nipple, 1¼-inch NPT x Close BM 5 813-0394 Tee, 1¼-inch NPT BM 6 813-0451 Nipple, 1¼-inch NPT x 12-inch Chromed Brass 7 813-0453 Nut, 1¼-inch NPT Chromed SS Slip 8 814-0047 Sleeve, Valve Handle (red, w/logo) 9 910-9527 Handle, Drain Valve

2-15

2.9 Gas Supply System Components

4 4

Non-CE Assembly CE Assembly

2-16

ITEM PART # COMPONENT

1 826-1374 Screw, #10 x ½-inch Hex Head (Pkg. of 25) 2 810-0691 Tube, Vent 3 Valve, Honeywell Gas (Non-CE)

826-1122

826-1123 Propane Gas 4 811-0800 5 813-0004 Elbow, ⅛-inch NPT 90° BM 6 813-0016 Nipple, ⅛-inch NPT x Close BM 7 813-0022 Nipple, ½-inch NPT x Close BM 8 Nipple, ¾-inch NPT BM

813-0137 28.5-inch (used on GSMS units)

813-0257 24.5-inch (used on GBC/GC units) 9 813-0154 Plug, ⅛-inch Hex Head Pipe

10 813-0301 11 813-0304 12 813-0354 Elbow, 90° ⅛-inch NPT x ⅛-inch Tube Brass 13 813-0378 Fitting, ⅛-inch NPT Female Cross 14 813-0405 Nipple, ⅛-inch NPT x 2.00-inch BM 15 823-2004 Mount, Front Gas Line 16 900-4642 Hanger, Rear Gas Line 17 900-4643 18 806-9678SP Plug, CE Honeywell Gas Valve 19 810-1006 Bushing, ¼-inch NPT to ⅛-inch NPT Brass 20 813-0567 Fitting, ¼-inch NPT Female Cross 21 810-1025 Connector, ¼-inch NPT male x ⅜-inch Tube Brass 22 813-0077 Nipple, ¼-inch NPT x Close Galvanized

23* 810-1041 Kit, CE Valve Accessory

24 810-1715 Valve, Honeywell CE Gas (Natural or Propane)

* Contains straight and elbow flanges, o-rings, and screws for mounting flanges to valve.

NOTE 1: Item 4 is delivered straight and must be formed by the installer to fit the unit. Item 17

is delivered formed, but may require further forming by the installer to fit the unit.

NOTE 2: In Manufactured Gas (MFG) units, item 10 is replaced by P/N 810-0926, item 11 is

not used, and item 17 is replaced by P/N 900-1945.

Natural or Manufactured Gas (See NOTE 2.)

Tube, 12.5-inch Enrichment (See NOTE 1.)

Tee, ¼-inch NPT Male x ⅜-inch Tube Brass (See NOTE 2.) Bushing, ½-inch to ¼-inch Flush BM (See NOTE 2.)

Tube, ⅜-inch Aluminum Gas (See NOTE 1 and NOTE 2.)

2-17

2.10 Water Supply System Components

Manual Fill Piping Assembly

Autofill Piping Assembly without Faucet

Autofill Piping Assembly with Faucet

Detail A

Item 6 (nipple) is threaded into item 1 (solenoid).

Item 3 (nut) is threaded onto item 6 to secure

item 14 (mount) to item 1.

See Detail A.

2-18

ITEM PART # COMPONENT

1 806-5565 Valve Assembly, Solenoid 2 826-1374 Screw, #10 x ½-inch Hex Head (Pkg. of 25) 3 809-0454 Nut, ½-inch Conduit 4 810-0907 Elbow, ⅜-inch NPT Compression 5 810-1208 Valve, Pressure Regulator 6 813-0022 Nipple, ½-inch NPT x Close BM 7 813-0302 Elbow, ¼-inch NPT x ⅜-inch Tube Compression 8 813-0412 Faucet, Double-Jointed Pantry 9 813-0448 Elbow, ¼-inch NPT Brass

10 813-0449 Tee, ¼-inch NPT Brass 11 813-0472 Nipple, ¼-inch NPT x 2.5-inch Brass 12 813-0473 Nipple, ¼-inch NPT x 4.0-inch Brass 13 900-1898 Tubing, Pressure Regulator to Faucet 14 900-1905 Mount, Solenoid Valve Assembly 15 910-2513 Tubing, Solenoid to Cookpot 16 900-2916 Bracket, Pressure Regulator 17 813-0471 18 200-5094 Bracket, Water Valve 19 809-0359 Screw, #8 X ¼-inch Slotted Hex Washer Head 20 810-2641 Valve, ⅜-inch Water 21 810-2648 Tube, Water Inlet 22 810-2649 Tube, Water Outlet 23 810-2650 Tube, Cookpot Water 24 813-0301 Tee, ¼-inch NPT Male X ⅜-inch Tube Brass

NOTE: In Autofill units without a faucet, water supply piping to item 17 appropriate for the

installation is provided by the purchaser or installer.

Nipple, ¼-inch NPT x 1.5-inch Brass (See NOTE below.)

2-19

APPENDIX A

NOTES AND PARTS UNIQUE TO GSW/GWB VARIANTS

A relatively small number of GSW/GWB variants have been manufactured. These two variants are very similar to the GC cooker. The principal differences are the use of a thermostat control rather than a computer and button-type water level sensors in the cookpot as opposed to the rod-type used in the GC cooker. There are also minor differences in the water supply systems. Most of these units have been manufactured as single units. The few double units constructed are basically two single units battered together. Neither variant has a

rinse tank.

The illustrations that follow identify assemblies and components that are used in the GSW/GWB units but not in the GSMS, GBC, or GC cookers. If a part is NOT listed in the pages that follow, it is used in the other units and illustrated Chapter 2.

ACCESSORIES

Item Part # Component

1 803-0226 Basket, Sauce 2 910-2766 Insert, Pan Holder 3 910-2545 Strainer 4 803-0234 Brush, Probe Cleaning 5 806-7569 Cover, Sauce Basket * 803-0218 Rack, Nine Cup

* Not illustrated.

A-1

CONTROL COMPONENTS

Item Part # Component

1 806-8667 GSW/GWB Control Box 2 806-9592 Interface Board (Water Board) 3 807-0800 Transformer, 120V/24VAC 50/60 Hz, 50 VA 4 807-2272 Thermostat, Operating 5 807-3366

Module, Dual Spark Honeywell Ignition (See NOTE below.)

6 807-3484 Connector, Rajah 7 809-0164 Screw, #8 X 1-inch Slotted Hex Washer Head 8 826-1366 Nut, 4-40 Keps Hex (package of 25)

9 809-0349 Spacer, 4 mm X 6 mm Aluminum 10 826-1359 Screw, 4-40 X ¾-inch Round Slot Head (package of 25) 11 809-0360 Screw, #8 X ⅜-inch Slotted Hex Washer Head 12 810-0045 Bushing, .875-inch Diameter (fits 11/16-inch hole) 13 810-0387 Knob, Thermostat Control 14 810-1164 Terminal Block, 1-Piece Screwless 15 900-2484 Mount, Operating Thermostat 16 900-2769 Top Cover, Control Box 17 900-2919 Front Cover, Control Box 18 900-2958 Bracket, Control Box Mounting

* 807-2273 Switch, SPDT (Skim Feature and Faucet ON/OFF Switch)

* 807-0495 Light, Split, 24V Red and White

* 807-2479 Switch, SPDT ON/OFF Rocker (Power Switch)

* 910-2454 Panel, Control

* Not illustrated.

NOTE: Units manufactured prior to October 2000 were equipped with two 807-1006 ignition modules. Use a single 807-3366 module to replace them. Refer to wiring diagram 805-0521 on Page A-6 for new wiring connections. The new modules also require the use of a new ignition cable (P/N 106-0676).

A-2

SERVICE COOKPOT

Note presence of

holes for mounting

button-type water

level sensors.

Note presence of

fitting for thermostat.

Order P/N 823-0491SP for the bare service cookpot (cookpot without insulation).

Order P/N 806-5497SP for the flue assembly only.

Order 106-2797SP (Natural Gas) or 106-2798SP (Propane) for the cookpot assembly with

insulation.

Order 106-2804SP (Natural Gas) or 106-2805SP (Propane) for the complete cookpot assembly

(including the cookpot, flue assembly, burners, blower, insulation, and associated hardware).

Order P/N 806-7552SP for button-type water level sensors.

For combustion system components, refer to Page 2-8.

For insulation and related components, refer to Page 2-14.

For drain system components, refer to Page 2-15.

For gas supply system components, refer to Page 2-16.

A-3

WATER SUPPLY COMPONENTS

FAUCET PLUMBING

DETAIL "D"

SINGLE COOKPOT PLUMBING

DETAIL "C"

DETAIL "A"

DETAIL "B"

DOUBLE COOKPOT PLUMBING

A-4

Item Part # Component

1 806-7551 Valve Assembly, GSMS Solenoid 2 809-0454 Nut, ½-inch Conduit 3 810-0907 Elbow, ⅜-inch NPT Compression 4 810-1025 Fitting, ¼-inch Straight Compression 5 810-1208 Valve, Water Pressure Regulator 6 812-1292 Tubing, Straight 21.75-inch Regulator to Solenoid Valve 7 812-1293 Tubing, 90° Formed 39.22-inch Regulator to Solenoid Valve 8 813-0022 Nipple, ½-inch Close BM NPT

9 813-0302 Elbow, ¼-inch NPT X ⅜-inch Tube 10 813-0448 Elbow, ¼-inch Brass NPT 11 813-0450 Nipple, ¼-inch NPT X 2.0-inch 12 813-0471 Nipple, ¼-inch NPT X 1.50-inch 13 813-0472 Nipple, ¼-inch NPT X 2.50-inch 14 813-0495 Tee, ¼-inch Brass NPT Male Branch 15 900-1905 Mount, GSMS Solenoid Valve 16 900-2915 Bracket, Pressure Regulator 17 900-2916 Bracket, Pressure Regulator 18 900-2917 Brace, Water Inlet 19 910-2513 Tubing, GSMS Valve to Cookpot 20 910-2926 Tubing, GSW/GWB Valve to Faucet

A-5