Frymaster OCF30ATOE User Manual

Oil Conserving Fryer (OCF30)

Electric Series Fryers

Service & Parts Manual

™

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

www.frymaster.com E-mail: service@frymaster.com

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

*8196686*

JAN 2013

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

DANGER

Copper wire suitable for at least 167°F (75°C) must be used for power connections.

DANGER

The electrical power supply for this appliance must be the same as indicated on the rating and serial number plate located on the inside of the fryer door.

DANGER

This appliance must be connected to the voltage and phase as specified on the rating and serial number plate located on the inside of the fryer door.

DANGER All wiring connections for this appliance must be made in accordance with the wiring diagrams furnished with the equipment. Wiring diagrams are located on the inside of the fryer door.

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

WARNING Do not attach accessories to this fryer unless fryer is secured from tipping. Personal injury may result.

WARNING Frymaster fryers equipped with legs are for permanent installations. Fryers fitted with legs must be lifted during movement to avoid damage and possible bodily injury. For a moveable or portable installation, Frymaster optional equipment casters must be used. Questions? Call 1-800-551-8633 or email at service@frymaster.com.

WARNING

Do not use water jets to clean this equipment.

WARNING This equipment is intended for indoor use only. Do not install or operate this equipment in outdoor areas.

DANGER Adequate means must be provided to limit the movement of this appliance without depending on or transmitting stress to the electrical conduit. A restraint kit is provided with the fryer. If the restraint kit is missing contact your local KES.

DANGER Prior to movement, testing, maintenance and any repair on your Frymaster fryer, disconnect all electrical power from the fryer.

ELECTRICAL POWER SPECIFICATIONS

Three (3) Phase Requirements

WIRE

kW VOLTAGE PHASE

14 208 3 3 6 16 39 39 39 14 240 3 3 6 16 34 34 34 14 480 3 3 8 10 17 17 17 14 220/380 3 4 6 16 21 21 21 14 240/415 3 4 6 16 20 20 21 14 230/400 3 4 6 16 21 21 21 17 208 3 3 6 16 48 48 48 17 240 3 3 6 16 41 41 41 17 480 3 3 6 16 21 21 21 17 220/380 3 4 6 16 26 26 26 17 240/415 3 4 6 16 24 24 24 17 230/400 3 4 6 16 25 25 25

SERVICE

MINIMUM SIZE AMPS PER LEG

AWG mm2 L1 L2 L3

OCF30™ SERIES ELECTRIC FRYERS

TABLE OF CONTENTS

CAUTIONARY STATEMENTS .............................................................................................................................. i

ELECTRICAL POWER SPECIFICATIONS ........................................................................................................ ii

CHAPTER 1: Service Procedures

1.1 General ................................................................................................................................................... 1-1

1.2 Replacing a Controller ........................................................................................................................... 1-1

1.3 Replacing Component Box Components ............................................................................................... 1-1

1.4 Replacing a High-Limit Thermostat ...................................................................................................... 1-3

1.5 Replacing a Temperature Probe ............................................................................................................. 1-3

1.6 Replacing a Heating Element ................................................................................................................. 1-5

1.7 Replacing Contactor Box Components .................................................................................................. 1-6

1.8 Replacing a Frypot ................................................................................................................................. 1-7

1.9 Built-In Filtration System Service Procedures ....................................................................................... 1-9

1.9.1 Filtration System Problem Resolution .................................................................................. 1-9

1.9.2 Replacing the Filter Motor, Filter Pump and Related Components .................................... 1-10

1.9.3 Replacing the Filter Transformer or Filter Relay ................................................................ 1-12

1.10 Basket Lift Service Procedures ............................................................................................................ 1-12

1.11 ATO (Automatic Top-Off) Service Procedures ................................................................................... 1-14

1.11.1 ATO (Automatic Top-Off) Troubleshooting) ....................................................................... 1-15

1.11.2 Testing ATO RTD Probes ..................................................................................................... 1-16

1.11.3 ATO (Automatic Top-Off) Board Pin Positions and Harnesses ........................................... 1-17

1.11.4 Replacing the ATO board, ATO Pump Relay or Transformer ............................................. 1-18

1.11.5 Replacing the ATO Pump ..................................................................................................... 1-18

1.11.6 Replacing the ATO Solenoids ............................................................................................... 1-18

1.11.7 Control Power Reset ............................................................................................................. 1-19

1.12 3000 Controller Service Procedures .................................................................................................... 1-19

1.12.1 3000 Controller Troubleshooting .......................................................................................... 1-19

1.12.2 3000 Controller Useful Codes ............................................................................................... 1-22

1.12.3 Service Required Errors ........................................................................................................ 1-22

1.12.4 Error Log Codes .................................................................................................................... 1-23

1.12.5 3000 Menu Summary Tree ................................................................................................... 1-24

1.12.6 3000 Controller Pin Positions and Harnesses ....................................................................... 1-25

1.13 Loading and Updating Software .......................................................................................................... 1-26

1.14 Interface Board Diagnostic Chart ........................................................................................................ 1-27

1.15 Probe Resistance Chart ........................................................................................................................ 1-28

1.16 Wiring Diagrams .................................................................................................................................. 1-29

1.16.1 Basket Lift Wiring 208-250V ............................................................................................. 1-29

1.16.2 Basket Lift Wiring 100-120V ............................................................................................. 1-30

1.16.3 FPEL Simplified Wiring ....................................................................................................... 1-31

1.16.4 FPEL Control Wiring Domestic w/ 3000 Controller ............................................................ 1-32

1.16.5 FPEL Control Wiring Domestic w/ CM3.5 Controller ......................................................... 1-33

1.16.6 Tilt Switch Wiring .............................................................................................................. 1-34

1.16.7 Contactor Box-Delta Configuration .................................................................................... 1-35

1.16.8 Contactor Box-WYE Configuration ................................................................................... 1-36

1.16.9 Terminal Block Wiring ....................................................................................................... 1-37

1.16.10 Simplified FPEL14/17 Full-Vat Delta Wiring .................................................................... 1-38

1.16.11 Simplified FPEL14/17 Dual-Vat Delta Wiring .................................................................. 1-39

1.16.12 Simplified FPEL14/17 Full-Vat Export WYE Wiring ........................................................ 1-40

1.16.13 Simplified FPEL14/17 Dual-Vat Export WYE Wiring ...................................................... 1-41

1.16.14 Series Data Network Flowchart .......................................................................................... 1-42

1.16.15 Shortening Melting Unit Wiring Diagram .......................................................................... 1-43

iii

OCF30™ SERIES ELECTRIC FRYERS

TABLE OF CONTENTS cont.

1.16.16 Bulk Oil Wiring Diagram ................................................................................................... 1-44

1.16.17 Bulk Oil Box Wiring ........................................................................................................... 1-45

CHAPTER 2: Parts List

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

2.2 Basket Lift Assembly and Associated Parts ................................................................................... 2-2

2.3 Doors, Sides, Tilt Housings, Top Caps and Casters ....................................................................... 2-4

2.4 Drain System Components ............................................................................................................. 2-5

2.4.1 Drain Tube Sections and Associated Parts ..................................................................... 2-5

2.4.2 Drain Valve Assembly ................................................................................................... 2-7

2.5 Electronics and Wiring Components .............................................................................................. 2-8

2.5.1 Component Boxes .......................................................................................................... 2-8

2.5.2 Contactor Boxes ........................................................................................................... 2-10

2.5.3 Fuse Boxes ................................................................................................................... 2-11

2.5.4 Terminal Blocks ........................................................................................................... 2-12

2.5.5 Heating Element Assemblies and Hardware ................................................................ 2-13

2.5.6 Element Tube Assemblies ............................................................................................ 2-15

2.5.7 Controllers .................................................................................................................... 2-15

2.5.8 Wiring .......................................................................................................................... 2-16

2.5.8.1 Contactor Box Wiring Assemblies 12-Pin Dual Vat .................................... 2-16

2.5.8.2 Contactor Box Wiring Assemblies 12-Pin Full Vat ..................................... 2-16

2.5.8.3 Contactor Box Wiring Assemblies 6-Pin Left Element ............................... 2-17

2.5.8.4 Contactor Box Wiring Assemblies 9-Pin Right Element ............................. 2-17

2.5.8.5 Main Wiring Harnesses ................................................................................ 2-18

2.5.8.6 Component Box, Filter Pump and Basket Lift Wiring Harnesses ................ 2-19

2.5.8.7 Component Box to Filter Pump Harness ...................................................... 2-19

2.5.8.8 Basket Lift Harness ...................................................................................... 2-20

2.5.8.9 Interface Board to Controller Wiring Harness 15-Pin .................................. 2-20

2.5.8.10 3000 and ATO Wiring Harnesses ................................................................. 2-20

2.6 Filtration System Components ..................................................................................................... 2-21

2.7 Filter Pump, Motor and Associated Components ......................................................................... 2-22

2.8 Frypot Assemblies and Associated Parts ...................................................................................... 2-23

2.9 Oil Return System Components ................................................................................................... 2-24

2.10 Auto Top-Off Components ........................................................................................................... 2-25

2.10.1 JIB Basket and Automatic Top-Off Board Assembly ................................................... 2-25

2.10.2 JIB Cap and Pick-up Assembly ..................................................................................... 2-25

2.10.3 ATO Pump Assembly ..................................................................................................... 2-26

2.10.4 ATO Top-Off Manifolds ................................................................................................ 2-27

2.10.5 Shortening Melting Unit ................................................................................................. 2-28

2.10.6 Bulk Oil Relay Box and Switch ..................................................................................... 2-29

2.10.7 Bulk Oil Plumbing .......................................................................................................... 2-30

2.10.8 Bulk Oil Dispose Waste Valve ....................................................................................... 2-31

2.11 Wiring Connectors, Pin Terminals and Power Cords ................................................................... 2-32

2.12 Fasteners… .................................................................................................................................. 2-33

OCF30™ SERIES ELECTRIC FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 General

Before performing any maintenance on your Frymaster fryer, disconnect the fryer from the electrical power supply.

To ensure the safe and efficient operation of the fryer and hood, the electrical plug must be fully engaged and locked in its pin and sleeve socket.

When electrical wires are disconnected, it is recommended that they be marked in such a way as to facilitate re-assembly.

1.2 Replacing the Controller

1. Disconnect the fryer from the electrical power supply.

2. Open the control panel by removing the screws on the bottom of the bezel. Carefully lower the

bezel.

3. Remove the two screws from the upper corners of the controller. The controller is hinged at the

bottom and will swing open from the top.

4. Unplug the wiring harnesses from the connectors on the back of the controller, marking their

position for reassembly, and disconnect the grounding wires from the terminals. Remove the controller by lifting it from the hinged slots in the control panel frame.

WARNING

Ground Wire Terminal

Communication Wires

Ground Wire Terminal

20-Pin Connecto

Locator Wire

5. Install the replacement controller. Reverse steps 1 thru 4.

6. Setup the controller following the instructions on page 4-3 in the Installation and Operation

manual. Setup MUST

be performed after replacement.

7. Once setup is complete on all replaced controllers, reset all control power following the

instructions in section 1.11.7 on page 1-19 to readdress the new 3000 controller. Check software version and if necessary update the software. If a software update was necessary, follow the instructions to update the software in section 1.13 on page 1-26.

1.3 Replacing Component Box Components

1. Disconnect the fryer from the electrical power supply.

1-1

2. Open the control panel by removing the screws on the bottom of the bezel. Carefully lower the

bezel.

3. Remove the two screws from the upper corners of the control panel and allow the control panel to

swing down.

4. Unplug the wiring harnesses and disconnect the grounding wires from the terminals on the back of

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

5. Disconnect the wiring from the component to be replaced, being sure to make a note of where each

wire was connected.

6. Dismount the component to be replaced and install the new component, being sure that any

required spacers, insulation, washers, etc. are in place.

NOTE: If more room to work is required, the control panel frame assembly may be removed by

removing the hex-head screws, which secure it to the fryer cabinet (see illustration below). If this option is chosen, all control panel assemblies must be removed per steps 1 and 2 above. The cover plate, on the lower front of the component box, may also be removed to allow additional access if

desired. Removing the component box itself from the fryer is not recommended due to the difficulty

involved in disconnecting and reconnecting the oil-return valve rods, which pass through openings in the component box.

Remove these three screws at each end.

Remove these two screws from the center supports.

Removing the Control Panel Frame and Top Cap Assembly

7. Reconnect the wiring disconnected in step 5, referring to your notes and the wiring diagrams on

the fryer door to ensure that the connections are properly made. Also, verify that no other wiring was disconnected accidentally during the replacement process.

8. Reverse steps 1 through 4 to complete the replacement and return the fryer to service.

1-2

1.4 Replacing a High-Limit Thermostat

1. Drain the frypots into a Shortening Disposal Unit (SDU) or other appropriate METAL container.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to the rear of

the fryer.

3. Remove the screws from the bottom of the lower back panel attaching the contactor plug guards.

4. Remove each of the guards.

5. Remove the four screws from both the left and right sides of the lower back panel.

6. Locate the high-limit that is being replaced and follow the two-black wires to the 12-pin connector

C-6. Note where the leads are connected prior to removing them from the connector. Unplug the 12-pin connector C-6 and using a pin-pusher push the pins of the high-limit out of the connector.

7. Carefully unscrew the high-limit thermostat to be replaced.

8. Apply Loctite

™

PST 567 or equivalent sealant to the threads of the replacement and screw it

securely into the frypot.

9. Insert the leads into the 12-pin connector C-6 (see illustration below). For full-vat units or the

right half of a dual-vat unit the leads go into positions 1 and 2 of the connector. For the left half of a dual-vat unit, the leads go into positions 7 and 8. In either case, polarity does not matter.

10. Reconnect the 12-pin connecting plug C-6. Use wire ties to secure any loose wires.

11. Reinstall the back panels, contactor plug guards, reposition the fryer under the exhaust hood, and

reconnect it to the electrical power supply to return the fryer to service.

1.5 Replacing a Temperature Probe

1. Disconnect the fryer from the electrical power supply and reposition it to gain access to the rear of

the fryer.

2. Remove each of the guards.

3. Remove the four screws from both sides of the lower back panel. Then remove the two screws on

both the left and right sides of the back of the tilt housing. Lift the tilt housing straight up to remove from the fryer.

1-3

4. Locate the red and white wires of the temperature probe to be replaced. Note where the leads are

connected prior to removing them from the connector. Unplug the 12-pin connector C-6 and using a pin-pusher push the pins of the temperature probe out of the connector.

5. Raise the element and remove the securing probe bracket and metal tie wraps that secure the probe

to the element (see illustration below). Remove the ground clip on the probe shield.

6. Gently pull on the temperature probe and grommet, pulling the wires up the rear of the fryer and

through the element tube assembly.

7. Insert the replacement temperature probe (wires first) into the tube assembly ensuring that the

grommet is in place. Secure the probe to the elements using the bracket which was removed in Step 5 and the metal tie wraps which were included in the replacement kit.

8. Route the probe wires out of the tube assembly following the element wires down the back of the

fryer through the Heyco bushings to the 12-pin connector C-6. Secure the wires to the sheathing with wire ties. Attach the ground clip.

9. Insert the temperature probe leads into the 12-pin connector C-6 (see illustration below). For full-

vat units or the right half of a dual-vat unit the red (or yellow) lead goes into position 3 and the white lead into position 4 of the connector. For the left half of a dual-vat unit, the red (or yellow)

lead goes into position 9 and the white lead into position 10. NOTE: Right and left refer to the

fryer as viewed from the front.

10. Secure any loose wires with wire ties, making sure there is no interference with the movement of

the springs. Rotate the elements up and down, making sure movement is not restricted and that the wires are not pinched.

11. Reinstall the tilt housing, back panels and contactor plug guards. Reposition the fryer under the

exhaust hood, and reconnect it to the electrical power supply to return the fryer to service.

1-4

1.6 Replacing a Heating Element

1. Perform steps 1-5 of section 1.5, Replacing a Temperature Probe.

2. Disconnect the wire harness containing the probe wiring. Using a pin pusher, disconnect the probe

wires from the 12-pin connector C-6.

3. In the rear of the fryer, disconnect the 6-pin connector for the left element (as viewed from the

front of the fryer) or the 9-pin connector for the right element from the contactor box. Press in on the tabs on each side of the connector while pulling outward on the free end to extend the connector and release the element leads (see photo below). Pull the leads out of the connector and out of the wire sleeving.

4. Raise the element to the full up position and support the elements.

5. Remove the hex head screws and nuts that secure the element to the tube assembly and pull the

element out of the frypot. NOTE: The nuts inside the tube can be held and removed using the RE

element tube nut spanner, PN# 2304028. Full-vat elements consist of two dual-vat elements clamped together. For full-vat units, remove the element clamps before removing the nuts and screws that secure the element to the tube assembly.

6. If applicable, recover the probe bracket and probe from the element being replaced and install

them on the replacement element. Install the replacement element in the frypot, securing it with the nuts and screws removed in Step 5 to the tube assembly. Ensure the gasket is between the tube and element assembly.

7. Route the element leads through the element tube assembly and into the wire sleeving to prevent

chafing. Ensure that the wire sleeving is routed back through the Heyco bushings, keeping it clear from the lift springs. Also ensure that the wire sleeving extends into the tube assembly, protecting the wires. Press the pins into the connector in accordance with the diagram on the following page,

and then close the connector to lock the leads in place. NOTE: It is critical that the wires be

routed through the sleeving to prevent chafing.

1-5

Index Marker marks Position 1

14253

5L 4L6L 1L2L3L

789

8. Reconnect the element connector ensuring that the latches lock.

9. Insert the temperature probe leads into the 12-pin wiring harness connector (see illustration

below). For full-vat units or the right half of a dual-vat unit, the red lead goes into position 3 and the white into position 4. For the left half of a dual-vat unit, the red lead goes into position 9 and

the white into position 10. NOTE: Right and left refer to the fryer as viewed from the front.

10. Reconnect the 12-pin connector C-6 of the wiring harness disconnected in Step 2.

11. Lower the element onto the basket rack.

12. Reinstall the tilt housing, back panels and contactor plug guard. Reposition the fryer under the

exhaust hood, and reconnect it to the electrical power supply.

1.7 Replacing Contactor Box Components

1. If replacing a contactor box component, remove the filter pan and lid from the unit.

2. Disconnect the fryer from the electrical power supply.

3. Remove the two screws securing the cover of the contactor box. The contactor boxes above the

filter pan are accessed by sliding under the fryer. They are located to the left and right above the guide rails (see photo below). The contactor boxes for frypots not over the filter pan are accessed by opening the fryer door directly under the affected frypot (see photo on following page).

1-6

Remove two screws to access contactor box components above the filter pan

4. The contactors and relays are held on by threaded pin studs so that only removal of the nut is

required to replace the component.

5. After performing necessary service, reverse steps 1-4 to return the fryer to operation.

Left and right views of mechanical contactor box components.

1.8 Replacing a Frypot

1. Drain the frypot into the filter pan or, if replacing a frypot over the filter system, into a Shortening

Disposal Unit (SDU) or other appropriate METAL container. If replacing a frypot over the filter system, remove the filter pan and lid from the unit.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to both the

front and rear.

3. Open the control panel by removing the two screws on the bottom of the bezel. Carefully lower the

bezel.

4. Remove the two screws from the upper corners of the control panels and allow them to swing

down (see photo on page 1-1).

1-7

5. Unplug the wiring harnesses and ground wires from the backs of the controllers. Remove the

controllers by lifting them from the hinge slots in the control panel frame.

6. Remove the screws from the bottom of the lower back panel attaching the contactor plug guards.

7. Remove each of the guards

8. Remove the tilt housing and back panels from the fryer. The tilt housing must be removed first in

order to remove the upper back panel.

9. To remove the tilt housing, remove the hex head screws from the rear edge of the housing. The

housing can be lifted straight up and off the fryer.

10. Remove the control panel by removing the screws on both sides.

11. Loosen the component boxes by removing the screws, which secure them in the cabinet.

12. Remove the top cap by removing the nuts at each end that secure it to the cabinetry.

13. Remove the hex head screw that secures the front of the frypot to the cabinet cross brace.

14. Remove the top-connecting strip that covers the joint with the adjacent frypot.

15. Unscrew the nut located on the front of each section of drain tube, and remove the tube assembly

from the fryer.

16. Remove the covers from the drain safety switch(es) and disconnect the wiring at the switch(es).

17. Disconnect any auto top-off sensors if equipped and wiring.

18. At the rear of the fryer, unplug the 12-pin connector C-6 and, using a pin pusher, disconnect the

high-limit thermostat leads.

19. Disconnect the oil return and top off flexline(s).

20. Raise the elements to the “up” position and disconnect the element springs.

21. Remove the machine screws and nuts that secure the element tube assembly to the frypot.

Carefully lift the element assembly from the frypot and secure it to the cross brace on the rear of the fryer with wire ties or tape.

22. Carefully lift the frypot from the fryer and place it upside down on a stable work surface.

23. Recover the drain valve(s), oil return flexline connection fitting(s), auto top-off sensors if equipped

and high-limit thermostat(s) from the frypot. Clean the threads and apply Loctite

™

PST 567 or

equivalent sealant to the threads of the recovered parts and install them in the replacement frypot.

24. Carefully lower the replacement frypot into the fryer. Reinstall the hex head screw removed in

step 9 to attach the frypot to the fryer.

25. Position the element tube assembly in the frypot and reinstall the machine screws and nuts

removed in step 21.

1-8

26. Reconnect the oil return and auto top off flexlines to the frypot, and replace aluminum tape, if necessary, to secure heater strips to the flexlines.

27. Insert the high-limit thermostat leads disconnected in step 18 (see illustration on page 1-3 for pin positions).

28. Reconnect the auto top-off sensors.

29. Reconnect the drain safety switch wiring to the switch(es) in accordance with the diagram below then reinstall the switch covers.

30. Reinstall the drain tube assembly.

31. Reinstall the top connecting strips, top cap, tilt housing, back panels and contactor plug guards.

32. Reinstall controllers in the control panel frame and reconnect the wiring harnesses and ground wires.

33. Reposition the fryer under the exhaust hood and reconnect it to the electrical power supply.

1.9 Built-in Filtration System Service Procedures

1.9.1 Filtration System Problem Resolution

One of the most common causes of filtration problems is placing the filter paper on the bottom of the filter pan rather than over the filter screen.

CAUTION Ensure that filter screen is in place prior to filter paper placement and filter pump operation. Improper screen placement is the primary cause of filtration system malfunction.

Whenever the complaint is “the pump is running, but no oil is being filtered,” check the installation of the filter paper, and ensure that the correct size is being used. While you are checking the filter paper, verify that the O-rings on the pick-up tube of the filter pan are in good condition. A missing or worn O-ring allows the pump to take in air and decrease its efficiency.

If the pump motor overheats, the thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch (button) located on the rear of the motor.

If the pump starts after resetting the thermal overload switch, then something is causing the motor to overheat. A major cause of overheating is when several frypots are filtered sequentially, overheating the pump and motor. Allow the pump motor to cool at least 30 minutes before resuming operation. Pump overheating can be caused by:

1-9

 Solidified shortening in the pan or filter

Sediment Particle

lines, or

 Attempting to filter unheated oil or

shortening (cold oil and shortening are

Oil Flow

more viscous, overloading the pump motor and causing it to overheat).

If the motor runs but the pump does not return oil, there is a blockage in the pump. Incorrectly sized or installed paper will allow food particles and sediment to pass through the filter pan and

Sediment Particle

Up for reverse

into the pump. When sediment enters the pump, the gears bind, causing the motor to overload, again tripping the thermal overload. Shortening that has solidified in the pump will also cause it to seize, with the same result.

Down for forward

A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a screwdriver or other instrument.

Disconnect power to the filter system, remove the input plumbing from the pump, and use a screwdriver to manually turn the gears.

● Turning the pump gears in reverse will release a hard particle.

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

and allow free movement of the gears.

Incorrectly sized or installed paper/pads will also allow food particles and sediment to pass through and clog the suction tube on the bottom of the filter pan. Particles large enough to block the suction tube may indicate that the crumb tray is not being used. Pan blockage can also occur if shortening is left in the pan and allowed to solidify. Blockage removal can be accomplished by forcing the item out with an auger or drain snake. Compressed air or other pressurized gases should not be used to force out the blockage.

1.9.2 Replacing the Filter Motor, Filter Pump, and Related Components

1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit

(SDU) or other appropriate metal container.

DANGER

DO NOT drain more than one full frypot into the SDU at one time.

2. Disconnect the fryer from the electrical power supply and reposition it to gain access to both the

front and rear.

1-10

3. Disconnect the flexline running to the oil-return manifold at the rear of the fryer as well as the

pump suction flexline at the end of the filter pan connection (see photo below). On some models a third flexline may need to be disconnected.

Disconnect flexlines indicated by the arrows.

4. Loosen the nut and bolt that secures the bridge to the oil-return manifold.

5. Remove the cover plate from the front of the motor and disconnect the motor wires.

6. Unplug the pump motor assembly 6-pin connector C-2.

7. Remove the two nuts and bolts which secure the front of the bridge to the cross brace and carefully

slide the bridge rearward off the cross brace until its front end can be lowered to the floor. Undo the single nut holding it in place in back. Be careful not to let the rear of the bridge slip off the manifold at this point.

8. Get a good grip on the bridge, carefully pull it forward off the oil-return manifold, and lower the

entire assembly to the floor. Once on the floor, pull the assembly out the front of the fryer.

9. When required service has been completed, reverse steps 3-8 to reinstall the bridge. NOTE: The

black motor wires go on the top terminal, the white on the bottom. The red/black heater tape wires go into position 3 and the violet/white wires go into position 6 (see illustration below).

10. Reconnect the unit to the electrical power supply, and verify that the pump is functioning correctly

(i.e., when a filter handle is placed in the ON position, the motor should start and there should be strong suction at the intake fitting and outflow at the rear flush port.)

1-11

11. When proper operation has been verified, reinstall the back panels and the filter pan and lid.

12. Reposition the fryer under the exhaust hood and reconnect it to the electrical power supply, if

necessary to return the fryer to service.

1.9.3 Replacing the Transformer or Filter Relay

Disconnect the fryer from the electrical power supply. Remove the left controller from the fryer to expose the interior of the left component box. The transformer and relay on the left are located as

shown in the illustration below. NOTE: The right component box is identical to the left except that

the transformer and relay on the left side are not present. Once replaced, reconnect the power.

When replacing a filter relay in the left component box, ensure the 24VAC relay (8070670) is used on 208-240V units and 8070012 is used on 120V units. This relay is the same relay used in the RE fryers.

1.10 Basket Lift Service Procedures

OCF30™ Series electric fryers may be equipped with automatic basket lifts. Basket lifts always come in pairs, although each operates independently.

A modular basket lift (illustrated on the following page) is a self-contained sub-assembly consisting

of a pair of toothed rods, which support removable basket lift arms, a pair of reversible-drive gear motors, and four microswitches. The gear motors engage the teeth of the rods, moving them up or down depending upon the motors’ direction of rotation. The microswitches at the upper and lower limits of movement stop the motors when the basket is in the full up or full down position. Timing circuitry in the controller initiates and stops basket lift operation depending upon the variables programmed by the operator. When the product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power to the lower microswitch. The microswitches stop the motor at the lift’s upper and lower travel limits and reverse the direction of current flow thus reversing the motor direction.

When the product button is pushed on the controller, current flows through a coil in the basket lift relay, causing the lower circuit to be activated. The basket lift lowers, closing the normally open upper-micro-switch. When the downward-moving rod opens the lower normally closed microswitch, the power to the motor ceases to flow. When the controller times out, the current to the relay coil is cut, allowing the upper circuit to be activated. The basket lift rises and re-closes the lower

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microswitch. When the basket lift rod clears the upper microswitch, the microswitch reopens, power to the circuit is cut, and the motor stops. Pushing the product button restarts the cycle.

Problems with the basket lift can be grouped into three categories:

● Binding/jamming problems

● Motor and gear problems

● Electronic problems

100-120V Configuration

208-250V Configuration

Binding and Jamming Issues

Noisy, jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and their bushings. Apply a light coat of Lubriplate® or similar lightweight white grease to the rod and bushings to correct the problem.

With the modular basket lift, another possible cause of binding is improper positioning of the motor, which prevents the gear from correctly engaging the teeth in the rod. To correct the problem, loosen the screws that hold the motor in place and move it forward or backward until the rod has just enough slack to be rotated slightly.

Motor and Gear Issues

With the modular basket lift, the most likely problem to be encountered in this category is erratic motion of the lift due to a worn drive gear. Failure to keep the lift rod and bushings properly lubricated will cause unnecessary wear of the gear. The problem is corrected by replacing the worn gear.

If the lift cycles correctly but fails to remain in the up position (i.e., goes up, but then slowly settles back down into the frypot), the problem is a failed motor brake. A failed motor brake cannot be repaired and requires replacement of the motor itself.

If power is reaching the motor but the motor fails to run, the motor is burned out and must be replaced.

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Electronic Issues

Within this category are problems associated with the relays, microswitches, capacitors, resistors, interface board, wiring, and controls. The most common problem in this category is a lift that continuously travels up and down. This is usually caused by a microswitch that is out of adjustment. Troubleshooting the electronics of a modular basket lift is simply a process of verifying current flow through the individual components up to and including the motor. Using a multimeter set to the 250 VAC range, check the connections on both sides of the component for the presence of the applied line voltage. The schematic below and the wiring diagram on page 1-27 and 1-28 can identify the components and wiring connection points.

1.11 ATO (Automatic Top-off) Service Procedures

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

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

Figure 1

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1.11.1 ATO (Automatic Top-off) Troubleshooting

Problem Probable Causes Corrective Action

A. JIB out of oil B. Supply line from JIB is clogged. C. Probe temperature lower than setpoint. D. Temperature in supply line or JIB is too

low.

Frypots won’t top off.

E. ATO board power loss F. Failed solenoid. G. ATO pump failed or over tightened. H. Failed transformer/harness. I. Failed ATO board. J. Top-off manifold solenoid failed closed.

Controller displays

TOPOFF OIL

EMPTY / CONFIRM

Frypot tops off cold.

Top off system out of oil.

Incorrect setpoint

A. J5 connection unplugged

No power to ATO board

B. Fuse blown C. Transformer malfunction

A. Filter error exists.

One vat doesn’t top off.

B. Pump, loose connection, RTD or ATO

issue.

A. Ensure the JIB is not out of oil and

supply line is in the JIB. Replace JIB and press the  button when prompted to reset top off system.

B. Remove supply line from pump and

blow air through line towards JIB.

C. Check to see that fryer is heating.

Fryer temperature must be at least 300°F (149°C). Check probe resistance. If probe is bad, replace the probe.

D. Ensure oil is above 70°F (21°C). E. Power to the ATO board has been cut

off. Restore power to the board and switch all controllers off and on again to readdress system.

F. Check solenoid to see if functioning

properly.

G. If the solenoid is working, ensure that

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

H. Ensure transformer in ATO box is

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

I. Check for proper voltages using the

pin position chart found on page 1-17. If ATO found defective, replace ATO board.

J. A pressure switch opens in the pump

with excessive pressure in the top-off manifold, shutting down the pump. Clear or replace solenoid.

Fill top off system with oil and press the  (CONFIRM) button.

Ensure setpoint is correct.

A. Check to ensure J5 on front of ATO

board is fully locked into connector.

B. Ensure fuse below right control box is

not blown and fuse on the right side of ATO box is not blown.

C. Check that proper voltage is present

at transformer.

A. Clear filter error properly. B. Check ATO pump, wire connections,

RTD and ATO board.

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Problem Probable Causes Corrective Action

A. Check power to the pump. If the

pump is hot, the solenoid has probably failed.

B. Ensure all wiring harnesses are

securely connected to ATO board and solenoids.

A. Ensure wires are wired correctly.

B. Switch flexlines to correct vat.

One vat tops off but

other vats fail to top off.

Incorrect vat tops off.

A. Failed solenoid B. Loose wire connection.

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

A. Ensure fuse on right side of ATO box

is secure and good. If the controller above the ATO box is missing power check the fuse below the component box.

B. With the controller OFF, press TEMP

3000 displays

SERVICE

REQUIRED – ATO

BOARD

A. Loose or bad fuse B. Bad Connection C. ATO Board power loss

button and ensure the ATO software version appears. If not, the connection between the ATO and the controller may be bad. Ensure the 6pin CAN connectors are tight between controller (J6 and J7) and ATO (J9 or J10) boards.

C. Power to the ATO board has been cut

off. Ensure there is correct voltage to the ATO transformer. Restore power to the board and clear any service required errors.

1.11.2 Testing ATO RTD probes.

The controller features a quick way to compare the temperature of the ATO RTD to the vat temperature. This is useful for diagnosing ATO issues.

With the controller OFF, press and hold the TEMP button. The controller will display AIF and ----followed by ATO and current resistance temperature. Ignore the AIF display. Compare the resistance of the ATO probe against the controller reading. If the values differ greatly a harness issue may exist.

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

Connector From/To Harness #

8075161

Solenoids

(4 or 5 battery)

Top Off Pump Relay

J4 (Rear) /

J5 (Front)

J3 - Vat 5&6 J2 - Vat 3&4 J1 - Vat 1&2

J10

J9 3000 J7 8074646

JIB Reset Switch

Solenoids

(4 or 5 battery)

Top Off Pump Relay

JIB Reset Switch

Transformer 8074553

ATO RTD

Network Resistor

(pins 2 & 3)

or to next ATO Board (4

& 5 vat units)

8075162-

8075161

8075162-

1080501 (FV) 1080502 (DV)

8074552

# Function Voltage

1 Output DV - Vat #1 2 Output FV - Vat #1 3 Output DV - Vat #2 4 Output FV - Vat #2 5 Output DV - Vat #3 6 Output FV - Vat #3 7 Top Off Pump 8 JIB Reset

9 24VAC DV - Vat #1 10 24VAC FV - Vat #1 11 24VAC DV - Vat #2 12 24VAC FV - Vat #2 13 24VAC DV - Vat #3 14 24VAC FV - Vat #3 15 Ground 16 Ground

1 24VAC Ret

2 24VAC Blue

5 12VAC Ret

6 12VAC Brown

1 DV - Probe Ground

2 DV - Probe Red

3 FV - Probe Ground White

4 FV - Probe Red

1 Ground Black

2 CAN Lo Red

3 CAN Hi White

4 5VDC+ 5VDC Black

5 24VDC 24VDC Red

6 Ground White

1 Ground Black

2 CAN Lo Red

3 CAN Hi White

4 5VDC+ 5VDC Black

5 24VDC 24VDC Red

6 Ground White

Ground

24VAC 16VDC

24VAC

24VAC 16VDC

24VAC

12VAC

Ohm

Wire

Color

Green

Red

Green

Red

Green

Red Red Red

White

Black

White

Black

White

Black Black Black

Orange

Red

White

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1.11.4 Replacing the ATO Board, ATO Pump Relay or Transformer

Disconnect the fryer from the electrical power supply. Locate the ATO box (see Figure 1 on page 14), behind the JIB (Jug In Box). Remove the cover to expose the transformer and ATO board (see Figure 2). Mark and unplug any wires or harnesses. Replace the defective component and reattach all wires or harnesses. Replace the cover. Once replaced, reconnect the

power. CYCLE POWER TO ENTIRE FRYER SYSTEM. See section 1.11.7 on page 1-19 to reset control power. Check software

version and if necessary update the software. If

Figure 2

a software update is necessary, follow the instructions to update the software in section 1.13. Remove and restore power to ALL controllers after power has been restored to the ATO board. Press the TEMP button on one of the M3000 controllers, with the controller in the OFF position, to verify software version of the ATO. If the version is not visible, the ATO may not be connected properly.

1.11.5 Replacing the ATO Pump

Disconnect the fryer from the electrical power supply. Locate the ATO pump (see Figure 3), behind the ATO box. Mark and unplug any wires or harnesses. Press up from the bottom on the quick disconnects to release the plumbing (see Figure 4). The plumbing can be pulled from the pump. Loosen the four nuts attaching the pump to the pump tray. Replace the defective component and reverse above steps. Once replaced, reconnect the power.

Figure 3 Figure 4

1.11.6 Replacing the ATO Solenoids

Disconnect the fryer from the electrical power supply. Locate the top off manifold in the rear of the fryer. The top off manifold is the smaller of the two manifolds. The solenoids are attached to the manifold (see Figure 5). Mark and unplug any wires. Replace the defective component and reattach

all wires or harnesses. Once replaced, reconnect the power.

Top off manifold

Figure 5

Solenoid

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1.11.7 Control Power Reset Switch

The control power reset switch is a momentary rocker switch located behind the control box, (see Figures 6 and 7) above the JIB, which resets all power to all the controllers and boards in the fryer. It is necessary to reset all power after replacing any controller or board. Press and hold the switch for at least ten seconds when resetting the control power to ensure power has sufficiently drained from boards.

Figure 6 Figure 7 (Rear view of Control Box)

1.12 3000 Controller Service Procedures

1.12.1 3000 Controller Troubleshooting Problem Probable Causes Corrective Action

A. Controller not turned on. B. No power to the fryer. C. Power switch turned off.

No Display on

Controller.

D. Loose fuse holder. E. Controller has failed. F. Damaged controller wiring harness. G. Power supply component or interface

board has failed.

3000 display shows

filter busy.

A. Another filtration cycle is still in

process.

A. Press the ON/OFF switch to turn

the controller on.

B. Verify controller power cord is

plugged in and that circuit breaker is not tripped.

C. Some fryers have a rocker power

switch inside the cabinet below the controller. Ensure the switch is turned on.

D. Ensure fuse holder is screwed in

properly.

E. Swap the controller with a

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

F. Swap with a harness known to be

good. If controller functions, replace the harness.

G. If any component in the power

supply system (including the transformer and interface board) fail, power will not be supplied to the controller and it will not function.

A. Wait until the previous filtration

cycle ends to start another filtration cycle. This may take up to one minute. If filter busy is still displayed with no activity, remove

and restore ALL power to the fryer.

3000 display shows

RECOVERY

FAULT.

Recovery time exceeded maximum time limit for two or more cycles.

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Silence the alarm by pressing the  button. Check that fryer is heating properly. Maximum recovery for an electric fryer is 1:40.

Problem Probable Causes Corrective Action

Fryers using the 3000 controller can toggle between F° to C° by pressing the

 button until Main Menu changing to Product setup is displayed. Press  to

3000 display is in

wrong temperature

scale (Fahrenheit or

Celsius).

3000 displays

SERVICE

REQUIRED followed

by the error.

Controller displays

CHANGE FILTER

PAPER?

3000 display shows

hot-hi-1.

3000 display shows

HI-LIMIT.

3000 display shows

temperature

alternating with

MLT-CYCL.

3000 display shows

low temp

alternating with

temperature.

Controller displays

lo or LOw temp.

3000 display shows

low temp,

heating

indicator cycles on and

off normally but fryer

does not heat.

Incorrect display option programmed.

An error has occurred.

Daily filter paper change prompt has occurred.

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

Controller in high-limit test mode.

Frypot temperature is below 180°F (82°C).

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

Frypot temperature has dropped more than 21ºF (12ºC) for CM3.5 or 40°F (17°C) for 3000 controllers below setpoint in idle mode or 45°F (25°C) in cook mode.

A. Failed controller. B. Damaged controller wiring harness.

scroll to Tech Mode and press . Enter

1658. Press the scan button. The controller displays OFF. Turn the controller on to check temperature. If the desired scale is not displayed, repeat. Fryers using the CM3.5 should refer to the separate Fryer Controllers User’s Manual. Press YES to silence alarm. The error is displayed three times. See list of issues in section 1.12.4. Fix issue. The controller displays SYSTEM ERROR FIXED? YES/NO. Press YES. Pressing NO will allow the fryer to cook but the error will be redisplayed every 15 minutes.

Press  (YES), follow prompts and change the filter paper.

This in an indication of a malfunction in the temperature control circuitry, including a failure of the high-limit thermostat. This is displayed only during a test of the high-limit circuit and indicates that the high-limit has opened properly.

This display is normal when the fryer is first turned on while in the melt cycle mode. To bypass the melt cycle press and hold the EXIT COOL button for three seconds. EXIT MELT

alternating with YES/NO is displayed. Press the YES button. This display is normal when the fryer is

heating and out of melt cycle until the

temperature reaches ±2° of setpoint.

This display is normal for a short while if a large batch of frozen product is added to the frypot or if the fryer is not heating properly.

A. Replace controller.

B. Replace controller wiring harness.

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Problem Probable Causes Corrective Action

3000 display shows

TEMP PROBE

FAILURE.

3000 display shows

PROBE FAILURE

with alarm sounding.

Controller will not go

into program mode or

some buttons do not

actuate.

3000 display shows HI

2 BAD.

3000 display shows

HEATING

FAILURE with

alarm sounding.

Heating indicator is

on, but fryer is not

heating.

3000 display shows

HEATING

FAILURE and alarm

sounds, but fryer

operates normally

(false alarm).

3000 display shows

CLOSE DRAIN

VALVE.

3000 display shows

software for only 3000

or ATO board.

3000 display shows

ERROR RM

SDCRD

3000 display shows

CALL TECH

Problem with the temperature measuring circuitry including the probe.

Damaged controller wiring harness or connector.

Failed controller. Replace controller

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

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

This is displayed only during a test of

Controller in high-limit test mode.

Failed controller, failed interface board or open high limit thermostat.

the high-limit circuit and indicates that the high-limit has failed.

Check high limit thermostat, interface board and controller.

Failed controller.

Replace controller.

Drain valve is open or switch is out of adjustment or failed.

Loose or damaged harness

Defective SD Card Replace card with another card.

Typically shown during software update. Also may be that parameter data has been corrupted or lost.

Ensure all drain valves are completely closed and that microswitches are adjusted and working.

Check that all harnesses between 3000’s and ATO are secure and no pins are pushed out or broken.

Press the FILTER button to bypass and

continue.

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