Frymaster GPC Installation Manual

Installation and Operation Manual

Gas Pasta Cooker

"Pasta Magic"

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

24-Hour Service Hotline

1-800-551-8633

NOVEMBER 2011

*8196556A*

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 CA LIFORNIA 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.

NOTICE
The commonwealth of Massachusetts requires any and all gas products to be installed by a licensed
plumber and/or gasfitter

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

steel parts.

PASTA MAGIC GAS COOKERS

INSTALLATION AND OPERATION MANUAL

TABLE OF CONTENTS

CHAPTER 1: General Information

1.1 Parts Ordering and Service Information ............................................................................ 1-1

1.2 Safety Information ............................................................................................................. 1-2

1.3 Equipment Description ...................................................................................................... 1-2

1.4 Installation, Operating, and Service Personnel .................................................................. 1-3

1.5 Definitions .......................................................................................................................... 1-3

1.6 Shipping Damage Claim Procedure ................................................................................... 1-4

CHAPTER 2: Installation Instructions

2.1 General Installation Requirements ..................................................................................... 2-1

2.2 Caster/Leg Installation ....................................................................................................... 2-3

2.3 Pre-Connection Preparations ............................................................................................. 2-4

2.4 Connection to Gas Line ..................................................................................................... 2-5

2.5 Converting to Another Gas Type ....................................................................................... 2-7

CHAPTER 3: Operating Instructions

3.1 Introduction ........................................................................................................................ 3-1

3.2 Controller ........................................................................................................................... 3-2

3.3 Operating Instructions ........................................................................................................ 3-3

3.4 Shutting the Cooker Down ................................................................................................. 3-5

CHAPTER 4: Preventive Maintenance

4.1 Daily Preventive Maintenance ........................................................................................... 4-1

4.2 Cleaning the Gas Valve Vent Tube ................................................................................... 4-2

4.3 Cleaning and Adjusting the Combustion Air Blower ........................................................ 4-2

4.4 Adjusting the Burner Gas Pressure .................................................................................... 4-4

4.5 Measuring Flame Current .................................................................................................. 4-5

4.6 Controller Simmer Mode Adjustment ............................................................................... 4-5

CHAPTER 5: Operator Troubleshooting

5.1 Introduction ........................................................................................................................ 5-1

5.2 Operator Troubleshooting Guides ...................................................................................... 5-2

i

PASTA MAGIC GAS COOKERS

INSTALLATION AND OPERATION MANUAL

CHAPTER 1: GENERAL INFORMATION

RETAIN AND STORE THIS MANUAL IN A SAFE PLACE FOR FUTURE USE

This appliance is only for professional use and shall be used by qualified personnel only, as
defined in Section 1.5.

1.1 Parts Ordering and Service Information

In order to assist you quickly, the Frymaster Factory Authorized Servicer (FAS) or Service Depart­ment representative requires certain information about your equipment. Most of this information is
printed on data plate affixed to the inside of the cooker door. Part numbers are found in the Installa­tion, Operation, Service, and Parts Manual. Parts orders may be placed directly with your local FAS
or distributor. A list of Frymaster Factory Authorized Servicers (FAS’s) is located on the Frymaster
website at www.frymaster.com. If you do not have access to this list, contact the Frymaster Service
Department at 1-800-551-8633 or 1-318-865-1711.

When ordering parts, the following information is required:

Model Number:
Serial Number:
Type of Gas or Voltage:
Item Part Number:
Quantity Needed:

Service information may be obtained by contacting your local FAS/Distributor. Service may also be
obtained by calling the Frymaster Service Department at 1-800-551-8633 or 1-318-865-1711. When
requesting service, please have the following information ready:

Model Number:
Serial Number:
Type of Gas:

In addition to the model number, serial number, and type of gas, please be prepared to describe the
nature of the problem and have ready any other information that you think may be helpful in solving
your problem.

1-1

1.2 Safety Information

Before attempting to operate your unit, read the instructions in this manual thoroughly.

Throughout this manual, you will find notations enclosed in double-bordered Caution, Warning, and
Danger boxes similar to the ones below.

CAUTION

Caution boxes contain information about actions or conditions that may cause or result in a malfunc-

tion of your system.

WARNING

Warning boxes contain information about actions or conditions that may cause or result in damage to

your system, and may cause your system to malfunction.

DANGER

Danger boxes contain information about actions or conditions that may cause or result in injury to

personnel, and may cause damage to your system and/or cause your system to malfunction.

You will also find information boxes like the one below containing valuable information regarding
the safe operation of the unit. The following is an example:

Standard for Incoming Gas Pressures

Gas Minimum Maximum

Natural

Propane

6.0" WC

1.62 kPa

16.19 mbar
11" WC

2.74 kPa

27.37 mbar

14" WC

3.48 kPa

34.87 mbar
14" WC

3.48 kPa

34.87 mbar

1.3 Equipment Description
Frymaster

Pasta Magic gas cookers are specifically designed to deliver high volumes of cooked or
blanched food automatically. All models feature a unique infrared burner system that delivers 80,000
BTUs (23.4 kW – 84.4, megajoules) to cook 7.22 pounds (3.25kg) of dry pasta per bulk basket. The
unit can cook 30 pounds of dry pasta per hour, the equivalent of 136 eight-ounce servings. It can
also retherm 12 individual servings of pasta, or other vacuum-sealed foods, at a time. The cookpot
measures 18 x 24 x 8 inches (457 x 610 x 203 mm) and holds 12.7 gallons (48-liters) of water.

1-2

Model Comparison:

GPCRB/GPCR: The “Gas Pasta Magic System” consists of a gas cooker and rinse tank

combination. The unit is equipped with a programmable controller, which controls water
temperature, water level, and cooking times. A swing-away water faucet is standard.
GPCRB units are equipped with a programmable basket lift system, which lowers and raises
bulk or individualized portions of pasta.; GPCR units are not equipped with a basket lift
system. The cookpot is safeguarded against over filling and boilover by a large overflow
drain. “SD” following the model designation indicates a stainless steel cookpot and door,
and enameled cabinet. “SC” following the model designation indicates all stainless steel
components.

GPCB/GPC: These standalone cookers are essentially the same as the GPCRB, but without
the built-in rinse tank. GPCB models have an automatic basket lift, automatic water filling,
and optional starch skimming. GPC models have no basket lifts. The cookpot in both is
safeguarded against over filling and boilover by a large overflow drain. “SD” following the
model designation indicates a stainless steel cookpot and door, and an enameled cabinet.
“SC” following the model designation indicates all stainless steel components.

All Models: All units are equipped with automatic water filling (Autofill). The Autofill
feature maintains the cookpot water level approximately 1-inch (32mm) below the overflow
drain.

The optional Autoskim feature adds eight gallons at the top of the cooker over a three minute
interval. This causes the water to swirl, moving surface starch to the overflow drain. The
Autoskim feature eliminates the need for manual skimming.

1.4 Installation, Operating, and Service Personnel

All installation and service on Frymaster equipment must be performed by qualified, certified,
licensed, and/or authorized installation or service personnel, as defined in Section 1.5.

1.5 Definitions

QUALIFIED INSTALLATION PERSONNEL

Qualified installation personnel are individuals, firms, corporations, and/or companies which, either
in person or through a representative, are engaged in and are responsible for the installation of
gas-fired appliances. Qualified personnel must be experienced in such work, be familiar with all gas
precautions involved, and have complied with all requirements of applicable national and local
codes.

1-3

QUALIFIED OPERATING PERSONNEL

Qualified operating personnel are those who have carefully read the information in this manual and
have familiarized themselves with the equipment functions, or who have had previous experience
with the operation of the equipment covered in this manual.

QUALIFIED SERVICE PERSONNEL

Qualified service personnel are those who are familiar with Frymaster equipment and who have been
authorized by Frymaster Corporation to perform service on Frymaster equipment. All authorized
service personnel are required to be equipped with a complete set of service and parts manuals, and
to stock a minimum amount of parts for Frymaster equipment. A list of Frymaster Factory Autho­rized Servicers (FAS’s) is located on the Frymaster website at www.frymaster.com. Failure to use

qualified service personnel will void the Frymaster Warranty on your equipment.

1.6 Shipping Damage Claim Procedure

Your Frymaster equipment was carefully inspected and packed before leaving the factory. The
transportation company assumes full responsibility for safe delivery upon its acceptance of the
equipment for transport.

What to do if your equipment arrives damaged:

1. File a claim for damages immediately, regardless of the extent of damages.

2. Inspect for and record all visible loss or damage, and ensure that this information is noted on

the freight bill or express receipt and is signed by the person making the delivery.

3. Concealed loss or damage that was unnoticed until the equipment was unpacked should be rec-

orded and reported to the freight company or carrier immediately upon discovery. A concealed
damage claim must be submitted within 15 days of the date of delivery. Ensure that the shipping
container is retained for inspection.

FRYMASTER DOES NOT ASSUME RESPONSIBILITY FOR DAMAGE OR LOSS

INCURRED IN TRANSIT.

1-4

PASTA MAGIC GAS COOKERS

INSTALLATION AND OPERATION MANUAL

CHAPTER 2: INSTALLATION INSTRUCTIONS

2.1 General Installation Requirements

Qualified, licensed, and/or authorized installation or service personnel, as defined in Section

1.5 of this manual, should perform all installation and service on Frymaster equipment.

Conversion of this appliance from one type of gas to another should only be performed by
qualified, licensed, and/or authorized installation or service personnel as defined in Section 1.5
of this manual.

Failure to use qualified, licensed, and/or authorized installation or service personnel (as
defined in Section 1.5 of this manual) to install, convert to another gas type, or otherwise
service this equipment will void the Frymaster warranty and may result in damage to the
equipment or injury to personnel.

Where conflicts exist between instructions and information in this manual and local or
national codes or regulations, installation and operation shall comply with the codes or
regulations in force in the country in which the equipment is installed.

Upon arrival, inspect the cooker carefully for visible or concealed damage. (See Shipping Damage
Claim Procedure in Chapter 1.)

CLEARANCE AND VENTILATION

The cooker(s) must be installed with 6 inches (150mm) clearance at both sides and back when
installed adjacent to combustible construction; no construction; no clearance is required when
installed adjacent to noncombustible construction. A minimum of 24 inches (600mm) clearance
should be provided at the front of the cooker. To provide the airflow necessary for good combustion
and burner operation, the areas surrounding the cooker front, sides, and rear must be kept clear and
unobstructed.

DANGER

This appliance must be installed with sufficient ventilation to prevent the occurrence

of unacceptable concentrations of substances harmful to the health of personnel in

the room in which it is installed.

One of the most important considerations of efficient cooker operation is ventilation. Cookers must
be installed in an area with an adequate air supply and adequate ventilation. Make sure the cooker is

2-1

installed so that products of combustion are removed efficiently, and that the kitchen ventilation sys­tem does not produce drafts that interfere with proper burner operation.

The cooker flue opening must not be placed close to the intake of the exhaust fan, and the cooker
must never have its flue extended in a “chimney” fashion. An extended flue will change the
combustion characteristics of the cooker, causing longer recovery time. It also frequently causes
delayed ignition.

When installed beneath a ventilation hood, adequate distance must be maintained from the flue
outlet of the cooker to the lower edge of the ventilation filter bank. Filters should be installed at an
angle of 45° with a drip tray placed beneath the lowest edge of the filter. For U.S. installation,
NFPA standard No. 96 states, “A minimum distance of 18 inches (450mm) should be maintained
between the flue outlet and the lower edge of the filter.”

For installations in other than the United States, installers should contact the appropriate local or
national agency for information on the construction and installation of ventilating hoods.

CAUTION

DO NOT install this appliance directly over a drain opening.

ELECTRICAL GROUNDING REQUIREMENTS

All electrically operated appliances must be grounded in accordance with all applicable national and
local codes. A wiring diagram is located on the inside of the cooker door. Refer to the rating plate
on the inside of the cooker door for the proper voltages.

DANGER

If this appliance is equipped with three-prong (grounding) plug, it must be plugged

directly into properly grounded receptacle. Do not cut or remove the grounding

prong from the plug.

DANGER

This equipment requires electrical power for operation.

Place the gas control valve in the OFF position in case of a prolonged power outage.

Do not attempt to use the equipment during a power outage.

NATIONAL CODE REQUIREMENTS

Pasta Magic cookers are manufactured to use the type of gas specified on the rating plate. The
rating plate is attached to the inside of the cooker door. Connect a cooker only to the type of gas
indicated on the rating plate.

Installation shall be made with a gas connector that complies with the national and local codes or
regulations in force in the country in which the appliance is being installed. Quick-disconnect
devices, if used, shall likewise comply with the national and local codes or regulations in force in the
country in which the appliance is being installed

2-2

When installing Pasta Magic cookers in the UNITED STATES, the installation must conform to the
latest edition of the Nation Fuel Gas Code, ANSI Z223.1. In addition, installation must comply with
all local codes. In CANADA, installation must conform to Standard CAN/CGA-B149.1 or
CAN/CGA-B149.2, Installation Codes for Gas Burning Appliances and Equipment. In addition,
installation must comply with all local codes. In AUSTRALIA, this appliance must be installed by
an authorized person in accordance with these instructions, local gas and electrical regulations, and
the requirements of AA601, Installation Requirements for Gas Burning Appliances.

For countries not specifically listed above, installation shall comply with the national and local
codes or regulations in force in the country in which the appliance is being installed.

FCC COMPLIANCE

The user is cautioned that any changes or modifications to Frymaster controllers not expressly
approved by the party responsible for compliance could void the user’s authority to operate the
equipment.

Frymaster controllers have been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC rules. While these devices are verified as Class A devices,
they have been shown to meet the Class B limits. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of the equipment in residential areas is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense. If
necessary, the user should consult the dealer or an experience radio and television technician for
additional suggestions. The user may find the booklet “How to Identify and Resolve Radio-TV
Interference Problems” helpful. It is prepared by the Federal Communications Commission and is
available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-000­00345-4.

2.2 Caster or Leg Installation

Depending upon the specific configuration ordered your cooker may have been shipped without
installed casters or legs. If casters or legs are installed, you may skip this section and proceed to
Section 2.3, Pre-Connection Preparations.

If your cooker requires the installation of casters or legs, install them in accordance
with the instructions included in your accessory package.

2-3

2.3 Pre-Connection Preparations

DANGER

Do not connect cooker to gas supply before completing each step in this section.

After the cooker has been positioned under the exhaust hood, ensure the following has been
accomplished:

1. Adequate means must be provided to limit the movement of cookers without depending upon

the gas line connections. If a flexible gas hose is used, a restraining cable must be connected
at all times when the cooker is in use. The restraining cable and installation instructions are
packed with the flexible hose in the accessories box that was shipped with your unit.

2. Single unit cookers (GPC) must be stabilized by installing restraining chains on cookers

equipped with casters or anchor straps on cookers equipped with legs. Follow the instruc­tions shipped with the casters/legs to properly install the chains or straps.

DANGER

Do not attach an apron drain board to a single cooker. The cooker may become

unstable, tip over, and cause injury. The appliance area must be free and clear of

combustible material at all times.

3. Level cookers equipped with legs by screwing out the legs approximately 1 inch then adjust-

ing them so that the cooker is level and at the proper height in the exhaust hood.
NOTE: There are no built-in leveling devices on cookers equipped with casters. The floor

where the cooker is to be installed must be level.

4. For units equipped with basket lifts, install the basket lift arms onto the rods (located at the

top rear of the cabinet) to ensure that the lift arms are guided by the basket lift rollers.

5. Connect the water supply to the faucet and, on units with the autofill option, the water

solenoid valve. (The valve is located on the lower frame behind the doorpost.)

CAUTION

Before connecting the water supply to units equipped with solenoid valves, purge

the water line to ensure there is no trash in the line.

DANGER

The maximum allowable incoming water pressure to the regulator for all units is

80 PSI (56.3 kg/cm2).

The maximum allowable incoming water temperature for all units is 180°F (82°C).

NOTE: Either hot or cold water supplies may be connected to the water solenoid valve. However,

connecting to a hot water supply will minimize the amount of time required to attain operating
temperature when filling the cooker with fresh water.

NOTE: In order for the water level sensors to work properly, a certain amount of mineral content is
necessary in the water. For that reason, purified, deionized, or highly filtered water should not be
used.

2-4

6. Connect the desired drain plumbing to the 1¼–inch drain valve.

7. Test the cooker electrical system:
a. Plug the cooker electrical cord into a grounded electrical receptacle of appropriate vol-

tage. (Check the rating plate on the cooker door to determine the proper voltage).

b. Place the power switch in the ON position and verify that the display indicates

LO.

c. Place the cooker power switch in the OFF position. Verify that the display is blank.

8. Refer to the rating plate on the inside of the cooker door to verify that the cooker is configured

for the types of gas being supplied before connecting the quick-disconnect device or piping from
the gas supply line.

9. Refer to the table below to verify the minimum and maximum gas supply pressures for the type

of gas being used.

Standard for Incoming Gas Pressures

Gas Minimum Maximum

Natural

Propane

6.0" WC

1.62 kPa

16.19 mbar
11" WC

2.74 kPa

27.37 mbar

14" WC

3.48 kPa

34.87 mbar
14" WC

3.48 kPa

34.87 mbar

2.4 Connection to the Gas Line

The Pasta Magic family of gas cookers has been approved for use with natural and propane (LP) gas.

The size of the gas line used for installation is very important. If the line is too small, the gas
pressure at the burner manifold will be low. This may cause slow recovery and delayed ignition.
Frymaster recommends the incoming gas supply line be a minimum of 1 ½” (38mm) in diameter.
Refer to the chart below for the minimum sizes of connection piping.

Gas Connection Pipe Sizes

(Minimum incoming pipe size should be 1½” (38 mm))

Gas Single Unit 2-3 Units

Natural ¾” (19 mm) 1” (25 mm)

Propane ½” (13 mm) ¾” (19 mm)

Note: For distances of more than 20 feet (6m) and/or more than four fittings
or elbows, increase the connection by one pipe size.

2-5

Before connecting new pipe to your unit, the pipe must be thoroughly blown out to remove any
foreign particles. If these foreign particles get into the burner and controls, they will cause improper
and sometimes dangerous operation.

1. Connect the quick-disconnect hose to the cooker quick-disconnect fitting at the rear of the cook-

er and to the building gas line.

NOTE: Some cookers are configured for a rigid connection to the gas supply line. These units
must be connected to the gas supply line at the rear of the unit using fittings approved for that
purpose by the appropriate regulatory agency of the county in which the appliance is installed.

NOTE: When using thread compound, use very small amounts on male threads only. Use a
pipe thread compound that is not affected by the chemical action of LP gases (i.e. propane, G31)
(Loctite™ PST56765 Sealant is one such compound). DO NOT apply compound to the first two
threads. This will ensure that the burner orifices and control valve do not become clogged.

2. Open the gas supply to the cooker and check all piping, fittings, and gas connections for leaks.

A soap solution should be used for this purpose.

DANGER
Never use matches, candles, or any other ignition source to check for leaks. If gas
odors are detected, shut off the gas supply to the cooker at the main shut-off valve

and contact the local gas company or an authorized service agency for service.

3. Close the cooker drain valve and fill the cookpot with water and detergent. Light the cooker and

perform the boil-out procedures that are described in the “Lighting Instructions” and “Boiling
Out the Cookpot” topics found in Chapter 3 of this manual.

WARNING

“Dry-firing” this equipment will cause damage to the cookpot. Always ensure that

water is in the cookpot before firing your unit.

4. It is recommended that the burner gas pressure be checked at this time by the local gas company

or an authorized service agent. Refer to “Check Burner Pressure” in Chapter 4 of this manual for
the proper procedure. The accompanying tables list the burner gas pressures for the various gas
types that can be used with this equipment.

Standard for Burner Gas Pressure

Gas Pressure

Natural

Propane

3" WC

0.87 kPa

8.718 mbar

8.25" WC

2.05 kPa

20.55 mbar

2-6

2.5 Converting to Another Gas Type

DANGER
Your cooker is configured at the factory for a specific type of gas. If you desire to
switch from one type of gas to another, specific gas-conversion components must
be installed.

Switching to a different type of gas without installing the proper conversion
components may result in fire or explosion! NEVER attach your cooker to a gas
supply for which it is not configured.

Conversion of this appliance from one type of gas to another should only be
performed by qualified, licensed, and/or authorized installation or service personnel,
as defined in Section 1.5 of this manual.

Gas Conversion Components

Natural Gas to LP (Propane) Gas: LP (Propane) Gas to Natural Gas:

Orifice: 810-0386 (2 required)
Ignitor Kit: 826-0386 (2 required)
Regulator: 807-1848 (1 required)
Conversion Rating Label 802-2144.

Orifice: 810-0403 (2 required)
Ignitor Kit: 826-0981 (2 required)
Regulator: 807-1847 (1 required)
Conversion Rating Label 802-2144.

Gas Conversion Instructions

1. Change the orifices.

2. Change the ignitors.

3. Install the regulator kit in the gas valve in accordance with the instructions furnished with the kit.

4. Adjust the incoming gas pressure for the new gas. (Refer to the Standard for Incoming Gas

Pressure table on Page 2-5.)

5. Adjust the gas pressure at the gas valve regulator. (Refer to the Standard for Burner Gas Pres-

sure table on Page 2-6 and adjustment procedure in Chapter 4.)

6. Affix the new label included with the conversion kit next to the existing rating plate stating that

the gas type has been converted. Remove any references to the previously used gas from the
existing rating plate. Label PN 802-2144.

7. If the destination language changes, replace the labels. (You must contact your local service

agency or KES for a label kit. The language of reference is indicated on the corner of the label.)

2-7

PASTA MAGIC GAS COOKERS

INSTALLATION AND OPERATION MANUAL

CHAPTER 3: OPERATING INSTRUCTIONS

3.1 Finding Your Way Around the Pasta Cooker

Trouble light

Blower

Gas valve

Controller

Drain valve

Overflow

Drain

Low-water sensor

High-water
sensor

Temp probe

Cook pot

3-1

1

543210

6

7

8 9

1 Numeric Keypad 6 Skim Switch
2 Boil Mode Indicator 7 Timer Start Switch
3 Boil Mode Switch 8 Simmer Mode Switch
4 Power Switch 9 Simmer Mode Indicator
5 LED Display 10 Trouble Light

3.2 Controller

The Pasta Magic Controller allows the operator to specify a cook time in minutes and seconds, and
then initiate a cooking cycle. This controller is available in three configurations. The standard
configuration has both automatic filling (Autofill) and automatic skimming (Autoskim) features.
Options include Autofill only, or neither Autofill nor Autoskim.

When in the BOIL mode, the burners are lit at all times. It is used when actually cooking pasta.
The SIMMER mode feature maintains the water temperature just below boiling, which conserves

energy and water. This feature is designed for rethermalizing previously cooked packaged products
and for keeping the cooker in standby.

The AUTOSKIM and SKIM features are independent of each other. The AUTOSKIM feature, on
units so equipped, adds water for approximately 3 seconds once a minute. It cannot be turned off.

The SKIM feature, when activated by pressing the skim button on the controller, delivers a conti-
nuous spray of water for approximately 2 minutes, and then stops until the button is again pressed.
In both cases, the purpose is to cause the water in the cookpot to overflow into the drain, carrying
floating starch with it. (A buildup of starch reduces the efficiency of the cooker and can cause erro­neous temperature and water level sensing.) NOTE: Do not use deliming solution to clean these units.
Use of deliming solution will damage all stainless steel parts.)

LOW WATER SENSING automatically closes the gas valve (thereby extinguishing the burner
flame) if the water in the cookpot drops too low. When the water level in the cookpot is below the

3-2

low-water sensor, such as when draining and cleaning the cookpot, the controller display will read
LO.

NORMAL WATER LEVEL SENSING, on units configured with the Autofill feature,
automatically adds water during or after a cooking cycle if the water in the cookpot drops to a level
lower than approximately 1¼-inch (32 mm) below the overflow drain. With this automatic filling
feature, the water level does not have to be continuously monitored. The cookpot always has the
correct amount of water.

FAHRENHEIT OR CELSIUS TEMPERATURE DISPLAY. There are two versions of the SMS
Controller: one that can be toggled between Fahrenheit and Celsius temperature display, and one
that cannot. To determine which version you have, turn the controller off by pressing the power

switch. The display will go blank. Press the Simmer button (right thermometer icon). If Code
appears in the display, the temperature display can be changed. If not, the display cannot be
changed.

1. If Code appears in the display, press 1, 6, 5, 8. The display will be toggled from Fahrenheit to

Celsius or from Celsius to Fahrenheit.

2. Press the Boil button (left thermometer icon) to display the cookpot temperature. If an F

follows the temperature, the display is in Fahrenheit; if a C follows the temperature, the display is
in Celsius.

3.3 Operating Instructions

Before turning the cooker on, ensure that:

• the unit is connected to the water supply.

• the water supply is turned on

• the unit is plugged in to an appropriate outlet.

• the electrical power supply is turned on

• the gas supply is turned on.

3.3.1 Start-up Procedure

CAUTION

If this is the first time the unit is being used after installation, refer also to

Section 3.3.3, Boiling Out the Cookpot.

1. Press the power switch to the ON position. If the cooker is equipped with the Autofill op-

tion, the cookpot will automatically begin to fill with water. If not, manually fill the cookpot us­ing the faucet until the water level is above the upper water level sensor located at the left front
of the cookpot as you face the unit. (On units with Autofill, the water will automatically shut off
when the water in the cookpot has reached the correct level.)

2. Turn the gas valve knob to the ON position (see illustration at

right.)

3-3

The burners should light for several seconds and then go out.
A few seconds later they should light again. This cycle will
repeat about 10 times, at which time the burners should remain
lit until the setpoint is reached.

If the burners fail to light, press the power

switch to the

OFF position, wait 60 seconds, then repeat this step.

3. After the burners have been lit continuously for at least 90 seconds, observe the burners through

the burner viewports. They should display a bright orange-red glow. If a blue flame is observed,
or if there are dark spots on a burner face, the air gas mixture requires adjustment, as explained
below.

NOTE: Adjusting the Air/Gas Mixture:

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

3.3.2 Normal Operation

1. Turn the controller on by pressing the power button .

2. The unit will automatically enter the boil mode and the boil mode indicator will illuminate. If

you do not intend to immediately begin cooking, press the Simmer Mode button . The
simmer mode indicator will illuminate. To re-enter the boil mode, press the Boil Mode button

.

3. Enter the desired cooking time using the numeric keypad. The time entered appears in the LED

display.

4. When ready to initiate a cooking cycle, press the Start Timer button . The basket lift (on units

so equipped) will automatically lower the basket or portion cups into the cookpot and the LED
display will begin to count down. At the end of the cooking cycle, an alarm will sound briefly to
alert you and the basket lift will automatically raise the basket or portion cups out of the water.

The display will automatically return to the previously set cooking time. If the same time is
desired for the next batch, simply press the Start Timer

switch when ready, otherwise enter

the new cooking time before pressing the switch.

5. To initiate the skim feature, press the Skim switch.

3-4

3.3.3 Boiling Out the Cookpot

To ensure that the cooker is free of contamination from manufacture, shipping, or handling during
installation, the cookpot must be boiled out before first use.

1. Close the drain valve and fill the cookpot with a mixture of cold water and 1 cup of detergent.

2. Place the unit into operation (see Sections 3.3.1 and 3.3.2).

3. Press the Simmer Mode button and allow the solution to simmer for at least 1 hour.

4. After the solution simmers for 1 hour, turn the unit off and add cold water until the solution is

cool. Drain the solution and clean the cookpot thoroughly with a solution of dishwashing
detergent and hot water.

5. Rinse the cookpot at least twice by filling with clean water and draining. Dry the cookpot

thoroughly with clean, dry towel.

6. For units equipped with a rinse tank, clean the tank with a solution of dishwashing detergent and

hot water. Drain the tank and dry it thoroughly with a clean, dry towel.

3.4 Shutting the Cooker Down

Turn the unit off by pressing the power button . If shutting down at the end of the day, place the
gas valve in the OFF position, drain and clean the cookpot (and rinse tank, if so equipped), and put
the cookpot and rinse tank covers in place.

3-5

PASTA MAGIC GAS COOKERS
INSTALLATION AND OPERATION MANUAL
CHAPTER 4: PREVENTIVE MAINTENANCE

4.1 Daily Preventive Maintenance

It is normal for a coating of starch to form on the sensors and temperature probes during operation. If the
coating is allowed to build-up, it will adversely affect the operation of the equipment. The preventive
maintenance routines below should be performed at least daily to keep your equipment functioning at peak
efficiency. The cookpot and rinse tank – especially the water-level sensors and the temperature probe –

may require more frequent cleaning, depending upon the product volume. NOTE: Do not use deliming

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

Inspect Equipment and Accessories for Damage

Look for loose or frayed wires and cords, leaks, foreign material in cookpot or inside cabinet, and
any other indications that the equipment and accessories are not ready for safe operation.

Clean Cabinet Inside and Out

Clean inside the cabinet with a dry, clean cloth. Wipe all accessible metal surfaces and components
to remove accumulations of oil, dust, or cooking residue.

Clean the outside of the cabinet with a clean cloth dampened with dishwashing detergent, removing
oil, dust, or cooking residue.

DANGER

Never attempt to clean this equipment during the cooking process or when the

cookpot is filled with hot water and/or food products.

Clean Water-Level Sensors, Temperature Probe, Cookpot, and Rinse Tank

1. Turn the equipment off and drain the cookpot (and rinse tank, if so equipped).

2. Remove the probe cover and clean the water-level sensors and temperature probe using a

Scotchbrite™ or similar abrasive pad and a solution of detergent and water.

3. Using a Scotchbrite™ or similar abrasive pad and a solution of detergent and water, clean the

inside of the cookpot (and rinse the tank, if so equipped).

4. Rinse the cookpot (and rinse tank, if so equipped) thoroughly with clean water at least twice.

WARNING

Do not use deliming solution to clean these units. Use of deliming solution will damage

all stainless steel parts.

4-1

4.2 Cleaning the Gas Valve Vent Tube

This procedure should be performed at least once every 90 days.

1. Set the power switch and the gas valve to the OFF position.

2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened

for ease in removal.

3. Pass a piece of wire 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.

4.3 Cleaning and Adjusting the Combustion Air Blower

1. Unplug the cooker. Mark and disconnect the four wires running from the motor at the inline

connectors.

2. Remove the four nuts and bolts securing the blower to mounting bracket. Remove the blower

from the cooker.

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

separate the two components.

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

4. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreaser or deter-

gent on the blower wheel and the blower housing. Allow it to soak for five minutes. Rinse the
wheel and housing with hot tap water, then dry with a clean cloth.

4-2

Wrap the motor and

wires with plastic wrap

or a plastic bag.

BLOWER HOUSING BLOWER WHEEL

5. Remove the plastic wrap from the blower motor assembly. Reassemble the blower motor

assembly and blower housing. Reinstall the blower assembly in the cooker and reconnect the
wires disconnected in Step 1.

4. Reinstall the blower shield or shield assembly.

5. Light the cooker in accordance with the procedure described in Chapter 3, Section 3.3.

6. After the burners have been lit for at least 90 seconds, observe the flames through the burner

viewing ports. The air/gas mixture is properly adjusted when the burner manifold pressure is in
accordance with the applicable table on page 4-4 and the burners display a bright orange-red
glow. If a blue flame is observed, or if there are dark spots on a burner face, the air/gas mixture
requires adjustment.

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

TYPICAL BLOWER ASSEMBLY

4-3

4.4 Adjusting the Burner Gas Pressure

DANGER

Frymaster recommends that ONLY qualified service personnel perform this task.

1. Ensure that the gas valve knob is in the OFF position.

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

Pressure Tap Plug

Typical Valve Assembly

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

4. Place the gas valve in the ON position.

5. Place the 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 below.

Burner Gas Pressure

Gas Pressure

3" WC

Natural

Propane

.087 kPa

8.718 mbar

8.25" WC

2.05 kPa

20.55 mbar

4-4

6. To adjust the burner gas pressure, remove the cap from the gas valve regulator and use a

flat-tipped screwdriver to adjust the regulator to obtain the correct pressure.

GAS VALVE REGULATOR CAP

7. Place the power switch and the gas valve in the OFF position. Remove the fitting from the pres-

sure tap hole and reinstall the pressure tap plug.

4.5 Measuring Flame Current

When the burner flame is properly adjusted, it will produce a current between 2.5 μA and 3.5 μA.
Flame current is measured by placing a microamp (not milliamp) meter in series with the white sens­ing wire on one of the ignitors. This is accomplished as follows:

1. Place the power switch in the OFF position.

2. Disconnect the sensing wire from one of the burner ignitors and connect it to the positive lead of

the meter. Connect the negative lead of the meter to the terminal from which the sensing wire
was removed.

3. Place the power switch in the ON position to light the burners. After the cookpot temperature

reaches 2000F (93

0

C), wait at least one minute before checking the reading. NOTE: The closer

the unit is to normal operation temperature, the more accurate the reading will be.

4.6 Controller Simmer Mode Adjustment

°

NOTE: The controller simmer temperature is adjustable form 185

F to 215°F (85°C to 102°C).
There are two versions of this controller; one is adjusted by programming, the other is manually
adjusted. To determine which version of the controller you have, turn the controller off by pressing
the power

switch. The display will go blank. Press the Simmer Mode (right thermometer

icon) switch. If Code appears in the display, the setpoint is changed via programming; if not, skip to

Manual Adjustment on the next page.

1. Press 1, 6, 5, 0 to enter the programming mode. The currently programmed simmer setpoint will

be displayed. If the setpoint is not correct

to program the simmer setpoint to 200

, enter the desired setpoint (for example, press 2, 0, 0

°

).

2. Press the Simmer Mode

switch again to lock the setpoint, then press the power switch to

turn the controller on and return to the normal operating mode.

4-5

PASTA MAGIC GAS COOKERS

INSTALLATION AND OPERATION MANUAL

CHAPTER 5: OPERATOR TROUBLESHOOTING

5.1 Introduction

This chapter provides a reference guide to the more common problems that may occur during the
operation of this equipment. The troubleshooting guides in this chapter are intended to help you
diagnose problems with the equipment.

If your have doubts as to the proper action to take, do not hesitate to call the Frymaster Technical
Service Department or your local Frymaster Factory Authorized Servicer for assistance.

Before calling a servicer or the Frymaster HOTLINE [phone]):

• Verify that electrical cords are plugged in and that circuit breakers are on.

• Verify that water supply valves are open and that the drain valves are fully closed.

• Verify that the main gas supply valve is open.

DANGER

Hot water can cause severe burns. Never attempt to move a cooker containing hot

water or to transfer hot water from one container to another.

DANGER

Use extreme care when performing electrical circuit tests. Live circuits will be

exposed.

DANGER

Inspection, testing and repair of electrical components should be performed only by

qualified service personnel. The equipment should be unplugged when servicing,

except when electrical tests are required.

5-1

5.2 Operator Troubleshooting Guides
Problem Probable Causes Corrective Action

A. Ignition module lockout (the

burners failed to light within 4
seconds).

Indicator: Red trouble light on

control panel is illuminated.

BURNERS DO NOT

LIGHT

(Main gas supply

valve verified to be

open, the gas valve is

verified to be ON, and

power switch is

verified to be ON.)

ON UNIT WITH

AUTOFILL,

COOKPOT DID

NOT FILL WHEN

UNIT WAS

TURNED ON

(Water supply to unit

verified to be ON.)

B. Dirty water level sensors. (If the

computer does not sense suffi­cient water in the cookpot, it will
not allow the burners to fire.)

C. Failed controller.

D. Failed ignition module or gas

valve, or broken or loose wiring.

A. Dirty water level sensors. A. Remove the probe block cover

B. Failed controller.

C. Shorted upper water level sensor,

failed water solenoid valve, or
loose/broken wiring.

A. Turn the controller OFF. Open

the control panel by removing
the screws in the upper corners.
If there are two ignition mod­ules, check for blown 2-amp
fuses and replace as necessary.
Close the control panel and
press the power switch. Wait at
least 4 minutes.

B. Remove the probe block cover

and clean the sensors using a
Scotchbrite™ or similar pad
and a solution of detergent and
water. NOTE: Do not use
deliming solution.

C. Order replacement controller

from FAS or distributor.

C. Call FAS.

and clean the sensors using a
Scotchbrite™ or similar pad
and a solution of detergent and
water. NOTE: Do not use
deliming solution.

B. Order replacement controller

from FAS or distributor.

C. Call FAS.

5-2

Problem Probable Causes Corrective Action

ON UNIT WITH

AUTOFILL,

WATER DID NOT

SHUT OFF WHEN

COOKPOT WAS

FULL

AUTOSKIM DOES

NOT WORK

(AUTOFILL func-

tions correctly.)

WATER WILL

NOT BOIL

(Cookpot verified to
be full of water with

Boil Mode selected,

i.e., left indicator is lit

and burners are lit.)

WATER BOILS IN

SIMMER MODE

WATER

TEMPERATURE IS

TOO LOW IN

SIMMER MODE

BASKET LIFT

MOVEMENT IS

JERKY OR NOISY

A. Dirty water level sensors. A. Remove the probe block cover

and clean the sensors using a
Scotchbrite™ or similar pad
and a solution of detergent and
water. NOTE: Do not use
deliming solution.

B. Insufficient mineral content in

water.

C. Failed upper water level sensor,

loose or broken upper water level
sensor wiring, failed water sole­noid valve.

A. Failed controller. (If the

AUTOFILL functions correctly,
the only cause possible is a failed
controller.)

A. Failed controller.

B. Failed temperature probe. B. Call FAS.

A. Controller out of adjustment. A. Adjust controller in accordance
B. Failed controller.

B. Failed/shorted temperature probe. C. Call FAS.
A. Controller out of adjustment. A. Adjust controller in accordance

B. Failed controller.

C. Open temperature probe or loose

probe wire.

A. Lack of lubrication on basket lift

rods.

B. Add ⅛-cup of baking soda to

the water in the cookpot as the

unit fills. DO NOT USE
SALT! Doing so will damage

the cookpot. Avoid using
distilled, highly filtered, or
deionized water.

C. Call FAS.

A. Order replacement controller

from FAS or distributor.

A. Order replacement controller

from FAS or distributor.

with procedure in Chapter 4.

B. Order replacement controller

from FAS or distributor.

with procedure in Chapter 4.

B. Order replacement controller

from FAS or distributor.

C. Call FAS.
A. Lubricate lifter rods with a

lightweight lubricant.

5-3

A

Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106

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

Price: $8.00

819-6556

NOVEMBER 2011

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SERVICE HOTLINE

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